MAINTENANCE OF TRANSFORMERS.

I. GENERAL:
Maintenance of transformers in these days has become prime importance,
since the cost of new equipments has considerably increased thereby increasing
the cost operation for restoration of power supply in addition to loss of revenue.
This has led the ESCOMS to adopt condition-based maintenance of the
transformers than the preventive maintenance. The general maintenance, which is
normally required to be done on transformer is as under.
a. Regular inspection of the external surface of the transformer for any dirt &
dust and when required the same shall be cleaned.
b. Regular inspection of the external surface for any damage
due to rust.
c. Possible rust damages when noticed are to be removed and surface treatment
restored in the original state by means of primer and finished paints for
minimizing the risk of corrosion and its subsequent spreading.
d. Check for any oil leakage.
e. Check for any mechanical damage.
f. Check for oil levels.
g. Check that the surrounding area is kept clean & tidy.
h. Check for the conditions of bushings for damages if any.
i. Check for connectors both on HV & LV side for their
tightness and
formation of sulphate formation if any.
j. Before carrying out any maintenance work ensure proper safety procedures.
II. TYPES OF MAINTENANCE:
Based on the above principle the types of maintenance may be classified as
under.
a. Breakdown maintenance: The nomenclature itself indicates that, the
maintenance is to be carried out when the transformer fails. In this case, as such
no maintenance is carried out, but the quantum of loss to the equipment can be
assessed, repaired and re-use the equipment. This will in no way reduce the loss
of revenue. As many as 5% of transformer failures are because of poor
maintenance.
b. Preventive maintenance: This type of maintenance is being carried out by
almost all ESCOMS. In this type of maintenance, all the transformers are
inspected at regular defined intervals. The determination of the maintenance
intervals are based on various reasons like, the life of the transformer already
served, different guide lines issued by the manufacturer and on the previous
experience.
c. Condition based monitoring: This type of maintenance is adopted to assess
the condition of the transformer, which is assessed based on different condition
monitoring tests at well determined periodicity.

d. Predictive maintenance: The basic objective of this type of maintenance is to

keep the transformer at a desired level of performance, to minimize the
maintenance and shutdown periods and to avoid replacement of components after
failure thereby reducing the period of total shutdown.

III. CAUSE OF FAILURE OF TRANSFORMERS:

As indicated already, the cause of failure of transformers is to the tune of 5%
because of poor maintenance. They are oil leakage, oil quality, defective
operation of tap changer, cracked/ dirty bushings, excessive loading, control over
the temperature and improper observation on the condition of the protective
instruments etc. Therefore, preventive maintenance is strongly recommended to
increase the efficiency on the transformers.
i. Oil leakage leads to deficiency in oil quantity, thereby less cooling effect,
entry of moisture to the open core & winding leading to failure of insulation of
winding.
ii. Poor quality of oil leads to damaging the insulation, formation of sludge and
hence increasing the temperature.
iii. Defective operation of tap changer may lead to un-balance current flowing
within the transformer leading to over heating and further reducing the
insulation quality.
iv. Cracked / dirty bushings lead to leakage path and further decreasing the safe
zone.
v. Excessive loading increases the temperature rise leading to damaging the
winding quality.
vi. If the protective equipments relays and instrument transformers are not
observed/maintained the transformer may be subjected to high surges and fault
currents.

IV. Preventive Maintenance schedule.

Sl.No
Checks to be carried out
1
Checking of bushing oil level
2
Checking of oil level in the Conservator
3
Checking of oil level in the OLTC Conservator
4
Checking of cooler oil pumps & fans
a.
Manual actuation
b.*
Auto starting
5
Checking of oil leaks
6
Checking of condition of silicagel in the breather.
7
Measurement of BDV of oil
8
Testing of oil for DGA and other parameters.

Periodicity
Monthly
Monthly
Monthly
Monthly
Yearly
Monthly
Monthly
Half yearly
Half yearly

Checking & filling up of oil in the oil trap of

breather
10 *
Measurement of BDV of OLTC oil
11 *
Tan measurement for bushing
12 *
Measurement of IR & PI on winding
13 *
Tan measurement for winding
14 *
Measurement of winding resistance
15 *
Measurement of winding ratio.
16 *
External cleaning of radiators
17 *
Cleaning of bushings
18 *
Maintenance of OLTC drive mechanism
19 *
Electrical checking of pressure relief valve, BH
relay, OLTC surge relay and replacement of gaskets
of the terminal block.
20 *
Checking the operation of BH relay by injecting air.
21 *
Checking and calibrating OTI & WTI
22 *
Filtration/replacement of OLTC oil
23 *
Filtration/replacement of main tank oil
24 *
Drying of the transformer
* The checks/testing on these items require shut down.

