. CONTENTS .

I. Acknowledgement
II. About NDPL
III. GRIDS
1) Power Transformers
2) Circuit Breakers
3) Current Transformers
4) Potential Transformers
5) Isolators
6) Lightening Arresters
7) Auto Reclosures
8) Capacitor Bank
9) Busbars
10) Insulators
11) Battery Bank And Charging System
12) Control Panel
13) Scada System
14) Switch Gear

IV. TRANSFORMER-Installation, Testing & Maintenance

a) Installation
 Unloading & Handling
 Inspection on Receipt
 Storage
 Fittings & Accessories
 Installation
b) Pre Commissioning Checks
c) Routine Tests
 Insulation Resistance Test
 Winding Resistance Test
 Magnetic balance Test
 Magnetizing current test
 Voltage Ratio Test
 Load balance test
 Vector Diagram test
 Tan Delta testing
d) Periodic Inspection
f) Oil Parameters
e) DGA
 Rogers Ratio Method
 IEC 599 Method
g) Maintenance
 Preventive Maintenance
 Corrective Maintenance
f) Thermography

V. Analysis of working of a power Transformer

a) Name plate Detail
b) Functional checks
c) Routine Tests
d) DGA
e) Thermography
 f) Conclusion & Recommendation

I take the auspicious opportunity to thank Mr. Pillai, under the aegis of whom, I undertook
my summer training. I owe my most sincere gratitude to Mr. Dharmadhikari whose valuable
and consistent guidance enabled me to complete this report. My warm thanks to
Ms.Sameeksha Raina, Mr.Vinay K. and Mr. Anoop Kumar Roy for their encouragement and
efforts throughout. Their kind support and patient guidance have been of great value in this
study.

I am deeply grateful to NDPL which gave me a chance to explore and comprehend the
practical way of working, apart from acquainting me with the importance and scope of
electrical engineering.

With all the knowledge and skills I have acquired during this period, I hope that I will apply
them in a positive way wherever and whenever possible.

I express my thanks to the whole NDPL family for their kind cooperation and congenial
demeanor.
NDPL (North Delhi Power Limited) distributes electricity in the North of Delhi.
The company is a joint venture of Tata Power and Govt. of NCT and came into existence as a result of
the privatization of electricity in Delhi. Tata Power Company acquired 51% stake in NDPL and took
control of the management effective from July 1st, 2002.

The NDPL area of distribution in Delhi has been organized into the following districts of Delhi:

NORTH AREA

City Circle encompassing Moti Nagar (MTN), KeshavPuram (KPM) and Pitampura (PRR) districts.
Town Circle encompassing Civil Lines (CVL), Shakti Nagar (SKN) and Model Town (MDT) districts.

NORTH WEST AREA

Urban Circle encompassing Shalimarbagh (SMB) and Badli (BDL) districts.

Metro Circle encompassing Rohini (RHN) and Mangolpuri (MGP) districts.
Sub-Urban Circle encompassing Bawana (BWN) and Narela (NRL) districts.

At NDPL, the peak demand (17:00/23:00) is around 1055MW with a daily energy
requirement of 22.4Mu.
NDPL has been the frontrunner in implementing power distribution reforms in the capital
city and is acknowledged for its consumer friendly practices. Since privatization, the AT&C
losses in NDPL areas have shown a record decline. On the power supply front too, NDPL
areas have shown remarkable improvement. The company has embarked upon an ambitious
plan to implement high-tech automated systems for its entire distribution network. Systems
such as SCADA& GIS are the cornerstone of the company's distribution automation project.
To fight the menace of power theft, modern techniques like High Voltage Distribution
(HVDS) System and LT Arial Bunch Conductor have been adopted.

NDPL has to its credit several firsts in Delhi: SCADA controlled Grid Stations, Automatic
Meter Reading, GSM based Street Lighting system, SMS based Fault Management System.
To ensure complete transparency, the company has provided online information on billing
and payment to all its 1 million consumers. This happened in the first year of operations
itself. NDPL believes in providing more value than just electricity and is even rewarding its
consumers for timely payment.
NDPL is the youngest company and the first power utility in India to receive the prestigious CII EXIM
Award for 'Strong Commitment to Excel'. It is also the only distribution utility to receive the ISO 9001,
ISO 14001 and OHSAS 18001 certification.

Grids Under NDPL

North
1 CIVIL LINES NEW 33
2 G.T.K. 33
3 GULABI BAGH 33
4 HUDSON LINE 33
5 INDER PURI 33
6 INDRA VIHAR 33
7 PUSA 33
8 PANDAV NAGAR 33
9 ROHTAK ROAD 33
1
0 SARASWATI GARDEN 33
1
1 SHAHZADA BAGH 33
1
2 SHAKTI NAGAR 33
1
3 TRPOLIA 33
1
4 SUDARSHAN PARK 33
1
5 RAMA ROAD 33
1
6 RIWARI LINE 66
1
7 WAZIRABAD 33
1
8 DIFR 33
1
9 PAYAL 33
North Central
1 ASHOK VIHAR 33
2 AZAD PUR 33
3 RAM PURA 33
4 RANI BAGH 33
5 TRI NAGAR 33
6 WAZIR PUR - I 33
7 WAZIR PUR - II 33
8 HAIDER PUR 33
9 SHALIMAR BAGH 33
1
0 MANGOL PURI - II 66
1
1 PITAM PURA - I 66
1
2 PITAM PURA - II 66
1
3 PITAM PURA - III 66
1
4 MANGOL PURI - I 66
1
5 ROHINI - I 66
1
6 ROHINI - II 66
1
7 ROHINI - III 66
1
8 ROHINI - IV 66
1
9 SAHLIMAR BAGH 33
2
0 FACILITY CENTRE 33
North West
1 A.I.R. KHAM PUR 33
2 S.G.T. NAGAR 33
3 BADLI 66
4 DSIDC NARELA 66
5 NARELA A-7 66
6 JAHANGIR PURI 66
7 POOTH KHURD 66
8 ROHINI - 23 66
9 ROHINI - V 66
1
0 ROHINI - VI 66
1
1 RG-22 66
1
2 Bawnan-6 66
1
3 Bawana Clear Water 66
1 DSIDC-II Narela 66
 4
1
5 TIGGIPUR 66
1
6 Bawana 7 66

STUDY OF 33KV GRID SUBSTATION

What is a grid substation?

A grid is essentially an interconnected power system that connects neighboring power stations into a
‘power pool’. The assembly of apparatus used to change some characteristics of the electric supply
(frequency, voltage etc.) is called substation.

Introduction:

In a 33 KV grid station, the incoming 33 KV lines are connected to the incoming buses through a line
isolator, a current transformer and a bus isolator. The 33KV supply reaches the HV side of the power
transformer through another bus, isolator, a circuit breaker, current transformer and a potential
transformer.
The power transformer steps down the voltage level to 11 KV for further distribution purpose. The LV
side of the transformer is connected to the 11KV bus through a CT and a circuit breaker which are
located indoor in a panel. The LV side of the transformer is connected to the panels using underground
cables.
Outgoing 11KV feeders are out of the 11KV buses each one connected to the bus through circuit
breakers, CTs and isolators.
The various incoming and outgoing voltages are measured using PTs.

At G.T. Karnal Road Grid sub station, the incoming feeders from Azadpur and Tripolia supply in
power (33KV) via underground cables. The phase lines are taken out of each cable through a P.G.clamp
and are fed to the HV side of power transformer, rated 20/25 MVA, through isolators, CTs, circuit
breaker and busbar. The PTs and lightening arrestors are connected across the lines.
The stepped down voltage (11KV) from the LV side of the power transformers is connected to the
switchgear room through underground cables. From the switchgear room, the power is fed into the
various outgoing feeders-C.C Colony, Ashok Vihar, Model Town, Arya Bhatt Poly Tech., Satyawati
College, FCI and Gurjwala town.

The d.c. power back up to the grid is supplied through a battery bank room. The control panel room
enables monitoring and remote control of its operation. The grid is SCADA controlled substation.

GRID SUBSTATION

The following are the important components at a grid substation:

1. POWER TRANSFORMERS
2. CIRCUIT BREAKERS
3. CURRENT TRANSFORMERS
4. POTENTIAL TRANSFORMERS
5. ISOLATORS
6. LIGHTENING ARRESTERS
7. CAPACITOR BANK
8. BUSBARS
9. INSULATORS
10. BATTERY BANK AND CHARGING SYSTEM
11. CONTROL PANEL
12. SCADA SYSTEM
13. SWITCH GEAR
 POWER TRANSFORMER

A power transformer in a grid substation steps down the incoming voltage (66KV or33KV) to 11(KV)
for further distribution. It transfers electric energy via electromagnetic induction, from one circuit to
another, at the same frequency, usually with changed values of current and voltage.
Usually, the HV winding is delta connected while LV winding is star connected. Typical power ratings
for power transformer are 12.5,16,20,25 or 50 MVA.

