Maintenance Handbook
on
Transformer of 3 Phase Electric Locomotive
END USER: Loco Maintenance Staff
Maintenance Handbook
on
Transformer of 3 Phase Electric Locomotive
QUALITY POLICY
To develop safe, modern and cost
effective Railway Technology
complying with Statutory and
Regulatory requirements, through
excellence in Research, Designs and
Standards and Continual
improvements in Quality
Management System to cater to
growing demand of passenger and
freight traffic on the railways.
FOREWORD
CAMTECH, Gwalior
Date: 26th March, 2015
A.R.Tupe
Executive Director
PREFACE
CAMTECH, Gwalior
Date: 26th March, 2015
Peeyoosh Gupta
Director/ Electrical
CONTENTS
Chapter No.
1.
Page No.
Foreword
Preface
Contents
Correction Slip
iii
iv
v
vii
GENERAL
01
1.1
Introductions
01
1.2
03
04
04
04
1.4
07
1.5
10
1.6
Transport of Transformer
11
11
12
Storage of Transformer
12
13
13
1.3
1.7
1.9
2.
Description
MAINTENANCE
15
2.1
15
2.2
Trip Inspection
16
2.3
17
2.4
18
2.5
19
2.6
20
2.7
21
22
2.8
22
2.9
23
Chapter No.
2.10
3.
Description
Page No.
24
2.10.1 Tests
24
2.11
Testing Equipment
25
2.12
26
2.13
29
2.14
Transformer Oil
31
2.14.1
Oil Specification
31
2.14.2
32
2.12.3
34
MODEL QUESTION
39
ANSWERS
45
46
ANNEXURE I
47
Date of issue
Remarks
CHAPTER 1
GENERAL
1.1
INTRODUCTION
Figure 1.1
The transformer is a static device, which transforms power from one AC circuit to
another AC circuit at same frequency but having different characteristics. These circuits are
conductively disjointed but magnetically coupled by a common time varying magnetic field.
It can raise or lower the voltage with a corresponding decrease or increase in current.
In all the electric locomotives, limiting the value of current during starting, speed
control is achieved by supply of variable voltage to the traction motors. This variation of
applied voltage can be carried out easily by the use of transformer along with Static
Convertor provided in the locomotive.
The windings which form the electrical circuit must fulfill certain basic
requirements, particularly the di-electric, thermal and mechanical stresses imposed on it
during testing as well as in service and cater for over loads under adverse conditions.
The WAG9 transformer unit consists of the main transformer active part and two
different types of reactors, hosed in a tank.
The main transformer converts the overhead line voltage (25 kV) to the lower
operating voltages for:
traction power supply 1268V
auxiliary 1kV
The main transformer is integrated into the traction circuit between overhead line
and rail return line.
The primary current line flows from the pantograph via roof line, vacuum circuit
breaker, the roof bushing into the primary winding of the main transformer. It then flows
back to the rail via the earth return brushes on four of the six axles. And WAP5, WAP7
transformer has total load winding in addition toWAG9 transformer.
March, 2015
Figure 1.2
March, 2015
1.2
When a conductor cuts the magnetic flux or magnetic flux cut the conductor, an emf
is induced in the conductor.
b.
Where,
-d/dt
=
=
emf
flux
Kinds of emf
The emf may be induced by two ways
i.
Dynamically induced emf
ii.
Statically induced emf.
a.
Mutually induced emf
b.
Self induced emf
An emf induced in a coil due to variation of flux in another coil placed near to first is
called mutually induced emf.
The emf induced in a coil due to change of its own flux linked with it is called selfinduced emf. (In case of autotransformer)
In its simplest form, a transformer consists of two conducting coils. The primary is
the winding which receives electric power, and the secondary is one which delivers the
electric power. These coils are wound on a laminated core of magnetic material.
The physical basis of a transformer is mutual induction between two circuits linked
by a common magnetic flux through a path of low reluctance as shown in fig.1.2
LAMINATED CORE
PRIMARY
SECONDARY
Figure 1.3
Ideal Transformer
The two coils possesses high mutual inductance. If one coil is connected to a source
of alternating voltage, an alternating flux is set up in the laminated core, most of which is
linked up with the other coil in which it produces mutually induced emf i.e.
E = M di/dt
If the second circuit is closed, a current flows in it and so electric energy is
transferred (entirely magnetically) from first coil (primary winding) to the second coil
(secondary winding).