If required.
Yearly
Yearly
3 yearly
3 yearly
3 yearly
If required.
Yearly
Yearly
Yearly
Yearly

Yearly
Yearly
If required.
If required.
If required

V. Degassing/Filtration of transformer oil.

When the transformer is subjected to various electrical stresses for any of the
reasons mentioned earlier, results in de-gradation of both the oil and insulating
materials, which in turn produces moisture and contamination of oil including
gasses being dissolved. When the quantity of dissolved gasses and contamination
increases in percentage than the permissible limits the oil needs to be de-gassed
or filtered to avoid further damage to the transformer.
Precautions to be taken for filtration/degassing.
1. As the sulpher in the rubber hose may react with hot oil, rubber hose pipes are
not suggested.
2. The temperature of the oil during filtration shall be limited to 80 C.
3. The main tank oil and the OLTC oil shall be filtered separately.
4. The filter machine needs to be put to reverse cycle before commencement of
process.
5. Guide lines issued by the manufacturers of the transformer and the filter
machine shall be followed strictly.
6. Check the direction of rotation of all pumps.
7. The inlet and outlet pipes for both the transformer and the filter machine are
connected properly.

Procedure:
1. For filtration of the transformer, first the inlet to the machine is taken from the
bottom of the transformer tank and the outlet is connected to the top of the
tank. These connections will be reversed at every 12 hours interval for better
results.
2. Ensure that all hose connections are air tight.
3. The inlet and outlet valves of the transformer to the plant are open after
evacuating the system for some time.
4. The oil first enters the preliminary filter where the coarse particles are filtered,
after which the oil enters heating chamber where the moisture is removed.
5. After this the oil enters degassing chamber wherein the dissolved gasses are
degassed.
VI.
Drying of the transformer:
Whenever, either the transformer is taken out for repairs or IR values have
gone down because of deterioration of cellulose material the moisture entered in
the paper insulation, the transformer needs drying.
Procedure:
1. Coolers are to be isolated to avoid heat loss in addition to the transformer be
covered with tarpaulin.
2. Additional room heaters may be provided for accelerating the drying process.
3. Oil level to be topped up to just above the winding in case of normal drying
process and totally drained in case of vacuum drying.
4. Care shall be taken that, all leaks are properly sealed by replacing the gaskets.
5. Drying process will be commenced by filtering the oil through a streamline
filter.
6. For speedy operation short circuit may be done simultaneously by shorting
LV side and connecting 415 Volts supply to HV side.
7. In case of the transformer core is opened for major repairs in the repair bay
vacuum drying is advised.
8. The IR values are measured at regular intervals ae same temperature and
noted down.
9. In case of power transformers of capacity 50 MVA & above, and in case the
moisture is absorbed in core & winding, drying process needs to be more
effective. Under such circumstances rigorous vacuum drying is done by using
dry ice. (Carbon dioxide in solid state)

VII. COMMISIONING TEST ON TRANSFORMERS

Necessity of testing of Transformers:
At manufacturers works:
1. To prove that the transformer meets the customers specifications &
design expectations. (Type Tests)
2. To check that the quality requirements have been met and the
performance is within the tolerances guaranteed. (Routine Tests)
3. Routine tests are carried out on every unit manufactured.
4. To obtain information useful to the users during operation & maintenance
of the transformer. (Special tests)
5. Transformer type & routine tests are according to IS 2026 & IEC
publication 60076 (latest edition)
At site:
During transport & installation, the transformer may be exposed to
conditions which can adversely affect its reliability and useful life.
a) Pre-commissioning tests.
b) Periodical tests.
c) Emergency tests.
6. Recommended field tests.
Field testing is one of techniques to ensure good operating healthy
conditions of the transformers.
1. Continuity test:
This test shall be done with only multimeter. Continuity is tested
between phase to phase both on HV side & LV side. If there is no
continuity between any of the phases, it is sure that, that portion of the
winding is open within the transformer. Further tests cannot be
conducted unless the fault is rectified.
2. Insulation resistance test:
This test is done by using Insulation resistance tester (IR Tester). These
IR Testers are available in capacity of 500 V, 1000 V, 2500 V, 5000 V
& 10000 V. In some of the kits, variable voltage provision is made
such that, one kit can be used for IR testing of any voltage class
transformers. A 1000 V IR kit can be used for testing insulation
resistance of distribution transformers and higher capacity IR kit shall
be used for power transformers of higher rating.
As a standard practice, IR value shall be 2 M/ kV at 60C. (Per kV
means the voltage on HV side of the transformer under test.) Hence, it
is very much essential to record the temperature of oil when IR test is
being conducted. To decide the good condition of the transformer shall
be computed as per the following table.