COMPONENTS OF POWER TRANSFORMER:

1. Main Tank It encloses the core and the windings. Structural steel is used for fabrication of
main tank. Size of tank is dependent on its MVA rating.

2. Core The core is made from silicon steel or cold rolled grain oriented (C.R.G.O steel) in the
form of laminations of 0.28-0.30mm in thickness with insulated coating. It may be shell type or
core type.
In core type, there is only one iron path and windings are wound on opposite limb.
In shell type there are two parallel magnetic paths into which flux from the central limb can
divide.

3. Windings Hard drawn Copper of high conductivity in the form of round conductors with
paper/ enamel insulation is used.
4. Solid Insulation Paper, cotton, fiber based board (laminated board and wood/wood laminations)
are used for inter turn and winding to earth insulation.

5. Insulating Oil Oil forms a significant part of the transformer. It acts as a coolant to dissipate the
heat losses in the transformer and, also as an insulating medium. It is obtained by fractional
distillation and subsequent distillation of crude petroleum.

6. Radiators These limit the temperature of oil and winding, by dissipating heat which is
generated due to losses in the Transformer. The different types of cooling may be:
ONAN (oil natural air natural)
ONAF (oil natural air forced)
OFAF (oil forced air forced)
OFWF (oil forced water forced)

7. Conservator This is a cylindrical vessel made of structured steel. It if used for accommodating
the volumetric expansion of oil in the transformer due to increase in pressure. Due to its
cylindrical shape, the area of interface of air and oil is reduced and hence reducing the oxidation
of oil. Its capacity is approximately 5% of the tank capacity and is filled up to one-third of its
volume.

8. OLTC On Load Tap Changer is used to regulate the incoming system voltage while the
transformer is delivering the load. Tap changing is completed within 40-70 milliseconds. This
high speed transfer is obtained by using a bank of energy storing springs. When energy is
released, the tap change is complete. The tap changing is done on the HV side for the two
reasons. Firstly, much lesser current flows on the HV side and secondly, because it is easier to
draw out connections from the HV windings which are wound on the outer portion of the core.

9. Silica Gel Breathers In oil filled transformers, space is required for volumetric expansion of oil
due to change in surrounding temperature and load. Hence oil always comes in contact with air.
Silica gel breather is a dehydrator which prevents entry of moisture from air to insulating oil.
Cobalt Chloride is used as Silica gel in the form of crystals.

10. Bushings It is an insulating structure which provides a central passage for a conductor. These
are meant for bringing out the LV & HV side leads out of transformer tank and enable
connection between transformer windings and phase lines.

Two types of bushings are mainly employed:

I. Porcelain Bushing
II. Condenser Bushing
Generally, there are three bushings on the delta connected HV side while on the star connected
LV side, three bushings are for the phase lines and one for neutral. Each bushing is provided
with arcing horns for protection.
PROTECTIVE ELEMENTS:

11. Buchholz relay It is used in oil immersed transformers to detect the faults such as arcing,
partial discharge, or local overheating, which normally results in generation of gas. The relay is
mounted in the pipe connected between the tank and the conservator tank at an inclination of 3-7
to the horizontal to ensure that all the gases are directed to this relay housing and actuates an
alarm circuit.
In case of occurrence of incipient fault, bubbles if gases are evolved by the heat generated which
rise up and the oil level drops, whereupon, the hollow float tilts, short circuiting the mercury
switch and an alarm device operates.
If however a serious fault has occurred, the gas generated is considerable which causes the gas
surge flap valve to be deflected, thereby closing the mercury contact switch and energizing the
trip coils of the circuit breaker.

12. Oil Surge Relay It gives trip command in case OLTC electric fault. Its functioning is same as of
Buchholz relay. It is mounted in OLTC to OLTC conservator pipelines.

13. Marshalling Box It consists of WTI, OTI and in some transformers cooler fan control system.

14. OTI Oil Temperature Indicator works on the principle of liquid expansion with change in
temperature and consequent change in volume of the liquid, which causes the
expansion/contraction of the bellows and is transmitted through linkage mechanism to the
indicating pointer and switching disc.

15. WTI Winding Temperature Indicator works by image process technique. An operating bellow is
provided with an additional heating element. A CT mounted on the LV side of the tank feeds this
heating current. The operating bellow thus gets an additional movement and indicates the
temperature of the winding.

16. Oil Level Indicator Plain or prismatic glass is generally used as oil level indicator. In large
transformers, magnetic oil gauge (MOG) is used. MOG works on bevel gear system. Oil in
conservator lifts up float and float arm. This rotates the bevel gear system, which through proper
magnetic linkage mechanism operates a mercury switch, wired to an alarm.

17. Pressure relief Valve PRV protects the transformer from excessive pressure which may occur
due to internal fault or other reasons. If a short circuit occurs inside a transformer, the arc
vaporizes the transformer oil and a heavy pressure is built. It is mounted on the top of the tank. It
 has stainless steel diaphragm which gets lifted under high pressure conditions, to reduce the
pressure.

CURRENT TRANSFORMER

A current transformer is a device used to step down the current from high values to low
values. It is essentially a step-up transformer, which steps down the current to a known ratio.

Its functions may be enumerated as:

• Measure / monitor current.

• Differential Current Protection.
• Over Current Protection.
• Earth fault Protection.

PRINCIPLE OF OPERATION

As the primary no of turn is less then secondary so the voltage we get in the secondary is more than
primary. Typical secondary current is 5A or 1A rms.
In case of fault, current of considerable value flows through its secondary and energizes the relay. The
plunger of the relay moves to close the contact of the trip circuit and the the circuit breaker operates.
TYPES OF CURRENT TRANSFORMER

Wound type: It has primary winding of more than 1 full turn on the core
Bar type: Primary winding consists of a bar of suitable size.
Dry type: It does not require any liquid or semi-liquid medium for cooling or insulating.
Oil type: It requires oil for cooling and insulation.
Live tank design: It has its secondary at the top and its housing at live potential.
Dead tank design: It has its secondary at bottom and its housing at earth potential.

NAME PLATE OF A CURRENT TRANSFORMER

 MAKE SKIPPER
SERIAL NO 1637A/70
RATIO 800-400/1-1-1
RATED VOLTAGE 36 KV
FREQUENCY 50 HZ
RATED SHORT TIME 25 KA,3 SEC
CURRENT
INSULATION LEVEL 70KV/170KV
CLASS 0.5 - 5P20 - PS
BURDEN 30VA - 30VA - NA

POTENTIAL TRANSFORMER

A Potential Transformer is a special type of transformer that allows meters to take readings from
electrical service connections with higher voltage (potential) than the meter is normally capable of
handling without at potential transformer. It is essentially a step down transformer.
The rating of the PT used at the grid studied is 20/25MVA, 33KV.
 ISOLATORS

Isolators are provided for isolating equipment from buses or live apparatus or for sectionalizing buses or
circuits or for transfer of loads. These devices break the circuit under off-load conditions. The main
purpose of isolator is to ensure protection of the maintenance person under any circumstance. The
isolator is operated only when circuit
Breaker connected to its line breaks.

TYPES OF ISOLATORS:

• BASED ON THEIR MOUNTING

1. Vertically mount
2. Horizontally mount
• BASED ON THE TYPE OF BREAKING
1. Centre break
2. Two-way break
 LIGHTENING ARRESTER

These are protective devices used to safely ground any surge in line e.g. due to lightening. These
conduct the HV surges on the power system to the ground. Typically, they are connected in parallel with
the equipment to be protected; between the phase and ground for three phase installation.
It essentially consists of a spark gap in series with a non-linear arrester. Its one end is connected to the
equipment to be protected and the other to the ground. The length of gap is so set that normal voltages
not enough to cause an arc across the gap but a dangerously high voltage will break down the insulation
and form an arc. The property of non-linear resistor is that its resistance decreases as the voltage or
current increases and vice-versa.

LIGHTENING ARRESTORS

Operation:
• Under normal operation, the LA is off i.e. , the line does not conducts
• On occurrence of over voltage, air insulation across the gap breaks down and arc is formed,
providing low resistance path to the surge to ground. Thus excess charge on the line is
conducted through LA to the ground.

CIRCUIT BREAKER

A Circuit Breaker is required to isolate the faulty section of the power system in case of abnormal
conditions. A CB has two contacts: a fixed contact and a moving contact.