Maintenance Handbook on Transformer of 3 Phase Electric Locomotives
March, 2015
N1 =
N2 =
m =
f =
v1 =
March, 2015
Figure 1.4
Figure 1.5
Cooling Arrangement
March, 2015
Figure 1.6
March, 2015
1.4
:
:
:
:
Aluminium
RAL-7009stain
966 kg with lid
HSTN 424007
SOD Winding
Identity No.
Make
: HSTN 424005
ABB Badodara, BHEL Jhansi,
CGL Mandideep Bhopal,
EMCO Thane Mumbai,
High volt electrical Ltd Mumbai,
GOD Winding
Identity No.
Make
: HSTN 424006
ABB Badodara, BHEL Jhansi,
CGL Mandideep Bhopal,
EMCO Thane Mumbai,
High volt electrical Ltd Mumbai,
March, 2015
v.
Transformer Bushing
Identity No. DT 1/250 : HSTN 310500
DT 1/630 : HSTN 310501
DT 1/1000 : HSTN 310502
DT 1/2000 : HSTN 310503
DT 1/3150 : HSTN 310504
vi.
: HSTN 420783P0001
vii.
Overflow Valve
Identity No.
: HSTN 4/12/0144R
Pressure setting : 0.8 bar
Supplier
: Millen Engineer or RDSO approved
HSTN 4274037P0001
NW80 ND6
Fatco or RDSO approved
x.
HSTN 422368P0001
NW32/25
Hofiman or RDSO approved
xi Two conservator tanks including - Air dehumidifier including valve -Oil level gauge
Identity No.
Material
Colour
Volume
:
:
:
:
HSTN
Aluminium
RAl 7030 stain
137DMQ
xii.
Breather
Identity No.
:
Technical Data :
Supplier
:
HSTN 422029P0001
EM3MA
Yogya or RDSO approved
Transformer is designed for feeding GTO/IGBT based Power and Auxiliary converter
load.
March, 2015
10
1.4
Power (kVA)
6531
4 x 1449
334
400
9450 3 % kg
Voltage
25000
4 x 1269
1000
1154
Current
261.25
4 x 1142
334
347
March, 2015
Power (kVA)
7475/7775
4 x 1449
334
400
945/1245
10000 3 % kg
Voltage
25000
4 x 1269
1000
1154
750/960
Current
299/311
4 x 1142
334
347
1260/1296
11
Weight
Unit
Quantity
Transformer active part LOT 7500/ LOT 1
6500
Kg per unit
5780/ 5380
Kg total
5780/ 5380
590/ 590
590/ 590
570/ 570
570/ 570
900/ 900
900/900
Insulation oil
1800/1780
1800/ 1780
Equipment
260/ 230
260/ 230
9900/ 9450
88
176
TRANSPORTATION OF TRANSFORMER
The transformer is transported full with oil. Any oil volume changing (which is
caused by temperature variations) during the transport or storage are taken up by the
transport expansion tank which is mounted on the transformer oil.
The breather is connected to the transformers expansion tank. The breather should
only be removed during the installation of the transformer in the locomotive, and rectified as
soon as possible. The breather must be filled with new or dried silica gel.
Figure 1.19
March, 2015
12
Figure 1.20
1.6
STORAGE OF TRANSFORMER
The transformer can be stored as long as required, if the maintenance is carried out
as required if it is under maintenance or ready to use. The various points for storage of
transformer is described below.
a.
Storing place
The oil-filled transformer should be
stored in covered area. The storing place must
be dry and the transformer must be covered
with a lose taped plastic sheet.
Figure 1.21
b.
Storing Place
Connecting flanges
All pipes, pumps and blocking valves should
be closed off using blanking flanges.
c.
Expansion tank
Fix the expansion tanks in vertical position on a
higher level than the transformers lid. Join then with
flexible pipes with transformer in the same way as they are
installed in the locomotive. The oil level in the expansion
tank should correspond with the temperature mark.
Figure 1.23 ExpansionTank
March, 2015
13
d.
Labels
Covering the transformer with stickers is
forbidden. If stickers need to be added then they
should be stuck on separate plates. The plates
should then be tied to the transformer using
strings (no wire).
TFPG No.
: 2027453
Make
: BHEL
Date of O/H : 11.05.2014
Checks
After transport and installation at the storing place the transformer should be
checked for any signs of oil leakage.
b.
