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Prolec GE India
Installation, Operation and Maintenance Manual
Distribution Transformers
Our Customer Service Mail ID: services@Prolec-GEIndia.com

Customer Service Contact No.: 044-30289843
INSTALLATION AND MAINTENANCE OF TRANSFORMER
"PROLEC GE" Transformers are thoroughly inspected and tested at the Works before
dispatch. For the convenience of transport, certain components and parts are dismantled and
packed separately in crates or boxes. The fittings such as drain valve, filter valve etc., are suitably
protected. The Tapping switch, Bushings etc., is also protected against transit damage or loss. In
case of large size transformers, the detachable Radiators/Banks are usually packed separately.
However, the parts which are usually dismantled and sent separately are listed below.
1. Detachable radiators with both flanges blank.

2. Cooling fans, brackets and supporting frames.
3. Conservator with oil gauge.
4. H.V. and L.V. Porcelain Bushings.
5. The control cubicals for OLTC and marshalling Boxes.
6. Fittings like Thermometer, Winding Temperature Indicator, Buchholz Relay,
Explosion Vent, Rollers and Breathers.
7. Oil for topping in separate sealed drums.
The specific items detached and packed separately against each supply are given in the packing
list accompanying each consignment. The tank with the core and the winding is generally sent
filled with oil blocking all valves and openings. The transformer on receipt at site should be
verified with the packing list and challan and should be closely examined for any damage in
transit.
The oil level in the main tank so also in the sealed drums should be checked and it should be
made sure no pilferage of oil has taken place. The Bushings should be checked for any crack or
breakage. Any damage or loss noticed should be promptly reported to the supplier with full
details.
Handling / Storage:
The transformer and its accessories should be handled in its upright position. The lifting
lugs/jacking pads which are provided should be made use of for shifting the unit. All the parts
should be cleaned and got ready for fitting prior to taking up assembly. However, if the unit is not
taken up for assembly immediately, the transformer with the accessories should be stored in a
clean dry place protected against weather and moisture. The Indoor type transformers should be
stored under cover and they should preferably be filled with oil to reduce the extent of possible
absorption of moisture. The operating plug should be plugged.
Installation:
The following precaution should be taken while erecting the transformer:
1. The transformer should be opened when there is fair weather to minimize the possibility of
moisture ingress.
2. Care should be taken that all tools are clean and dry and no foreign matter or dust has
entered into the tank while working on a transformer. All tools should be preferably tied with
a tape to prevent it from accidentally slipping inside the transformer.
3. The main tank should be placed on the plinth and the carriage should be anchored. In case
of transformer erected/installed with rollers, proper stop blocks should be provided.
4. In case, the transformer is installed indoor, care should be taken that proper ventilation, free
movement of air around all four sides is maintained. The transformer should be kept well
away from the wall. The site should be so chosen that it is not normally damp.
5. The OLTC mechanism if sent separately should be checked and ascertained that the
Selector Switch and the mechanism are in identical position. In case of transformer with tap
changer housed in the main tank, it will be necessary only to couple the driving mechanism
at the correct position.
The conservator with its support frames should be assembled, along with the valves if
provided. The HV and LV Bushings should be thoroughly cleaned before installation, ensuring
that they are dry. The H.V. Bushing beyond 66 KV class are generally sent in cases with the
bottom condenser portion protected and smeered with Vaseline. Hence this should be properly
cleaned. The H.V Bushing leads from the transformer winding are usually anchored to the
dummy plate. This plate should be carefully removed without damaging the washer.
The Bushings of below 66 kV class are normally of oil communicating type and the
assembly of these should be done after removing the blanking plate and carefully lowering the
Bushing and simultaneously drawing the HV, lead through the Bushing hole with the help of thin
wire. In case of 66 KV class and above, the Bushing after fixing on the tank the internal terminal
connections should be made through the inspection cover. The Arcing Horns should be fitted
properly and gaps should be carefully adjusted.
In case of other connections where the magnitude of current is large, it is advisable to use
conductors of copper which are flexible type and the cross section either rectangular or hollow
circular as external jumpers. Where the connections are rigid and more than 3 to 4 meters long,
special expansion type of connections are recommended to prevent the terminals. Bushings
being unduly stressed due to thermal expansion. If aluminium or ACSR conductors are used for
connection to the transformer terminals, suitable bimetallic type connector should be used to
prevent electrolytic corrosion.
The Buchholz Relay, thermometer, Winding Temperature Indicator and other fittings
should be carefully mounted avoiding any rust and the gasket should be properly fixed to avoid
any leakage. The Marshalling Kiosk, is to be mounted either on the brackets provided on the
transformer or on separate foundation as per the provision made and the inter-connecting cables
should be fixed to the appropriate terminals. Proper care should be taken to support the cables
as well as the capillary tubes avoiding sharp bends.
Filling the Transformer with oil:
Before filling the transformer completely with oil, all the accessories should be properly fixed
and checked. In case of detachable radiators, they should be properly cleaned and flushed with
hot oil. The radiator banks should be properly aligned taking care that all joints, expansion joints
etc., are properly matched, the oil sample should be drawn from the drums and if in the event the
dielectric strength is low, then the recommended value of oil should be obtained by filtering. It
should be ensured that during the process of filling, no air pockets should be left in the tank, so
also in the Radiator Bank and that no moisture, or dust enters the oil. The removal of air traps
can be avoided by opening the air vents. The oil should be filled through the centrifuge/vacuum
filter press, using metal hoses. Rubber hoses should be avoided since the same will deteriorate
in oil. It is advisable to fill the transformer tank through the bottom drain valve but, however, if
this facility is not available, the oil could be filled through conservator in which case, the flow of
oil should be kept to the minimum. Any air trapped in the Buchholz Relay should also be
released. After topping up the transformer completely with oil, it would be advisable to energize
the unit on no load for the minimum period of 6/12 hours, to enable all air trapped inside to
escape.
Drying Out:
After filling the oil, the IR value of the transformer should be measured with megger of not less
than 1000 Volts. In case of abnormally low IR value, the drying out of the unit at site may be
necessary and for this purpose, the following procedure may be adopted:
(a) Hot Oil Circulation:

Hot oil circulation can be easily effected at site by an oil filter machine with heater and
vacuum arrangement. The suction side of the filter is to be connected to the bottom filter
valve and the delivery end to be connected at the top. In case of radiator Bank with valves
one set of radiator valves preferably the bottom valves
should be closed, to prevent radiation of heat through radiators. The oil in the main tank is
to be gradually heated till uniform temperature of approximate 70 to 75 deg Celsius, is
outlined. During this process the silica gel breather may be removed to allow the trapped
moisture to escape. After completion of this process of drying, the oil in the radiator should
be also circulated by opening 2 radiator valves at a time, to prevent temperature of oil from
falling suddenly. In case of separately mounted radiators, the filtration may be carried out
separately after ensuring that the valves connecting the radiator to the main tank are
closed completely.
(b) Short Circuit Method:

This method is well suited for core type transformers but, is not recommended for shell
type transformer because of the mass and location of fibrous material used. In this case
one winding should be short circuited and the other winding should be supplied with most
convenient voltage. But, however, this voltage should not be more than the impedance
voltage. To accelerate the drying the radiator valves, may be kept closed but, care should
be take that in no case, temperature of the oil should exceed more than 85 deg. C.
(c) Drying out by heat and vacuum:
This method is the most expeditious in drying the core and coil as it is more thorough
and even drying. Before adopting this method, it is essential to obtain confirmation that the tank,
Tap changer, terminal board etc., are designed to withstand vacuum.
Drying in all the above cases should be continued till oil samples from the top and
bottom of the tank withstands 40 KV or higher value across a standard gap of 4 mm. During the
drying out, the megger readings should be taken at least on hourly intervals and a graph may be
plotted to ascertain the progress of drying.
Care should be taken to disconnect the supply in case the drying is done by short circuit
method before taking the IR value readings. No transformer should be left unattended and
control must be kept on the temperature.
Naked Flames:
Naked flames must not be exposed near the transformer to avoid danger of fire by
ignition of oil vapour. In case drying under vacuum, the megger reading should not be taken
under vacuum and the drying should be carried out in the main tank with all accessories and
fillings removed. Adequate fire extinguishers should be kept on hand at all times during drying
out process. It is advisable to use inert gas type extinguisher such as Carbon Dioxide. In case
of current being drawn from a long transmission line proper protection should be provided to
prevent the unit from being damaged due to over voltage.
Earthing:
Earthing should be properly done and connected to the Main earth bus with an adequate
capacity conductor.
The following points should be connected in case of Power Transformer:
1. Main tank at 2 points.
2. Marshalling Box.
3. Main tank cover.
4. Tertiary Winding (When provided).
5. L.V. and H.V. Neutral.
6. Tap changer mechanism.
7. Control Cubical.
Oil- Level:
Oil level should be checked at the following places:

(a) Main Tank Conservator.
(b) Auxiliary Conservator.
(c) OLTC tap changer and diverter chamber.
(d) Disconnecting chambers.
(e) Thermometer and winding temperature indicator pockets.
CHECK ON ACCESSORIES:
Bushings:
Normally three types of bushings are used:
(1) Plain porcelain type.
(2) Plain oil-filled.
(3) Condenser type.
Plain porcelain type bushings are used to rated voltage 12kV. Plain oil-filled type bushings can
either have its oil in communication with the main tank or separately sealed. These bushings will
be bulkier in appearance.
Condenser type bushings are also of two categories, one is the SRBP type and the other
is the oil impregnated paper condenser type. The latter is distinguishable by the presence of
porcelain shell below the flange level.
The bushings shall be checked for any damage at the oil end as well as the porcelains
before fixing, bushings shall be cleaned thoroughly. The bushings shall be lifted by using the
lifting eyes and soft manila ropes. Wire ropes or slings shall not be used. The fine lead of H.V
winding if coiled inside the transformer is drawn through the bushing using a string when the
bushing is lowered into position.
The cable ferrule is fixed in position at the top of the bushing brass tube. The lower end
of the bushing shall be inspected through the inspection cover for proper sealing. The line
connection should be tight and should not strain the terminals. Sufficient flexibility in the
connecting leads should also be provided to avoid mechanical stress on the bushing. The arcing
horns if any shall be in proper position as shown in general arrangement drawing.
Tap Changers:
Change over switch or link arrangement provided in a multi-ratio transformer has to be
checked for proper ratio.
Off-Circuit Tap Switch:
The off-circuit Tap Switch form an integral part of the transformer. Since the operation is
to be carried out from outside, the operating handle may at times be dispatched separately. This
has to be fitted as per the instructions. Care has to be taken to have correct alignment of the
handle. The tap number on the outside should correlate with the actual position of tap changer.
This is confirmed when the ratio tests are done.
Before changing taps, isolate the transformer from supply on all windings. In no case
should the tap switch handle be left half way and unlocked to prevent damage due to inadvertent
operation.
On-Load Tap Changers:

If the tap changer is dispatched separately from works, it is to be fitted on the tank.
Before mounting on the tank, the insulation resistance value of each tap changer leads to earth
should be measured and in case of low value, the cause should be investigated. The leads from
the tap changers are then connected to their respective position on the terminal board provided
on the tank. The tightness of all connections on the selector switch and terminal board is
ensured.
The tap changer is then to be filled with clean oil and drying out is to be carried out. Oil
filling and drying out is carried out simultaneously along with the transformer as explained earlier.
Cooling Equipments:
The cooling equipments and associated pipe work and fittings are to be thoroughly
cleaned and flushed with clean dry transformer oil before assembly. The pressure gauges,
differential pressure gauges, etc., if any, are fitted in position. The cooler and associated pipe
work is then filled with clean dry oil keeping all the cooler circuit open, except the transformer
inlet and outlet valves. Air is released from all the pipe work during filling. The oil is circulated
through a filter press using the filter valves provided in the cooler inlet and outlet branches.
The cooler control circuit is to be checked for correct operation in all positions of the
selector switch. Test push buttons are provided for checking of the working of motors
individually. The cooler system is then connected to the main tank by opening the tank inlet and
outlet valves.
Cooling Fans:
Cooling fans are to be mounted as per instructions. The fans are tested for insulation
value and normal running before they are mounted.
SEPARATE COOLERS
(i) Forced Oil Cooled Transformers:
In the case of forced oil cooled transformers, oil pumps are provided for circulating the
oil. The pumps are dispatched separately after blanking both suction and delivery sides. The
pump is connected at the proper position as per the general arrangement drawing. New gaskets
should be used at the joints and the bolts tightened. The pipe work at the pump connection is
done as per the matching marks on the flanges to avoid undue stress on the flanges of the pump
when the bolts are tightened. In some pumps an air release plug is provided on the body. This
plug should be checked for tightness.
Oil flow meters are provided on the pipe line connecting the pump. The flow meter being
a delicate instrument is packed separately and sent. The flow meter should be taken out
carefully and mounted on the flange provided on the pipe connection. The mounting position
should be as per the outline general arrangement drawing.
In large transformers the radiators are sometimes separately mounted. In such cases
there will be a header each at top and bottom which are supported on frames. Flanges are
provided on these headers for fixing the radiators. Radiator valves are fitted to the headers and
dispatched. The end frames are to be erected first. The frames should be positioned correctly
with respect to the transformer. The distances between centre lines of transformer and cooler
should be strictly as per the general arrangement drawing as otherwise the connecting pipe work
will not match. After erecting the end frames the top and bottom headers are mounted. The
headers will have to be properly leveled so that the connecting pipe work can be easily fixed.
Then radiators are fixed.
If the conservator is to be provided on the cooler the same may be mounted on it and all
fittings for the same attached.
The interconnecting pipe work may be done taking care to connect correct pieces at the
correct location. Usually expansion joints are provided in the pipe line connecting the transformer
tank to the cooler. Special care should be taken to see that this is installed correctly.
(ii) Forced Water Cooled Transformers:
In the case of forced water cooled transformers the oil to water shell tube heat
exchangers are dispatched separately and properly blanked. On receipt at site, it shall be
checked whether blanking is all right. If the blanking is found to be defective, the matter has to be
referred to the manufacturer, in such a case, moisture/rain water might have entered the heat
exchanger oil circuit and there might be rusting. It may be necessary to take out the different
parts of heat exchangers separately and clean them thoroughly and put them back.
The brackets for mounting the heat exchanger may be attached to the transformer first
taking care of the matching marks. The heat exchanger may then be mounted on the support in
the correct position after referring to the general arrangement drawing.
The oil pump, oil flow meter and the connecting pipes may be fixed after this, in the
correct position. In the water circuit the necessary water pipes may be connected. It is also to be
made sure that on the outlet side water is allowed to discharge freely without any obstructions.
Usually a water flow meter is placed on the outlet pipe to indicate that there is a positive water
flow. It is to be made sure that there is no restriction in the water outlet pipe as any obstruction in
this pipe will increase the pressure in the water circuit and may result in the water pressure
exceeding the oil pressure and creating leakage of water into oil circuit which is detrimental to
the transformer.
The heat exchanger oil circuit is sealed from the water circuit with special seals and the
circuit is pressure tested at the works to make it absolutely sure that there is no leakage. The
sealing should not be tampered in any manner as it is detrimental to the transformer. If there is