Basic Operation:
 Under normal conditions, these two contacts remain in closed position.
 When the CB is required to isolate the faulty section, the moving contact moves to interrupt the
circuit.
 On separation of the contacts, the flow of the current is interrupted resulting in formation of arc
between the contacts.
 The contacts are placed in close chamber containing some medium which extinguishes the arc.
Classification:
1) Air Blast Circuit Breaker
2) Minimum Oil Circuit Breaker
3) Bulk oil Circuit Breaker
4) Vacuum Circuit Breaker
5) SF6 Circuit Breaker

TERMINOLOGIES IN CIRCUIT BREAKERS

Recover Voltage: Voltage that appears across the terminals of each pole of the CB immediately after
breaking of the circuit is known as recover Voltage.
Rate of Rise of Recovery Voltage: It is the rate at which recover voltage rises. It is expressed in Volts
per microseconds.
Breaking Current:
Symmetrical breaking current: It is the rms value of a.c. component of current at the instant of
contact separation
Asymmetrical breaking current: It is expressed as the rms value of the total current (ac + dc)
present at pole at the instant of contact separation.
Breaking Capacity:
Symmetrical breaking Capacity: The value of the Symmetrical breaking current that the CB is
capable of breaking at the stated recovery voltage frequency and under prescribed conditions.
Asymmetrical breaking Capacity: The value of the Symmetrical breaking current that the CB is
capable of breaking at the stated recovery voltage frequency and under prescribed conditions.
Making Capacity:
It is the peak value of the maximum current in the first cycle of current after the circuit is closed by the
circuit breaker.

VACUUM CIRCUIT BREAKER

A vacuum circuit breaker utilizes a vacuum to extinguish arcing when the circuit breaker is opened and
to act as a dielectric to insulate the contacts after the arc is interrupted.
High vacuum has two outstanding properties:
• The highest insulating strength known.
• When an AC circuit is opened by the separation of contacts in a vacuum, interruption
occurs at the first current zero, with a dielectric strength across the contacts building up at a
rate thousands times higher than that obtained with conventional CBs. The contacts are of
butt joints.
A high vacuum gap recovers most of its dielectric strength within 10μs.
.
These properties make the VCBs more efficient, less bulky and cheaper.
 Vacuum Circuit Breaker

SF6 BREAKERS

Current interruption in a high-voltage circuit-breaker is obtained by separating two contacts in a

medium, such as sulfur hexafluoride (SF6), having excellent dielectric and arc quenching properties.
After contact separation, current is carried through an arc and is interrupted when this arc is cooled by a
gas blast of sufficient intensity.

SF6 CIRCUIT BREAKER

The SF6 Gas circuit Breakers are extremely simple and compact in their design owing to the fact that no
gas blast valves are required and the force of contact separation simultaneously drives the puffer piston
which builds up gas pressure according to the contact stroke. It consists of male-female contact joint
comprising two coaxially aligned electrode sections.
The gas breaker assures a high level of performance required for reliable operation of electrical system.
Its reliability increases further by the use of SF6 gas insulating system (GIS) and a single pressure dual
flow gas puffer interrupter.

NAME PLATE SPECIFICATION OF A SF6 USED IN 33KV GRID SUBSTATION

Circuit breaker type ABB
No. EDF SK1-1
Order 312331
 Rated Voltage 72.5KV
Power Freq. withstand voltage 140KV
Lightening imp. with voltage 325KV
Switching imp. with. Voltage -
Rated frequency 50Hz
Rated normal current 1600A
Gas Pressure SF6 abs (+20ºC)
Maximum working pressure 9bar
Filling 7bar
Signal 6.2bar
Blocking 6bar
Volume/pole 18
Operating Device Type FSA-1(T)
Rated breaking current 25KA
DC component 40%
Rated making current 62.5KA
First pole to clear factor 1.5
Rated short time current 25KA
Duty cycle O-0.3 sec-CO-3 min- CO/CO-15 sec-CO
Line charging breaking factor 10A
Mass total 1053Kg
Mass of gas 25Kg
Temperature Class -30C
Yr. of Manufacture 2006
Inst. Manual no. 1HYB 80001-25

CAPACITOR BANK

A capacitor bank is used to improve the power factor at which the power is supplied. The power factor
of a system is given as:
P.F. = Useful power/apparent power=KW/KVA
They improve the voltage regulation and/or restore it to an acceptable level for a given load.

PRINCIPLE OF WORKING

In case of induction motors, magnetizing of the core first occurs in each half cycle of the ac supply, and
then the power is imparted. The magnetizing power is then after returned to the generator. This
magnetizing Reversal Energy is not actually doing any job in the motor, but is still absolutely essential
in the working of the motor. This is called “Reactive Power”.

Capacitor Bank

If suitable capacitors are connected at the terminals of the motor, the Magnetic reversal energy, which
would otherwise been pushed back into the system, could e stored and released i.e. supplied to the load
for magnetizing purpose when needed in the other parts of the electrical cycle. The advantage here being
that he capacitor eliminates the need for feeding reactive energy along power lines and reduce the
burden. In other words, the capacitor behaves as ‘local generator of the reactive power’.

BUSBARS

An ideal busbar is characterized by zero impedance .The materials normally used for bus bars and
connectors are copper and aluminum. Maximum current density in copper bus bars and connections in
direct contact with air should be such that as not to exceed the following operational temperature:

Maximum permissible temperature: 70ºC

Maximum hot spot temperature: 75ºC
Current Density generally adopted:
Indoor or enclosed bus bars:-750 A/sq. inch (116 A/sq. mm)
Outdoor bus bars:-1200-1400 A/sq. inch (186-216 A/sq. mm)
For Aluminum bus bars the current density of 61% of that of copper are usually permissible. Maximum
permissible current density under short circuit conditions should not normally exceed 18600 A/sq. cm.

BUS BAR CONFIGURATIONS:

SINGLE BUSBAR:
Suitable for smaller installations, a bus sectionalizer allows the station to be split into two separate parts
and the parts to be disconnected for the maintenance purpose.

DOUBLE BUSBAR:
Provides for possibility of cleaning and maintenance without interrupting supply. Possibility of separate
operation of station sections exists. Busbar sectionalizing increases operation flexibility.

MAIN & TRANSFER BUS:

Duplicate busbar with one spare breaker allows considerable flexibility for maintenance.

BUS COUPLER

This is a section comprising of circuit breaker, CTs and isolators made to connect the two buses or bus
sections in case of failure in any incomer. This ensures continuity in supply from both the buses.

BATTERY ROOM

The battery room consists of 24 batteries, each of 2V, connected in series, giving the supply of 48V.It is
meant for power back-up in case of supply failure. The following points should be kept in mind for
safety reasons:
1. Room should be well ventilated i.e. provided with an exhaust fan.
2. The flooring should be resistant to acidic corrosion.
3. The room should be free from birds and rodents.
4. The specific gravity of the lead acid should have an optimum value of 1290 m/s2.
The bank is supplied with two chargers. The boost charger is for quick charging at constant current. The
float charger is for steady charging at constant voltage.
 BATTERY ROOM BATTERY CHARGER

SCADA
(Supervisory Control And Data Acquisition)

SCADA is used to monitor, control and alarm plant or regional operating system from a central location.
It essentially has three main elements:
1. RTUs (Remote Telemetry Units)
2. Communication
3. HMI (Human Machine Interface)
It significantly reduces the operating labor cost, while at the same time, it actually improves plant or
regional system performance and reliability.
 SCADA ROOM

CONTROL PANEL ROOM

It is used for remote control and monitoring of the various equipments in the grid yard. The L/R switch
enables selection of local or remote control operation. TNC switch may be set in either Tripped, Neutral
or Closed condition of the circuit breaker. Each relay has a graphic display screen, a trip circuit
supervisor and a dc fail supervisor. For each transformer, the CT brings in current that may be
monitored and is fed into a numeric relay 50/51/50n/51n that works as instantaneous, inverse over-
current, earth fault instantaneous and earth fault overcurrent relay. A differential protection relay is
meant to detect any unbalance in the current in the HV and LV windings. In case of operation of any of
the relays, the Master relay, 86 is operational. The BCU switch enables the interconnection of the grid
with the SCADA control room. All the equipments are operated at 50V dc.
 CONTROL PANEL

SWITCH GEAR ROOM

The term switchgear, used in association with the electric power system, or grid, refers to the
combination of electrical disconnects, fuses and/or circuit breakers used to isolate electrical equipment.
Switchgear is used both to de-energize equipment to allow work to be done and to clear faults
downstream.

The 11KV voltage supply through the underground cables is headed to the switchgear room and is fed to
the various outgoing feeders through circuit breakers, bus coupler, bus riser etc.
 SWITCH GEAR ROOM

Based on the size & input voltage rating, transformers may be classified into two
categories:

1. Power Transformers
 2. Distribution Transformers

Distribution Transformer Power Transformer

Both power and distribution transformers are used for T&D applications
(transmission & distribution). The difference between power and distribution
transformers refers to:

• Distribution transformers vary between 25 kVA and 10 MVA, with

input voltage between 1 and 36 kV.