Checks
According to the atmospheric conditions the oil level and the silica gel in the
breather should be checked every 6 months.
Oil level
If the oil level is lower than the equivalent temperature mark, oil can be
added by the filling cap on the expansion tank with the oil of the same quality.
Mixing with oils which have significantly different parameters should be avoided.
If the oil level is not visible at the expansion tank, the reason for the low oil
level must be found. Oil should not be added by the filling cap of the expansion tank
as long as reason has not been found.
c.
Breather
If more than half of the silica gel is saturated (moisturized), then it must be
completely replaced. The old silica gel may be regenerated.
The transformer must not stay longer than 3 hours without functional breather.
1.7
Moisture
Oxygen
Solid Impurities
Varnishes
Slackness of winding
a.
March, 2015
14
oxidizes, acids are formed. These acids increase moisture solubility of oil. Acids
coupled with moisture further decompose the oil forming more acids and moisture.
Thus the rate of deterioration of oil increases.
Check the colour of silica gel in each inspection and if found pink, replace or
reactivate crystals at 150 degree C. Test transformer oil for electric strength and
water content in IC schedule & POH and carry out purification with high vacuum
type transformer oil filtration plant if required. Arrest the oil leakage if any.
b.
Effect of Oxygen
Oxygen may be present inside the transformer due to air remaining in oil.
The oxygen reacts and decomposes the cellulose of insulation. This forms an organic
acid soluble in oil and sludge, which blocks the free circulation of the oil. The
adverse effect of oxygen, which may be aggravated by catalytic action between hot
oil and bare copper, increase the operating temperature.
Carry out oil purification with high vacuum type transformer oil purification
plant periodically to remove atmospheric gases (air) and sludge.
c.
d.
Effect of Varnishes
Some varnishes having oxidizing effect, react with transformer oil
and precipitate sludge on windings. Synthetic varnishes having acid
inhibiting properties, generally delay the natural formation of acid and sludge
in the oil.
e.
March, 2015
15
CHAPTER 2
MAINTENANCE
2.1
Duration
2 hrs
IA
90 days
4 hrs
IB
180 days
6 hrs
IC
270 days
8 hrs
MOH
18 months
6 working days
IOH
POH
9 years + 6 months or
24 lakh kms. whichever is
earlier.
28 working days
Periodicity
45 days
IA
90 days
IB
180 days
IC
270 days
MOH
18 months
IOH
POH
March, 2015
16
2.2
TRIP INSPECTION
1.
No leakage
2.
MAIN TRANSFORMER
Inspect the color of the silica gel. If it is pink, remove the filter
from the locomotive
Blue
ii
Blue
Middle strip
iii
Read off the oil level on the gauge situated on the conservator.
Top up the oil as necessary and
Check for any signs of leakage
No leakage
iv
Cleaned & No
leakage
Examine the flanges of the pipe couplings and flexible hose that
link the transformer and conservator and check the holding
clamps.
Checked &
Found intact
vi
Intact
vii
Check the main TFP and its protection cover of drain cock for
damage/crack & oil leakage
Checked &
Found intact
viii
Checked &
Found intact
ix
Intact/ No
leakage
No leakage
xi
Checked /
Replaced
xii
No leakage
3.
Checked/ intact
ii
Remove all dust, dirt and debris from the radiator chamber via
the machine room access cover (using vacuum cleaner) in case
of less air flow booking
Cleaned
iii
Visually check the oil cooler radiator for any oil leakage /
external damage from top and bottom
No leakage/No
damage
March, 2015
+/- 6,
17
2.3
IA, IB SCHEDULE.
1
Visually examine all SR & TFP oil pumps for any oil leakage Normal
/any abnormal sound and take needful action
ii
2.
MAIN TRANSFORMER
Normal
i
ii
Inspect the colour of the silica gel. If it is pink, remove the filter Blue
from the locomotive
iii
iv
Read off the oil level on the gauge situated on the conservator. Middle strip
Top up the oil as necessary and
+/- 6
Check for any signs of leakage
No leakage
Prismatic level gauge-clean the gauge with a dry cloth and Cleaned & No
check/attend for leaks
leakage
vi
vii
viii
ix
xi
xii
xiii
xiv
Check the main TFP and its protection cover for damage / crack No crack / No
& oil leakage. (RDSO/TC/076)
leakage
xv
Blue
No
No leakage
March, 2015
18
2.4
IC SCHEDULE.
