Manual On Transformers

Publication No.
317
Manual on
Transformers
Editors
M. Vijayakumaran
V.K. Lakhiani
V.K. Kanjlia
P.P. Wahi
Central Board of Irrigation & Power

Malcha Marg, Chanakyapuri, New Delhi 110021
April 2013
2013
ISBN 81-7336-324-2
“Reproduction of any part of this publication in any form is permissible subject to proper
acknowledgement and intimation to the publisher. The publisher/author/editors have taken
utmost care to avoid erros in the publication. However, the publisher/author/editors are in no
way responsible for the authenticity of data or information given in the book.”
(ii)
Expert Group
CHAIRMAN
Shri M. Vijayakumaran
Sr. Technical Expert
ALSTOM T&D India Ltd
Naini, Allahabad 211008
SUB-GROUP CONVENORS
Shri P. Ramachandran Shri M.M. Goswami

Sr. Advisor - Design & Development General Manager
Power Transformers Division Power Grid Corporation of India Ltd.
ABB Ltd., Maneja Saudamini, Plot No. 2, Sector 29
Vadodara – 390013 Gurgaon – 122001
Shri Dinkar Devate Shri Sanjay Kar Chowdhury

General Manager Sr. Dy. Manager
NTPC Ltd. CESC Ltd.,
A-8A, Sector 24 Poddar Court
Noida – 201301 18, Rabindra Sarani
Kolkata – 700001
Shri A. Kulshreshtha
Addl. General Manager Ms. Elizabeth Johnson
Bharat Heavy Electricals Ltd. Sr. Manager - Technical Solution Group
BHEL, Jhansi (U.P.) – 284129 Alstom Grid
Plot No.46, Zuzuwadi Village
Shri S.K. Mahajan SIPCOT
Dy. General Manager (TRE) Industrial Complex
Bharat Heavy Electricals Ltd. Hosur 635 126
Piplani, Tamil Nadu
Bhopal (M.P.) – 462022
(iii)
Members
Shri Mata Prasad Shri V.K. Lakhiani

Founder President CIGRE India Technical Director
5/100, Vinay Khand Transformers and Rectifiers (India) Limited
Gomti Nagar Survey No. 427 P/3-4, & 431 P/1-2
Lucknow 226010 Sarkhej-Bavla Highway, Moraiya,
Taluka: Sanand, Dist. Ahmedabad–382213
Shri Ratish Kumar Shri R.K. Tiwari

Executive Director – Design E&M General Manager (TCB)
NHPC Ltd. Bharat Heavy Electricals Ltd.
NHPC Office Complex, Sector 33 Piplani,
Faridabad – 121003 Bhopal – 462022
Shri S.K. Ray Mohapatra Shri Y.V. Joshi

Director Executive Engineer – Equip. Engg.
Central Electricity Authority Gujarat Energy Transmission Corp. Ltd.
Sewa Bhavan, R.K. Puram Sadar Patel Vidyut Bhavan
New Delhi 110066 Race Course, Vadodara – 390007
Shri B.V. Raghavaiah Shri Ranjan Banerjee

Unit head General Manager – Technical Services and
Central Power Research Institute R&D – Engg. & Technology
Switchgear Testing & Development Station Larsen & Toubro Limited
Govindpura, Bhopal – 462023 Vadodara - 390 019, Gujarat
Shri M.L. Jain Shri V.M. Varkey

Sr. Vice President (Technology & Quality) Head – Transformer Design
Transformer Business Unit Siemens Ltd.
EMCO Ltd. Transformer Works,
Plot No. F-5, Road No. 28 Thane Belapur Road
Wagle Industrial Estate, Thane (W) 400604 Airoli, Navi Mumbai – 400708
Shri Amit Mittal Shri Anilkumar Bhatia

Addl. General Manager Deputy General Manager -
NTPC Ltd. Design & Technology
A-8A, Sector 24 Crompton Greaves Limited
Noida – 201301 Kanjur Marg (East), Mumbai 400 042
(iv)
Shri S. Victor P. Selvakumar Shri J.S. Kuntia
Addl. General Manager (OS) AGM – Design
Power Grid Corporation of India Ltd. BHEL
Plot No. 2, Sector 29, Piplani,
Gurgaon, Haryana Bhopal (M.P.)
Shri R.K. Tyagi Shri Aseem Dhamija

Dy. General Manager AGM (Bushing,Capacitor
Power Grid Corporation of India Ltd. & Instrument Trfr Engg.)
Saudamini, Plot No. 2, Sector 29 BHEL,
Gurgaon – 122001 Bhopal (M.P.)
Shri Sudhir Agarwal Shri S.K. Gupta

Dy. General Manager Dy. General Manager (TRE)
Power Grid Corporation of India Ltd. Bharat Heavy Electricals Ltd.
Saudamini, Plot No. 2, Sector 29 Piplani
Gurgaon – 122001 Bhopal – 462022
Shri T.K. Ganguly Shri N.K. Dahiwale

Sr. General Manager – Engg. DGM – Manufacturing Transformers
EHV Power Transformers Division BHEL,
Vijai Electricals Ltd. Piplani,
Rudraram – 502329, A.P. Bhopal (M.P.)
Shri Oommen P. Joshua Shri R.K. Mohapatra

General Manager (Technical) DGM – TRE
TELK Bharat Heavy Electricals Ltd.
(A joint Venture of Govt. of Kerala & NTPC Piplani,
Ltd), Angamally, Kerala – 683573 Bhopal – 462022
Dr. K. Rajamani Shri Pradeep Singh

Chief Consultant Manager
Reliance Infrastructure Ltd Bharat Heavy Electricals Ltd.
DAKC, I Block, North Wing, Thane Belapur Piplani,
Road, Koparkhairane, Bhopal – 462022
Navi Mumbai - 400 709
Shri B.M. Mehra Shri Manish Kumar

Joint Director Bharat Heavy Electricals Ltd.
Central Power Research Institute Piplani,
Noida Bhopal – 462022
(v)
Shri. N.G. Patel Shri R.S. Thakkar
Divisional Engineer – Testing Junior Engineer
Gujarat Energy Transmission Corp. Ltd. Gujarat Energy Transmission Corp. Ltd.
Sadar Patel Vidyut Bhavan Sadar Patel Vidyut Bhavan
Race Course, Vadodara – 390007 Race Course, Vadodara – 390007
Shri Vibhu Tripathi Shri A.K. Panwar

Assistant Director – I, DP&D Assistant Director – I DP&D
Central Electricity Authority Central Electricity Authority
Sewa Bhavan, R.K. Puram Sewa Bhavan, R.K. Puram
New Delhi 110066 New Delhi 110066
Shri Gunjan Agrawal Shri Minal Kataria

Manager NTPC Ltd.
Power Grid Corporation of India Ltd., A-8A, Sector 24
Plot No. 2, Sector 29, Gurgaon, Haryana Noida – 201301
Shri K. Jayakrishnan Shri Govind Srivastava

NHPC Ltd. Sr. Manager
NHPC Office Complex Siemens Ltd.
Sector 33 Transformer Works,
Faridabad – 121003 Thane Belapur Road,
Haryana Airoli, Navi Mumbai– 400708
Miss Tanvi Srivastava Ms. Mary Mody

Dy. General Manager General Manager
Alstom, Allahabadad EMCO Ltd, Thane
Shri Pramod Srivastava Ms. Anagha Dixit

Dy. General Manager (Design) General Manager - Engineering (E)
Alstom T&D India Limited EMCO Limited
Shri Abhilash Mishra Shri Meet Patel

Alstom T&D India Ltd. L&T Power Ltd.
Vadodara Vadodara
Shri Pravin Jain Shri T. Murlikrishna

Chief Manager (Corp Engineering) Chief Manager (Testing)
The Tata Electric Company The Tata Electric Company
Mumbai Mumbai
(vi)
Shri Tarun Garg Shri Vikrant Joshi
Design Head, Power Transformers Crompton Greaves Ltd.
ABB Ltd Mumbai
Shri Abhay Agrawal Shri Manish Yadav

Design Head, Small Power Transformers DGM – Design Testing
ABB Ltd. Crompton Greaves Ltd.
Shri Maneesh Jain Ms. Shubhangi Kulkarni

Business Unit manager - Bushings Sr. Manager Design
ABB Limited Crompton Greaves Ltd.
Maneja, Vadodara - 390013, Gujarat Mumbai
Shri Surojit Roy Shri Prasenjit Paul

Director Head – Technology
Schneider Electric Infrastructure Ltd. Schneider Electric Infrastructure Ltd.
Naini, Allahabad Naini, Allahabad
Shri Subrata Dutta Shri Sameer Gaikwad

Schneider Electric Infrastructure Ltd. Manager, Regional Sales – South Asia
Naini, Doble Engineering Company
Allahabad 2nd Floor “Suvidhi Pride”, Gorwa Refinery
Road, Vadodara 390 003
Shri R.V. Talegaonkar Shri Rakesh Sardana

President President & CEO
Group I Skipper Electricals (India) Ltd.
CTR Mfg Ind Ltd F-667-668, RIICO Indl. Area Ph-II
Nagar Road, Pune 411014 Bhiwadi 301019 Distt. Alwar
Shri S.A. Rajan Shri R. Prakash

Sr. Design Manager Head - Mktg & Service
CTR Mfg. Ind Ltd. Easun - MR Tap Changers Pvt. Ltd.
Nagar Road, 612, (232) M.T.H Road
Pune Thiruninravur - 602 024, Chennai
Shri B.D. Raut Shri D.M. Jadhav

Sr. Development Manager Sr. Applications Manager
CTR Mfg. Ind Ltd. CTR Mfg. Ind Ltd.
Pune Pune
(vii)
Shri V.K. Kanjlia Shri P.P. Wahi
Secretary Director
Central Board of Irrigation & Power Central Board of Irrigation & Power
Malcha Marg, Chanakyapuri Malcha Marg, Chanakyapuri
New Delhi 110021 New Delhi 110021
Shri Manish Kataria Shri S.K. Batra

Jt. General Secretary Sr. Manager (Technical)
Hydraulic Trailers Owner’s Association Central Board of Irrigation & Power
(HTOA) Malcha Marg
429, Vyapar Bhavan, P. D’Mello Road, Chanakyapuri
Mumbai 400 009 New Delhi 110021
(viii)
Message
Central Board of Irrigation and Power (CBIP) has been playing a key role to
disseminate the latest technological advancement information covering almost
all aspects of power and renewable sector and it was in 1976, CBIP brought out
detailed first edition of the Transformer Manual.
I understand that the manual issued by CBIP is being widely used by power
engineers as a reference book in the country & elsewhere.
I am happy to note that this manual is being revised/updated now under the
chairmanship of Shri M. Vijayakumaran, Sr. Technical Expert, ALSTOM
T&D India Ltd. and with the help of Expert Group members from all eminent
organizations in the country. This contains the latest updated technological
information on the subject of Transformer.
I congratulate CBIP and all experts of the Expert Group for bringing out this
manual covering latest state-of-art technology and I am sure that this document
will be of great benefit to engineering fraternity as a reference book.
A.S. Bakshi
(ix)
PREFACE
“Manual on Transformers” is the most popular publication
of CBIP. It has been widely appreciated by practising
transformer engineers associated with all facets of
transformers: Design, Materials, Manufacturing, Testing,
Erection and Commissioning. Utility Engineers and End
users have also found this manual, a good guide and
reference book.
Although the transformer is a matured product of Electrical Engineering with

matured science and technology, yet, to keep pace with the needs of changing
times, several technological advancements take place on continuous basis.
To keep pace with the fast changing technology, it is desired that this Manual is
updated from time to time, at least once in 5 years.
Third Revision was undertaken in 2005 with a reprint in 2007 with minor
modifications.
The working group reconstituted in 2012 with experts drawn from Indian
Utilities, Institutes, Transformer Manufacturers etc. reviewed the Manual and
finalized modifications for Fourth revision to be published now in 2013.
The manual is reformatted and divided in to two Volumes: Vol. I to cover

specifications of standard transformers and Vol. II to include various guidelines
and specifications of fittings and accessories used in the transformers. Chapters
have been reorganized in these two volumes being published together.
In this revision, existing sections have been updated as recommended by the