any doubt about this sealing, the matter should be intimated to the manufacturer.
Conservator:
Conservator, where fitted, should be assembled with its pipe work, etc., making sure that
all gasketed joints are oil-tight and the pipe work is clean and free from moisture. The
mechanism of the float type oil gauge inside the conservator might be locked to prevent damage
during transit. After placing the conservator in position, it should be released by turning the
locking belt in the direction indicated on the plate.
While topping up oil in the transformer it should be ensured that oil is filled to a level
indicated by the oil gauge on the conservator in commensurate with the filling oil temperature.
Buchholz Relay:
The Buchholz is checked for correct functioning of the mercury switches by injecting air
through the test petcock when full of oil. When mounting on the pipe work, the correct direction is
maintained with the help of arrow provided. The angle of inclination is also to be checked and
should be between 3° and 7°. The gas release pipe if provided is to be connected to the top
petcock. In service the top petcock should be open and the gas release pipe should be -full
initially the oil will flow out and then the gas can be collected.
Dehydrating Breather:
The breather pipe work shall be properly cleaned. The oil level in the oil seal at the
bottom should be filled to the correct level with transformer oil. Any oil that might have overflow
should be wiped off. It is to be ensured that the breathing hole at the bottom of the seal is not
blocked by dirt, etc. The silica gel to be filled into the breather shall have blue colour.
Explosion Vent:
The temporary cover which is provided over the explosion vent flange on the tank cover,
should be removed and the explosion vent fitted with suitable gaskets. Care being taken to
ensure that the top diaphragm with its gaskets makes an air-tight joint. As the top diaphragm is
sent blanked from works, the blanking plate shall not be removed till the oil level inside the
transformer comes above the tank cover.
Temperature Indicators:
Before installing, the accuracy of the instrument shall be checked by hot oil or water bath
the switches are adjusted to make contact at the desired temperature depending upon the site
conditions, i.e., ambient temperature, loading conditions, etc.
The capillary tube is protected adequately to withstand all normal handling. It should not,
however, be bent sharply or repeatedly and should be supported by clips to prevent sagging. On
no account it must be cut. The thermometer pocket should be filled with transformer oil. The
connection of the winding temperature indicator C.T. is made to the thermometer pocket as per
instructions given on the WTI Terminal Board.
Current Transformers:
Great care shall be taken in handling current transformers. Current transformer should
be kept flat at all times. If the transformer is not handled properly, it will deform in shape resulting
in an increase in excitation current. All C.T. secondary terminals should be short circuited or
loaded before energizing the transformer. This will prevent excessive voltage developing across
C.T. secondary which can damage the C.T. and be a hazard if touched.
Completion of Erection Work:
Final topping up is now done to a level in conservator commensurate with filling oil
temperature with clean dry oil and any other work such as wiring of various alarm/trip contacts,
fan motors, pump motor and other apparatus, earthing of neutral and tank is completed. The
interposing valves between the radiators and the tank are opened. Tank surface is retouched
with paint wherever required and transformer is made ready for the commissioning tests.
Testing and Commissioning:
If the foregoing instructions have been carefully followed, the transformer can now be
safely put into service after pre-commissioning tests. The following pre-commissioning tests shall
be carried out.
Checking of Ratio, Polarity and Phase Relationship:
The ratio shall be checked on all taps and between all the windings and the results
should tally with the supplier's test. Turns ratio meter should be used. Polarity and inter phase
connections shall be checked.
Resistance Measurement of Windings:
Kelvin Bridge meter should be used for the measurement of resistance. Tapped winding
resistance shall be measured at all tap positions.
Insulation Resistance:
IR values between windings and between windings to earth are checked; while checking
these values no external lines, lightning arresters, etc., should be in circuit. Bushings are
thoroughly cleaned before taking IR values. A 2500/1000 volts megger preferably motor
operated should be used for measuring IR values. Care should be taken that the lead wires of
the megger do not have joints.
Magnetizing Current and Iron Loss:
A three-phase 415 volts supply is given to the H.V. winding of the three-phase
transformer and simultaneous current readings of the three phases are taken. The watt input
during this test is also measured and compared with the works value.
Tap Changer:
The sequence of operation of the tap changers shall be checked. Check should be made
for:
a) Manual Operation.
b) Local Electrical Operation.
c) Remote Electrical Operation.
d) Parallel Operation.
Buchholz Relay Test:
Check whether the Buchholz relay is mounted at an angle by placing a spirit level on the
top of the relay. Confirm that the relay does not operate when pumps are switched on in forced
oil cooled transformers. Buchholz relay operation for alarm and trip are checked by injecting air
through the test petcock.
Magnetic Oil Level Gauge:

The float level of the oil level indicator is moved up and down between the end positions
to check that the mechanism does not stick at any point. The low oil level alarm of the oil gauge
shall be checked.
Temperature Indicators:
The contacts of WTI and OTI for alarm and trip are checked and set at required
temperatures depending upon ambient temperatures and loading conditions.
Fans and Pumps:
It shall be checked that the specified number of fans are mounted on radiators as per
general arrangement drawing. IR values and settings for operation of fan motors and oil pumps
are checked. Check also the direction of rotation of fans and pumps for correctness.
Marshalling Box:
The wiring from various accessories to marshalling box shall be checked.
Oil:
Oil samples from top and bottom of tanks selector switch and diverter switch tanks of tap
changer and radiator banks, etc., are tested as per IS:335.
General Checks:
a) All oil valves are in correct positions, closed or opened as required.

b) All air pockets are cleared.
c) Thermometer pockets are filled with oil.
d) Oil is at correct level in the bushings, conservator, diverter switch tank, etc.
e) Earthing connections are done.
f) The condition of silica gel in the breather.
g) Arcing horn gaps on bushings are properly adjusted.
h) Heaters in cubicles, conservator, etc., where provided should be checked.
i) Any other alarm/trip contacts of flow meters, differential pressure gauges, etc.,
In the case of water cooled transformers, the pressure gauge readings on both water and oil
sides to confirm that the water pressure is less than the oil pressure. The quantity of oil and
water flow should not be less than that specified.
If all the above tests/checks are found satisfactory, allow a settling time of at least 24
hours for oil and release air from all points. Now the transformer can be energized after setting
the protective relays to the minimum extent possible. Wherever possible, the voltage should be
built up in steps. Any abnormality during commissioning such as vibration of radiator parts, hum
etc. should be observed. After a few hours of energization at no load, the transformer shall be
switched off. The Buchholz relay should be checked for collection of air/gas. Abnormalities
noticed should be corrected. Ail protective relays should be reset to normal values. Transformer
can now be re-energized and loaded gradually.
I. Details of transformer including its serial number.

II. Date of commissioning.
III. Substation/generating station where commissioned.
IV. Protection given to the transformer such as lighting arrester, differential protection, circuit
breaker on H.V/ L.V., etc.
Recommended Maintenance Schedule For Transformers
Item Item To Be Inspected Inspection Notes Frequency Action Required

No.
1 Ambient Temperature -- Daily --
2 Winding & Oil Check The Temperature Daily shut down transformer &
Temperature investigate if found abnormal
3 Load & Voltage Check Against Rated Figures Daily --
4 Oil Level -- Weekly if low, top up with dry oil, examine
transformer oil for leakages
5 Oil Level In Bushings -- Weekly if low, top up with dry oil, examine
6 Relief Diaphragm -- Monthly replace if cracked or broken
7 Ambient Temperature -- Daily --
8 Winding & Oil Check The Temperature Daily shut down transformer &
Temperature investigate if found abnormal
9 Load & Voltage Check Against Rated Figures Daily --
10 Oil Level -- Weekly if low, top up with dry oil, examine
11 Oil Level In Bushings -- Weekly if low, top up with dry oil, examine
Dehydrating Breather Check For Air Passage, Monthly if found pink change by spare
12 Colour Of The Agent charge or old charge may also be
reactivated
13 Bushing Examine For Cracks And Dirt Quarterly clean or replace
14 Oil Check For Dielectric Strength Half Yearly clean and replace
And Water Contents
15 Cooler Fans, Bearings, Lubricate Bearings, Check Half Yearly replace burnt or worn contacts or
Motor And Control Gearbox, Examine Contacts, other parts
Mechanism Controls And Inter Locks
16 Oil In Cooler Test For Pressure Half Yearly --
17 Oil In Transformer Check For Sludge Yearly filter or replace

18 Oil Filled Bushing Test Oil Yearly filter or replace
19 Gasket Yearly tighten bolts evenly
20 Cable Box Check For Ceiling Yearly replace