1
i.
Visually examine all SR & TFP oil pumps for any oil Normal
leakage / any abnormal sound and take needful action
ii
iii
2.
MAIN TRANSFORMER
30 kV (serviceable
oil)
ii
Done
iii
Inspect the color of the silica gel. If it is pink, remove the Blue
filter from the locomotive
iv
Read off the oil level on the gauge situated on the Middle strip +/- 6
conservator. Top up the oil as necessary and
No leakage
Check for any signs of leakage
vi
Prismatic level gauge-clean the gauge with a dry cloth and Cleaned & No
check for leaks
leakage
vii
Examine the flanges of the pipe couplings and flexible hose Checked & Found
that link the transformer and conservator
intact
viii
ix
xi
Visually inspect the condition of oil cooling metallic pipes, Checked Intact
check for leakage / damage & check all fixing clamps
found no leakage
xii
Examine the HV bushing for sings of damage, burning etc. Checked / Replaced
Replace if defective. Ensure RTV on base.
xiii
xiv
Check the main TFP and its protection cover for Checked & Found
damage/crack & oil leakage. (RDSO/TC/076)
intact
xv
xvi
xvii
Check the deformity of TFP drain cock cover guard, if Checked / Replaced
deformed, replace it.
March, 2015
Normal
Blue
No leakage
19
2.5
ii
iii
iv
Read off the oil level on the gauge situated on the Middle strip +/conservator. Top up the oil as necessary and
6
check for any signs of leakage
No leakage
Prismatic level gauge-clean the gauge with a dry cloth and Cleaned &
check for leaks
No leakage
vi
vii
Examine the flanges of the pipe couplings and flexible hose Checked & Found
that link the transformer and conservator
intact
viii
ix
xi
xii
xiii
xiv
Check the main TFP and its protection cover for Checked & Found
damage/crack & oil leakage. (RDSO/TC/076)
intact
xv
xvi
xvii
Blue
&
No Leakage
&
March, 2015
20
2.6
ii
iii
iv
Prismatic levels gauge-clean the gauge with a dry cloth and Cleaned
check for leaks.
leakage.
vi
vii
Examine the flanges of the pipe couplings and flexible hose Checked & Found
that link the transformer and conservator.
intact.
viii
ix
xi
xii
Examine the HV bushing for sings of damage, burning etc. Checked & Cleaned.
Replace if defective & ensure red marking.
xiii
xiv
Check the main TFP and its protection cover for damage / Checked & Found
crack & oil leakage. (RDSO/TC/076)
intact.
xv
xvi
Examine the bushing for signs of damage, burning etc. Checked & Cleaned.
Renew if defective. Clean off all deposits and dirt from the
insulators.
Check conservator foundation welding and conservator Intact.
stand bolts for tightness & ensure provision of double nut.
xvii
No
No Leakage
xviii
xix
Replace all rubberized cork sheet and bushing oil seal & Done
gasket as per TC-76.
March, 2015
&
2.7
21
Figure 2.1
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
Visually inspect the electrical connections, earthing cable, bushing and insulators on
the main transformer for cracks, chips and evidence of impact damage. Renew if
defective. Clean the connectors and replace any damaged chipped or cracked
insulators.
Test oil sample for BDV, DGA, acidity and other lab tests. DGA to be done as per
RDSO SMI (RDSO/SMI/138 & OEM Doc. Dt. 27th Nov. 1995).Incoming oil test.
Check any leakage sign of oil from bushing, tank, pipe line, oil gauge
If any attend the same/replased.
Visually inspect the condition of oil cooling metallic pipes, check for leakage /
damage & check all fixing clamps. Ensure instructions contained in RDSO s letter
no. EL/3.2.1/3-Ph dated 30.07.09 for arresting oil leakages cases.
Examine the flanges of the pipe couplings and flexible hose that link the transformer
and conservator.
Maintenance of assembly of electrical terminal of traction winding bushing 2U12V1, 2U2-2V2, 2U3-2V3 & 2U4-2V4 in indigenously manufactured transformers
type LOT 6500/7500 used in 3-phase drive locomotives type WAG9/WAP5.(
RDSO/ELRS/SMI/0228 dt. 13.08.02)
Replace all sealing gaskets including tank cover gasket.