Correction factor for analyzing the IR values.

Difference in temperature
Correction factor
5
1.23
10
1.50
15
1.84
20
2.25
25
2.76
30
3.35
35
4.10
40
5.00
The IR values are measured between HV to ground, HV to LV and LV
to ground. If there is third winding like tertiary winding then IR values
are measured between HV to ground, HV to LV, HV to TV, LV to
ground, LV to TV and TV to ground. All the measurements are taken
in steps of 10 secs up to 1 minute and then at every minute up to 10
minutes.
Then Polarization Index & DC absorption is computed based on the
following formula.
Reading taken at 10th Minute
Polarization Index=-------------------------------------Reading taken at 1st Minute.
Reading taken at 1st Minute.
DC Absorption Ratio=------------------------------------Reading taken at 15th Sec.
These PI & DC absorption are measured and used for deciding the
healthiness of the transformer as per the table below.
Polarization Index.
Less than 1
1.0 to 1.1
1.1 to 1.25
1.25 to 2.0
Above 2.0

Dangerous
Poor
Questionable
Fair
Good

3. Ratio Test:
This test is conducted by applying 400 V AC across HV terminals
keeping LV open. Voltage both on HV & LV side are recorded for
each tap position of the transformer and compared with the factory test
results or with the name plate, wherein the variation in the voltages at
each tap positions are indicated.
4. Winding Resistance Test:
This test is done with a separate kit called the winding resistance test
kit. The resistance is measured and then computed at 75C for all
practical purposes of comparison with the design specified values,
previous values and diagnostics. The cold temperature of winding shall
be determined as accurately as possible when measuring the cold
resistance.
The results of transformation/voltage ratio are absolute and may be
compared with the specified values measured during factory testing.
The acceptance criteria should be that the measured values are within
0.5% of the specified values for all windings. One should also consider
the trend of voltage ratio values with reference to voltage ratio values
measured during commissioning tests. The results of this test will help
to identify whether there is open circuit in any of the tap position.
5. Short Circuit Test:
This test is conducted by applying 400 V AC across HV terminals
keeping LV short circuited. Current both on HV & LV side are
recorded for each tap position of the transformer and compared with
the factory test results. Care shall be taken to see that suitable size
shorting wire shall be used for shorting, which can be calculated based
on the impedance voltage, mentioned on the name plate and it is in
percentage. This indicates the voltage that needs to be applied to allow
the full load current to flow. The proportionate current can be
calculated, since the maximum voltage that is available for
testing/handling is limited to 440 volts.
The results of this test will help to identify whether there is
open
circuit or short circuit in any of the tapping winding or main winding.
6. Magnetic Balance Test:
This test is conducted only on three phase transformers to check the
imbalance in the magnetic circuit, mainly when the transformer is
transported or the transformer has sustained severe faults.
a) Keep the transformer in normal tap position.
b) Disconnect the neutral earthing.

c) Apply 230 V/440 V on two phases of HV winding keeping LV

open.
d) Measure the voltage across the two pairs of HV terminals and
record. The results shall be in the order furnished hereunder.
RY
YB
BR
180
235
415
210
205
415
240
175
415
Zero voltage or negligible voltage induced may be investigated.

