INSTALLATION,

OPERATION
and

MAINTENANCE MANUAL

Client : FRIEM
Project: E436 SNC ES
Serial Number: 35707-8

TABLE OF CONTENTS
Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 1

1.

DESCRIPTION..................................................................................................................................3
1.1
TRANSFORMERS CHARACTERISTICS.............................................................................3
1.2
GENERAL DESCRIPTION......................................................................................................5
1.2.1
MAGNETIC CIRCUIT.....................................................................................................5
1.2.2
WINDINGS.......................................................................................................................5
1.2.3
ELECTRICAL INSULATION...........................................................................................5
1.2.4
TANK.................................................................................................................................5
1.2.5
OIL CONSERVATOR........................................................................................................6
1.2.6
INSULATING OIL............................................................................................................6
2. SHIPMENT AND STORAGE...........................................................................................................7
2.1
DESPATCH................................................................................................................................7
2.2
ACCEPTANCE..........................................................................................................................7
3. ERECTION AND INSTALLATION.................................................................................................8
3.1
TRANSFORMER......................................................................................................................8
3.2
FITTINGS AND ELECTRICAL EQUIPMENT.....................................................................10
3.2.1
TRANSFORMER SILICA GEL BREATHER................................................................10
3.2.2
TRANSFORMER OIL LEVEL GAUGE........................................................................10
3.2.3
TRANSFORMER BUCHHOLZ PROTECTION RELAY..............................................11
3.2.4
DIAL-TYPE THERMOMETER.....................................................................................12
3.2.5
WINDINGS TEMPERATURE INDICATOR..................................................................12
3.2.6
PRESSURE-RELIEF VALVE..........................................................................................13
3.2.7
H.V. BUSHINGS..............................................................................................................13
4. COMMISSIONING.........................................................................................................................14
4.1
CHECKS ON COMPLETION OF ERECTION.....................................................................14
4.2
ELECTRICAL TESTS.............................................................................................................14
4.2.1
TRANSFORMER PROTECTION..................................................................................14
4.3
NORMAL OPERATION.........................................................................................................14
4.3.1
Bushings...........................................................................................................................14
4.3.2
Buchholz relay.................................................................................................................14
4.3.3
Oil level indicator............................................................................................................15
4.3.4
Air drier...........................................................................................................................15
4.3.5
Dial-type thermometer.....................................................................................................15
4.3.6
Gaskets.............................................................................................................................15
4.4
NORMAL SHUT-DOWN........................................................................................................16
4.5
START-UP AFTER A NORMAL SHUT-DOWN....................................................................16
4.6
FORCED AND EMERGENCY SHUT-DOWN......................................................................16
4.6.1
Trouble-shooting..............................................................................................................17
4.6.2
Recommended check-list in case of damages.................................................................17
4.7
START-UP AFTER A FORCED AND EMERGENCY SHUT-DOWN..................................17
4.8
INSTRUCTIONS FOR PRESERVATION DURING SHUT DOWN.....................................18
4.9
CHECK-LIST FOR START-UP COMMISSIONING AFTER MAJOR REPAIR OR
OVERHAUL........................................................................................................................................18
5. MAINTENANCE............................................................................................................................19
5.1
INTRODUCTION...................................................................................................................19
5.1.1
Programmed Inspection and Maintenance......................................................................21

1.

Job: E436-SNC-ES

Serial no.: 35707-8

DESCRIPTION

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 2

1.1

TRANSFORMERS CHARACTERISTICS

Serial no.:

35707

Tag No.:

36060-TF-001

No. of phases:

3/6

Type of cooling:

ONAN

Frequency:

50 Hz

Rated power:

13079/2x9248 kVA

Primary voltage:

20000 V

No-load secondary voltage:

589.1 V (Max)

Primary line current:

377.6 A (Max)

Secondary current:

9064 A

Primary connection:

Delta

Secondary connection:

Double star with IPT

Vector group:

Dyn1- Dyn7

HV insulation level:

24/50/125kV

LV insulation level:

3.6/10/ kV

Installation type:

Outdoor

For further details please refer to rating plate.