Replace all rubberized cork sheet.
Replace all TFP bushings rubber seals
Cleaned the transformer winding & tank with filtered transformer oil.
Fit the tank & bushing cover with new gasket
Fit the all bushings, safety valve, temperature censer, gate valve, drain cock with
new gasket.
Dry out the windings moisture in vacuumed drying plant & fill the filtered oil.
Carry out Insulation Resistance test and Tan delta test.
Check the winding resistance, inductance and continuity test , ratio test of the
windings.
Replace Transformer foundation bolts and bushing nuts.& Tighten with proper
torque.
Prismatic level gauge Clean the gauge with dry cloth to check for leaks. If any
attend it.
Replace the silica gel , in clean & attended breather assembly.
Replace the transformer oil. .
Conduct centrifuging of the oil (Use separate plant, the shell DIALA-DX oil should
not be mixed with any other type of transformer Oil).
Check the oil level on the gauge situated on the conservator. Top up if required and
any sign of leakage.
Finally cleaned & paint the transformer with accessories.
March, 2015
22
Figure 2.2
March, 2015
Gaskets of Lid
2.9
23
glass bottles made out of dark-coloured glass, with a polished glass stopper.
Tinned steel cans with a screw top.
Clear glass bottle which should be covered with an opaque cover after the sample
has been taken.
The oil sample should be at least 2 litres. For laboratory tests, 5 litres are required. If an
oil sample is required to determine the amount of water gas or air content, then special
vacuum bottles should be used. In such a case we recommend that we should be notified
about the preparation of bottles and suction equipment.
Checking for any solid impurities in the oil.
A test tube should be filled with the oil sample and held up against a light source. If
there are any solid impurities in the oil, then the oil from which the sample comes should be
filtered.
Simple test for water content
This is done using the so-called Spatter-test, i.e. the oil sample heated in the test
tube up to 105-110C. If there is any water in the oil then this will be noticeable if the oil
cracles, snaps or bubbles. If the oil is overheated then the presence of water is falsely
indicated; the upper temperature should therefore not be exceeded.
Dielectric strength (IEC test)
In accordance with the IEC standard 156 (which also complies with the Swiss
standard), this test should be performed using 12.5mm ball electrodes with a diameter of
2.5mm or with the half ball electrodes (so-called VDE Kalloten) also with a diameter of
2.5mm. The oil sample (temperature 15-25C) should be slowly poured (to avoid air
bubbles) into the clean test container; the test should be carried out immediately. The
voltage should be increased evenly up to break down at a rate of 2 kV/second; this should be
carried out 6 consecutive times. After each time the space between the electrodes must be
free of traces of breakdown; use a clean and dry glass rod (diameter 2mm) and move it
slowly in-between the two electrodes. All six break down voltages should be noted and the
arithmetic average calculated (i.e. the sum of the individual values divided by six). None of
the individual values should lie more than 15% below the average value, otherwise the test
must be repeated using a new oil sample.
March, 2015
24
2.10
2.10.1 Tests
Following common tests to be carried out in the transformer either in case of failure or
during overhauling in oil filled conditions.
a.
b.
c.
d.
e.
a.
b.
Continuity Test
Check the continuity of the following windings with the multimeter:
c.
Primary winding
Secondary windings
BUR winding
H.L. winding.
SOD. winding.
GOD. winding.
March, 2015
RESISTANCE VALUE
LOT-6500
LOT 7500
Primary winding
Secondary
windings
BUR
winding
H.L.
winding.
SOD. winding
GOD. winding
Maintenance Handbook on Transformer of 3 Phase Electric Locomotives
25
d.
e.
2.11
And 2V1
2U3 & 2U4.
2U1 & 2U2
2U3 & 2U4
23.35 V
23.35 V
0V
0V
WINDING
INDUCTANCE VALUE
LOT-6500
LOT 7500
1
2
3
4
5
6
Primary winding
Secondary windings
BUR winding
H.L. winding.
SOD. winding
GOD. winding
TESTING EQUIPMENT
LIST OF TESTING INSTRUMENTS
Sr.No.
Instrument
Range/Capacity
As per manual
Power Analyzer
SEV or similar
SEV or similar
0-100 KV
--
As per manual
Digital Megger
5KV
Prestige or similar
200 HZ
Power analisor
Megger
100 kV HV SET
March, 2015
26
2.12
b.
c.