Expert group. New sections viz. 420 kV & 800 kV Shunt reactors, Furnace
transformers, Rectifier Transformers, Traction Transformers etc. have been
added. A chapter on new technologies describing Smart Transformers, UHV
Transformers, Phase shifting transformers etc. has been included to indicate
emerging trends in Technology. A chapter on Reference standards and Books
(xi)
also has been added to facilitate readers to locate the standards, as a ready
reckoner.
Technology evolves dynamically. Full-fledged revision is a voluminous task. It

is decided that the revision of Manual shall be normally undertaken in 5 years’
time span. However, a core group has been formed to address urgent amendments
to make the Volumes updated all the time.
Core group shall welcome suggestions / improvements / amendment proposals

from the distinguished users of this Manual.
I am sure that the users will find the Fourth Edition of the Manual more
meaningful.
M. Vijayakumaran
Chairman of the Expert Group
(xii)
Foreword
With the Indian economy growing year by year, the target of
providing reliable power supply to consumers is becoming
increasingly important. To meet this challenge new power
stations are being added and T&D networks are continuously
being strengthened.
As you know, the transformer is one of the most important
and vital asset in a power system. Reliability and availability
of such an asset plays an important role in the operation of
a power system. Emphasis needs to be laid on improved design, quality control
during manufacturing, use of right components / accessories, maintenance and
safety during operation of such vital equipment. The adoption of state-of-art
technology for important components like bushings & OLTC which have been
the major items causing failure of transformer is the urgent need for all concerned
professionals. The review of the protection philosophy would further improve
the performance of the system. The residual life assessment and condition
monitoring of the transformers will also add reliability to the power system.
CBIP has brought out the first Manual on Transformers in 1976. This was updated
in 1987, 1999, 2005 and again in 2007. To incorporate the latest developments
and innovations, this manual has again been updated and new sections viz. 420
kV & 800 kV Shunt reactors, Furnace transformers, Rectifier Transformers,
Traction Transformers etc. have been added. A chapter on new technologies
describing Smart Transformers, UHV Transformers, Phase shifting transformers
etc. have also been included to indicate emerging trends in Technology. For
updating this manual, CBIP had constituted the Expert Group, comprising of
highly experienced engineers from large power utilities, designs organization,
manufacturers etc. This group was headed by Shri M. Vijayakumaran, National
Representative in CIGRE Study Committee A2 on Transformers and Sr. Technical
Expert, ALSTOM T&D India Ltd., who is recipient of many National and
International awards. The expert group after working ceaselessly brainstorming/
working for more than one year have helped CBIP in updation of this document
covering all aspects of Transformers for various voltages as mentioned above.
The Central Board of Irrigation & Power wishes to acknowledge the valuable
contributions made by Shri M. Vijayakumaran, Chairman of the Expert Group
(xiii)
for revision of this manual. Contribution made by Shri Virendra K. Lakhiani,
Technical Director, Transformers and Rectifiers (India) Limited is deserves
special mention, who has put in the best efforts for updation and synthesizing
this manual.
Our thanks are also due to Conveners Shri P. Ramachandran, Sr. Advisor - Design
& Development, Power Transformers Division, ABB Ltd., Shri M.M. Goswami,
General Manager, Power Grid Corporation of India Ltd., Shri Dinkar Devate,
General Manager, NTPC Ltd., Shri R.K. Tiwari, General Manager (TCB), Bharat
Heavy Electricals Ltd., Shri A. Kulshreshtha, AGM (TRE-SPTR, FES, RPD
& T), Bharat Heavy Electricals Ltd., Shri S.K. Mahajan, DGM (TRE), Bharat
Heavy Electricals Ltd., Ms. Elizabeth Johnson, Sr. Manager - Technical Solution
Group, Alstom Grid, Shri Sanjay Kar Chowdhury, Sr. Dy. Manager, CESC Ltd.
& Members of all the Sub-Group for revision of this manual.
Contibution made by Shri R.K. Tyagi, Dy. General Manager, Power Grid
Corporation of India Ltd., Shri Ranjan Banerjee, General Manager – Technical
Services and R&D – Engg. & Technology, Larsen & Toubro Limited, Shri S.K.
Ray Mohapatra, Director, Central Electricity Authority, Shri B.V. Raghavaiah,
Unit Head, CPRI, Bhopal, Shri M.L. Jain, Sr. Vice President (Technology &
Quality), Transformer Business Unit, EMCO Ltd., Shri Y.V. Joshi, Executive
Engineer – Equip. Engg., Gujarat Energy Transmission Corp. Ltd., Shri
Anilkumar Bhatia, Deputy General Manager - Design & Technology, Crompton
Greaves Limited needs special mention.
I also appreciate the dedication & the contribution made by Shri S.K. Batra, Sr.
Manager, CBIP for getting this document revised.
I trust that this manual would cover the existing knowledge gap on this subject
and help the practising engineers in the power sector as well as students in the
technical institutions in enhancing their technical skills.
V.K. Kanjlia
Secretary
Central Board of Irrigation and Power
(xiv)
CONTENTS
Page
Preface (v)
Foreword (vii)
Vol I: Standard Specifications of Transformers

SECTION A General 3
SECTION B Specifications for Outdoor type, Completely Self protected,
3 Phase Distribution Transformers (up to and including 100 kVA) 41
SECTION C Specifications for Outdoor type, Completely Self Protected,
Single Phase Distribution Transformers (Single Phase
11 kV/250 V & 11/√3 kV/250 V, 5, 10, 16 & 25 kVA ratings) 57
SECTION D Specifications for Three Phase Distribution Transformers
(above 100 kVA and up to 33 kV class) 71
SECTION E Specifications for Power Transformers of

Voltage Class below 145 kV 83
SECTION F Specifications for 145 kV Class Power Transformers 91
SECTION G Specifications for 245 kV Class Power Transformers 99
SECTION H Specifications for 420 kV Class Power Transformers 107
SECTION I Specifications for 800 kV Class Power Transformers 119
SECTION J Specification for 420 kV class Shunt Reactors and
associated 145 kV Neutral Grounding Reactors 129
SECTION K Specifications for 800 kV class Shunt Reactors and
associated 145 kV Neutral Grounding Reactor 145
SECTION L Specifications for Earthing Transformers 155
SECTION M Specifications for Furnace Transformers 165
SECTION N Specifications for Rectifier Transformers 175
SECTION O Specifications for Electrostatic Precipitator Transformers 185
SECTION P Specifications for Traction Transformers 191
SECTION Q Specifications for Dry type Transformers 197
Vol II: Application, Standard Fittings and Accessories

SECTION AA Capitalization Formula for Transformer Losses 211
SECTION BB Test Requirements for Transformers 215
(xv)
SECTION CC Guidelines for Erection, Commissioning and Maintenance 277
SECTION DD Guidelines for Condition Monitoring and Diagnostic
Techniques for Power Transformers and Reactors 347
SECTION EE Guidelines for Fire Protection of Power Transformers 371
SECTION FF Guidelines for Repair of Power Transformers at Site 386
SECTION GG Guidelines for Voltage Control of Power Transformers 409
SECTION HH Guidelines for Protective Schemes for Power and
Distribution Transformers 427
SECTION II Specifications for Transformer Bushings up to
1200 kV Voltage Class 439
SECTION JJ Specifications for Valves for Transformers 455
SECTION KK Specifications for Cable Boxes for SF6 Gas Insulated
Transformer Terminations for Rated Voltages of
72.5 kV and above 463
APPENDICES
APPENDIX-I New Technologies, UHV AC/DC Transformers, Phase Shifting
Transformers, Controlled Shunt Reactors 479
APPENDIX-II Reference Standards and Books 503
APPENDIX-III Typical Quality Assurance Plan 523
APPENDIX-IV Guaranteed Technical and Additional Technical particulars 527
APPENDIX-V List of Transformer Accessories and test certificates required 537
APPENDIX-VI Design Review Parameters 543
APPENDIX-VII Salient Technical Specifications and Particulars of Power
Transformers for Power Plant Application 549
APPENDIX-VIII Test Windings for Bushing Current Transformers 559
APPENDIX-IX Pictures of Transformer Installations 563
(xvi)
Vol. I
Standard Specifications of Transformers
SECTION A
General
SECTION A
General
1.0 GENERAL DESIGN OF APPARATUS
1.1 Compliance with Specifications
1.1.1 Except where otherwise specified or implied herein, the transformers shall comply with
the latest edition of Indian Standard 2026 (hereinafter referred to as “IS”).
1.2 Design and Standardization
1.2.1 The transformer and accessories shall be designed to facilitate operation, inspection,
maintenance and repairs. All apparatus shall also be designed to ensure satisfactory operation
under such sudden variations of load and voltage as may be met with under working conditions
on the system, including those due to short circuits.
1.2.2 The design shall incorporate every reasonable precaution and provision for the safety
of all those concerned in the operation and maintenance of the equipment keeping in view the
requirements of Indian Electricity Rules.
1.2.3 All material used shall be of the best quality and of the class most suitable for working
under the conditions specified and shall withstand the variations of temperatures and atmospheric
conditions arising under working conditions without undue distortion or deterioration or the
setting up of undue stresses in any part, and also without affecting the strength and suitability of
the various parts for the work which they have to perform.
1.2.4 Corresponding parts liable to be replaced shall be interchangeable.
1.2.5 Cast iron shall not be used for chambers of oil filled apparatus or for any part of the
equipment which is in tension or subject to impact stresses. This clause is not intended to
prohibit the use of suitable grades of cast iron for parts where service experience has shown it to
be satisfactory, e.g., large valve bodies.
1.2.6 All outdoor apparatus, including bushing insulators with their mountings, shall be
designed so as to avoid pocket in which water can collect.
1.2.7 Means shall be provided for the easy lubrication of all bearings and where necessary of
any mechanism or moving part, that is not oil immersed.
1.2.8 All mechanism shall, where necessary, be constructed of stainless steel, brass or gunmetal
to prevent sticking due to rust or corrosion.
1.2.9 All taper pins used in any mechanism shall be of the split type complying with IS: 2393
for these items.
1.2.10 All connections and contacts shall be of ample section and surface for carrying
continuously the specified currents without undue heating and fixed connections shall be
secured by bolts or set screws of ample size, adequately locked. Lock nuts shall be used on stud
5
6 Manual on Transformers
connections carrying current All leads from the winding to the terminal board and bushings shall
be adequately supported to prevent injury from vibration including a systematical pull under
short circuit conditions. Guide pulls shall be used where practicable.
1.2.11 All apparatus shall be designed to minimise the risk or accidental short-circuit caused by
animals, birds or vermin.
1.2.12 Provision shall be made to fix safety fence around top cover of transformers of rating
100 MVA and above, for safe working during installation and servicing for large capacity
transformers.
1.2.13 In tank on load tap changers shall be located such that the space above the diverter
switch chamber will be free of inter connecting pipes etc. for lifting the diverter switch unit for
inspection and maintenance purposes.
1.2.14 Dryness of the insulation may be ensured by measuring the water extraction during
vacuum drying. The water extraction per tonne of insulation per hour may be limited to 5030
grams maximum. Alternatively dryness can be judged by dew point measurement.
1.3 Galvanising
1.3.1 Galvanising where specified shall be applied by the hot-dipped process or by