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 3

 Serial no.:

35708

Tag No.:

36060-TF-002

No. of phases:

3/6

Type of cooling:

ONAN

Frequency:

50 Hz

Rated power:

13079/2x9248 kVA

Primary voltage:

20000 V

No-load secondary voltage:

589.1 V (Max)

Primary line current:

377.6 A (Max)

Secondary current:

9064 A

Primary connection:

Star

Secondary connection:

Double star with IPT

Vector group:

Yyn0- Yyn6

HV insulation level:

24/50/125kV

LV insulation level:

3.6/10/ kV

Installation type:

Outdoor

For further details please refer to rating plate.

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 4

1.2

GENERAL DESCRIPTION

1.2.1 MAGNETIC CIRCUIT

The limbs and yokes comprising the magnetic circuit are built up of laminations of
grain-oriented cold-rolled steel. The individual plates are insulated from one another by
coating both sides of each plate with oil proof insulating material. The limb laminations
in the core are held together by stout webbing tape tightly applied. The top and bottom
mitred yokes which complete the magnetic circuit are interleaved with the limbs and
are clamped by steel sections.
1.2.2 WINDINGS
Winding conductors are made of electrolytic copper, insulated by pure cellulose paper.
The more recent studies of problems in the high current field led to consider the
windings as a mechanical structure subjected to compression, tension or bending
stresses which depend on the position of each winding as regards to core and on the
currents' distribution in each one.
Therefore, windings are mechanically designed as above said and, depending on the
design requirements, are made not only of annealed copper but of hard copper or
copper alloy too. All welding are made by brazing.
The whole coil structure is mechanically sound and rigid and capable of resisting the
stresses set up under the most onerous service conditions.
1.2.3 ELECTRICAL INSULATION
The conductors insulation is obtained by a required number of overlapped layers of
cellulose paper with very high and uniform dielectric strength. The windings are
insulated one another by pressboard cylinders or barriers and/or special bakelisedpaper cylinders with high mechanical and dielectric strength.
Particular attention is given to the cylinders, barriers and spacers arrangement in order
to improve the cooling effect, to avoid the hot spots and to guarantee the required
insulation characteristics.
The end insulation between coils and yokes is obtained by the insertion of pressboard
collars or angle rings and caps. Spacers, between the insulating parts at the winding
ends, allow the free circulation of the cooling oil through the coil ducts.
1.2.4 TANK
The tank is fabricated with steel plates suitably reinforced and welded in order to allow
lifting the complete transformer. Diamagnetic steel is used in critical areas to avoid
local over-heating due to leakage flux from the windings or caused by current flowing
into connections.
The upper part of the tank is always bolted to the lower one.
All bolts are properly spaced to achieve uniform distribution of the pressure on
gaskets. Gaskets are of hot oil resistant synthetic rubber; they are placed in proper
slots to avoid over-compression of the rubber.
Cover shape is such as to make a more easy flow to the conservator of possible gas
coming from core and coils during service.

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 5

The tank is provided with eyes for lifting the transformer filled with oil and lugs to
displace the unit on its base. In addition to the required fittings, the tank is provided
with: filter press, drain, sampling, valves and ground terminals.
1.2.5 OIL CONSERVATOR
The volume of oil conservator is approx. 14% of the respective volume of the tank.
The conservator is divided in two parts: one for the main tank and one for the OLTC
and both are fitted with:
one filling hole.
one oil level indicator (magnetic type)
one pipe connection for silica gel breather
one drain plug
one pipe connection to the Buchholz relay.
1.2.6 INSULATING OIL
The transformers are delivered complete with enough oil for the first filling. The oil
used is mineral oil.
For service in an electric transformer, oil is required to serve as both an insulating and
a cooling medium. To satisfy these requirements it must:
have a low viscosity
have a high dielectric strength
have a high flash point
be free of acid, alkali and corrosive sulphur
resist oxidation and slugging
have a low pour point
be compatible with the materials used in transformer construction
Below you can found the characteristics of the mineral oil ( SHELL Diala D); Push on
the icon near the file name :
Oil SHELL Diala D - characteristics
Oil DIALA D - Data
sheet.pdf

Oil SHELL Diala D safety characteristics

Oil DIALA D Material safety data sheet.pdf

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 6

2.
2.1

SHIPMENT AND STORAGE

DESPATCH

All transformers are carefully dried out and filled with dehydrated and de-aerated oil
before factory test. All transformers are carefully factory tested before despatching.
Transformers are then despatched not full-filled with oil but for transport motivations
some oil are despatched separately in apposite drums and the transformer filled up with
nitrogen gas. The accessories are packed in strong wooden crate, and every precaution
is taken to ensure that they arrive at their destination in perfect condition. Any effort
has to be done in order to avoid any kind of shock to the transformer during
transportation, handling and storage.