Electrical Connections
The electrical terminations of the bushings have to be carried out in a way,
that the nut 11.1 stay accessible to be re-tightened.
Electrical connections must not be numb. They should be made flexible so
that the bushing isnt stained. Cable connections should be made with a loop, for
bars use flexible ribbon to connect them
on the bushing.
When assembling the electrical
connections, make sure that the nut 11.1
does not become loose. Keep a distance
of min. 3 mm between the 2nuts. After
assembling of the connection re-tighten
the nut 11.1. The tightening torque for
each type of bushing is indicated in the
table given below
Figure 2.3
March, 2015
Electrical Connection
27
DIN type
DT 1/250
DT 1/ 630
DT 1/1000
DT 1/2000
d.
10
30
65
150
50
60
80
100
Figure 2.4
e.
Inside Earthing
Figure 2.5
Outside Earthing
f.
g.
March, 2015
28
h.
Oil pumping
Before the pump is put up into action, make sure that the pumps, piping and
heat exchanger are filled with oil. Never start the pump without oil.
j.
k.
29
Venting
Once all pumps, pipes and heat exchangers are filled up with oil, the
transformer main valves can be opened. Secure the valves in open position. To drive
any remaining air out of the system, put the two oil pumps in operation for 30
seconds. Let the whole system resting during 30 minutes. Connect the filling system
to one of the draining taps, put it into action and crack open all vent plugs (15.1) on
the transformers lid until oil leaks out. Repeat this procedure until the total breathing
of the system. Adjust the oil level in the expansion tank after.
Figure 2.8
2.13
b.
c.
March, 2015
30
If the distance between upper side of the plug and the oil level is more than
100mm then the level can only be topped off under vacuum conditions. For this
reason the transformer must be removed from the locomotive and put in a vacuum
oven.
d.
Figure 2.9
e.
Expansion Tank
Bad Condition
Figure 2.10
f.
Silica Gel
March, 2015
31
2.14
TRANSFORMER OIL
The transformer unit is filled with 2000 kg of mineral oil. The oil serves as a
cooling and insulating agent.
2.14.1
Oil Specification
Ref. no Characteristic
00001 Ident. Text
Unit
--
Value
Test method
Insulation oil T1
00002
Ident no.
--
NBT 402614P0201
01000
Description
--
01120
Density at 20C
g/ml
0.895
01500
Delivery instructions
--
01800
Documentation
--
ZN 02125
ZLC documentation and QZ
HSTC 419458
05100
Colour
--
07900
Special properties
--
26350
Pour point
IEC class IA
IEC class IIA
Flash point in
enclosed crucible
- 30
- 45
ISO 3016
ASTM D 97-66
DIN 51597
a C
130
ISO2719
ASTM D 93 66
DIN 51758
29300
ISO 3675
DIN 51757
22500
Standard NB
214200
31300
0.005
35300
Break-down voltage
kV
50
43700
Interface tension
mN/m
40
ASTM D 971-50
45100
Cinematic viscosity
At + 20C
At + 40C
At 15C class IEC
IA
At 30C class IIA
mm2/s
25
11
800
1800
ISO 3104
51370
Corrosive
content
None
DIN 51353
55100
Neutralisation value
55350
Aniline point
sulphur --
mgKOH/g 0.03
C
80
32
Figure 2.11
The object of oil purification is to remove all contaminants such as water, carbon
deposits, dirt, sludge, dissolved moisture and gases. The most important quality to be
preserved is the di-electric strength, which is affected by the presence of moisture.
The insulating materials used in the winding are hygroscopic by nature and therefore
moisture is absorbed through defective breathers, gaskets and addition of untreated make up
oil. It is essential to remove these impurities by purifying the oil when the dielectric strength
goes below the permissible limits.
The purification plant should be capable of removing dissolved air/ moisture in the
form of free and finely dispersed water vapour and moisture in solution, sludge and fibers,
gases, carbonaceous products formed due to arcing and drum scale or any other solid
particles from insulating oil.