clectrogalvanising process and for all parts other than steel wires shall consist of a thickness
of’zinc coating equivalent to not less than 610 gm of zinc per square meter of surface. The zinc
coating shall be smooth, clean and of uniform thickness and free from defects. The preparation
of galvanising and the galvanising itself shall not adversely affect the mechanical properties
of the coated material. The quality will be established by tests as per IS: 2633. Alternative to
galvanising, zinc spraying or aluminising can also be considered.
1.3.2 All drilling, punching, cutting, bending and welding of parts shall be completed, and all
burrs shall be removed before the galvanising process is applied.
1.3.3 Galvanising of wires shall be applied by the hot-dipped process and shall meet the
requirements of the relevant Indian Standard. The zinc coating shall be smooth, clean and of
uniform thickness and free from defects. The preparation for galvanising itself shall not adversely
affect the mechanical properties of the wire.
1.3.4 Surfaces which are in contact with oil shall not be eleclrogalvanised/cadmium plated.
1.4 Labels
1.4.1 Labels shall be provided for all apparatus such as relays, switches, fuses, contained in
any cubicle or marshalling kiosks.
1.4.2 Descriptive labels for mounting indoors or inside cubicles and kiosks shall be of material
that will ensure permanence of the lettering. A matt or satin finish shall be provided to avoid
dazzle from reflected light. Labels mounted on dark surfaces shall have white lettering on a
black background. Danger notices shall have red lettering on a while background.
1.4.3 All plates shall be of material which is corrosion resistant.

General 7
1.4.4 Labels shall be attached to panels with brass screws or with stainless steel screws or
these can be stuck with suitable adhesive also.
1.5 Bolts and Nuts
1.5.1 Steel bolts and nuts exposed to atmosphere shall be of following material:
• Size 12 mm or below - stainless steel
• Above 12 mm - steel with suitable finish like electrogalvanised with passivation
/hot dip galvanised.
1.5.2 All nuts, bolts and pins shall be locked in position with the exception of those external
to the transformer, under gasket pressure.
1.5.3 All bolts, nuts and washers exposed to atmosphere and in contact with non-ferrous parts
which carry current shall be of phosphor bronze.
1.5.4 If bolts and nuts are placed so that they are inaccessible by means of ordinary spanners,
suitable special spanners shall be provided by the supplier.
1.5.5 Bolts and nuts shall not be less than 8 mm in diameter except when used for small wiring
terminals.
1.6 Cleaning and Painting
1.6.1 Before painting or filling with oil or compound, all ungalvaniscd parts shall be completely
clean and free from rust, scale and grease, and all external surface cavities on castings shall be
filled by metal deposition.
1.6.2 All blast cleaned surfaces (except machined faces that have to be protected) must be
cleaned in accordance with ISO specification no. ISO 8501 Part l (This standard specification
is based on and now supersedes Swedish Standard SIS 05 59 00) to a minimum standard of
‘ASa21/2’ or ‘BSa21/2’ prior to paint application.
1.6.3 External and internal surfaces of all transformer tanks and chambers and other fabricated
steel items shall be cleaned of scale, rust and surface dirt by blast cleaning or other suitable
approved method. After cleaning, these surfaces should be immediately covered with paint. Hot
oil resistant varnish on white synthetic enamel/epoxy paint is to be used for painting the inside
of all oil filled chambers, including transformer tanks. Only one thin layer (~ 25 microns) of this
is to be applied.
1.6.4 Except for hardware, which may have to be removed at site, all external surfaces shall
receive at least four coats of paint. The type and thickness of paint shall be chosen to suit
pollution level at site.
1.6.5 Selection of paint system for different environmental conditions shall be in line with
ISO: 12944.
1.6.6 For rural or mild atmosphere, alkyd enamel primer and finish system may be used in
four coats to give a total dry film thickness of at least 80 microns.
1.6.7 For urban or industrial situation two coats of epoxy zinc phosphate or zinc chromate
primer topped with two coats of aliphatic polyurethane glossy finish paint is recommended.
The total dry film thickness should preferably be between 100 and 130 microns.
1.6.8 In case of highly polluted area, chemical atmosphere or at a place very near the sea
coast, paint as above with one intermediate coat of high build MIO (Micaceous iron oxide) as
an intermediate coat may be used to give a total dry film thickness of 150 to 180 microns.
1.6.9 All interior surfaces of chambers or kiosks that are in contact with air shall receive
at least three coats of paint, of which the topcoat shall be of a light shade. If heaters are not
provided in the chamber, then the top coat should be of anti condensation type.
1.6.10 Any scratch, bruise or paint damage incurred during transportation and unloading at
site should be made good by the purchaser as soon as the damage is detected. This is to be done
by thoroughly cleaning the damaged area and applying the full number of coats as was applied
originally. Manufacturer should supply the necessary paint for this touch up painting at site.
1.6.11 One coat of additional paint shall be given at site over all external surfaces, including
hardware, after erection by the purchaser. Supplier shall furnish necessary information on the
make and grade of the lop-coat paint. In general, it is possible to apply enamel paint over epoxy
polyurethane coating and the vice versa is not recommended. As far as possible the make and
grade of the recoat shall be same as the original coat.
1.7 Oil
1.7.1 The transformers and all associated oil-filled equipment shall normally be supplied
alongwith the first filling of oil and 5/10 percent (as per user requirement) excess quantity of
oil shall also be supplied in non-returnable drums. The oil shall conform to IS: 335 or IEC
60296 (as per user requirement). Alternatively, if the purchaser so desires, oil may be supplied
in tankers directly from the refinery for transformers which are dispatched from factory to site
in gas filled condition.
1.8 Prevention of Acidity
1.8.1 The design and all materials and processes used in the manufacture of the transformer,
shall be such as to reduce to a minimum the risk of the development of acidity in the oil.
Special measures, such as nitrogen sealing or the use of inhibited oil shall not be resorted to,
unless otherwise specified by the purchaser.
2.0 ELECTRICAL CHARACTERISTICS AND PERFORMANCE
2.1 Type of Transformers and Operating Conditions
2.1.1 All transformers, unless otherwise specified shall be oil immersed and may be either core
or shell type and shall be suitable for outdoor installation. Normally oil immersed transformer
shall be provided with conservator vessels. Where sealed transformers are specified, there shall
be no conservator but adequate space shall be provided for expansion of oil without developing
undue pressure. The types of cooling shall be as stated in the relevant specifications.
General 9
2.1.2 Transformers designed for mixed cooling shall be capable of operating under the natural
cooled condition upto the specified load. The forced cooling equipment shall come into operation
by pre-set contacts in WTI and the transformer will operate as a forced cooled unit.
2.1.3 Transformer shall be capable of remaining in operation at full load for 10 minutes after
failure of the oil and/or water circulating pumps or blowers without the calculated winding
hot-spot temperature exceeding 140° C. Transformer fitted with two coolers each capable of
dissipating 50 percent of the losses at Continuous Maximum Rating (CMR) shall be capable of
remaining in operation for 20 minutes in the event of failure of the oil and/or water circulating
pumps or blowers associated with one cooler without the estimated winding hot-spot temperature
exceeding 140° C.
2.2 Continuous Maximum Rating and Overloads
2.2.1 Transformers provided with mixed cooling shall comply, as regards its rating, temperature
rise and overloads, with the appropriate requirements of IS: 2026 when operating with natural
cooling and with mixed cooling.
2.2.2 All transformers, except where stated shall be capable of operation continuously, in
accordance with IS loading guide at their CMR and at any ratio. In case bi-directional flow of
power is required, that shall be specifically stated by the purchaser.
2.2.3 Temperature rise test shall be performed at the tapping as desired by the purchaser. If
nothing has been stated by the purchaser, the test shall be carried out at the tapping with the
highest load losses.
2.2.4 The transformer may be operated without danger on any particular tapping at the
rated kVA provided that the voltage does not vary by more than ±10 percent of the voltage
corresponding to the tapping.
2.2.5 The transformer shall be suitable for continuous operation with a frequency variation of
±3% from normal 50 Hz. Combined voltage and frequency variation should not exceed the rated
V/f ratio by 10%.
Note: Operation of a transformer at rated kVA at reduced voltage may give rise to excessive tosses and temperature rise.
2.3 Voltage Ratio
2.3.1 The voltage between phases on the higher and lower voltage windings of each transformer
measured at no-load and corresponding to the normal ratio of transformation shall be those
stated in the ordering schedule.
2.3.2 Means shall be provided in accordance with clauses 8 and 9 for varying the normal ratio
of transformation.
2.4 Electrical Connections
2.4.1 Transformers shall be connected in accordance with the IS vector symbol specified in
ordering schedule of the requirements.
2.4.2 Auto connected and star/star connected transformers shall have delta connected stabilising
windings if specified in the order. Two leads from one open comer of the delta connection
shall be brought out to separate bushings. Links shall be provided for joining together the two
terminals so as to complete the delta connection and earthing it external to the tank.
2.5 Duty under Fault Conditions
2.5.1 Except where modified below, it is to be assumed that the capacity of generating plants
simultaneously connected is such that normal voltage will be maintained on one side of any
transformer when there is a short-circuit between phases or to earth on the other side. Any
transformer may be directly connected to an underground or overhead transmission line and
switched into and out of service together with its associated transmission line.
2.5.2 All transformers shall be capable of withstanding any external short-circuit according to
IS: 2026 without damage.
2.5.3 Transformers with tertiary windings shall be capable of withstanding the mechanical
and thermal effects of any external short-circuit to earth with the short-circuit MVA available at
the terminals not exceeding the values given in the ordering schedule with the neutral points on
both HV and LV windings directly connected to earth as per the requirements of IS: 2026.
2.5.4 Transformers directly connected to generator (generator step-up transformers) shall be