2.2

ACCEPTANCE

Immediately upon receipt of the equipment, check the transformer and accessories
accurately for detecting any damage due to transportation.
Check the transformer and other parts for obvious signs of damage or movement on
the wagon or for loose or broken tie rods. If there is evidence of rough handling, make
a critical inspection of the shipment. Claims must be sent to the transportation
company immediately, and soon after notified Specialtrasfo service.
Inspect tank for leaks. Use a crane to unload the transformer, after checking that the
crane and chains are of adequate strength. Ensure that the lifting chains (ropes) are of
sufficient length to prevent excessive horizontal stress. Keep the chains (ropes) clear of
bushings or auxiliary equipment on the top of the unit and attach them only to the lugs
provided.

3.
3.1

ERECTION AND INSTALLATION

TRANSFORMER

The transformer is suitable for outdoor installation.

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 7

Locate the transformer in its permanent position using when it is possible a crane of an
adequate load: otherwise move it on rollers - do not drag.
The erection of H.V. transformers must be arranged so as to comply with the official
safety regulations (the minimum distance from live parts to fences is given by (7 + 0.7
kV) cm and in any case not less than 15 cm).
In order to prevent crane harm, lifting equipment or their loads from any accidental
touch with alive elements, the latter shall be de-energised and grounded during all the
lifting operations.
The voltage shall not be reset in this areas until workers, once the operations are over,
have received from the foreman a clear notice that works are over and that voltage can
be reset.
It is forbidden to remove the safety protections and to carry out works on electric
equipment prior to open the circuit feed external multi-pole circuit breakers.
Anywhere high voltage equipment exist, a suitable "danger of death" signal shall be
provided.
For particularly dangerous works on electric equipment, even if carried out by one
skilled person, a second person must be present.
For connection between metal structures to the main earthing system, leads suitable for
grounding current shall be used; the cross section of these leads shall be higher than or
equal to 16 mm if copper type, or 50 mm if galvanised iron type.
The connections of the lead with the metal components to be protected to the earthing
rod shall be carried out by tightening the relevant bolts, after removing any kind
whatsoever of paint or insulating layers.
The connection between the various components shall be so strong as to withstand
mechanical stresses due to possible ground fault current.
All bolts and nuts must be tightened properly so that they cannot work loose as a result
of vibrations and preventing any dangerous overheating. Once the power line either
H.V. or L.V. side of the transformer are connected no mechanical force as weight of
connection bars, bending, stretching forces,... has to act on bushings.
Since the cooling radiators are of two types (small and large), their assembly has to be
carried out with reference to the outline drawing bearing in mind that they can be
exchanged among the two categories. The erection of radiators begins with removal of
blank flanges placed on butterfly valves fixed on the radiator connection pipes on the
tank walls. Then the radiators have to be positioned using an adequate crane and fixed
by means of bolts provided (care must be taken in order not to damage o-ring gasket
between the radiator flange and the butterfly valve). We suggest waiting to open the
shut-off butterfly valves after completion of erection.
The following step is oil conservator assembly; in this case the connection from the
conservator to the main tank is through the Buchholz relay, provided with a shut-off
butterfly valve that has to be opened after conservator fixation (carried out after
removal of a blank flange on the valve as done for radiators).
At this point oil filling can take place using insulating oil supplied in loose drums
through the oil filing hole on top of the conservator. When oil level gauge reaches the
level corresponding to 20 C it is necessary to open the radiator valves in order to
allow complete filling of the transformer (a warning plate reminds that after radiators
assembly oil has to be topped up). When filling appears to be complete (check oil level
gauge) it is necessary to vent all radiators through the venting caps placed on their
Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 8

higher point and top up oil in the meanwhile in order to reach a steady-state in which
oil level is correct and no more air is coming out from the venting caps. To complete
this operation, HV bushings (primary side) and Buchholz relay have to be vented using
respectively the screws on top of each stud for the bushings and the appropriate
venting cap on the relay.
At this point the upper valve has to be closed and the silicagel breather screwed on its
pipe after having filled its lower cap with a small quantity of oil (instructions are clearly
marked on the breather itself).

