Manual for

Maintenance of Distribution Transformers

Source: TQM activities of MeSEB, 2007-08

January 21, 2010

Meghalaya State Electricity Board

MANUAL FOR MAINTENANCE OF DISTRIBUTION TRANSFORMER

Source: TQM activities of MeSEB, 2007-08

A Distribution Transformer (DT) is utilized to step down the voltage from 11 KV to 0.433 KV/0.250KV so that the electrical power is usable for providing supply to the customers such as domestic, commercial, industrial, LT, etc. A registered consumer expects uninterrupted power supply because during the failure of power supply, all works be it domestic, official, commercial or industrial comes to a standstill. Hence, transformer failure leads to consumer complaints and unnecessary emergency for the Utility to restore the power supply. In urban areas, the reason for failure of power supply due to failure of transformer is not too frequent, whereas in rural areas most of the power failures are attributable to the failure of distribution transformers. Failure of distribution transformers results in considerable revenue loss and entails heavy expenditure for replacement. This manual on DT maintenance and reduction of failure does not describe the engineering know-how of prevention but ensures the use of these skills from the huge collective knowledge of our vast human resources. Reasons for failure of Distribution Transformers and the remedial measures thereof:
The reasons for failure of Distribution Transformers in both urban and rural areas are the following:

Sl Probable Causes No
1. Overloading

Factors
A) Absence of record on the loading of the transformer. B) Granting of load sanction without taking into account loading on the transformer. C) Unauthorized usage/theft of power

Remedial Measures
A) Maintaining proper record of the total number of consumers along with the connected load. B) Maintaining proper record on loading of the transformer. C) DT metering (static). D) Augmentation of transformer or construction of new sub-station. E) Disconnection of illegal connections A) Maintaining the record of the phasewise loading and regular load balance accordingly B) Service connection to be given from the appropriate phase(s) only after taking proper shutdown C) Phase conversion

2.

Imbalance loading

A) Absence of record on the phase B) loading of the transformer. C) B) Improper service connection to consumers without taking into account the phase load

D) Long single/two phase line. 3. Low transformer oil level A) Leakage of oil B) Theft of oil A) Proper tightening of terminals and joints and replacement of loose/burnt out gaskets B) Proper sealing of valves C) Use of REC valves A) Augmentation of transformer or construction of a new substation. B) Proper tightening of terminals and joints. C) Replacement of deteriorated gaskets. D) Replacement of cracked bushings. E) Prompt replacement of deteriorated silica gel & dirty oil in the breather. F) Periodical testing of oil. G) Filtration/overhauling of transformer oil as & when required after testing

4.

Low break Down Value (BDV) of the transformer oil and poor insulation resistance(IR) Value

5.

Poor earthing or absence earthing

of

6.

Lightning

7.

Improper or poor cable terminal

8.

Burning transformer

of

9.

External circuit

short

A) Overheating of transformer. B) Entry of moisture and contaminants. C) Burnt out insulation in the winding & core. D) Acidity formation due to the combined effect of heat, dissolution of varnishes & cellulose. E) Sludge formation due to continuous heating and thereby decomposition of the insulation material which then gets dissolved in the oil. A) High soil resistivity of the A) Periodical checking of the soil earth pit resistivity. Renovation of earth pit or B) Disconnected earth wire or making a new earth pit. rusted earth wire. B) Periodical checking of earth connections. Tightening of the terminal connections. A) High soil resistivity of the A) Periodical checking of the soil earth pit resistivity. Renovation of earth pit or B) Undersized loop, especially making a new earth pit. from the conductor to the B) Usage of the appropriate size of L.A. earthing loop C) Disconnection earth wire and C) Periodical checking of earth wire rusted earth wire. and earth connection. D) Common earthing. D) Tightening of the terminal connections. E) Absence of lightning E) Earthing loop of LAs is to be arrestors / damaged lightning separate. arrestors. F) Installation/ replacement of LAs A) Loose connection A) Proper tightening of terminal B) Poor lugging connections. B) Proper lugging and usage of appropriate size of lugs. A) Leakage of oil at terminals. A) Proper tightening of terminals and B) Short circuit between cables joints, and replacement of loose burnt due to failure of insulation. out gaskets C) Fire due to weeds/ jungles etc B) Regular check of the insulation of cables. C) Periodical cleaning of substation. A) Long LT line span A) Erection of intermediary poles where B) Poor safety clearance. necessary. C) Sagging of conductors. B) Place spacers where necessary and

10.

Overrated fuses

11.

Flash over

12.

Lack of testing of transformer and sub-station equipments

13.

Vandalism

D) Accumulation of dust on maintain safety clearance between bushings. conductors. E) Contact of the conductor with C) Maintain sag of conductors as per trees / branches. standard. D) Cleaning of bushings E) Regular jungle clearing A) Non availability of rated A) Prompt requisition and procurement of fuse. fuse. B) Ignorance of the field staff on B) Training of staff on the purpose of the appropriate ratings. fuse, correct size and implications of C) Use of conductor as fuse overrating. C) Discourage the use of conductor as fuse wire A) Absence of arcing horn or A) Proper fitting of arcing horns. arcing horns are not fitted B) Periodical cleaning of bushings. properly. B) Dirty bushings A) Non availability of megger A) Each sub-division should have megger, earth tester, filter machine, oil tong tester, and earth tester and each testing kit. division should have an oil filter B) Absence of a routine for machine and oil testing kit. testing. B) Testing schedule to be compiled and C) Shortage of staff implemented. C) Outsourcing of the testing. A) Unsecured sub-station A) Proper fencing and the gate(with lock B) Lack of awareness among the if needed). public B) Danger plate in the substation. C) Public awareness through media and meetings.