The plant should be capable of purifying the rated capacity of transformer oil to the
following parameters in maximum three phases.
a. Suspended impurities maximum 1 micron particle size.
b. Water content
from 100 ppm to less than 5 ppm
c. Gas removal
from fully saturated i.e. 10 to 12% by volume with air/gas
down to less than 0.25%
d. Acidity correction
with addition of clay filters the neutralization index should go
down from 0.5 to 0.05 mg KOH/ gm
of oil.
e. Dielectric strength
Minimum 60 kV
f. Dissipation factor of
oil/ tan delta at 90C 0.002
The switching ON & OFF of the heater groups should be thermostatically controlled
so that the temperature of the oil during treatment is not be permitted to rise above 60C.
Operating vacuum should be better than 1 torr.
March, 2015
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:
:
:
:
:
Figure 2.12
Acidity in Oil
Test
Test method
Periodicity
Permissible limit
Requirement of new oil
:
:
:
:
:
Total Acidity
As per IS:1448-67
IC/ AOH/ IOH/ POH
0.5mg KOH/gm (Max.)
0.03mg KOH/gm (Max.)
Figure 2.13
:
:
:
:
:
:
:
:
:
:
Flash point
As per IS: 1448-1970
IOH/ POH
125 deg. C (Min)
140 deg. C (Min)
Flash point
Test
Test method
Periodicity
Permissible limit
Requirement of new oil
March, 2015
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TEMPERATURE
Figure 2.14
Initially the insulation resistance drops down to a low value because of rise in
temperature of the oil up to about 60 degree C.
B.
Insulation resistance will continue to remain at a low level despite temperature being
maintained at a high level until most of the moisture from the windings and oil has
been driven out.
C.
The insulation resistance will thereafter rise gradually and level off, indicating that all
moisture has been driven out and the drying out operation has been completed. At
this point oil circulation should be discontinued.
D.
As the oil cools off, the insulation resistance will rise much above the leveling off
point at the end stage (C). This is because the insulation resistance value doubles for a
fall in temperature of about 10C to 15C.
:
:
:
:
:
Figure 2.15
March, 2015
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A.
Introduction
In order to detect incipient faults in the transformer and to arrest
deterioration/ damage to the transformer insulation, gases dissolved in the
transformer oil are detected, analysed and preventive measures adopted.
Gas Chromatography method is used for detection of the dissolved gases and
identification of incipient faults. The most significant gases generated by
decomposition of oil and deterioration of paper insulation on the conductor are
hydrogen, methane, ethane, ethylene and acetylene. The quantities of these gases
dissolved in transformer oil vary depending upon the type and severity of the fault
conditions.
B.
Sensitivity Limits
Gas Chromatography apparatus should be able to detect the following
minimum concentration of dissolved gases:
Hydrogen
:
Hydrocarbon :
Carbon oxides :
5 ppm
1 ppm
25 ppm
March, 2015
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Figure 2.16
March, 2015
37
C.
D.
Establishment of Norms
The contents of various dissolved gases in the transformer oil vary with
design and operating conditions. It is desirable that the values of concentration of
gases of healthy transformers of different age groups are to be gathered by the
Railways concerned to evolve suitable norms. However, as a starting point, the
permissible concentrations of dissolved gases in the oil of a healthy transformer are
given below as guidelines:
Gas
E.
Word of Caution
To start with the diagnosis, it is necessary to be satisfied that measured gas
concentrations are significant and high enough to warrant diagnosis, because some
amount of gases will always be there due to normal operating conditions without any
fault but it can be sufficient to be misleading. The reasons for the situation are:
Gases formed during the refining processes and not completely removed by oil
degassing.
March, 2015
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G.
Gases formed in the event of previous faults and not completely removed from
the oil-impregnated insulation before being refilled with degassed oil.
Compare the concentrations with sensitivity limits. These should be at least ten
times the sensitivity.
If one or more gases are above norms, compare with the last sample results; if
increase is sufficient, obtain a check sample.
If the check sample confirms the results, calculate the rate of increase of gas. If
rate of increase is more than 10% per month, it is considered rapid and warrants
immediate further investigations including lifting of core and internal inspection.
If the gas production rate is medium, i.e., less than 10% per month, sampling
frequency to be increased from quarterly to monthly.
March, 2015
Figure 2.17
39
March, 2015
40
Figure 2.18
Recording
March, 2015
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CHAPTER 3
MODEL QUESTIONS
3.1 OBJECTIVE
1.
2.
The faulty circuit has been isolated from power supply and earthed.
b.
c.
d.
One can protect himself from electric shock by wearing hand gloves of good.
a.
Conducting material
b.
Insulating material
c.
Semiconductor material
d.
Any of the above.