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 9

3.2

FITTINGS AND ELECTRICAL EQUIPMENT

3.2.1 TRANSFORMER SILICA GEL BREATHER

The silica gel breather consist of a cylinder filled with
air-drying agent (silica gel) (see Fig. 1) The cylinder is
firmly clamped via ring gasket to the upper part 1 by
means of 3 screws 2. In the lower part 3 is located the
valve that allows the air flow when the volume of the
oil in the transformer changes.
The assembled breather is despatched separately, filled
with silica gel and closed airtight by two caps 4 & 5.
therefore operating the transformers, both caps are to
be removed and the breather is to be mounted on the
oil conservator.
The air-drying agent is silica gel impregnated. In the
active condition its appearance is crystalline orange. On
taking up moisture a colour change to colourless takes
place over an area progressing upward from the
bottom.
Silica gel can be regenerated by heating to a
temperature of 120-130C.
Fig. 1 Silica gel breather
A temperature of 140C should not be exceeded as in
this event the colouring indicator can give off hydrogen
chloride gas which combines with the moisture driven off to form injurious
hydrochloric acid. Moreover, the desiccant would become very brittle which would
make itself noticeable afterwards as wear. Heating can be carried out most expediently
in a temperature controlled oven with natural or forced air circulation. Drying can be
accelerated by spreading the desiccant in thin layers. First, one waits until the desiccant
achieves a deep orange colour. Then it remains for approximately another hour in the
hot oven.
3.2.2 TRANSFORMER OIL LEVEL GAUGE
The oil level indicator consists of a transmitter and an indicator, capable of separation
by means of a magnetic coupling. The float lever in the transmitter portion transfers the
lifting motion of the float to the float shaft which is connected to the pointer axis in the
indicator portion by means of a magnetic coupling. This method prevents the indicator
from coming into contact with oil. The oil level can be fitted with one or two contacts.
These contacts act when the oil level falls down to minimum or exceeds the maximum
level.

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 10

3.2.3 TRANSFORMER BUCHHOLZ PROTECTION RELAY

This relay is shown in the following figure:

Fig. 2: Buchholz protection relay

This relay comprises an oil-tight container fitted with two internal floats which operate
mercury switches connected to external alarm and tripping circuits. Normally the
device is full of oil and the float, due to its buoyancy, rotates on its supports until it
engages its stop. An incipient fault within the transformer generates small bubbles of
gas which, in passing upwards towards the conservator, become trapped in the housing
of the relay, thereby causing the oil level to fall. The float rotates as the oil level within
the relay falls, and when sufficient oil has been displaced the mercury switch contacts
act, thus completing the external alarm circuit. In the event of a serious fault within the
transformer, the gas generation is more violent and the oil displaced by the gas bubbles
flows through the connecting pipe to the conservator. This abnormal flow of oil causes
the float to be deflected thus actuating the contacts of the second mercury switch and
completing the tripping circuit of the transformer circuit-breaker, so disconnecting the
transformer from the supply. Gas within the device can be collected from a small valve
at the top of the relay for analysis and from the results obtained an approximate
diagnosis of the trouble may be formed. Some of the faults against which the relay will
give protection are: (1) Core bolt insulation failure (2) Bad electrical contacts (3)
Local overheating (4) Loss of oil due to leakage. These would normally initiate an
audible or visible alarm via the upper contact whilst the following more serious faults
would trip the transformer from the supply:
(a) short-circuit between phases (b) winding earth fault (c) winding short circuit (d)
puncture of bushings
Buchholz relay is fitted with two contacts (alarm and trip).

3.2.4 DIAL-TYPE THERMOMETER

A dial-type thermometer is supplied having one alarm contact as a warning of rising
temperature and a trip contact. The setting of this alarm is depending on local ambient
and loading conditions. Alarm thermometer depending to oil temperature might be set
Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 11

at 85C to take account of the inherent time lag between maximum and top oil
temperatures. It must be borne in mind that there will be a temperature gradient
between the actual minimum temperature of the copper conductors and that registered
in the top of the oil the former of course being the higher. This accounts for the
differences suggested between the permissible continuos temperature and the alarm
temperature. Correct settings for alarm and trip contacts are shown on auxiliary wiring
diagram.

Fig. 3: Dial-type top oil thermometer

3.2.5 WINDINGS TEMPERATURE INDICATOR

See Attached file for more informations.