• Power transformers are typically units from 5 to 500 MVA, with input
voltage above 36 kV.

NAMEPLATE DETAILS OF A POWER TRANSFORMER

Make Crompton
Greaves Limited
MVA 16/20
KV (No load) 66-HV
11-LV
Amperes 140/175-HV
839.7/1049.7-
LV
Phases 3
Frequency 50 Hz
Makers W.O. No. T 8251
Makers serial No. 8251/2
Diagram DRG No. T 62B1511H
Year of manufacture 1990
Type of cooling ONAN/ONAF
Rating MVA 16 20
Guaranteed temp. rise Oil 50ºC
Winding 55C
Connection symbol Dyn11
Untanking Mass 21000 Kg
Total oil 9800/11200
Kg/litre
Total mass 42000 kg
Heaviest package Without oil-
26180kg
With oil-3330kg

OLTC HV volts HV In each Impedance

position amperes phase voltage at
No. OLTC 75ºC on 20
connection MVA base
1 69300 166.6 20-19 14.44%
5 66000 175 20-15 14.56%
The transformers are dispatched and full assembled, oil filled condition and ready for
erection, testing and commissioning.

STEPS POINTS TO BE KEPT IN MIND

• Transformer should be unloaded by means of crane, or

lifting device of sufficient capacity.
• All lifting lugs should be used to avoid unbalanced and
UNLOADING
uneven stress.
& • While lifting, slings should not rest/touch any other parts of
HANDLING the transformer especially for bushings.

• Immediately after received at site, transformers must be

physically verified with a packing slip and drawings and
closely inspected for any transit damage and welding,
gasket leakages.
INSPECTION • Transformers which are dispatched with oil filled in them;
ON RECEIPT oil level must be checked for any pilferage or leakage
AT SITE during transportation. Oil level is indicated by the “oil level
gauge” provided on the oil filling pipe.
• If any damages, shortages and leakages are observed, then
open delivery certificate from the carrier is to be obtained,
for others enclosed format to be filled and reported to the
firm within 15 days of receipt to enable the firm to lodge
insurance claim if applicable and to attend the complaint.

• On receipt of the transformer at site, it is desirable to install

and commission the transformer with minimum delay.
• Transformers should be kept over wooden support to avoid
rusting.
STORAGE • It is desirable to keep the transformer in a place where
temperature variation is minimum or energized even at a
low voltage so that the oil temperature is about 10º-15ºC
higher than the surrounding ambient temperature.
 • Rating & Terminal marking plate :
The transformer is supplied with rating and terminal marking of
plate made out of noon corrosive metal. The plate contains
information concerning the rating, voltage ratio, weights, oil
quantity, vector group, etc. the plate also includes unit Sr. No.
and Year of Manufacturing.

• Earthing Terminals:
The core laminations assembly is connected to core clamping
frame which is in turn connected to the tank. Two earthing
terminals are provided on the transformer tank. The earthing
terminals should be connected to the earth.

• Lifting lugs
Two lifting lugs of adequate capacity arc provided on top cover
to lift fully assembled transformer filled with oil.
FITTINGS &
• Valves
ACCESSORIES
Every transformer is provided with drain cum filter valve at
bottom of the tank, and valves are fitted with blanking plates
with locking and sealing to stop oil coming out.

• BUSHINGS:
Oil Communicating Type:
Transformer windings are connected to the external circuit
through bushings. The bushings are installed on the cover of the
transformer tank and hence protrude into the tank. These ends
are provided with suitable fasteners to connect the line leads
inside the transformer and external conductors outside it.
• Tank with Corrugated walls
1. The corrugated walls panels are manufactured from
CRCA sheet in thickness ranging between 1.2mm
and 1.5mm.
2. The role of the corrugated panels is to increase the
surface area of the tank which is in contact with the
cooling air.
3. As the panels are welded on transformer tank, keen
attention is required during unloading, handling and
erection to protect from physical damages.

• Pressure Relief Valve

PRV is provided on the transformer tank. In case of heavy fault
in transformer, this valve will operate and release pressure.
 • Location:
The transformer should be installed in a well ventilated place,
free from excessive dust, corrosive fuels etc. Adequate
ventilation is necessary for tank and corrugation so that they
can dissipate heat,. There should be clear place of about 1.25m
INSTALLATION
on all sides of the transformer if it is enclosed in a room.

• Foundation:
Foundation should be firm, horizontal and dry.
PARTS OF TRANSFORMERS BEING INSTALLED
AT NARELA 66/11kV GRID

Bushings Transformer Testing

Radiators Marshalling Box

Cooling Fans

OLTC
Prior to energizing the transformer, several pre-commissioning checks are made to ensure that
transformer has not suffered damage during transit, for maintenance purpose and, in future comparison
if the transformer gets mal-functioning.

• Check the oil level in the oil filling pipe gauge.

• Check for oil leakage in all gasketed joints and any crack in bushings.
• Check the drain value for closing.
• Check the transformer for proper and neutral earthing.
• Check the external electrical connections.
• Check the HRC fuse rating.
• Check for any tools lying above the transformer.
• Check the protection circuits.
• If any painting peel off, touching up can be done after erection.

Pre-Commissioning Check Points Records

1. Oil level in oil filling pipe.

2. There is no oil leakage from anywhere.
3. Tank earthing is done.
4. Neutral earthing is duly done.
5. External connection is duly tightened.
 The routine tests are performed as a part of:
• Pre-commissioning test, during installation.
• Commissioning test, at regular interval.

Insulation Resistance Test

It is done to measure the reliability of the transformer insulation. The test reveals the condition if
insulation (i.e. degree of dryness of insulation paper), presence of any foreign
containments/moisture in oil and also any gross defect in the transformer.
It is measured as a function of leakage current, which passes through the volume of insulation or
external surface under a constant DC voltage.

Procedure:

 The circuit arrangement is done as shown in the figure.

 A Megger is used (either hand driven or motored) of suitable voltage rating.
 IR measurements are done between H.V winding to L.V winding, H.V winding to
earth, L.V. winding to earth.
 Acceptance:

IR values are checked with the values in the manufacture’s test certificate and these values. With
every 10ºC drop in temperature, IR values increase by approximately 1.5 times.

Rated Voltage Insulation resistance at 20ºC

Up to 1.1KV 200 MEG.OHMS (MIN).

1.1 to 3.3KV 250 MEG.OHMS(MIN).
3.3 to 6.6KV 400 MEG.OHMS(MIN).
6.6 to 11KV 450 MEG.OHMS(MIN).

Precautions:

• It is ensured that the test specimen is discharged by short-circuiting for a period at least
four times as long as the test voltage was applied.
• In case of hand driven megger, it is rotated at constant speed for 60 seconds.
• Transformer tank is properly grounded.

Winding Resistance Test

These are measured at site in order to check for any abnormalities due to loose connections,
broken strands and high contact resistance in tap changers.

The resistance is usually measured either with the bridge techniques, (Kelvin Bridge or Wheat
Stone Bridge), Voltmeter Ammeter Method or a micro Ohmmeter. The resistance is below 1
ohm.

Procedure:

• For star connected winding with neutral brought out, the resistance is measured between
the line and neutral terminal and average of these shall be the tested value.
 • For delta connected windings, such as tertiary winding of auto transformer, measurements
is done between pairs of line terminals and resistance per winding shall be winding is
calculated as:
• Resistance per winding=1.5 × Measured Value.
• The winding temperature is noted while recording the resistance.
• The resistance at 75ºC is measured as:
• R 75=R1 (235+75)/ (235+t) for copper.
• R1 is the resistance measured at temperature t.

Acceptance
The Measured values are compared with the factory value a deviation of 5% of the factory value
is acceptable.

Precautions:
• Care is taken to minimize the self inducting effects.
• To reduce the high inductive effect, a sufficiently high current is used to saturate the
core, but should not exceed 15% if the rated current as it would cause heating and thereby
change the resistance.
• Care is taken for accurate measurement of the winding temperature.
Magnetic Balance Test

This test is carried only in three phase transformers to check the imbalance in the magnetic
circuit.

Procedure:

• The OLTC is kept at its nominal tap position.

• The transformer neutral is disconnected from ground.
• Single phase 230V supply from a 50Hz regulating ac power source is applied across
one phase of HV winding terminals and neutral (v1).
• The voltage is measured in other two HV terminals across neutral (v2 & v3)
respectively.
• The test is repeated for each of the three phases.
 Acceptance:

The acceptance criteria are usually when the supply is fed to outer (extreme) phase of a
transformer, the voltage induced in the centre phase shall be 50-90% of the applied voltage.
However, when the centre phase is excited, the voltage induced in the outer phases shall be 30-
70% of the applied voltage.