7. Measurement of Magnetizing current:

This test is performed to locate the defects in the magnetic core
structure, shifting of winding, failure in turn to turn insulation or
problem in the tap changer. These conditions change the affective
reluctance of the magnetic circuit, thus affecting the current required to
establish flux in the core.
a) Keep the transformer in the lowest tap and HV & LV open.
b) For power transformers apply 3-phase, 415 VAC on LV side and
measure the voltage across each terminal on LV side and current
flowing in each phase.
c) Repeat the above test keeping the transformer at normal & highest
tap positions.
d) Care shall be taken to see that, under no condition the HV terminals
are contacted.
The measurements will be such that, the middle phase draws less
current than the other phases.
8. High voltage excitation test:
The following equipments are required for conducting this test.
A water rheostat.
Clamp meter of low range.
Clamp meter of higher range.
A high voltage potential transformer.
A current transformer.
A distribution transformer.
Accurate voltmeter.
A pair of HV insulated cables.
Other materials like wires, safety materials like hand gloves,
rubber mat etc.

Single phase 230 V power supply is given to phase and neutral

of the distribution transformer. Neutral from the source is directly
connected to the neutral of the distribution transformer. The phase from
the source is connected to the bottom of the water rheostat. The other
end of the rheostat, a copper tube, is connected to the phase of the
distribution transformer. Across which a voltmeter is connected.
Corresponding HV winding of the distribution transformer is
selected. One HV bushing of the distribution transformer is connected
to one of the LV bushing of the power transformer under test using HV
insulated cable.
One more corresponding HV bushing of the
distribution transformer is connected to other corresponding LV
bushing of the power transformer under test, using HV insulated cable,
through a CT in series duly inserting a clamp meter in the CT
secondary. A PT is connected across the HV cable, with a multimeter
across PT secondary terminal.
The copper rod of the rheostat is immersed in water till the
required voltage is built up. At this stage, the power transformer under
test is charged in single phase. Record the corresponding voltage and
current. Observe and listen to to the humming sound of the transformer
for its homogeneous effect.
Repeat the test for other phases.

9. Pre-commissioning Checks:
a) Checking of Magnetic Oil gauge. (MOG): This is located on the
conservator tank. The function is to indicate the oil level in the
conservator tank. There are two NO contacts. Alarm is given for
low & high trip. The circuit is to be checked.

b) Checking of BH Relay: This is located between the main tank and

the conservator tank. There are two NO mercury contacts. For any
internal fault of the transformer or if the transformer has sustained
any severe fault, transformer being a petroleum product, likely to
decompose generating some hazards gasses. The gasses so
generated, gets accumulated in BH Relay, thereby replacing the oil
in the BH Relay by gas. Under such condition the mercury contacts
because of self weight of mercury, fall down, making the NO
contacts to NC contacts. Depending on which contact has actuated,
there will be alarm or the incoming breaker trips. The circuit is to
be checked.
c) Explosion Vent: This is provided on the top cover of the
transformer, with an in-built diaphragm. In case of severe fault
inside the transformer, the oil expels out duly breaking the
diaphragm protecting the transformer from further damages. The
diaphragm is to be checked.
d) Pressure Relief Valve: (PRV) This is provided on the top cover of
the transformer, with an in-built diaphragm. In case of severe fault
inside the transformer, the oil expels out duly breaking the
diaphragm protecting the transformer from further damages, in
addition to tripping the breaker.
Note: Explosion vent is a old version, is being replaced by PRV.
The circuit and the diaphragm are to be checked.
e) Thermometers: Depending on the capacity of the transformers,
thermometers are installed for different activities like indicating top
oil temperature (OTI) and/or winding temperature (WTI). Also
depending on the requirement deferent settings are housed with the
thermometers, like Alarm, Trip, Fan ON, Fan OFF, Pump ON and
Pump OFF. In the name plate it is clearly mentioned that, the
maximum guaranteed temperature rise in oil and that in winding.
Based on the guide lines/instructions by the manufacturer all the
above setting shall be done in all the thermometers.
The probes of all these thermometers are inserted in the pockets
located on the top cover of the transformers. This pocket shall be
filled with transformer oil, shall be verified.
f) Breather: It is a fact that the transformer breaths just like any
living animals. A pipe is brought from the top of the conservator
tank at the end of which the breather is connected. This breather is a
container which is filled with silica jell, and at the bottom an oil
trap is fixed. When the transformer gets overheated, the oil expands
and air cushion in the conservator tank compresses and air under
pressure will go to the atmosphere through breather. This action is