Winding_Temperatur
e_Indicator.pdf

3.2.6 PRESSURE-RELIEF VALVE

The transformer casing is structurally, designed constructed and tested to resist to all
internal pressures associated with the static head applicable.

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 12

However, to safeguard against instantaneous internal over pressure due to an

unexpected trouble as short circuit, or oil arcing, a pressure-relief valve is sometimes
fitted on transformer casing.
During transformers operation safety valve mounted on the transformer, does not
require particular maintenance.
However it is advisable periodically to check the correct functioning of the electrical
contacts and to ensure that no accumulated gas has been trapped with the valve.
Pressure relief valve is fitted with a normally closed contact.
3.2.7 H.V. BUSHINGS
Damaged porcelain bushings can be replaced without opening the transformer:

lower the oil level in the tank just below the cover
unscrew nuts (1)
remove cap (2) and gasket (3)
unscrew nuts (4) and remove ring (5)
dismount porcelain being careful that dirt and moisture do not enter in the tank
mount a new porcelain, out nuts and gasket as required and fill up the transformer
with oil.

1
2
3

4
5

Fig.4 H.V. porcelain bushing

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 13

4.
4.1

COMMISSIONING

CHECKS ON COMPLETION OF ERECTION

We recommend that the following items be checked and that the results be recorded
after completion of the erection:
tightness of transformer tank
oil level of transformer
tightness of bushing connections
silica gel breather air flow unrestricted - filling o.k.
tap changer position o.k.
transformer tank and cover electrically grounded
control devices complete - connections complete
thermometer pockets oil-filled
all valves of cooling system open.

4.2

ELECTRICAL TESTS

We recommend that the following tests be performed and the results recorded prior to
commissioning the transformer:
4.2.1 TRANSFORMER PROTECTION
All devices designed for the protection of the transformer, such as a differential
overcorrect fault current protection devices, etc. as well as the protective devices
mounted on the transformer such as oil level, dial-type thermometer, Buchholz relay,
etc. should be checked for perfect operation.

4.3

NORMAL OPERATION

The following paragraphs shows the accessories of the transformer Outline Dwg. No.
85167 with the procedures to be followed for inspection and checks during service
(Tables 1-2).
4.3.1 Bushings
For the output and feeding there are mounted:
3 H.V. Bushings
6 L.V. Bus-bars
4 IPT Bus-bars
4.3.2
Buchholz relay
See point 3.2.3
NOTE
The alarm trip contacts also act in the event that the oil level should become
exceedingly low. When the alarm and tripping contacts act, it is necessary to check
through the relay window the quantity of gas.
Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 14

4.3.3 Oil level indicator

On the conservator of transformer it is mounted:
1
Transformer tank oil level indicator
2
Transformer OLTC oil level indicator
It is necessary to check that the insulating oil quantity inside the conservator is at the
right level, and that the oil does not outflow during the service, or that a level
reduction takes place with the consequent risk that the upper part of the transformer
remains without insulating oil.
Oil level indicator device is fitted with two normally closed contacts, that are operated
when oil level becomes exceedingly low.
4.3.4 Air drier
On the oil conservator of the transformer it is mounted:
1
Transformer tank air drier
2
Transformer OLTC air drier
It is necessary to keep the negligible humidity degree existing in the transformer
unchangeable in time, after treatment. The reload periods change according to the
humidity degree, the season and the load-cycle of transformer.
See point 3.2.1

4.3.5 Dial-type thermometer

The insulating oil temperature dial thermometer is used for taking the oil maximum
temperature.
Table 1 shows the temperatures causing automatically the alarm and the trip of
transformer.
It is equipped with:
1
dial-type thermometer
4.3.6 Gaskets
Material usually adopted for gaskets is the synthetic rubber. Should some leakage be
found, contact the maintenance personnel.
TABLE 1
TEMPERATURE FOR ALARM AND TRIP OF TRANSFORMER
1 ST CONTACT (ALARM) C
2 ND CONTACT (TRIP) C

85
90

TABLE 2 CHECKS DURING NORMAL OPERATION

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 15

ITEM
General

PANEL CHECKS
Voltage, currents, frequency
ambient temperature, alarm
tests

Cooling system
Connection
Buchholz relay Alarm signalling recording
Air drier

Conservator

LOCAL CHECKS

EVERY

Copper & oil Temp, oil leakage,

vibrations, noisy

tour
day

Normal pump operation

tour

existing gas, must be immediately

signalled
silica gel colour:

orange:dry

violet : humidity 2030%

colourless: moisture
oil level according to oil
temperature
existing trip, must be
immediately signalled

Pressure-Relief
Valve
O.L.T.C.
Operation number recording &
relevant working positions
Oil
No. of alarms No. of tripping Temperature value
Thermometer

tour
(*)
tour

tour
tour
tour
month

NOTE:
(*) it is always advisable to perform a chemical analysis of the gas.