Precautions:

• None of the winding terminals is grounded.

• The test is performed before being subjected to direct voltage/current tests.

Magnetizing Current Test

The test is performed to locate defect in magnetic core structure, shifting of windings, failures in
turn insulation or problems in tap changers.

Procedure:

• The tap position is kept in the lowest position and LV terminals are opened.
• Single phase 415V supply is applied on HV terminals.
• The voltage and current value is measured for each phase on HV terminals.
• The above procedure is repeated for normal and highest tap position.
Acceptance:

• Magnetizing current measured on HV side shall confirm to increasing trend between highest
voltage tap positions to lowest voltage tap position for all phases.
• The set of reading for current measurement for each of the tap position should be equal.
Unequal current shall indicate possible short circuits in the winding.

Precautions:

• This test is done before DC measurement of winding resistance to reduce the effect of
residual magnetism.
• On HV, low range AC ammeter is used.

Voltage Ratio Test

The test is performed to determine the correctness of the turn ratio between the different
windings on each tapping of the transformer.
It is required to confirm constant output voltage on LV windings at all tap positions.

Procedure:

• The OLTC is kept at nominal tap position and LV is kept open.

• 415 V supply is applied on HV terminals.
• The phase to phase voltage between the LV terminals is measured by means of switch
selectable voltmeters and current on each phase of LV terminals is also measured.
• The above steps are repeated for each tap position separately.
Acceptance:

• The tolerance for turn ratio should be within 0.5% of the declared ratio in the name plate
specification.
• The measured voltage on LV phase shall confirm to increasing trend between highest
voltage tap positions to lowest voltage tap position for all phases
.

Precautions:

• Suitable fuses or tripping arrangement to be provided on HV side before starting test.

• The voltage is applied only in the high voltage winding in order to avoid unsafe voltage.

Load Balance Test

The test is performed to confirm the balancing of currents in all three phases when transformer is
fully loaded.

Procedure:

• The circuit is arranged as shown in figure below.

• Single phase 415 V voltage is applied on HV winding.
• The values of voltage, current of HV, and current of LV windings are recorded
instantaneously.
• The test is performed for each phase of the transformer.

Acceptance:

Considering applied voltage constant on HV, the ammeter reading of all three phases should be
within 2-5% variation.

Precautions:

• The secondary terminals of all the CT’s are shorted before starting the test.
 • Suitable value of cross section of copper cables is selected such that the current
density should not exceed 2.5 A/sq. mm.

VECTOR DIAGRAM TEST

The test is performed to verify the polarity and phase relationship of HV and LV connections.

Procedure:
• The terminals 1U, 2U are shorted.
• Three phase supply is applied on 1U, 1V and 1W.
• The voltage between the following terminals is measured and recorded:

1U-1V
1V-1W
1U-1w
1V-2v
1V-2w
1W-2w
1W-2u
 Acceptance:

Condition to be satisfied is given by the vector diagram

Precautions:

• Neutral terminal is maintained in floating condition.

• The three phase supply is connected to the HV windings only.
• 1U-2U terminals are shorted with insulated wire.

Tan Delta testing:

Dielectric Dissipation factor

The dielectric dissipation factor of oil is the ratio of the power dissipated in the oil in watts, to the
product of the effective voltage and current in VA, when tested with a sinusoidal field under prescribed
conditions.
This is numerically equivalent to the cosine of the phase angle or sine of the loss angle. It is a
dimensionless quantity.
This angle varies according to the quality of insulation, moisture content, contamination, heterogeneity,
ageing of the material etc. The ratio Ir/Ic is a measure of the dielectric loss in the insulation and is
known as the dielectric loss angle or dissipation factor.

The watt loss =VI CosΦ

=VI cos (90-δ)
=VI sin δ

=VIc sin δ
cos δ
 = VIc tan δ
=VωVCtan δ
= V²ωC tan δ

Dielectric loss in insulating equipment is thus proportional to tan δ and to the square of voltage. Since
the amount of resistance loss of the insulating material is very small, the angle δ is also very small and
hence tan δ is approximately equal to cosΦ (power factor).

TAN DELTA AND CAPACITANCE MEASUREMENT OF TRANSFORMER

BUSHING

It is one of the most powerful tests to monitor the health of the transformer. It is an indication of the
quality and soundness of the insulation in the bushing.

Procedure:

• The capacitance multiplier dial is set to the short position and the capacitance measuring dials to
their respective “O” position.
• The interference suppressor switches is kept in OFF position.
• The ground terminal of the test is set to low impedance.
• The control unit is connected to the high voltage unit using shielded cables.
• The HV cable is connected to the top terminal of the bushing and the LV cable is connected to the
test tap (strip/central stud) to the C and tan-delta kit through a screen cable and measurements are
recorded.

Acceptance:

Maximum values of tan- delta of class A insulation should be 0.007.

For bushings, tan-delta value should not exceed 0.7% and the main capacitance value should be within
10% of the factory test values.

Precautions:

• The operator must use all practical safety precautions to prevent contact with energized parts of the
test equipment and related circuits.
• Measurement should be made at low voltage usually below 10 KV.
• Porcelain of the bushings should be cleaned and dried and removal of any dirt /oil with clean dry
cloth should be ensured.

TAN DELTA AND CAPACITANCE MEASUREMENT OF WINDING

INSULATION OF TRANSFORMER
This test is carried out to ascertain the general condition of the ground and inter winding insulation of
transformer and reactors.

Procedure:
• Measurement is made between all windings connected together and the grounded tank.
• The test set is positioned at least 6 feet away from the test specimen to be tested.
• The capacitance multiplier dial is set to the short position and the capacitance measuring dials to
the respective “O” positions.
• The interference suppressor switches is kept in OFF position.
• The ground terminal of the test is set to low impedance.
• The control unit is connected to the high voltage unit using shielded cables.
• The HV cable is connected to the top terminal of the bushing and the LV cable is connected to the
test tap (strip/central stud) to the C and tan-delta kit through a screen cable and measurements are
recorded
Acceptance:

Maximum values of dissipation factor of class “A” insulation should be 0.007

Rate of change of tanδ and capacitance value should be within 10% of the factory test value.

Precautions:

• The ground cables must be connected first and removed last.

• The test set should never be connected to the energized equipment.
• The high voltage flux should be kept free from moisture, dust during installation and operation.
• It was ensured that the test specimen is denergized and grounded before making any further
connections.

INSPECTIO ITEMS TO BE INSPECTION ACTION, IF REQUIRED

N INSPECTED NOTES
FREQUENC
Y

Monthly Winding temperature Checking for Check for:

reasonable temp. .Correct indication by
rise & no abnormal instruments
increase w.r.t • Winding temperature under
earlier records. no loads conditions.
• Dust & foreign particles on
the finned area of radiators

Monthly Oil temperature Checking for Check for:

reasonable temp. • Correct indication by
rise & no abnormal instruments
increase w.r.t • Winding temperature under
earlier records. no loads conditions.
• Dust & foreign particles on
the finned area of radiators

Monthly Load & Type of Checking against Reduction of load in case

cooling rated values oil/winding temperature
reading is excessive.

Monthly Voltage & noise of Checking the tap Ensuring proper tap position
main unit position matches to avoid core loss/noise due to
with voltage over fluxing.

Monthly Oil level in Checking against If low, it is planned to top

Conservator transformer oil with filtered oil, and
temp. transformer is examined for
leakages.
Monthly Dehydrating Breather Checking the If silica gel is pink, it is
colour of the active replaced/ reactivated.
agent & oil level in
oil cup.
Monthly Main unit Checking leaks in For oil leakages from gaskets,
radiators/Cooler pipes, main tank, bolts are tightened.
bank/pipe connection etc
Monthly Fans Checking for Ensure proper mounting.
abnormal noise.
Monthly All external Checking visually In case of any sign of heat,
connections that all connection bolts are cleaned and
is normal without tightened.
any discoloration.
Quarterly Bushings Examination of Cleaning for dirt/ deposits.
cracks & dirt Replacement in case of
 deposits. cracks.

Quarterly Oil in transformer Reference to the Reference to the preventive

maintenance table maintenance.

Quarterly Dissolved gases in oil Reference to the Reference to the preventive

maintenance table maintenance

Yearly Insulation Resistance Comparison with Checking for the cleanliness

value at time of and soundness of bushing. If
commissioning. very low, process needs to be
planned.

Yearly Gasketed joints Checking for any Bolts are tightened evenly to
leaks. avoid uneven pressure.