designed for exceptional circumstances arising due to sudden disconnection of the load and shall
be capable of operating at approximately 25 percent above normal rated voltage for a period
not exceeding one minute and 40 percent above normal rated voltage for a period of 5 seconds.
However, the purchaser will install the over fluxing protection device in case of generator step-
up transformers.
Note : All inter-connected Transformers of 50MVA and above shall also be provided with over fluxing protection by
the purchaser.
2.6 Stabilising Windings
2.6.1 If specified in the order, the stabilising winding shall be capable of carrying continuously
the load specified therein.
2.6.2 The design of stabilising winding shall be such as to take care of the effect of transferred
surges and the tenderer shall offer suitable surge protection wherever necessary.
General 11
2.7 Losses
2.7.1 The accepted losses of each transformer shall be stated in the order. The tolerance on the
losses of each transformer shall be in accordance with IS: 2026, except where maximum losses
are specified.
2.8 Regulation and Impedance
2.8.1 The impedance voltage at principal tap and rated kVA shall be stated in the order and
tolerance shall be in accordance with IS: 2026.
2.8.2 For all transformers, the value of impedance on any other tapping shall be generally
subject to the approval of the purchaser at the time of order. Any specific requirement may be
mentioned at the time of enquiry as a prequalification instead of at the time of order.
2.9 Flux Density
2.9.1 The maximum flux density in any part of the core and yokes, of each transformer at
normal voltage and frequency shall be such that the flux density in over-voltage condition as per
clause 2.2.5 shall not exceed 1.9 Tesla (19,000 lines per cm2).
However, in case of transformers with variable flux the voltage variation which would affect
flux density at every tap shall be kept in view while designing transformers.
2.10 Vibration and Noise
2.10.1 Every care shall be taken to ensure that the design and manufacture of all transformers
and auxiliary plant shall be such as to have minimum noise and vibration levels following good
modem manufacturing practices.
2.10.2 The manufacturers will ensure that the noise level shall not exceed the figures as per
NEMA Pub. No. TR - 1.
2.11 Suppression of Harmonics
2.11.1 All the transformers shall be designed with particular attention to the suppression of
harmonic voltage, especially the third and fifth, so as to eliminate wave-form distortion and
from any possibility of high frequency disturbances, inductive effects or of circulating currents
between the neutral points at different transforming stations reaching such a magnitude as to
cause interference with communication circuits.
3.0 CORES
The cores shall be constructed from high grade cold rolled non-ageing grain oriented silicon steel
laminations or Amorphous Metal. For medium rating transformers, the core may be constructed
of similar to M4 or better grade cold rolled non-aging grain oriented silicon steel laminations.
For larger rating transformers, core may be constructed from high-grade non-aging, cold rolled,
super grain oriented, silicon steel laminations similar to MOH / Hi-B steel or better grade.
The selection of Grade much depends upon loss capitalization formula(Section AA ) for an
optimized design and also upon stipulation in customer specification.
3.1 Magnetic Circuit
3.1.1 The design of the magnetic circuit shall be such as to avoid static discharges, development
of short-circuit paths within itself or to the earthed clamping structure and the production of flux
components at right angles to the plane of the laminations which may cause local heating.
3.1.2 Every care shall be exercised in the selection, treatment and handling of core steel to
ensure that as far as is practicable, the laminations are flat and the finally assembled core is free
from distortion.
3.1.3 Adequate oxide/silicate coating is to be given on the core steel. However, laminations
can be insulated by the manufactures if considered necessary.
3.1.4 Oil ducts shall be provided where necessary to ensure adequate cooling. The winding
structure and major insulation shall not obstruct the free flow of oil through such ducts. Where the
magnetic circuit is divided into pockets by cooling ducts parallel to the planes of the laminations
or by insulating material above 0.25 mm thick, tinned copper strip bridging pieces shall be
inserted to maintain electrical continuity between pockets.
3.1.5 The framework and clamping arrangements shall be earthed in accordance with clause 5.2.
3.1.6 When insulation is provided for the core to core bolts and core to clamp plates, the same
shall withstand a voltage of 2000 2500 V AC for one minute.
3.1.7 Transformers shall withstand, without injurious heating, combined voltage & frequency
fluctuations, which produce the following over fluxing condition:
• 110 %- continuous
• 125%- for one minute
• 140%- for five seconds
3.2 Mechanical Construction of Cores

3.2.1 All parts of the cores shall be of robust design capable of withstanding any shocks to
which they may be subjected during lifting, transport, installation and service.
3.2.2 All steel sections used for supporting the core shall be thoroughly sand blasted or shot
blasted after cutting, drilling and welding. Any non-magnetic or high resistance alloy shall be of
established quality.
3.2.3 Adequate lifting lugs shall be provided to enable the core and windings to be lifted.
3.2.4 Adequate provision shall be made to prevent movement of the core and winding relative
to the tank during transport and installation or while in service.
3.2.5 The supporting framework of the cores shall be so designed as to avoid the presence of
pockets which would prevent complete emptying of the tank through the drain valve, or cause
trapping of air during filling.
4.0 WINDINGS
4.1 General
4.1.1 All star connected windings for system of 66 kV and above shall have graded insulation
as defined in IS: 2026. All windings for system voltages lower than 66 kV shall be fully insulated.
All neutral points shall be insulated for the voltages specified in IS: 2026.
General 13
4.1.2 Power transformers shall be designed to withstand the impulse and power frequency test
voltages as specified in IS: 2026.
4.1.3 The windings shall be designed to reduce to a minimum the out-of-balance forces in the
transformer at all voltage ratios.
4.1.4 The insulation of transformer windings and connection shall be free from insulating
composition liable to soften, ooze out, shrink or collapse and be non-catalytic and chemically
inactive in transformer oil during service.
4.1.5 The slacks of windings shall receive adequate shrinkage treatment before final assembly.
Adjustable devices shall be provided for taking up any possible shrinkage of coils in service.
4.1.6 The coil clamping arrangement and the finished dimensions of any oil ducts shall be
such as will not impede the free circulation of oil through the ducts.
4.1.7 No strip conductor wound on edge shall have a width exceeding generally six times its
thickness.
4.1.8 The conductors shall be transposed at sufficient intervals in order to minimize eddy
currents and equalize the distribution of currents and temperatures along the windings.
4.2 Bracing of Windings
4.2.1 The windings and connections of all transformers shall be braced to withstand shocks
which may occur during transport, or due to switching short-circuit and other transient conditions
during service.
4.2.2 Coil clamping rings, if provided, shall be of steel or of suitable insulating material.
5.0 INTERNAL EARTHING ARRANGEMENTS
5.1 General
5.1.1 All metal parts of the transformer with the exception of the individual core laminations,
core bolts and associated individual clamping plates shall be maintained at same fixed
potential.
5.2 Earthing of Core Clamping Structure
5.2.1 The top main core clamping structure shall be connected to the tank body by a
copper strap. The bottom clamping structure shall be earthed by one or more of the following
methods:
(a) By connection through vertical tie-rods to the top structure
(b) By a connection to the loop structure on the same side of the core as the main earth
connection to the lank
5.3 Earthing of Magnetic Circuit
5.3.1 The magnetic circuit shall be earthed to the clamping structure at one point only through
a link placed in an accessible position beneath an inspection opening in the tank cover. The
connection to the link shall be on the same side of the core as the main earth connection. The
link should be brought out using bushing/terminal board on all transformers above 31.5 MVA.
5.3.2 When magnetic circuits are subdivided into separate isolated sections by duels
perpendicular to the plane of laminations all such sections should be earthed.
5.4 Earthing of Coil Clamping Rings
5.4.1 Where coil clamping rings are of metal at earth potential, each ring shall be connected
to the adjacent core clamping structure on the same side of transformer as the main earth
connections.
5.5 Size of Earthing Connections
5.5.1 All earthing connections with the exception of those from the individual coil clamping
rings shall have a cross-sectional area of not less than 0.8 cm, Connections inserted between
laminations of different sections of core as per clause 5.3.2 shall have a cross-sectional area of
not less than 0.2 cm2.
6.0 TANKS
6.1 Tank Construction
All transformer reactor tanks should generally be of conventional type i.e., tank body with top
cover, Bell shaped construction can be specified for 100 MVA and higher rating transformer
unless otherwise mutually agreed between Purchaser and Manufacturer
Top cover of conventional type transformer and Bell type construction may be bolted or welded
to the tank body rim. Transformers with bell type tank may have joint either at tank bottom or
close to bottom of the tank.
Inspection covers shall always be bolted type.
6.1.1 The transformer tank and cover shall be fabricated from low carbon steel suitable for
welding and of adequate thickness. The tanks of all transformers shall be complete with all
accessories and shall be designed so as to allow the complete transformer in the tank and filled
with oil, to be lifted by crane or jacks, transportation by road, rail or ship/boat without over
straining any joints and without causing leakage of oil.
6.1.2 The transformer conservator tank, if equipped with an air cell, need not be designed
for full vacuum but a vacuum-tight valve should be provided in the Buchholz relay pipe
connection.
Alternatively an equalizing connection may be provided between the inside of air cell and
conservator for evacuating the conservator along with air cell, which may be removed after
evacuation and oil filling.
General 15
6.1.3 The main tank body excluding tap-changing compartments, radiators and coolers shall
be capable of withstanding vacuum given in the following tabic:
Vacuum
Highest system
MVA rating gauge (mm of Hg)
voltage kV
pressure kN/m2
Up to 72 kV Up to 1.6 34.7 250
above 1.6 and up to 20 68.0 500
above 20 100.64 760
Above 72 kV for all MVA
ratings 100.64 760
6.1.4 The base of each tank shall be so designed that it shall be possible to move the complete
transformer unit by skidding in any direction without any damage when using plates or rails.
6.1.5 Normally a detachable base will be used, but in case transport facilities permit, a fixed
base can be used.
6.1.6 Where the base is of a channel construction, it shall be designed to prevent retention of
water.
6.1.7 Tank stiffeners shall be designed to prevent retention of water.
6.1.8 Wherever possible the transformer tank and its accessories shall be designed without
pockets where gas many collect. Where pockets cannot be avoided, pipes shall be provided to
vent the gas into the main expansion pipe. The vent pipes shall have a minimum inside diameter
of 15 mm except for short branch pipes which may be 6 mm minimum inside diameter.
6.1.9 All joints other than those which may have to be broken shall be welded when required
they shall be double welded. All bolted joints to the tank shall be fitted with suitable oil-tight
gaskets which shall give a satisfactory service under the operating conditions and guaranteed
temperature rise conditions. Special attention shall be given to the methods of making hot oil
tight joints between the tank and the cover as also between the cover and the bushing and all
other outlets to ensure that the joints can be remade satisfactorily at site and with ease with the
help of semi-skilled labour.
6.2 Lifting and Haulage Facilities
6.2.1 Each tank shall be provided with:
(a) Lifting lugs suitable for lifting the transformer complete with oil.
(b) A minimum of four jacking lugs, in accessible positions to enable the transformer
complete with oil, to be raised or lowered using hydraulic or screw jacks. The minimum
height of the lugs above the base shall be:
• Transformers upto and including 40 tonnes weight - 300 mm (approx.) so as to

accommodate suitable jacks beneath the jacking parts
• Transformers above 40 tonnes weight - 500 mm (approx.) so as to accommodate

suitable jacks beneath the jacking lugs
• When bell joint is at tank bottom and thick bottom plate is used, 300 and 500 mm
jacking pad height may not be applicable.
(c) Suitable haulage holes shall be provided