4.4

NORMAL SHUT-DOWN

Open the circuit breaker to disconnect the transformer from the network.

4.5

START-UP AFTER A NORMAL SHUT-DOWN

Before a reinsertion of the transformer after a normal shut-down.

Removal of all earthing connections put for safety during this operation if any.

4.6

FORCED AND EMERGENCY SHUT-DOWN

In case of forced or emergency shut-down for tripping of protective devices or for

transformer faults, it is necessary, before re-energising, to carry out the checks listed
and classified according to the fault, as described below.

4.6.1 Trouble-shooting
ITEM

Job: E436-SNC-ES

TROUBLE

Serial no.: 35707-8

PROBABLE CAUSE

Date: 06/08/07

RECOMMENDED
CHECKS

Comp.: A.R. Checked: A.F.

Page 16

Transformer
Buchholz

Gas accumulation internal flash over ionisation

tripping or alarm
core & coil assembly
overheating
pump faulty tightness
Pressure-Relief Valve Intervention
flash over gas production
slow gas accumulation
Temperature
Alarm or tripping overloading
detectors
overheating
cooling equipment damage
Differential protection Intervention
flash over between windings
or starting
or towards earth
short circuit between turns or
on the line
Maximum current
Intervention or
flash over between windings
protection
starting
or towards earth
short circuit between turns or
on the line

C1-C2-C3-C4-C6

C1-C2 -C8
C5-C7
C1-C2-C3-C4

C1-C2-C3-C4

4.6.2 Recommended check-list in case of damages

These actions to be carried out by the maintenance operators:
C1 Voltage ratio measurement
C2 Winding resistance measurement
C3 Check of tap-changer operation
C4 Winding insulation test with Megger at 5 kV
C5 Check of pumps and heat exchangers
C6 Check of gas relay
C7 Check of temperature indicators
C8 Check of safety valve

4.7 START-UP AFTER A FORCED AND EMERGENCY SHUTDOWN

After an emergency shut-down, before re-energising, carry out a check as made under
item 4.2 of this chapter before the initial energising.

4.8 INSTRUCTIONS FOR PRESERVATION DURING SHUT

DOWN
During the shut-down, perform these checks:
every week start the cooling system
every day evaluate the silica gel service ability of air washers
every day check if there are oil leakage
if the temperature drops below -20C (check that the core is at the -10C), then it
is necessary to proceed with a vacuum drying with relevant treatment.
Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 17

4.9 CHECK-LIST FOR START-UP COMMISSIONING AFTER

MAJOR REPAIR OR OVERHAUL
After having carried out considerable maintenance it is necessary to follow the
directions about the checks as made during the initial energising.