Yearly Relays, alarm, their Examination of the Components are cleaned.

circuit etc. relays n alarm Contacts & fuses replaced if
contact and their necessary.
operation fuses.
Yearly Control boxes, terminal Checking the water If required, gaskets are
box, cables tightness of replaced.
terminal boxes and
wiring
connections.
Yearly Temperature Indicator Pockets holding Oil to be replenished, if
thermometer is required.
checked
Yearly Dial type oil gauge Checking pointer Adjust, if required.
for freedom.
 PARAMETER DESCRIPTION LIMITS
Electric Strength • It is the voltage at which a breakdown
occurs between two electrodes when
oil is subjected to an electric field The minimum electric strength
under prescribed conditions. of new oils should be 30kV
• The transformer oil should have high (RMS) and after
dielectric strength in order to minimize filteration60KV (RMS).
clearance between coils and from
windings to tank.
Water Content • Water content in oil is to be measured The moisture content in new
periodically to access the quality of unfiltered oil should be less than
oil. 50ppm and after filter it should
• It is measured in ppm (parts per be less than 20ppm.
million)
Specific Resistance • It should be as high as possible. An At 90ºC, 30 X 1012ohms cm
increase in temperature reduces the At 27ºC, 500 X10 12 ohms cm
specific resistance.
Dielectric • Known as tan-delta, is a measure of
Distribution factor imperfection of dielectric nature of oil. For a perfect dielectric, when
• It is the ratio of power dissipated in the applied with a sinusoidal ac
oil to the product of the effective voltage, the current should lead
voltage and current in volt amperes the voltage by 90ºC
when tested under prescribed
conditions in a sinusoidal field.
Acidity
• It is due to the acid products which are
formed by the oxidation of oil. This
encourages deterioration of insulating Total acidity, max-0.03mg
paper and press board. KOH/g
• It is measured in mg of KOH required
to neutralize the acids present in a
gram of oil. Hence it is also known as
neutralization number.

PARAMETER DESCRIPTION LIMITS

Interfacial Tension • It is a force necessary to detach a
planar ring of platinum wire from the The interfacial tension of the
surface of the liquid of higher surface mineral insulating oil should be
0.04.
 tension i.e. upward from water oil
surface. It is expressed in dynes/cm or
milliN/m and is measured using a Pt
tensiometer.
Flash Point • It is the temperature at which oil vapor The minimum value of the flash
ignites spontaneously. It characterizes point of the transformer oil
the tendency of oil to evaporate. should be 140ºC
Lower the flash point, the greater is
the vaporization of oil.
Sludge • It is a slow formation of solid The lowest temperature of the
hydrocarbons due to heating and mineral insulating oil is -10ºC
oxidation. It is a poor conductor of
heat and hence produces temperature
gradient across winding insulation
causing overheating of conductors. Its
deposition in the oil duct blocks the
free circulation of oil, thereby
impairing cooling, the process of
sludge formation continues till the
transformer becomes unserviceable.
When a fault occurs in a very small area, or if the severity of the fault is less, the gases evolved due to
decomposition of oil, get dissolved in oil. As the composition and quantity of the gases generated is
dependent on type and severity of fault, regular monitoring of these dissolved gases reveals useful
information about healthiness of a transformer.

The advantages of fault gas analysis are as follows:

• Advance warning of developing faults.

• Determining the improper use of units.
• Status checks on new and repaired units.
• Convenient scheduling of repairs.
• Monitoring of units under overload.

DECOMPOSITION OF OIL

Small amounts of H2, CH4and CO are produced by normal aging.

Thermal decomposition of oil impregnated cellulose produces CO, CO2, H2, CH4 and O2.
Decomposition of cellulose insulation begins at only about 100ºC or less.
Faults will produce internal “hot spots” of far higher temperatures than these, and the resultant gas
shows up in DGA.
Hydrogen and methane begin to from in small amounts around 150ºC.
At about 250ºC, production of ethane (C2H6) starts.
At about 350ºC, production of ethylene (C2H4) begins.
At about 450ºC, hydrogen production exceeds all others until about 750ºC to 800ºC.
Acetylene (C2H2) production starts between 500ºC and 700ºC.

FAULT GASES
The cause of fault gases can be divided into three categories; corona or partial discharge, pyrolysis or
thermal heating, and arcing. The major fault gases can be categorized as follows by the type of material
that is involved and the type of fault present:

FAULT TYPE GASES EVOLVED

1. CORONA
a. Oil H2
b. Cellulose H2, CO, CO2
2. PYROLYSIS
a. Oil
Low Temperature CH4 C2 H 6
High Temperature C2H4, H2 (CH4, C2 H 6)
b. Cellulose
Low Temperature CO2 (CO)
High Temperature CO (CO2)
3. ARCING H2, C2 H2 (CH4 C2 H 6,C2H4)

The solubility of the fault gases in mineral oil as well as their temperature dependence are also important
factors for consideration in fault gas analysis.

SOLUBILTY OF GASES IN TRANSFORMER OIL.

STATIC EQUILIBRIUM AT 760mm Hg & 25ºC.
Hydrogen 7% by volume
Nitrogen 8.6%
Carbon monoxide 9%
Oxygen 16%
Methane 30%
Carbon dioxide 120%
Ethane 280%
Ethylene 280%
Acetylene 400%

FAULT GAS DETECTION

One of the methods of fault gas detection is dissolved gas analysis (DGA) technique.
In this method a sample of the oil is taken from the unit and the dissolved gases are extracted. Then the
extracted gases are separated, identified, and quantitatively determined. Since this method uses an oil
sample it is applicable to all type units and like the gas blanket method it detects all the individual
components.

The main advantage of the DGA technique is that it detects the gases in the oil phase giving the earliest
possible detection of an incipient fault. This advantage alone outweighs any disadvantages of this
technique.

If a transformer has been operating normally for some time and a DGA shows a sudden increase in the
amount of gas, the first thing to do is take a second sample to verify there is a problem.. If the next DGA
shows gases to be more in line with prior DGA’s, the earlier oil sample was contaminated, and there is
no further cause for concern. If the second sample also shows increases in gases, the problem is real.

Two of the frequently used interpretation techniques of DGA are:

• Rogers Ratio Method

• IEC 599 Method

ROGERS METHOD OF DGA

Rogers ratio method compares quantities of different key gases by dividing one into the other. This
gives a ratio of the amount of one key gas to another. By looking at the Gas Generation Chart we can see
that at certain temperatures, one gas will be generated more than another gas. Rogers’s ratio method uses
four key gas ratios.

 CH4/H2
 C2H6/CH4
 C2H4/ C2 H 6
 C2H2/C2H4

These ratios and the resultant fault indications are based on large numbers of DGA’s and transformer
failures and what was discovered after the failures.
 Code Definition of Rogers Refined Ratio Method

Gas Ratio Range Code

R1: CH4/H2 Not greater than 0.1 5
Between 0.1 and 1.0 0
Between 1.0 and 3.0 1
Not less than 3.0 2
R4: C2H6/CH4 Less than 1.0 0
Not less than 1.0 1
R5: C2H4/C2H6 Less than 1.0 0
Between 1.0 and 3.0 1
Not less than 3.0 2
R2: C2H2/C2H4 Less than 0.5 0
Between 0.5 and 3.0 1
Not less than 3.0 2

DIAGNOSIS BY RATIO

CODE
0 0 0 0 Normal
5 0 0 0 Partial discharge
1, 0 0 0 Slight over heating<150º C
2
1, 1 0 0 Slight over heating 150-200ºC
2
0 1 0 0 Slight over heating 200-300ºC
0 0 1 0 General conductor overheating
1 0 1 0 Winding circulating currents
1 0 2 0 Core & Tank circulating current
0 0 0 1 Flash over, no power flow through
0 0 1,2 1,2 Arc, with power flow through
0 0 2 2 Continuous sparking to floating potential
5 0 0 1,2 Partial discharge with tracking
CO2/CO>11 Higher than normal temp. in insulation
 GUIDELINE BY ABSOLUTE VALUE
GAS FORMULA NORMAL< <ABNORMAL> INTERPRETATION
Hydrogen H2 150 ppm 1000 ppm Corona, Arcing
Methane CH4 25 80 Sparking
Ethane C2 H 6 10 35 Local over
heating
Ethylene C2H4 20 150 Severe
overheating
Acetylene C2 H2 15 70 Arcing
Carbon CO 500 1000 Severe over
Monoxide heating
Carbon CO2 10000 15000 Severe over
Dioxide heating
Nitrogen N2 1 to 10% NA NA
Oxygen O2 0.2 to 3.5% NA NA
Total 0.03% 0.5 % NA
Combustibles

Applicability:

Ratio methods are only valid if a significant amount of the gases used in the ratio is present. A good rule
is: Never make a decision based only on a ratio if either of the two gases used in a ratio is less than
10 times the amount the gas chromatograph can detect.