the transformer is breathing out. (Exhale) When the transformer

cools down, the oil gets contracts. The level in the conservator goes
down. The air cushion in the conservators gets partially vacumized.
The external air from the atmosphere rushes in to the conservator
through the breather. This action is the transformer is breathing in.
(Inhale) The normal color of good silica jell is blue. It turns in to
pink or white when the moisture is absorbed. When the color is
pink or white, the silica jell can heated up to 120 degrees and reactivated. If, for some reason, oil is passed through breather, then
the color turns to black. In such condition, it cannot be re-activated.
It shall be replaced.
At the bottom of the breather, an oil trap is fixed. This trap will be
filled with oil. Whatever air passes in or out, it passes through this
oil. Because, oil is highly hygroscopic most of the moisture is
absorbed by this oil and further drying is taken care of by silica jell.
g) Operation of OLTC (Diverter Switch): Check the operation of
the tap changer for the following functions.
Manual operations from first tap to the last tap for raising the
taps.
Manual operations from last tap to the first tap for lowering
the taps.
Power supply to motor and the phase sequence.
Electrical-Local/Remote through RTCC panel operations
from first tap to the last tap for raising the taps.
Electrical-Local/Remote through RTCC panel operations
from last tap to the first tap for lowering the taps.
Locking below tap 1
Locking beyond the highest tap.
Interlocking arrangements for start & stop after every tap
changing operation.
Tripping circuit in case of diverter switch.
10.Transformer Oil Testing: The transformer oil is tested for the
following parameter as specified in IS 1866:2000.
a) Break down Voltage Test: The dielectric strength of insulating oil is a
measure of the oils ability to withstand electrical stress without failure. The
test involves applying a ac voltage at a controlled rate to two electrodes
immersed in the insulating fluid. The gap is a specified of 2.5 mm distance.
When the current arcs across this gap the voltage recorded at that instant is
the dielectric strength/ breakdown strength of the insulating liquid. The kit
used for conducting this test is called BDV kit. In this case, oil is collected

in a container called the cell. Oil required for this purchase is about 0.5 ltr.
First oil is collected allow it settle for one minute so that it does not contain
any air bubbles or floating impurities or impurities settle down. As the kit
is motorized, voltage is slowly built up at the rate of 2 kV/Sec. when the
kit is switched on. At certain voltage, the kit trips when the oil sample
under test attains break down value. Note the value. Repeat the test on the
same sample six times. The average of these six readings is the BDV value
of the oil under test.
b) Moisture Content/Water content Test: Water, in minute quantities, is
harmful in power equipment because it is attracted to the places of greatest
electrical stress and this is where it is the most dangerous. Water
accelerates the deterioration of both the insulating oil and the paper
insulation, liberating more water in the process (heat catalysed).There are
different kits available for conducting this test. The results are directly
available from the kit,
when the oil sample under test. There is a relation with the values
of BDV & Moisture Content values. If the BDV value
decreases, the Moisture content value increases and vice versa.
c) Tan Delta & Resistivity Test: Also called the Dissipation test measures
the leakage current through an oil, which is the measure of the
contamination or deterioration i.e. Reveals the presence of moisture resin,
varnishes or other products of oxidation oil or of foreign contaminants
such as motor oil or fuel oil. The test is not specific in what it detects i.e. is
more a screening test. Both these tests are conducted in one set of testing
kit and are simultaneously.
d) Acidity or Neutralization number: Acids in the oil originate from oil
decomposition/oxidation products. Acids can also come from external
sources such as atmospheric contamination. These organic acids are
detrimental to the insulation system and can induce corrosion inside the
transformer when water is present. An increase in the acidity is an
indication of the rate of deterioration of the oil with SLUDGE as the
inevitable by-product of an acid situation which is neglected.
e) The Interfacial Tension (IFT): This test measures the tension at the
interface between two liquid (oil and water) which do not mix and is
expressed in dyne/cm. The test is sensitive to the presence of oil decay
products and soluble polar contaminants from solid insulating materials.
f) Flash point: Flash point measures the oil at which the oil may catch fire
because of internal fault of the transformer.
g) Sludge/Sediment: This measures the quantity of sludge present in the oil,
which is not supposed to be. During test, if sludge is detected, then it will
be recommended for replacement of transformer oil.

The specified permissible values of different parameters are as under.