Arrangements, Examine
Compound Cracks
21 Relays, Alarm And Circuit Examine Relays And Alarm Yearly clean components, replace contact
Contacts and fuses if necessary
22 Earth Resistance -- Yearly take suitable action if resistance is

high
23 OLTC Overhauling Check OLTC, RTCC For Quarterly clean and grease all moving
Proper Functioning contacts. check oil in diverter
arrangements
24 Buchholz Relay Check Contacts And Floats Monthly rectify or replace defective contacts
25 IR Test Of Winding Measure By Megger Yearly take suitable action if found low
26 Overall Inspection -- Once In 5 wash by hosing down with clean

Including Lifting Of Core Years dry oil
27 Sludging Oil For All Valves Once In 10 replace if test values are not
Years attained
Common Defects Noticed And The Clause
Item Parts Defects Causes

No.
1 Tank Leakage Of Oil / Deformation Corrosion/Mechanical Damage-Gaskets
/ Overheating Worn-out-Excessive Internal Pressure-
Improper Circulation Of Cooling Oil And / Or
Inadequate Ventilation.
2 Radiators Leakage Of Oil / Deformation Corrosion/Mechanical Damage-Gaskets
3 Conservator Leakage Of Oil / Deformation Corrosion/Mechanical Damage-Gaskets
4 Breather Ineffective Inlet Choked-Silica gel Saturated
5 Explosion Glass Broken Mechanical
6 Core Loose / Increased Losses / Bolts Loosening Up - Change In
Excess Noise Characteristics Due To Heating - Vibration
Of Stampings
7 Winding Short Circuited / Loosening / Overloading - Air Bubbles - Loss Of
Insulation Brittle / Open Insulation - Shrinkage Displacement -
Circuited Overheating Decomposition Burn Out
8 Oil Discoloration / High Acidity / Contamination - Increased Moisture -
Low BDV / Sludge Decomposition - Chemical Action With
Other Parts
9 Terminal Bushing Breakage / Leakage Of Oil Strain - Gasket Worn Out - Loose Fit
10 Tap Switching Inoperative Broken Lever / Mal-operation - Insulation Failure - Failure
Burnt Contact / Short Circuit Of Operating Mechanism - Overheating
Installation, Operation and Maintenance
Manual Distribution Transformers
Distribution Transformer Plant Large Power Transformer Plant

DP 36, Sidco Industrial Estate, P.O. Rajakulam,
Thirumazhisai, Chennai-600124. KM. 64, Chennai Bangalore Highway,
Tamil Nadu, India. Ph.: +91 (0) 44 37290518
Ph: +914430289830/ 30289833/ Fax: +91 (0) 44 37290518
30289836 Fax: +91-44-30289874
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INSTALLATION AND MAINTENANCE OF TRANSFORMER

1. Detachable radiators with both flanges blank.

The following precaution should be taken while erecting the transformer:

Filling the Transformer with oil:

(a) Hot Oil Circulation:

(b) Short Circuit Method:

(c) Drying out by heat and vacuum:

Oil level should be checked at the following places:

Off-Circuit Tap Switch:

On-Load Tap Changers:

(i) Forced Oil Cooled Transformers:

(ii) Forced Water Cooled Transformers:

Completion of Erection Work:

Testing and Commissioning:

Checking of Ratio, Polarity and Phase Relationship:

Resistance Measurement of Windings:

Magnetizing Current and Iron Loss:

Buchholz Relay Test:

Magnetic Oil Level Gauge:

Fans and Pumps:

The wiring from various accessories to marshalling box shall be checked.

a) All oil valves are in correct positions, closed or opened as required.

I. Details of transformer including its serial number.

Recommended Maintenance Schedule For Transformers

Item Item To Be Inspected Inspection Notes Frequency Action Required

17 Oil In Transformer Check For Sludge Yearly filter or replace

20 Cable Box Check For Ceiling Yearly replace

22 Earth Resistance -- Yearly take suitable action if resistance is

26 Overall Inspection -- Once In 5 wash by hosing down with clean

Common Defects Noticed And The Clause

Item Parts Defects Causes

Distribution Transformer Plant Large Power Transformer Plant

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