6.2.2 To facilitate safe handling at site, the longitudinal and transverse axes and the center of
gravity of main transformer tank should be marked permanently on all four sides.
6.3 Tank Cover
6.3.1 Each tank cover shall be of adequate strength, and shall not distort when lifted. Inspection
openings shall be provided as necessary to give easy access to bushings or changing ratio or
testing the earth connection. Each inspection opening shall be of ample size for the purpose for
which it is provided and at least two openings one at each end of the tank, shall be provided.
6.3.2 A ladder (with anti-climbing lock arrangement) shall be provided for tank above 3 m
height.
6.3.3 The tank cover and inspection covers shall be provided with suitable lifting arrangements.
Unless otherwise approved inspection covers shall not weigh more than 25 kg each.
6.3.4 Tank shall be designed so as to avoid collection of rain water at the tank top.
6.3.5 The tank cover shall be fitted with pockets for a thermometer and for the bulbs of oil
and winding temperature indicators. Protection shall be provided, where necessary, for each
capillary tube.
6.3.6 The thermometer pocket shall be fitted with a captive screwed top to prevent the ingress
of water.
6.3.7 The pockets shall be located in the position of maximum oil temperature at CMR and it
shall be possible to remove the instrument bulbs without lowering the oil in the tank.
6.4 AXLES AND WHEELS
6.4.1 Requirement of the roller will be specified for plinth mounted transformers. If required
only one set of roller of each size to be asked for.
6.4.2 If specified, transformers are to be provided with wheels and axles. They shall be of
such dimensions and so supported that under any service conditions they shall not deflect
sufficiently to interfere with the movement of the transformer. Suitable locking arrangements
will be provided to prevent the accidental movement of the transformer.
6.4.3 Roller/skid shall be provided with suitable rail gauge as per user requirement.
6.4.4 All rollers should be detachable and shall be made of cast iron or steel as required. The
direction of withdrawal shall be specified.
General 17
6.4.5 Wherever specified, flanged wheels shall be provided suitable for use on gauge track as
specified in the detailed specification and shall be so placed that pinch bar can be used to move
the transformer.
6.4.6 If wheels are required to swivel, they shall be arranged so that they can be turned through
an angle of 90° when the tank is jacked up clear of the rails or floor. Means shall be provided for
locking the swivel movements in positions parallel to and at right angles to the longitudinal axis
of the tank.
6.5 Conservator Vessels, Oil Gauges and Breathers
6.5.1 A conservator complete with sump and drain valve shall be provided in such a position
as not to obstruct the electrical connections to the transformer having a capacity between highest
and lowest visible levels of 7.5% of the total cold oil volume in the transformer and cooling
equipment. The minimum indicated oil level shall be with the feed pipe from the main tank
covered with not less than 15 mm depth of oil and the indicated range of oil level shall be from
minimum to maximum. For 10.0 MVA & above rating, the conservator shall be equipped with
aircell separator, unless otherwise specified.
6.5.2 If the sump is formed by extending the feed pipe inside the conservator vessel, this
extension shall be for at least 25 mm. The conservator shall be designed so that it can be
completely drained by means of the drain valve provided, when mounted as in service.
6.5.3 One end of the conservator shall be bolted into position so that it can be removed for
cleaning purposes.
6.5.4 Normally one oil gauge, magnetic/prismatic/plain type as specified shall be provided.
6.5.5 The oil level at 30°C shall be marked on the gauge.
6.5.6 Taps or valves shall not be fitted to oil gauge.
6.5.7 The oil connection from the transformer tank to the conservator vessel shall be
arranged at a rising angle of 3 to 7 degrees to the horizontal up to the Buchholz Relay and
shall consist of:
(a) For transformers up to and including 1000 kVA 25 mm inside diameter pipes as per IS:
3639
(b) For transformers from 1001 to 10,000 kVA 50 mm inside diameter pipes as per IS: 3639
(c) For transformers of over 10,000 kVA 80 mm inside diameter pipes as per IS: 3639
6.5.8 A valve shall be provided at the conservator to cut-off the oil supply to the transformer,
after providing a straight run of pipe for at least a length of five times the internal diameter of
the pipe on the tank side of the gas and oil actuated relay and at least three times the internal
diameter of the pipe on the conservator side of the gas and oil actuated relay.
6.5.9 Each conservator vessel shall be fitted with a breather in which silica gel is the dehydrating
agent and deigned so that:
(a) The passage of air is through the silica gel.
(b) The external atmosphere is not continuously in contact with the silica gel.
(c) The moisture absorption indicated by a change in colour of the tinted crystals, can be
easily observed from distance.
(d) All breathers shall be mounted at approximately 1,400 mm above ground level.
(e) Self indicating (blue) silica gel contains the dye cobalt chloride which has potential
health hazards.
An alternative to the blue self indicating silica gel is SILICA GEL ORANGE with
an organic indicator. The color changes from orange to light yellow as it absorbs
moisture. Automatic regenerative breather with internal heater & humidity sensor
are also available.
6.5.10 One non-return valve, which may automatically cut off the flow of oil from conservator
towards the main tank may be provided in the pipe connection between the Buchholz relay and
conservator for transformers 10 MVA and above.
6.6 Filter and Drain Valves Sampling Devices and Air Release Plugs
6.6.1 Each transformer shall be fitted with the following:
(a) The filter and drain valves as specified.
(b) A drain valve as specified below shall be fitted to each conservator.
For diameter up to 650 mm: Size of the valve 15 mm.
For diameter above 650 mm: Size of the valve 25 mm.
(c) A robust oil sampling device shall be provided at the top and bottom of the main tank.
The sampling device shall not be fitted on the filler valves specified under (a) above.
(d) One 15 mm air release plug.
(e) For transformers above 100 MVA rating, one 100 mm bore valve shall be provided
for attaching vacuum connection and with provisions for attaching a vacuum gauge, a
pressure gauge or an oil level indicator.
6.6.2 All other valves opening to atmosphere shall be fitted with blank flanges.
6.7 COOLER AND RADIATOR CONNECTIONS
Valves and valve mountings shall be provided as specified under “Cooling Plant” Clause 7.
6.7.1 All valves up to and including 50 mm shall be of gunmetal or of cast steel. Larger valves
may be of gunmetal or may have cast iron bodies with gunmetal fittings. They shall be of full
General 19
way type with internal screw and shall be opened by turning counter clock-wise when facing the
handwheel.
6.7.2 Means shall be provided for padlocking the bottom valves in the open and closed
positions. This is required for the valves where opening device like hand-wheel, keys, etc., are
the integral part.
6.7.3 Every valve shall be provided with an indicator to show clearly the position of the
valve.
6.7.4 All valves shall be provided with flanges having machined faces.
6.7.5 The drilling of valve flanges shall comply with the requirements of IS: 3639.
6.8 PRESSURE RELIEF DEVICE
6.8.1 The pressure relief device shall be provided for 16 MVA & above rating transformer.
PRD shall be of sufficient sizes for rapid release of any pressure that may be generated within
the tank, and which might result in damage to the equipment. The device shall operate at a static
pressure of less than the hydraulic test pressure for transformer tank. Means shall be provided to
prevent the ingress of rain water.
6.8.2 Unless otherwise approved the relief device shall be mounted on the main tank, and, if
on the cover, shall be fitted with skirt projecting 25 mm inside the tank and of such a design to
prevent gas accumulation.
6.8.3 If a diaphragm is used it shall be of suitable design and material and situated above
maximum oil level.
6.8.4 If a diaphragm is put at the base of pipe, an oil gauge is required on the stand pipe for
indicating fracture of diaphragm.
6.8.5 One of the following methods shall be used for relieving or equalising the pressure in the
pressure relief device:
(a) An equaliser pipe connecting the pressure relief device to the conservator, or
(b) The fitting of a silica gel breather to the pressure relief device. The breather being
mounted in a suitable position for access at ground level.
6.8.6 If specified, the pressure relief valve (spring operated type) capable of releasing the
pressure in the lank when it rises above a predetermined safe limit, shall be provided. It shall
be provided with a micro switch for actuating trip contact when it operates. It shall also give
a visual indication of valve operation by raising a flag. The flag and the switch shall remain
operated until they are reset manually. The operating pressure of the pressure relief valve shall
always be less than the tank test pressure. The micro switch shall have IP 55 protection and the
fasteners shall be of rust proof material.
6.8.7 PRD shall be provided with an outlet pipe which shall be taken right up to the bottom of
the transformer up to the oil catchment pit. This is to avoid injury to personnel in event of PRD
operation and subsequent splashing of oil.
6.9 Accommodation for Auxiliary Apparatus
6.9.1 If specified, facilities shall be provided for the mounting of internal/external neutral
current transformer(s) adjacent to the neutral terminal(s) and tank.
6.10 EARTHING TERMINAL
6.10.1 Two earthing terminals capable of carrying for 4 seconds the full lower voltage. Short
circuit current of the transformer. Provision shall be made at positions close to each of the
bottom two corners of the tank for bolting the earthing terminals to the tank structure to suit
local conditions. The design of earthing terminals shall be as per IS 3639 - Part 3 (Fittings and
accessories for Power Transformers Part 3: Earth Terminals.
6.11 RATING, DIAGRAM AND PROPERTY PLATES
6.11.1 The following plates shall be fixed to the transformer tank at an average height of
about 1750 mm above ground level as shown in Fig. 1.
(a) A rating plate bearing the data specified in the appropriate clauses of IS: 2026
(b) A diagram plate showing the internal connections and also the voltage vector relationship
of the several windings in accordance with IS: 2026 and in addition a plan view of
the transformer, giving the correct physical relationship of the terminals. When links
are provided in accordance with clause 2.3 for changing the transformer ratio, then
approved means shall be provided for clearly indicating ratio for which the transformer
is connected. No load voltage shall be indicated for each tap. R&D plate shall also
consist of copper weight, core weight, commissioning date & factory tested capacitance
value. A warning plate shall also be provided for OCTC operation during de-energized
condition only.
(c) Where specified a plate showing the location and function of all valves and air release
cocks or plugs is to be provided. This plate shall also warn operators to refer to the
maintenance instructions before applying the vacuum treatment for drying (Fig. 2).
6.11.2 The above plates shall be of material capable to withstanding continuous outdoor
service.
6.12 Joints and Gaskets
6.12.1 All gaskets used for making oil tight joints shall be of proven material such as granulated
cork bonded with synthetic rubber or synthetic rubber gaskets conforming to IS: 4253, unless
otherwise specified.
General 21
General 23
Fig. 3 Typical value schedule for power transformer
7.0 COOLING PLANT
7.1 General
7.1.1 Radiators and coolers shall be so designed as to avoid pockets in which moisture may
collect and shall withstand the pressure tests.
7.1.2 Unless the pipe work is shielded by adequate earthed metal the clearance between all
pipe work and live parts shall be more than the clearance for live parts to earth.
7.2 Radiators Mounted Directly to the Tank/Banked
7.2.1 Detachable radiators as per Section JJ of this manual.
7.2.2 Valves shall be provided on the tank at each point of connection to the tank.
7.2.3 Where separate radiator banks are provided, the conservator vessels specified in clause
6.5 can be mounted thereon.
7.2.4 All coolers shall be suitable for mounting on a flat concrete base.
7.2.5 The oil circuit of all coolers shall be provided with the following:
(a) A valve at each point of connection to the transformer tank