DISSOLVED GAS ANALYSIS DETECTION LIMITS

GAS LIMITS
Hydrogen (H2) 5 ppm
Methane (CH4) 1 ppm
Acetylene (C2 H2) 1 to 2 ppm
Ethylene (C2H4) 1 ppm
Ethane (C2 H 6) 1 ppm
Carbon monoxide (CO) & Carbon 25 ppm
dioxide(CO2)
Oxygen(O2) & Nitrogen (N2) 50 ppm

To apply Ratio Methods, it helps to subtract gases that were present prior to sudden gas increases. This
takes out gases that have been generated up to this point due to normal aging and from prior problems.
This is especially true for ratios using H2 and the cellulose insulation gases CO & CO2. These are
generated by normal ageing.
IEC599 METHOD
The following table shows the IEC-599 method of gas interpretation where in various limits of the
ratio corresponding to normal ageing and to various types of fault from which diagnosis of the nature
of a fault may be determined.

Detection limits and 10x

Code range of C2H2 CH4 C2H4 detection limits are shown
ratios C2H4 H2 C2 H 6 below
C2H2 1 ppm 10 ppm
<0.1 0 1 0 C2H4 1 ppm 10 ppm
0.1-1 1 0 0 CH4 1 ppm 10 ppm
1-3 1 2 1 H2 5 ppm 50 ppm
>3 2 2 2 C2H6 1 ppm 10ppm
Cas Fault Type Problems Found
e
0 No Fault 0 0 0 Normal Aging
Lo Electric discharge in bubbles
1 w energy 1 1 0 caused by insulation voids or
partial super gas saturation in oil or
discharge cavitations or high moisture in
oil.
High Same as above but leading to
2 energy 1 1 0 tracking or perforation of solid
partial cellulose insulation by sparking,
discharge or arcing; this generally
produces CO & C O2.
Low energy Continuous sparking in oil
3 discharges, 1-2 0 1-2 between bad connections of
sparking, different potential breakdown of
arcing oil dielectric between solid
insulation materials.
High Discharges with power follow
4 energy 1 0 2 through; arcing breakdown of
discharges, oil between windings or coils,
arcing or between coils and ground. Or
load tap changer arcing across
the contacts during switching
with the oil leaking into the
main tank.
Thermal Insulated conductor
5 fault temp. 0 0 1 overheating; this generally
range produces CO and C O2 because
150ºC this type of fault generally
involves cellulose insulation.
 Thermal Spot overheating in the core due
6 fault temp. 0 2 0 to flux concentrations. Items
range 150- below are in order of increasing
300ºC temperatures of hot spots. Small
hot spots in core. Shorted
laminations in core. Overheating
of copper conductor from eddy
currents. Bad connection on
winding to incoming lead, or
Thermal bad contacts on-load or no-load
7 fault temp. 0 2 1 tap changer. Circulating
range 300- currents in core; this could be an
700ºC extra core ground, this could
also mean stray flux in the tank

These problems may involve

cellulose insulation which will
produce CO & CO2
Thermal
8 fault temp. 0 2 2
range over
700ºC
Transformer maintenance is needed for:
1. To ensure highest availability
2. To ensure serviceability at all times
3. To ensure safety of personnel and
4. To extend useful life.

Presently, the emphasis is given more towards predictive maintenance as the downtime of the power
equipment is unaffordable.
The term ‘preventive maintenance’ describes measures aimed at discovering potential faults or
preventing the faults from developing for smooth operation of the equipment.

The maintenance activity consists of:

• Regular Inspection
• Testing
• Reconditioning wherever necessary.

Recommendations for maintenance:

• Transformer tank, cover and other parts should be inspected periodically for oil leakages,
peeling of paint or rust formation.
• The rusted portion should be properly cleaned and painted.
• Oil leakages should be immediately attended to.
• Clamping bolts on gasketed joints should be tightened properly and if necessary, gaskets to
be replaced.

The maintenance of transformer is categorized into following types:

Preventive Maintenance
Corrective Maintenance
TRANSFORMER MAINTENANCE REQUIRED
PARTS

Conservator:
• The inside of the conservator should be cleaned
periodically.
• Detachable end plate is provided to facilitate
Conservator & Oil cleaning on all power transformers.
level indicator Oil level indicator:
• Oil indicator glass should be kept clean so that oil
level is clearly visible.
• Broken indictor glass should be replaced
immediately.
• Float should be checked to see that there is no oil
in the float.

• Whenever temperature and humidity changes are

considerable and transformer is subjected to
Silica Gel breather fluctuating loads, breather should be inspected
frequently.
• When the colour of the breather changes from dark
blue to pale blue/pink, the breather of the silica gel
should be reactivated.

Buchholz Relay It should be ensured that isolating valves of buchholz relay are
kept fully open for unhindered oil flow.

If the diaphragm of the vent is broken, because of fault in the

Explosion Vent transformer, an inspection should be carried out to determine
the nature and cause of the fault.

• The level of the oil in the pockets holding the

thermometer bulbs should be checked and the oil
replenished, if required.
• Dial glasses should be kept clean and if broken should
Temperature be replaced immediately.
Indicator • Temperature Indicator found reading incorrectly
should be calibrated with standard thermometer
 immersed in hot water bath.

• Porcelain insulators and connectors should be cleaned

at convenient intervals and minutely examined for any
cracks or defects.
Bushings • Oil inside the oil communicating type bushings should
be checked by unscrewing air release screws provided
on bushing top.

• All connections should be tight

External • If the connections appear corroded, unbolt the
Connections connection and clean down to the bright metal with
including Earthing emery paper.

• Check the transformer for leakages periodically

Gaskets • The bolts should be tightened evenly around the joints
to avoid uneven pressure.

They should be greased and rotated to see that they turn

Rollers freely.

OLTC The temperature of the OLTC should not exceed the

temperature of the main tank. Any increase in the
temperature indicates internal problem.
FAULT PREPARATION DISMANTLING SAFETY REPAIR REAASEMBLY
REQUIRED PROCEDURE NOTES PROCESS

Abnormal Replace with spare Disconnect sensor Short WTI CT Replace Fix the new
indication instrument & inform from thermometer terminals instrument, insert the
of supplier for repair of pockets, disconnect before sensor in the
temperatur the instrument. alarm/trip contacts & disconnection. pockets, and
e at CT connection. De-energize reconnect the trip
OTI/WTI Remove the transformer. contacts & CT
instrument. terminals

De-energize Test & ensure Admit oil to Air release from

Abnormal transformer. Connect oil BDV of normal level. conservator process
drop in oil
level of
oil filter machine to - 60KV & valves.
top filter valve of water of
main transformer 15ppm before
conservator filling.

De-energize Oil BDV

Low oil transformer & open should be of Close the filling
level in the top filling plug of 60 KV Admit oil to plug.
condenser the bushing .Prepare moisture of normal level
bushing 1 adaptor between the 5ppm before
filling plug & filter - filling.
hose The plug
should not be
left open
when not
filling.

De- Oven for heating the Dismantle the Re-activate till Refill in the breather
hydrating active agent to 60 ºC. breather & take out _ blue colour
breather the active agent appears.,
active
agent
changes to
pink
colour.
FAULT PREPARATION DISMANTLING SAFETY REPAIR REAASEMBLY
REQUIRED PROCEDURE NOTES PROCESS

_
Low oil in Transformer oil for Unscrew the oil cup Adjust oil level. Refix the oil. Cap.
the de- filling & take it out.
hydrating
breather

Gaskets Unfasten, and Foreign Replace the Fit the component

leak, not Spare gasket. dismantle using particles gasket. back.
stopped by crane. Open should not fall
tightening. inspection covers for in the active
access to disconnect part. Ensure
electrical minimum
connections. exposure.

Low Cables Dismantle the old Replace the _

insulation cables. _ cable
resistance
in the
wiring of
central
panel.

Non – Spare instruments. Drain oil to required _ Replace

functional Oil filter machine and level. After refilling oil, air
MOG, B oil storage tank. release.
Relay,
OSR

Abnormal Spare Bushings. Disconnect the Excess pull on Replace the Refer the manual.
tan delta electrical connection internal bushing
valve of referring the bushing connection
bushings. manual. should be
avoided.

Low High vacuum pump Drain oil from main Refer the Fill fresh oil or Complete oil filling
insulation and filter machine. tank and evacuation manual right quality. & air release.
resistance to one Torr for 24
hrs.
Thermography is the use of an infrared imaging and measurement camera to see and measure thermal
energy emitted from an object.

Thermal, or infrared energy, is light that is not visible because its wavelength is too long to be detected
by human eye. Infrared thermography cameras produce images of invisible infrared or heat radiation and
provide precise non contact temperature measurement capabilities. Nearly everything gets hot before it
fails, making infrared cameras extremely cost effective, valuable diagnostic tools in many diverse
applications.