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 18

5.
5.1

MAINTENANCE

INTRODUCTION

Proper maintenance is a very important subject for getting safe and reliable
operation of transformers.
General concepts of good maintenance applicable to all electric apparatuses and to
the electric power system as a whole, are suitable also for transformers, taking into
account that they are very often key components in the electric power transmission
system.
A transformer should be kept clean, avoiding any heavy accumulation of dust, oily
substance, sand, salt and foreign matter any kind, especially on bushings and living
parts.
Control cubicles must be maintained dry and clean, replacing the relevant gaskets at
due time, if tightness is suspected or checked to be precarious.
Accumulation of dust and water obviously impairs proper operation of electric
apparatuses.
Outdoors located measuring and protecting devices, like oil level, oil temperature
indicator, winding temperature indicator, Buchholz relay, etc. although specifically
built for this sort of installation, may suffer infiltration of sand and rain, with
consequent rust, in case tightness is poor. Replacing defective gaskets and/or
assuring tightness is definitely necessary for reliable operation.
Good efficiency of the cooling plant is extremely important for transformers any
size, since they operate always at full load.
Consequently keeping all parts devoted to heat transfer, extruded tubes in oil/water
cooling units, clean and free from deposits of any kind, is necessary to maintain the
oil temperature within acceptable limits.
Excessive oil temperature due to poor cooling efficiency does cause accelerated
ageing of insulating parts and reduced transformer life, as well as higher load loss,
since winding ohmic resistance increases with temperature.
Checking of oil level is also important, although any dangerous lack of oil inside the
tank should be prevented by minimum level warning.
Abnormal oil level can be settled by sucking out the excessive oil by means of a
narrow hose or by topping-up, using in case and dry and clean transformer oil
available on site.
Oil leakage from the tank, though not very infrequent, may require some welding
work, that should be carried out by skilled workmen.
Generally small welding works on oil filled tanks can be performed safely.
Taking care of the paint and restoring it when necessary, helps preventing rust and
poor looking of the unit.
All thermal protection devices are very important.
At last during few months after the start of operation it is advisable to observe the
mean operating conditions of the transformer, making a correlation, if possible,
between the temperature readings and the average voltage on the primary side.
NOTE
It is important to keep records of all important events related to operation of the
transformer.
Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 19

All short circuits, occurred on the transformer or in the line, wrong paralleling,
misoperation of other electric devices, like circuit breakers, disconnectors, etc.,
must be recorded together with all useful information, like evaluation of short
circuit currents, type and time of intervention of protective devices, sequence of
intervention, etc.
In case of alarm or tripping of the Buchholz relay it is important to collect the gas, if
any, and to have it analysed by means of the relevant set.
In case information or instruction are needed from Specialtrasfo because of
anomalous operation of the transformer or damage, please care to transmit most
comprehensive information on the following items:

complete rating plate data

unit's serial number and year of manufacture
duty cycle and details on duty normally performed by the unit
period during which the equipment has been operating and singular events
occurred meanwhile
actual supply voltage and frequency of the equipment
complete description of the circumstances related to fault occurrence
User's opinion on the cause(s) of the fault or proposed means to overcome
misoperation.

IMPORTANT NOTE
Any Buchholz tripping, especially in the case that there is sudden appearing of an
appreciable amount of gas (some hundreds of cm) and gas mixture is flammable,
does rise doubt that a significant event has affected the unit. In this case it is
absolutely necessary to carry out appropriate measurements and checks before any
new energising.
The following tests are the most significant and are relatively easy to be carried out:

measurement of insulation resistance between winding and ground.

measurement of the phase currents drawn by the unit when fed at a.c. low voltage.

In a transformer the current should be closely proportional to the supply voltage.

Any significant deviation from the expected value of the current and significant
unbalances among the phase-currents should induce some doubt about the
soundness of the unit .

5.1.1 Programmed Inspection and Maintenance

Identification of transformer components
Various items and sub-items on the transformer, which require maintenance, check
or supervision, are identified by one or more figures, according to the following list
Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 20

(not all of the listed items are mounted on the transformer covered by these
instructions):

Items mounted are indicated with an .

1

TANK
X
X

1.1
1.2
1.3
1.4
1.5
1.6
1.7

X
X
X
X
2

BUSHINGS
X

2.1
2.2
2.3
2.4

Butterfly valves
Manholes, terminal boards
Gatevalves, cocks
Gaskets
Bolts & nuts
Painting
Earthing

Porcelain
Pfisterer type
Current transformers
Adaptors
2.4.1
Bolts & nuts
2.4.2
Gaskets
2.4.3
Terminal boards

CABLE BOXES
3.1 Bolts & nuts
3.2 Gaskets
3.3 Oil/oil bushing

4
4.1

TAP-CHANGER
Off-load
4.1.1 Contacts
4.1.2 Manual/motor drive

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 21

4.2

On-load
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8

Control cabinet
Diverter switch contacts
Transit. Resistors
Remote control
Remote position indicator
Oil in switch compartment
Protection relay
Tap selector contacts

CONSERVATOR
X
X
X
X
X

5.1
5.2
5.3
5.4
5.5

Draining piping
Buchholz relay
Oil level indicator
Protect. diaphragm
Air drier

COOLING EQUIPMENT
X

6.1 Piping and brackets

6.2 Oil/air coolers
6.3 Oil/water coolers
6.3.1
Manometers
2.4.2
Thermometers
6.4 Fans
6.4.1
Blades
6.4.2
Bearings
6.5 Pump-motor
6.5.1
Oil flow indicator
6.5.2
Bearings
6.5.3
Gaskets
6.6 Radiators
6.7 Oil, air, water flow indicators
6.8 Thermostats