Sl.No Test data
.
1
Transformer oil
a) BDV
At the time of first 60 kV with a gap of 2.5 mm
charging
During O&M
50 kV with a gap of 2.5 mm for
transformers of above 145 kV, 40 kV
for 72.5 to 145 kV and 30 kV for below
72.5 kV transformers.
b)
Moisture
content.
At the time of first 15 PPM (Max)
charging
During O&M
25 PPM (Max)
c) Resistivity at 0.1*10 12 Ohm.Cm(Min)
90C
d) Acidity
0.5 mg.KOH/gm(Max)
e) IFT at 27 C
0.018N/M(Min)
f) Tan at 90C
0.20(Max)
g) Flash point
140 C(Min)

Reference

IS 1866
IS 1866

IS 1866
IS 1866
IS 1866

IS 1866
IS 1866
IS 1866

11. Dissolved Gas Analysis. (Ref: IS;10593;1992, IS 9434)

This has been considered as one of the important tool in diagnosing the
internal fault or aging of the transformer. Any abnormal fault or electrical stress
that has been sustained by the transformer causes decomposition of transformer
oil and or paper insulation, which in turn may produce certain gases that create
hazards. Such gases so generated will accumulate in the BH relay. Some of these
gases get dissolved in the oil. The composition and quantity of gas so generated
depends upon the severity of the fault. The testing of this gas for its DGA
indicates the nature and type of fault or aging of the transformer or its
components. The gases, which are of great interest along with the permissible
values and probable internal fault, are listed hereunder.
Even though there is no precise interpretation method available which can
scan the exact type and location of fault, the various interpretation methods
available provide only guidelines. The following are the some of the gas
concentration that may persist while the transformers are in service based on the
experience of the persons who are in service in this field for a long period.

Sl.No.
1
2
3
4
5
6
7

Gases

Period of Service
4 Years 4 to 10 Yrs.
Methane (CH4) PPM
50/70
100/150
Ethylene (C2H4) PPM
100/150
150/200
Ethane (C2H6) PPM
30/50
100/150
Acetylene (C2H2) PPM
20/30
30/50
Carbon Monoxide (CO) 200/300
400/500
PPM
Carbon Dioxide (CO2) 3000/3500 4000/5000
PPM
Hydrogen (H2) PPM
100/150
200/300

10 Years
200/300
200/400
800/1000
150/200
600/700
9000/12000
200/300

But as per IS 10593:1992, the following are the specified values of gas
concentrations. These are the values that have been arrived at, by conducting DGA
test on 15000 power transformers, in 15 different utilities, where are transformers
are in service.
Sl. No.
Gasses
Test results
1
Methane (CH4) PPM
40-110
2
Ethylene (C2H4) PPM
60-280
3
Ethane (C2H6) PPM
50-90
4
Acetylene (C2H2) PPM
3-50
5
Carbon Monoxide (CO) PPM
540-900
6
Carbon Dioxide (CO2) PPM
5100-13000
7
Hydrogen (H2) PPM
60-150
There are different methods adopted for analyzing the DGA results.
1. IEC 599
C2H2
CH4
C2H4
C2H4
H2
C2H6
Ratios of
characteristic gases
0.1
0.1-1.0
0
1
0
1.0-3.0
1
0
0
3.0
1
2
1
2
2
2
Case Characteristic fault
Typical examples
No.
0
No fault
0
0
0
Normal ageing
1
Partial discharges
0
1
0
Discharges in gasof Low energy
But not
filled cavities

density.

significant

Partial discharges
of Low energy
density.

Discharges of low
energy

1-2

1-2

Discharges of High
Energy

Thermal fault of
Low Temperature
<150C
Thermal Fault of
Low Temperature
range 150C-300C
Thermal fault of
Medium
temperature
range 300C-700C
Thermal fault of
high temperature
>700C

resulting
from incomplete
impregnation, or
super saturation
or cavitations or high
humidity.
As above, but leading
to tracking or
perforation
of solid insulation.
Continuous sparking
in oil between bad
connections of
different potential or
to floating potential.
Breakdown of oil
between solid
materials.
Discharges with
power followthrough.
Arcing-breakdown of
oil between windings
or coils, or between
coils to earth.
Selector breaking
current.
General insulated
conductor
overheating
Local overheating of
the core due to
concentrations
of flux. Increasing hot
spot temperatures;
varying from small
hot spots in core,
overheating of copper
due to eddy currents,
bad
contacts/joints
(pyrolitic carbon

formation)
up to core and tank
circulating currents.
2. SUGGESTED DIAGNOSIS FROM GAS RATIOS-ROGERS
RATIO METHOD