(b) Removable blanking plates to permit the blanking off the main oil connection of each
cooler.
(c) A drain valve of 25 mm at the lowest point of each bank of cooler
(d) A thermometer pocket fitted with a captive screwed cap on the inlet and outlet oil
branches of each separately mounted cooler bank.
(e) A filter valve as specified in clause 6.6 at the top and bottom of each cooler bank of
cooler.
(f) Air release plugs of 15 mm.
7.2.6 In addition the following are to be provided only with water cooled oil coolers which
shall be as per IS: 6088.
(a) A suitable differential pressure gauge or equivalent suitable device fitted with electrical
contacts to give an alarm when differential pressure between cooler oil outlet and water
inlet pressure drops below a preset value.
(b) Oil and water flow switches, fitted with electrical contacts, in the pipe work adjacent to
the coolers.
7.2.7 The disposition of flow indicators is to be as shown in Fig. 3.
7.2.8 Water cooled oil coolers shall be double tube type in which water shall circulate through
the inner tube and oil in between the outer tube and shell. The design of shell and tube assembly
shall be such as to facilitate cleaning without any risk of water mixing with the oil. The material
of the tube plates and tube shall be such that corrosion shall not take place due to galvanic
action. A water analysis report shall be furnished, in time, to enable supplier to ensure a suitable
material for tube and tube plates.
7.2.9 Any leakage which may take place in the oil cooler shall be of the oil into the water and
not the reverse, and means shall be provided to ensure that the pressure of the oil in the cooler
General 25
is always greater than the pressure of the water. The water pressure in the cooler will be kept as
low as possible. Further, the cooling water discharge should be free to the atmosphere to reduce
the pressure in the cooler. Provision for leakage detector system shall be provided along with
alarm contacts for water coolers.
7.3 Oil Piping and Flanges
7.3.1 The necessary oil piping shall be provided for connecting each transformer to the coolers
and oil pumps. The oil piping shall be with flanged gasket joints. Cast iron shall not be used.
7.3.2 The drilling of all water and oil pipe flanges shall comply with IS: 3639 and IS: 1536
(Section JJ -specification for valves for transformers.)
Fig. 4 Flow indicators and alarms

7.3.3 A suitable expansion piece shall be provided in each oil pipe connection between the
transformer and the separately mounted oil coolers.
7.3.4 Drain valves/plugs shall be provided in order that each section of pipework can be
drained independently.
7.4 Oil Pumps
7.4.1 Each forced oil cooler shall be provided with a motor driven oil pump of the submerged
motor type and of adequate capacity. It shall be possible to remove the pump and motor from
the oil circuit without having to lower the level of oil in the transformer or coolers and without
having to disturb the pump foundation fixing. Oil pump shall be capable of dealing with the
maximum output of transformer and total head which may occur in service and with the varying
head due to changes in the viscosity of the oil.
7.4.2 Each pump assembly shall be furnished with oil flow indicator with alarm contacts to
indicate normal pump operation and oil flow.
7.4.3 For mixed type cooling, the pump should be of axial flow type to permit oil circulation
when pump is idle.
7.4.4 For forced oil cooling, the coolers shall be of 2 X 50% and oil pumps 2 X 100%, one
pump running and one standby in each group.
7.4.5 Under no circumstances, the degree of forced circulation creates a static electrification
hazard in any part of a transformer under any operating condition.
7.5 Air Blowers and Ducts
7.5.1 Air blowers for use with oil coolers or for air blast cooling shall be motor driven. They
shall be suitable for continuous operation outdoors and capable of dealing with the maximum
output and total head required in service. The bearings shall be of sealed type, which does not
require frequent lubrication.
7.5.2 Air blowers shall be capable of withstanding the stresses imposed when brought up to
full speed by the direct application of full line voltage to the motor.
7.5.3 Air blowers shall be complete with all necessary air ducting and coolers shall be designed
so that they operate with a minimum of noise or drumming. In order to reduce the transmission
of noise and vibration the blowers shall be either mounted independently from the coolers or,
alternatively, an approved form of antivibration mounting shall be adopted. It shall be possible
to remove the blower complete with motor without disturbing or dismantling the cooler structure
framework.
7.5.4 Blades or runners fabricated to form hollow sections shall not be used.
7.5.5 Blades shall be suitably painted for outdoor use.
7.5.6 If fans are mounted at a height less than 2.5 m suitably painted wire-mesh guards with
a mesh not greater than 25 mm shall be provided to prevent accidental contact with the blades.
Fans mounted at more than 2.5 m height shall be provided with outside guards against birdage.
Guards shall be provided over all moving shaft and couplings.
General 27
7.6 Motors
7.6.1 Motors shall be of the squirrel cage totally enclosed weather-proof type and shall comply
with Indian Standards as applicable for continuously rated machine. The motors shall be capable
of operating at all loads without undue vibration and with a minimum of noise. They shall be
suitable for direct starting and for continuous running from 415-240 volts three-phase, 4 wire 50
Hz supply.
7.6.2 All motors shall be capable of continuous operation at any frequency between 48 and
51 Hz, together with any voltage within 5 percent of the nominal value. Motors upon which
the primary equipment depends for its continued operation at full load shall also be capable of
continuous operation at 85 percent of the nominal voltage at normal frequency without injurious
over-heating.
7.6.3 All motors shall have ball or roller bearings and grease lubricators shall be fitted with
hexagon nipples to relevant Indian Standard.
7.6.4 Vertical spindle motors shall have bearings capable of withstanding the thrust due to the
weight of the moving parts and the action of impeller.
7.6.5 The stator windings shall be adequately braced and suitably impregnated to render them
non-hygroscopic and oil resistant. Weather-proof motors shall be provided with suitable means
of breathing and drainage to prevent accumulation of water.
7.6.6 Each terminal box shall be fitted with means of terminating the external wiring for
outdoor use.
7.6.7 Varnished cambric or glass insulation shall be used for connections from the winding to
the terminals. All motor terminals shall be of the stud type and totally enclosed.
7.6.8 Each pump, or blower and its motor shall be mounted on a common base plate and the
drive shall be direct.
7.7 Cooler Control
7.7.1 Each motor or group of motors shall be provided with a three pole electrically operated
contactor and with control gear of suitable design both for starting and stopping the motor
manually and also automatically from the contacts on the winding temperature indicating device
specified in clause 13. Additional terminals for remote manual electrical control of motors shall
be provided. Overload and single phasing protection shall be provided but no-volt release shall
not be fitted. MCB/MCCB shall be provided for the main supply. This equipment shall be
accommodated in the marshalling box specified in clause 15.
7.7.2 Where small motors are connected in groups, the group protection shall be arranged so
that it operates satisfactorily in the event of a fault occurring on a single motor.
7.7.3 Where blowers and oil pumps are provided, the connections shall be arranged as to
allow the motors or groups of motors to be started up and shutdown either collectively or
individually.
7.7.4 All motor contactors and their associated apparatus shall be capable of holding in and
operating satisfactorily and without over heating for a period of ten minutes if the supply voltage
falls for the period, to 75 per cent of normal at normal frequency. The motor contactors and
associated apparatus shall be capable of normal operation with a supply voltage of 85 per cent
of the normal value and at normal frequency.
7.7.5 All contacts and other parts which may require renewal, adjustment or inspection shall
be readily accessible.
7.7.6 The control arrangements are to be so designed as to prevent the simultaneous starting
of motors of a total rating of more than 20 HP.
7.7.7 Alarm indication for failure of group of fans and oil pump shall be provided. Also for
forced oil cooled transformers, alarm indication for “low oil flow” shall be provided.
7.7.8 Alarm indication shall be provided to indicate failure of power supply.
7.7.9 The start up or shut down of any pump or combination of pumps must not cause
mal-operation of any gas and oil actuated relay.
7.7.10 For transformers with OFWF cooling required to meet peak load requirements and are
thus switched on or off during the day, the oil pump shall be kept running when the transformer
is off for a short period but water circuit is switched off. In case the transformer is switched off
for a longer time, the oil pump can also be switched off but it shall be ran at least one hour earlier
before the transformer is energised again.
7.7.11 Transformers with only OFAF cooling with unit coolers shall have provision of alarm for
“more than one cooler fail”. Cooler failure alarm shall be interfaced with DCS/ECMS/SCADA
system as applicable.
7.7.12 An alternate to the conventional cooler control “Intelligent Cooler Control & Monitoring
System” which is a PLC based system can be recommended for critical power transformers,
where cooler control and monitoring are interfaced with DCS/ECMS/SCADA system as
applicable.
8.0 VOLTAGE CONTROL (OFF-CIRCUIT TYPE)
Voltage Control (off-circuit type) should conform to Section GG of the specification.
9.0 VOLTAGE CONTROL (ONLOAD TYPE)
Voltage control (on-load type) should conform to Section GG of the specification.

General 29
10.0 PARALLEL OPERATION OF TRANSFORMERS WITH ONLOAD

TAPCHANGER
10.1 Besides the local and remote electrical control specified in clause 9, on-load tap changers,
when specified, should be suitable for remote electrical parallel control as in clause 10.2.
10.2 Remote Electrical Parallel Control
10.2.1 In addition to the methods of control as in clause 9, the following additional provision
shall be made.
10.2.2 Suitable selector switch be provided, so that any one transformer of the group can at a
time be selected as “Master”, “Follower” or “Independent”.
10.2.3 Necessary interlock blocking independent control when the units are in parallel, shall be
provided.
10.2.4 The scheme will be such that only one transformer of a group can be selected as
“Master”.
10.2.5 An out-of-step device shall be provided for each transformer which shall be arranged to
prevent further tap changing when transformers in a group operating in “Parallel control” are
one tap out-of-step.
11.0 BUSHING INSULATORS AND TERMINALS
The bushing should comply with IS 2099, IS 12676 and Section II of this specification. The over
voltage power frequency test level or the BIL of bushings should be one step higher than that
of the windings.
11.1 Transformers shall be fitted either with bushing insulators or with cable boxes, as stated
in order. Where accommodation for current transformers is required on 72.5 kV bushings and
above, the requisite details will be notified to the supplier at the time of tendering.
11.2 Special precautions shall be taken to avoid ingress of moisture into paper insulation
during manufacture, assembly, transport and erection.
11.3 Each porcelain bushing or insulator, and paper bushing shall have marked upon it the
manufacturer’s identification mark, and such other mark as .may be required to assist in the
representative selection of batches for the purposes of the sample tests.
Clamps and fittings made of steel or malleable iron shall be hot dip galvanised. All fasteners of
size 12 mm and above shall be hot dip galvanised and fasteners of size less than 12 mm shall be
of stainless steel. LV Bushing (rated current≥ 1000 Amps) palm shall be silver/tin plated.
11.4 The bushing flanges shall not be of re-entrant shape which may trap air.
11.5 Bushing turrets shall be provided with vent pipes which shall be connected to route any
gas collection through the Buchholz relay. The take off point of the vent pipes shall be the top
most point on the bushing turret so that there will not be any air trapped in the -bushing turret.
11.6 The minimum clearances in air between live conductive parts and conductive parts to
earthed structure shall be as follows:
Highest Voltage for Basic Insulation level Minimum clearances

Equipment (kV) kV peak Phase to Phase to
phase (mm) earth (mm)
12 75 280 140
24 125 330 230
36 170 350 320
52 250 530 480
72.5 325 700 660
145 550 1220 1050
145 650 1430 1270
245 950 2000 1800
245 1050 2350 2150
420 1425 4000 3500
800 1950 6700*/5800* 5800*/5000*
* depending upon lightening & switching impulse level.