CABINETS & STANDARD ACCESSORIES

X
X
X

Job: E436-SNC-ES

7.1
7.2
7.3
7.4
7.5

Cables
Terminal boxes
Tap-changers, remote control relays, etc.
Winding temperature indicators
Oil temperature detectors (PT100)
Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 22

7.6 Core temperature detectors

7.7 Dial type oil thermometer
7.8 Pressure relief valve

X
X
8

SPECIAL ACCESSORIES
8.1
8.2
8.3
8.4
8.5

Automatic voltage regulator

Autom. parallel control device
Lightning arresters
Arcing horns on bushings
Condenser

OIL
X

9.1 Mineral
9.2 Silicon

NOTE
In the following pages there is a list of "Maintenance Codes" which consist of sets of
two or more figures, identifying the transformer components as per the above
schedule.
For example:6.5.2=pump with motor bearings;
7.5=oil temperature detector

MAINTENANCE SCHEDULE
TRANSFORMER
MAINTENANCE
CODE

TYPE OF CHECKS

OPER.
COND.

FREQUENCY
(MONTHS)
1

1.1 - 1.2 - 1.3 - 1.4

1.5 - 1.7
1.6
2.1
2.2 - 2.3
2.4.1
2.4.2 - 2.4.3
Job: E436-SNC-ES

Ageing & oil tightness

Clamping & contact checks
Ageing
Cleaning - fitness verification
Visual & electrical check
Clamping check
Ageing & oil tightness
Serial no.: 35707-8

Date: 06/08/07

12

o.o.s.
o.o.s.
o.o.s.
o.o.s.

o.o.s.

Comp.: A.R. Checked: A.F.

Page 23

3.1
3.2
3.3
4.1.1 - 4.1.2
4.2.1 - 4.2.5
4.2.2 - 4.2.3 - 4.2.6
4.2.7
5.1 - 5.3 - 5.4
5.2
5.5
6.1
6.2 - 6.6
6.3
6.3.1 - 6.3.2
6.4.1
6.4.2
6.5.1
6.5.2 - 6.5.3
6.7 - 6.8
7.1 to 7.8
8.1 - 8.2
8.3 - 8.4
8.5
9

Clamping check
Ageing & oil tightness
Visual inspection
Driving gear check
Check, cleaning of remote switch contacts &
coils
Visual check & eventual replacement of contacts
& oil
Operation check
Oil tightness & level check
Mechanical / electrical operation check
Silica gel colouring check
Bolt clamp, ageing & oil tightness
Ageing & oil tightness
Scale removal & radiator bank cleaning
Check of given val.
Blade clamping check
Clearance check
Noise level check
Oil tightness & clearance check
Mechanical & electrical check
Ageing, cleaning & operation verification
Ageing, cleaning & operation verification
Cleaning, operation verification
Ageing, oil tightness, cleaning
Dielectric strength
Contents & nature of gases
Humidity contents
Chemical-physical charact. check
Power factor verification

o.o.s.
o.o.s.
o.o.s.
o.o.s.
o.o.s.

o.o.s.

o.o.s.
o.o.s.
o.o.s
i.s.
o.o.s.
o.o.s
o.o.s.
i.s.
o.o.s.
o.o.s.
i.s.
o.o.s.
o.o.s.
o.o.s.
o.o.s.
o.o.s.
o.o.s.
i.s.
i.s.
i.s.
i.s.
i.s.

X2

3
X3

X
X
X
X
X
X
X
X
X
X
X
X

(*) = Occasionally / o.o.s. = Out of service; i.s. = in service

NOTE 1
The frequency of the checks depends on the type of tap-changer used,
on the number of switching operation and on the type of service performed by the
transformer.
NOTE 2
Ambient and load condition may suggest more frequent checks.
NOTE 3
The frequency of checks is obviously dependent on the type of
water used for cooling (the harder and more corrosive is the water, the more frequent
should be the checks).

Job: E436-SNC-ES

Serial no.: 35707-8

Date: 06/08/07

Comp.: A.R. Checked: A.F.

Page 24