ELECTROMAGNETIC SPECTRUM

As seen from the electromagnetic spectrum, the short wavelength end of the infrared radiation lies at the
limit of visual perception, in the deep red. At the long wavelength end, it merges with the microwave
radio wavelengths in the millimeter range.

The infrared band is further subdivided into four smaller bands. They include:

• The near infrared (0.75 to 3 μm).

• The middle infrared (3 to 6 μm).
• The far infrared (6 to 15 μm).
• The extreme infrared (15 to 100 μm).
 THERMOGRAPHIC MEASUREMENT TECHNIQUES
An infrared camera measures and images the emitted infrared radiation from an object. The fact that
radiation is a function of object surface temperature makes it possible for the camera to calculate and
display the temperature.

However, the radiation measured by the camera does not only depend on the temperature of the object
but is also a function of the emissivity. Radiation also originates from the surroundings and is reflected
in the object. The radiation from the object and the reflected radiation will also be influenced by the
absorption of the atmosphere.

To measure temperature accurately, it is therefore necessary to compensate for the effects of a no. of
different radiation sources. This is done online automatically by the camera. The following object
parameters must however be supplied by the camera:

 The emissivity of the object

 The reflected temperature
 The distance between the object & the camera
 The relative humidity

EMISSIVITY

It is a measure of how much radiation is emitted from the object, compared to that from a perfect
blackbody.

Normally, object materials and subject treatments exhibit emissivity ranging from
approximately0.1 to 0.95. A highly polished (mirror) surface falls below 0.1, while an oxidized or
painted surface has much higher emissivity. The emissivity of metals is low, while for non metals,
with high emissivity, it tends to decrease with temperature.

Finding the emissivity of an object:

 Using a thermocouple
Select a reference point and measure its temperature using a thermocouple. Alter the emissivity
until the temperature measured by the camera agrees with the thermocouple reading. This is the
emissivity value of the reference object. However, the temperature of the reference object must not
be too close to the ambient temperature.

 Using a reference Emissivity.

A tape or paint of a known emissivity should be put onto the object. Measure the temperature of
the tape using the camera, setting emissivity to the correct value. Note the temperature. Alter
emissivity, until the area with the unknown emissivity adjacent to the tape/paint has a same
temperature reading. The emissivity value can now be read.
REFLECTED TEMPERTURE
This parameter is used to compensate for the radiation reflected in the object and the radiation
emitted from the atmosphere between the camera and the object.
If the emissivity is low, the distance very long, and the object temperature relatively close to that
of the ambient, it will be important to set and compensate for the ambient temperature correctly.

DISTANCE
It is the distance between the object and the front lens and the camera.
This parameter is used to compensate for the fact that radiation is being absorbed between the
object and the camera and the fact that transmittance drops with distance.

RELATIVE HUMIDITY
The camera can also compensate for the fact that transmittance is somewhat dependent on the
relative humidity of the atmosphere. To do this, set the relative humidity to the correct value. For
short distances and normal humidity, the relative humidity can normally be left at a default value
of 50%.

THEORY OF THERMOGRAPHY

BLACKBODY RADIATION

A blackbody is defined as an object which absorbs all radiations that impinges on it at any
wavelength.
The construction of a blackbody source is, in principle, very simple. The radiation characteristics
of an aperture in an isotherm cavity made of an opaque absorbing material represents almost
exactly the properties of a blackbody. A practical application of the principle to the construction of
a perfect absorber of radiation consists of a box that is light tight except for an aperture in one of
the sides. Any radiation which then enters the hole is scattered and absorbed by repeated
reflections so only an infinitesimal fraction can possibly escape. The blackness which is obtained
at the aperture is nearly equal to a blackbody and almost perfect for all wavelengths.

If the temperature of blackbody radiation increases to more than 525ºC the source becomes to be
visible so that it appears to the eye no longer black. This is the incipient red heat temperature of the
radiator, which then becomes orange or yellow as the temperature increases further.

Planck’s Law
The spectral distribution of the radiation from a blackbody is given by the given formula, called as
Planck’s formula

Wλb= 2πhc3 x 10-6[Watt/m2μm]

5 hc/λkT
λ (e -1)

where Wλb is blackbody spectral radiant emittance at λ

wavelength
c is velocity of light
h is Planck’s constant
k is Boltzmann’s constant
T is absolute temperature
λ is wavelength

Wien’s Displacement Law

By differentiating Planck’s formula wrt to λ, and finding the maximum, we have:

λ max=2898[μm]
T
This is Wien’s formula.
This implies that colour variance from red to orange or yellow as the temperature of the thermal
radiator increases.

Stephan-Boltzmann’s Law

The integration of Planck’s formula from λ=0 to λ =00 , we obtain the total radiant emittance (Wb)
of a blackbody.

Wb=σT4 [Watt/m2]

This is Stephan Boltzmann formula which states that the total emissive power of a blackbody is
proportional to the fourth power of its absolute temperature.
 NON-BLACKBODY EMITTERS

There are three processes which can occur that prevent a real object from acting like a black body:
a fraction of the incident radiation α may be absorbed, a fraction ρ may be reflected and fraction τ
may be transmitted. All these factors are more or less wavelength dependent.
The sum of these three factors adds up to the whole at any wavelength.
αλ+ρλ+τλ=1 ………..(1)

For opaque material τλ =0.hence eqn (1) reduces to

αλ+ρλ =1

Another factor, called the emissivity, is required the fraction ε of the radiant emittance of a black
body produced by an object at a specific temperature.
The spectral emissivity ελ is equal to the ratio of the spectral radiant power from an object to that
from a black body at the same temperature and radiant.
Mathematically, it is expressed as the ratio of spectral emittance of the object to that of a black
body.
ελ = Wλo
Wλb

There are three types of radiation source distinguished by the ways in which the spectral emittance
of each varies with wavelength.
 A black body, for which ελ = ε=1.
 A gray body, for which ελ = ε<1.
 A selective radiator, for which ε varies with wavelength.
.
 TRANSFORMER
Rewari Line
20 MVA TR-3

Name Plate Details

Make: Bharat Bijlee Limited

Rating (MVA): 20
Sl No.: 3195/3
Amp HV/LV: 175/1050
Cooling: ONAF
Ratio (kV): 66/11
% Imp: 13.19%
Vector Group: Dyn11
M.Year: 2005

FUNCTIONAL CHECKS

Alarm Trip
Buchholz OK OK
OSR NA OK
PRV NA OK
MOG OK NA
OTI OK OK
WTI OK OK
Insulation Resistance & PI measurement test:

Connection 15secs 60secs PI

HV-Earth 526 M ohms 582 M ohms 1.11
LV-Earth 749 M ohms 918 M ohms 1.23
HV-LV 732 M ohms 985 M ohms 1.35

Turn ratio Test

TAP RATIO
POSITION
R Y B
1 6.297 6.298 6.297
2 6.223 6.221 6.221
3 6.151 6.151 6.151
4 6.077 6.076 6.075
5 6.003 6.002 6.001
6 5.925 5.926 6.927
7 5.850 5.853 5.851
8 5.775 5.775 5.577
9 5.702 5.703 5.703
10 5.627 5.626 5.626
11 5.552 5.553 5.552
12 5.478 5.477 5.478
13 5.401 5.402 5.403
14 5.375 5.328 5.326
15 5.252 5.252 5.253
16 5.117 5.178 5.178
17 5.102 5.103 5.102

Winding resistance measurement Test

Tap HV winding Resistance in M ohms LV winding Resistance in M ohms

Position RY YB BR rn yn bn
1 933 934 931 11.36 11.26 11.34
2 916 907 912
3 911 897 904
4 897 887 892
 5 889 877 881
6 880 865 869
7 873 854 858
8 862 845 851
9 864 831 837
10 841 821 825
11 832 812 814
12 817 800 805
13 810 798 793
14 807 788 780
15 811 769 771
16 792 764 761
17 773 671 767

Magnetic Balance Test

Tap Position Voltage applied(Volts) Magnetizing

current (mA)
HV UV VW WU
Normal 240.2 210.7 28.8 10
Tap 123.5 239.9 116.2 7.98
35.2 205.7 242.8 10.52
LV Un Vn Wn
241.5 212.7 28.25 135.6
123.3 240.4 116.7 103
30.52 210.3 240.1 136.7

Capacitance and Tanδ Measurement test

Switch Tanδ (%) Capacitance (F)

position
HV/LV + Gr 2.88 0.003163
LV/HV + Gr 2.62 0.0068
HV/LV(UST) 3.1 0.005708
CONCLUSION & RECOMMENDATIONS

 The Power transformer Rewari Lines TR-3 has been satisfactory examined for all the functional
checks.
 The routine tests have been satisfactory performed and the results are acceptable.
 It has been observed that OLTC electric operation is getting stuck between taps due to over
travel and operation of limit switch is to be attended.