From the table above it can be seen that the main factors which contribute to Distribution Transformer failure are: 1. Non implementation of the construction standards. 2. Absence of records on number of consumers, loading and history of the sub-station. 3. Absence of a well prepared action plan for distribution transformer failure reduction. 4. Absence of inspection, testing and maintenance schedule and non-implementation thereof. 5. Absence of inspection, testing and maintenance record on every sub-station. 6. Irresponsibility and carelessness on the part of some personnel. 7. Absence of proper reporting and clear guidelines at different levels. 8. Shortage of staff.

Steps to be taken for Distribution Transformer Maintenance

1. Data collection & upkeep of database a. b. c. d. e. f. g. 2.
Sl

Total number of DTs in the Division/Sub-division. Monthly DT failure report in each sub-division. A separate report in a uniformly prescribed format for each DT failure. Weekly/Monthly interruption report in a sub-division. HT feeder with sub-stations including the single line diagram showing line length and sub-station capacity. LT feeder single line diagram indication the line length. Monthly record of consumer complaints and records of failure against each DT. Computerization of database in uniformly prescribed formats throughout the board.

Inspection & Maintenance Schedule for Distribution Transformers:

Inspection frequency Fortnightly Items to be inspected Inspection notes Action required if inspection shows un-sactisfactory conditions Clean air passages. If silica gel is pink, change with spare. Charge. The old charge may be reactivated for use again. If oil level is low, top up with dry oil. Examine transformer for leaks. If loose. Tighten: replace if cracked Tighten the terminal connections Replace lugs if required Replace the gasket

1.

(i) Dehydrating Breather (ii) Oil Level in Transformer (iii) Physical Condition (i) Connections (HT & LT terminals) (ii) Explosion vent (iii) Diaphragm (Pressure relief device) Bushings

Check that air passages are clear Check colour of active agent (silica Gel) Check transformer oil level Check tightness Check for cracks/ damages Check for any oil spillage Examine for cracks and dirt deposits Check for external connection Check for moisture under cover Inspect

2.

Monthly

3.

Quarterly

Clean or replace Tighten, if required

4.

Half yearly

(i) Non oil conservator tank transformer (ii) Cable boxes, gasket joints, gauges and general

Improve ventilation Maintenance of breathers to be ensured Take remedial measures

5.

Yearly

paint work (i) Oil in transformer

(ii)Earth resistance

Check for dielectric Oil filtration to restore quality of strength Check for oil. acidity and sludge <I ohm Take suitable action if earth resistance is high

3.

Communication

a. b. c.

Monthly meetings on DT maintenance among AEE/AE/JE and line staff. Monthly/biomonthly meetings of CEOs with EEs and AEEs. Quarterly meetings convened by the CE (Distribution) with the Zonal ACEs, ACE (MM), CEOs & EEs.

d. e.

Coordination with local dorbars on DT problems and pilferage. Capacity building programs for different levels.

NOTE :

It has also been observed that one of the reasons for failure of distribution transformers is the supply of sub-standard transformers, which is a result of improper vendor rating and lack of routine test prior to dispatch by the manufacturer & issue for use. It is therefore proposed as follows: a. Vendors should be approved only after confirming the adequacy of the manufacturing & testing facilities at the works. b. Procurement should be on the guaranteed technical particulars and not necessarily L-I rate. c. Routine tests should be observed at the works and the transformer should be tested prior to issue for utilization.

4.

Inspection & Maintenance of transformer and accessories within the sub-station and its proximity. A. Overall Sub-station Inspection cum Maintenance Report.
(to be filled up by the concerned inspector viz. Lineman/ES/JE/AE/AEE)

a. b. c. d. e. Sl 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Name of Sub-station Code of Sub-station Capacity of Transformer Number of LT feeders Date of inspection Condition/Observations/Remarks

Items to be inspected Physical condition of the transformer DOs/Main switch/Cut-Out LT feeders Cable Lugs Earthing, Earthing Leads, etc Lightening Arrestor Arching Horn Transformer Bushing Breather Condition of silica gel Radiator Oil level Oil leakage in any HT Terminal LT Terminal Current (Amps) Peak Hours

17 18 19 20

a. R-phase b. Y-phase c. B-phase Off-Peak Hours a. R-phase b. Y-phase c. B-phase a. HT-LT I R Value b. HT-E c. LT-E Number of illegal consumers receiving supply from DT Number of illegal consumers disconnected from the DT General upkeep and overall cleanliness of substation (weeds, litter, etc)

21 22 23

Fencing & gate of the substation Danger plate Others

B. Sub station premises: Sl No. 1. 2. 3 4. 5. 6. Items to be inspected during sub-station Inspection notes maintenance work HT & LT Fuses LAs Earthing DOs Main switch, Cut out Cleanliness of sub-station Checking of sub-station station loading by tong tester or DT metering C. HT /LT Lines in the proximity of the substation: Sl Items to be inspected during sub-station Inspection notes maintenance work Condition of HT/LT Poles including stay wire Span of LT lines/need for LT spacers Whether poles are covered with creepers Whether HT/LT Lines are having minimum clearance from trees/branches Whether illegal connection like hooking, illegal service connection are present or not Likely cause of failure due to nearby HT Lines Action required if inspection shows unsactisfactory conditions Action required if inspection shows unsactisfactory conditions

1. 2. 3. 4. 5.

6.

NOTES:

Signature/seal of person(s) inspecting

Compiled by HRD Centre MeSEB,Umiam