Note:
(1) These clearances are applicable for transformers to be installed up to an altitude of 1000 m above mean sea level.
(2) For altitude exceeding 1000 in the clearance should be increased by 3 percent for every additional 300 m.
(3) Air clearance of 3500 mm between phase to earth for 420 kV system can be relaxed by maximum 200 mm as far as
air release pipe emanating from bushing turret is concerned.
11.7 Vertical Bushings for 52 kV & above shall be of the oil filled condenser type (OIP) &
shall be of draw lead/ rod type to facilitate removal. Bushings of rating below 52 kV may be
solid porcelain or oil communicating type. Condenser type bushings shall be provided with :
(1) Oil level gauge

(2) Oil filling plug & drain valve
(if not hermetically sealed)
(3) Tap for capacitance & tan delta test.
An alternate to OIP Bushing is Resin Impregnated Paper (RIP) Bushing. However it has to be
specified by the user.
12.0 CABLE BOXES AND DISCONNECTING CHAMBERS
12.1 Cable boxes shall be suitable for terminating the cables directly or alternatively shall be
in the form of sealing end-chambers for accommodation sealing ends into which the cable will
be terminated, as specified in the order.
12.2 Cable boxes shall be designed to accommodate all the cable joint fittings or sealing ends
General 31
required by the manufacturers of the cables, including stress/cones or other approved means for
grading the voltage stress on the terminal insulation of cables operating at voltages of 22 kV
and above, between phases. They shall also be provided with expansion chambers for the filling
medium and means of preventing the formation of air spaces when filling. Drain plugs of ample
size shall be provided to enable the filling medium to be removed quickly.
12.3 The cable boxes shall be fitted with suitable non-ferrous wiping glands with combined
armour and earthing clamps. The ends of all wiping glands shall be tinned before dispatch to site.
Wiping glands for single core cables shall be insulated from the box. Wiping glands insulation
cables shall be capable of withstanding a dry high voltage test of 2,000 volts AC for one minute.
Air insulated cable boxes for PVC cables may be provided with compression glands. Sufficient
wiping glands shall be provided for the termination of required number of cables.
12.4 Where cable boxes are provided for three core cables, the seating sockets on the two
outer phases shall preferably be inclined towards the centre to minimize bending of the cable
cores. Where there is more than one core per phase, the socket block shall be so designed as to
minimize bending of the cable cores.
12.5 Where cables for 1 kV and above are terminated in the cable box, oil filled disconnecting
chamber with removable links shall be provided for testing purposes. A barrier shall be provided
on both sides of the disconnecting chamber to prevent ingress of the oil used for filling the
chamber into the cable box or the transformer. It shall only be necessary to remove part of the
oil in the chamber itself when making the necessary testing connections.
12.6 Where sealing end chambers are provided, the disconnecting chamber may be omitted
and the facilities for testing shall be provided in the sealing end chamber itself. A barrier shall
then be provided between the sealing end chamber and the main tank subject to the provision of
the next paragraph.
12.7 The barrier between the main tank and the disconnecting or cable sealing end chamber
may be omitted, where the design is such that the cover of the disconnecting or cable sealing
end chamber can be removed without lowering any oil level other than in the chamber itself, in
order to make the necessary testing connections.
12.8 The disconnecting or sealing end chamber shall have a removable cover and the design
of the chamber shall be such that ample clearances are provided to enable either the transformer
or each cable to be subjected separately to high voltage tests when filled with transformer oil.
Insulating Fire resistant barriers should be provided between each phase of HV cable box.
12.9 An earthing terminal shall be provided in each disconnecting or sealing end chamber to
which the connections from the transformer winding can be earthed during cable testing.
12.10 The cable boxes and disconnecting or sealing end chambers shall also be capable of
withstanding for 15 minutes, both at the time of the first tests on the cables and at any subsequent
time as may be required, between phases and to earth a DC test equal to 2E kV or an AC test
equal to 4E/3 kV.
12.11 During these tests the links in the disconnecting or sealing end chamber or cable box
will be withdrawn and the transformer winding with connections thereto will be earthed.
12.12 Unless otherwise approved the creepage distances and clearance to earth and between
phases shall not be less than those specified in Table 1. In case of compound filled cable box with
shrinkable tape, the allowable minimum clearances shall be subject to the agreement between
manufacturer and the user.
12.13 Cable boxes suitable for semi-fluid compound filling shall be tested with transformer oil
at room temperature and at a pressure of 0.7 kg/cm for 12 hours during which no leakage shall
occur.
12.14 Terminals shall be marked in a clear and permanent manner.
12.15 Unless otherwise specified main cabling jointing and filling of cable boxes will be
carried out by the customer. However, filling medium will be supplied as a part of the cable box
by the manufacturer.
Table 1
Highest Insulating Clearance Clearance Creepage Creepage
System medium between to earth over over
Voltage phases direct porcelain to cable
kV similar surface
(mm) (mm)
material (mm)
(mm)
1.1 Ail- 25 20 25 -
3.6 Air 50 50 90 -
7.2 Ail- 90 70 - -
12 Air 130 80 192 192
Compound 50 50 75 125
24 Air 241 140 384 384
Semi-fluid 100 75 125 190
compound or oil
36 Air 351 222 576 576
Semi-fluid 125 100 150 250
compound or oil
13.0 TEMPERATURE INDICATING DEVICES AND ALARM
13.1 Oil temperature indicator shall be provided as required in detail specification, i.e.,
Section E to K.
13.2 All transformers above 10 MVA shall be provided with a device for indicating winding
temperature. The device shall have a dial type indicator and in addition a pointer to register the
highest temperature reached. The number of contacts as specified will be provided.
13.3 Except where outdoor types of indicators are supplied, the temperature indicators shall
be housed in the marshalling box. If specified, for transformers above 10 MVA a remote repeater
indicator electrically operated from winding temperature indicator is to be provided for mounting
General 33
on the control panels. Unless otherwise specified the remote repeater indicator shall be of flush
mounting type.
13.4 The tripping contacts of winding temperature indicators shall be adjustable to close
between 60°C and 120°C and alarm contacts to close between 50°C and 100°C and both shall
re-open when the temperature has fallen by about 10°C.
13.5 The contacts used to control the cooling plant motors on the above devices shall be
adjustable to close between 50°C and 100°C and re-open when the temperature has fallen by any
desired amount between 15°C and 30°C.
13.6 All contacts shall be adjustable on a scale and shall be accessible on removal of the
cover. Micro switches shall be preferred to mercury switches.
13.7 The temperature indicators shall be so designed that it shall be possible to check the
operation of the contacts and associated equipment.
13.8 Connections shall be brought from the device to terminals placed inside the marshalling
box.
13.9 Cooler failure or oil and water flow alarm shall be provided as specified in clause 7.2.6.
13.10 Accuracy class of temperature indicators shall be ± 1.5% or better.
13.11 An alternate to conventional dial type WTI/OTI is Digital WTI/OTI.
14.0 GAS AND OIL ACTUATED RELAYS
14.1 Each transformer shall be fitted with gas and oil actuated relay equipment to IS; 3637
having contacts which close following oil surge or low oil level conditions. Micro switches shall
be preferred to mercury switches.
14.2 Each gas and oil actuated relay shall be provided with a test cock to take a flexible pipe
connection for checking the operation of the relay.
14.3 Where specified to allow gas to be collected at ground level, a pipe approximately 5 mm
inside diameter shall be connected to the gas release cock of the gas and oil-actuated relay and
brought down to a point approximately 1.25 m above ground level, where it shall be terminated
by a cock.
14.4 A machined surface shall be provided on the top of each relay to facilitate the setting of
the relays and to check the mounting angle in the pipe and the cross level of the relay.
14.5 The design of the relay mounting arrangements, the associated pipework and the cooling
plant shall be such that mal-operation of the relays shall not take place under normal service
conditions.
14.6 The pipework shall be so arranged that all gas arising from the transformer shall pass
into the gas and oil-actuated relay. The oil circuit through the relay shall not form a delivery
path in parallel with any circulating oil pipe, nor shall it be tied into or connected through the
pressure relief vent. Sharp bends in the pipework shall be avoided.
14.7 When a transformer is provided with two conservators, the gas and oil actuated relays
shall be arranged as follows:
• If the two conservators are connected to the transformer by a common oil pipe, one relay
shall be installed in the common pipe.
• If the two conservators are piped separately to the transformer, two relays shall be
installed, one in each pipe connection.
• Adequate clearance between oil pipework and live metal shall be provided.
15.0 MARSHALLING BOX
15.1 A steel weather and vermin proof enclosure having degree of protection IP 55 shall be
provided for the transformer ancillary apparatus. The box shall have domed or sloping roofs and
the interior and exterior painting shall be in accordance with clause 1.6.
15.2 The marshalling box, wherever provided shall accommodate the following equipments,
alternatively weather proof instruments can be mounted outdoor.
(a) Temperature indicators

(b) Control and protection equipment for the local electrical control of tap changer, if the
same cannot be accommodated in the motor driving gear housing.
(c) Control and protection equipment for the cooling plant; and
(d) Terminal boards and gland plates for incoming and outgoing cables
(e) Capillary entrance should preferably be from bottom of the box.
15.3 All the above equipments except (d) shall be mounted on panels and back of panel
wiring shall be used for interconnection.
15.4 The temperature indicators shall be so mounted that the dials are not more than 1600
mm from ground level and the door(s) are of adequate size.
15.5 To prevent internal condensation, an approved type of metal clad space heater shall be
provided, controlled by a suitable thermostat. For illumination, a suitable lamp or CFL shall be
provided whose switching shall be controlled by the door switch.
General 35
15.6 All incoming cables shall enter the kiosks from the bottom and the gland plate shall be
not less than 450 mm from the base of box. The gland plate and associated compartment shall
be sealed in suitable manner to prevent the ingress of moisture.
15.7 Undrilled gland plate shall be provided for accommodating glands for incoming and
outgoing cables.
15.8 Separate kiosk may be provided for control & power circuit of OFAF cooled Power
Transformers.
16.0 CONTROL CONNECTIONS AND INSTRUMENT WIRING, TERMINAL