3.
4.
5.
6.
March, 2015
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March, 2015
7.
8.
9.
10.
11.
12.
13.
14.
Transformer is an example of
a.
Current transformer
b.
Potential transformer
c.
Auto transformer
d.
15.
16.
17.
18.
19.
20.
43
Pale yellow
b.
Dark brown
c.
Blue
d.
Colourless
b.
c.
d.
The saturated silica gel can be dried out in the oven at the max temperature until
silica gel turn blue again.
a.
60C
b.
160C
c.
150C
d.
115C
Ltrs.
b.
1 Ltrs.
c.
2 Ltrs.
d.
1 Ltrs.
2 Ltrs.
b.
3 Ltrs.
c.
4 Ltrs.
d.
5 Ltrs.
Dielectric strength of oil should be performed using 12.5 mm ball electrodes with a
gap ofa.
04mm
b.
05mm
c.
2.5mm
d.
03mm
March, 2015
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3.2.
In G-9 Loco The primary side is protected from the voltage surges by means of
.placed on the roof of the locomotive.
9.
45
6.
Constructional features of a loco transformer are more or less same other power
transformer.
7.
25 kV condenser/ cable head bushing is mounted on the top of the tank cover.
8.
The cooling arrangement of the loco transformer is force oil forced air type.
9.
In G-9 Loco the complete cooling equipment is mounted on the cover of the loco
transformer.
10.
In G-9 Loco spring-loaded safety valve is fitted to the top of the conservator.
11.
12.
The oxygen present in transformer reacts with insulation and forms an organic
acid.
13.
The solid impurities present in insulation oil strengthen its dielectric strength as
well as insulation of windings.
14.
15.
16.
The tightening torque of the bolts of tank and lid must be 70 Nm.
17.
To arrest the oil leakage from bushing RDSO has recommended to use ISI make
gaskets.
18.
19.
20.
ANSWERS
3.1-
1 (a), 2 (b), 3 (d), 4 (b), 5 (d), 6 (a), 7 (a), 8 (a), 9 (d), 10 (d), 11 (a),
12 (a), 13 (c), 14 (d),
3.2-
1- Static,
2- 04,
1-T,
2-T,
3-F,
4-T,
10-Air dehumidifire,
5-T,
17-Incipien fault,
6-T,
7-T,
17-F,
18-T,
8-T,
19-F,
9-F,
10-T, 11-F,
20-T.
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On Failure Aspects
1. Occurrence
2. Date of occurrence
3. Past similar occurrences if any
4. Analysis of failure i.e. why did it happen?
5. Whether the rate of failure is worse than other installations?
B.
On Maintenance Aspects
1.
Whether schedule maintenance & required testing have been carried out on the
failed equipment as per norms stipulated?
2.
Does the frequency of maintenance require change?
3.
Was the work properly supervised?
4.
Was any RDSO modification required to be done?
5.
Is any modification possible to avoid failure?
C.
About Staff
1.
Is the quality of work done satisfactorily?
2.
Is the skilled staff properly trained to carry out the work?
3.
Is the SMI available with them?
4.
Are proper tools available with the staff?
D.
About Material
1.
Is the material received from approved source?
2.
Whether the material is as per approved specification?
3.
Can a better material be used?
E.
About Testing
1.
Is the testing equipment available?
2.
Could testing procedure be improved to weed out the failures?
3.
Whether testing equipment are calibrated?
F.
General Points
Whether following points were checked / performed properly?
1.
Proper contact
2.
Clearances
3.
Capacity
4.
Proper contact pressure
5.
Crack detections
6.
Cleaning
7.
Proper connections/alignment
8.
Cross checks/super checks
March, 2015
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ANNEXURE I
March, 2015
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REFERENCE
1.
2.
3.
4.
RDSO MS 0228.
5.
RDSO TC - 076
6.
7.
6.
March, 2015
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OUR OBJECTIVE
To upgrade maintenance technologies and
methodologies and achieve improvement in
productivity, performance of all Railway
assets and manpower which inter-alia would
cover reliability, availability, utilisation and
efficiency.
Director (Elect.)
Postal Address
Indian railways
Centre for Advanced
Maintenance technology,
Maharajpur, Gwalior.
Pin code 474 005
Phone
0751 2470740
0751 2470803
direlcamtech@gmail.com
Fax
0751 - 2470841
March, 2015