CH4
H2
>0.1
<1.0
0.1

C2H6
CH4
<1.0

C2H4
C2H6
<1.0

C2H2
C2H4
<0.5

Suggested Diagnosis

<1.0

<1.0

<0.5

0.1

<1.0

1.0

>0.1
<1.0
>1.0
<1.0

<1.0

3.0

0.5 or
3.0
<3.0
3.0

Partial Discharge
corona
Partial
Dischargecorona
with tracking
Continuous discharge

<1.0

1.0 or
3.0
<3.0
<1.0

>1.0
<1.0
1.0 or
3.0
<3.0
1.0 or
3.0
<3.0
>0.1
<1.0
>0.1
<1.0
1.0
<3.0
1.0
<3.0

Normal

<1.0
<1.0

<1.0

0.5 or
3.0
<3.0
0.5
<3.0
<0.5

1.0

<1.0

<0.5

Overheating
150-200C

1.0 <1.0

1.0 <1.0

<0.5

>1.0

1.0
<3.0
1.0
<3.0
3.0

<0.5

Overheating 200300C
General conductor
Overheating
Circulating currents
in windings
Circulating currents
core and tank;
overloaded joints

<1.0
<1.0

<0.5
<0.5

Arc - with power

follow
Through
Arc - no power follow
Through
Slight Overheatingto
150c

There are methods like Key gas method of analysis, in which reports are given based
on the prominent gasses generated and Dornenburg Ratio Method, wherein it is
indicated that, minimum gas concentration shall be 100 ppm, otherwise no gas ratio
method can be adopted.
ORIGIN OF GASES IN TRANSFORMER OIL
Fault gases are caused by corona (partial discharge), thermal heating (pyrolysis) and
arcing.
PARTIAL DISCHARGE is a fault of low level energy which usually occurs in
gas-filled voids surrounded by oil impregnated material.
The main cause of decomposition in partial discharges is ionic bombardment of the
oil molecules.
The major gas produced is Hydrogen. The minor gas produced is Methane.
THERMAL FAULTS. A small amount of decomposition occurs at normal
operating temperatures. As the fault temperature rises, the formation of the
degradation gases change from Methane (CH4) to Ethane (C2H6) to Ethylene
(C2H4).
A thermal fault at low temperature (<300deg/C) produces mainly Methane and
Ethane and some Ethylene.
A thermal fault at higher temperatures (>300deg/C) produces Ethylene. The higher
the temperature becomes the
greater the production of Ethylene.
ARCING is a fault caused by high energy discharge.
The major gas produced during arcing is acetylene. Power arcing can cause
temperatures of over 3000deg/C to
be developed.
NOTE : If the cellulose material (insulating paper etc.) is involved , carbon
monoxide and carbon dioxide are
generated.
A normally aging conservator type transformer having a CO2/CO ratio above 11 or
below 3 should be regarded as perhaps indicating a
fault involving cellulose, provided the other gas analysis results also indicate
excessive oil degradation.
EARTHING OF THE TRANSFORMER CENTERS.
1. The earthing pipe shall be of 40 mm diameter and 2.5 mtr. Long and is a
galvanized pipe.
2. The pits shall be dug to the complete depth and at a distance of twice the
length of the electrode.
3. The earth electrodes can be laid in triangular configuration if the space is
insufficient.

4. These earth pits shall be back filled, after inserting the earth electrode, by
means of alternate layers of Charcoal, Salt, sand with excavated stuff, if it is
soft soil. Borrowed stuff shall be laid if the excavated stuff is hard soil/rocky
soil. Sufficient watering shall be done to get good results.
5. Earthing leads may be multi strand GI wire or MS flat shall be run from i)
Neutral, ii) body and all the structure included and iii) lightening arrestors, to
independent electrodes and shall be firmly joined.
6. All the three earth electrodes shall be interconnected in the ground.
7. The earth resistance of all the electrodes shall be less than 5 ohms.
8. If the results are above the acceptable values, proper strengthening shall be
done by using bentonite clay or cast iron pipes or plate earthing may be
proposed. On the other hand, an earth mat also be designed and provided.

Space between any two electrodes is twice the length of the electrode