BOARD AND FUSES
16.1 All wiring connections, terminal boards, fuses and links shall be suitable for tropical
atmosphere. Any wiring liable to be in contact with oil shall have oil resisting insulation and
the bared ends of stranded wire shall be sweated together to prevent creepage of oil along
with wire.
16.2 There shall be no possibility of oil entering connection boxes used for cables or wiring.
16.3 Panel connections shall be neatly and squarely fixed to the panel. All instruments and
panel wiring shall be run in PVC or non-rusting metal cleats of the limited compression type.
All wiring to a panel shall be taken from suitable terminal boards.
16.4 Where conduits are used, the runs shall be laid with suitable falls, and the lowest parts
on the-run shall be external to the boxes. All conduit runs shall be adequately drained and
ventilated. Conduits shall not be run at or below ground level.
16.5 When 415 volt connections are taken through junctions boxes or marshalling boxes they
shall be adequately screened and 415 “VOLTS DANGER” notices must be affixed to the outside
of the junction boxes or marshalling boxes.
16.6 All box wiring shall be in accordance with relevant IS. All wiring shall be of stranded
copper of 660 V grade and size not less than 4.00 sq mm for CT leads and not less than 2.5 sq
mm for other connections.
16.7 All wires on panels and all multicore cables shall have ferrules which bear the same
number at both ends.
16.8 At those points of interconnections between the wiring carried out by separate contractors,
where a change of number cannot be avoided, double-ferrules shall be provided on each wire.
The change of numbering shall be shown on the appropriate diagram of the equipment.
16.9 The same ferrule number shall not be used on wires in different circuits on the same
panels.
16.10 Ferrules shall be provided with glossy finish to prevent the adhesion of dirt. They shall
be clearly and durably marked and shall not be affected by damp or oil.
16.11 Stranded wires shall be terminated with tinned Ross Courtney terminals, claw washers
or crimped tubular lugs. Separate washers shall be used for each wire. The size of the washer
shall be suited to the size of the wire terminated. Wiring shall in general be accommodated on
the sides of the box and the wires for each circuit shall be separately grouped. Back of panel
wiring shall be arranged so that access to the connecting stems of relays and other apparatus is
not impeded.
16.12 Wires shall not be jointed or tied between terminal points.
16.13 Wherever practicable, all circuits in which the voltage exceeds 125 volts, shall be kept
physically separated from the remaining wiring. The function of each circuit shall be marked on
the associated terminals boards.
16.14 Where apparatus is mounted on panels, all metal cases shall be separately earthed by
means of copper wire or strip having a cross-section of not less than 2 sq mm where strip is used,
the joints shall be sweated.
16.15 All wiring diagram for control and relay panel shall preferably be drawn as viewed from
the back and shall show the terminal boards arranged as in service. All diagrams shall show
which view is employed.
16.16 Multicore cable tails shall be so bound that each wire may be traced without difficulty to
its cable.
16.17 The screens or screen pairs of multicore cables shall be earthed at one end of the cable
only. The position of the earthing connections shall be shown clearly on the diagrams.
16.18 All terminal boards shall be mounted obliquely towards the rear doors to give easy
access to terminations and to enable ferrule numbers to be read without difficulty.
16.19 Terminal board rows should be spaced adequately not less than 100 mm apart to permit
convenient access to wires and terminations.
16.20 Terminal boards shall be so placed with respect to the cable gland (at a minimum distance
of 200 mm) as to permit satisfactory arrangement of multicore cable tails.
Terminal boards shall have pairs of terminals for incoming and outgoing wires. Insulating barriers
shall be provided between adjacent connections. The height of the barriers and the spacing
between terminals shall be such as to give adequate protection while allowing easy access to
terminals. The terminals shall be adequately protected with insulating dust-proof covers. One
dummy terminal block in between each trip wire terminal shall be provided. No Loop in Loop
out shall be adopted for power circuit.
16.21 No live metal shall be exposed at the back of the terminal boards.
16.22 All fuses shall be of the cartridge type.
16.23 Fuses and links shall be labeled.
16.24 The terminal blocks preferably shall be fully enclosed with removable covers & made of
molded, non-inflammable plastic material with blocks & barriers molded integrally. The terminal
blocks shall be 650V grade & have 10 A continuous rating. At least 20 % spare terminals shall be
General 37
provided on each panel. Terminal blocks for CT/PT secondary leads shall be provided with test
links & isolating facilities. Also current transformer secondary leads shall be provided with short
circuiting & earthing facilities. All CT/PT terminals shall be provided as fixed type terminals in
M. Box to avoid any hazard due to loose connection leading to CT opening or any other loose
connection. In no circumstances Plug In type connectors shall be used for CT/PT connections in
M. Box. Terminal block shall preferably be stud type suitable for ring (O) type lugs.
17.0 TESTS
17.1 Tests shall be carried out to evaluate the performance of the material and appliance
generally as per the provision of IS: 2026 and as detailed out in Section BB of this
specification.
A test method is referred in Appendix-VIII for Bushing CT Characteristic testing without passing
current to primary winding.
17.1.1 Where customers’ inspection is specified, not less than 15 days notice shall be given
to the customer in order that he may be represented. Four copies of test certificates will be
supplied.
17.2 Tests are not required to be performed on bought out equipments like oil coolers, oil
actuated relays, etc., at the works of the transformer manufacturer. Furnishing test certificates
from the original equipment manufacturer works shall be deemed to be satisfactory evidence.
Inspection of tests at the sub-contractors works will be arranged by the supplier wherever
required.
17.3 Tanks
17.3.1 Routine Tests
(a) Fabrication stage:

(al) The tank shall be tested for leakage by being completely filled with air at a pressure
corresponding to twice the normal head of oil or to normal pressure plus 35 kN/m2 whichever is
lower. The pressure shall be maintained for a period of minimum one hour during which time no
leakage shall occur. The equivalent air pressure corresponding to oil pressure calculated at the
base of the tank to be considered for air pressure test. Permanent deflection of flat plates shall
be measured on one tank of each design, if specified by customer, after the excess pressure has
been released and shall not exceed the figures specified below:
Horizontal length of flat plate Permanent deflection
(total length of tank wall) in mm (in mm)
Up to and including 750 5
751 to 1250 6.5
1251 to 1750 8
1751 to 2000 9
2001 to 2250 11
2251 to 2500 12.5
2501 to 3000 16
Above 3000 19
(a2) The conservator shall be tested for leakage by being completely filled with air at 35
kN/m2. The pressure shall be maintained for a period of one hour during which time no
leakage shall occur.
(a3) The radiators shall be tested for leakage by placing them horizontally in a tank filled
with clean water and applying air pressure 2 kg/cm2 for atleast 15 minutes during which
time no leakage shall occur.
(a4) The pipes shall be tested for leakage by applying air pressure of 4 kg/cm2 for 15 minutes
during which time no leakage shall occur.
(b) Transformer assembly stage
Oil pressure test to be conducted on tank with turret and all other accessories as assembled
for routine test by filling completely with oil at a pressure corresponding to twice the
normal head of oil or to normal pressure plus 35 kN/m2 whichever is lower. The pressure
to be maintained for eight hours during which time no leakage shall occur.
17.3.2 Type Tests
(a) Vacuum test (at fabrication stage)
When required by customer, one transformer tank of each design shall be subjected to
the specified vacuum as in clause 6.1.3. The tanks designed for full vacuum (760 mm of
mercury at sea level or the barometric reading at the location of test) shall be tested at a
maximum internal pressure of 3.33 kN/m2 (25 mm of Hg) for one hour i.e., 760-25=735
mm of Hg at sea level and (Barometric reading -25) mm Hg at other location.
The permanent deflection of flat plates after vacuum has been released shall not exceed
the values specified in clause 17.3.1 (al) without affecting the performance of the
transformer.
(b) Pressure test
When specified, one transformer tank of each design with its active part as assembled
for type test (i.e., including pipe work and cooling equipment and excluding PRV and
conservator when air cell is provided) shall be subjected to a pressure corresponding to
twice the normal head of oil or to normal pressure plus 35 kN/m2 whichever is lower
measured at the base of the tank and will be maintained for 8 hours during which time
no leakage shall occur.
Before conducting the pressure test, the following are to be taken care of:
(i) Pressure relief valve/relief vent are to be removed and the opening blanked.
(ii) Transformer and tap changer conservators are to be disconnected.
(iii) Diverter switch compartment of tap changer to be connected with transformer tank for
equalizing the pressure on both sides.
(iv) Oil should be completely filled and all trapped air released.
17.3.3 Note: User may also specify Tank Routine/Type Tests in line with latest revision of IEC
60076-1
When IS eventually gets revised in line with latest revision of IEC, CBIP Manual shall be
amended to fall in line with IS.
General 39
18.0 QUALITY ASSURANCE

The supplier should include a quality assurance programme (QAP) that will be used to ensure
that the transformer design, materials, workmanship, tests, service capability, maintenance
and documentation, will fulfill the requirements stated in the contract documents, standards,
specifications and regulations. The QAP should be based on and include relevant parts to fulfill
the requirements of ISO-9001.
A quality plan describes:
• Lists of activities involved in design, procurement of raw materials and components,

manufacture, stage inspection and final testing, preparation for dispatch, delivery,
installation and commissioning.
• The identification reference of all documentation, standards, procedures, works
instructions, drawings, test methods, acceptance criteria etc.
Typical QAP format is provided for illustration as Appendix III.
19.0 A list of guaranteed technical particulars and additional technical particulars are given in
Appendix IV. A list of standards for transformers is given in Appendix II. A list of transformer-
accessories and routine test certificate required for them is given .at Appendix V.
20.0 NEUTRAL EARTHING ARRANGEMENT /FORMATION
Neutral terminals of winding of three single phase Transformer shall be formed by connection
to an overhead common copper grounding bars, supported from tank and firewalls by using
insulators. Puncturing/support from firewall may not be permitted.
21.0 DESIGN REVIEW
The design of critical Power Transformer/ Reactor may be reviewed by user/their consultant. The
design review shall be finalized before commencement of manufacturing activity. This design
review may be carried out inline with CIGRE “Guideline for Conducting Design Review”, 204,
SC WG12.22. A format for required Design Review parameters is given in Appendix-VI for
reference.
22.0 REFERENCE TECHNICAL PARTICULARS OF POWER TRANSFORMERS &

SITE PHOTOGRAPHS
Salient Technical Particulars of Power Transformers for Coal Fired or Gas Based Thermal Power
Plants are given in Appendix-VII for reference.
Photographs of transformers & accessories already installed in various power projects are shown
in Appendix-IX.
SECTION B
Specifications for Outdoor type, Completely Self

Protected, 3 Phase Distribution Transformers (upto
and including 100 kVA)
SECTION B
Specifications for Outdoor type, Completely Self Protected, 3 Phase
Distribution Transformers (upto and including 100 kVA)
1.0 SCOPE
1.1 This section covers, technical requirements/parameters of Completely Self Protected

distribution transformers of rating upto and including 100 kVA, 11 kV 3 phase and does not
purport to include all the necessary provisions of a contract.
1.2 Standard Ratings
The standard ratings shall be 16, 25, 63 and 100 kVA. For general requirement reference shall
be made to Sections A & BB of this manual.
2.0 STANDARDS
2.1 The materials shall conform in all respects to the relevant Indian / International Standard
Specification, latest, amendments thereof, some of them are listed below:
Indian Standard Title International & Internationally

recognisedstandard
IS-2026 Specification for Power Transformer IEC 60076
IS-1180 Outdoor Distribution Transformer upto and including 100 kVA
IS 12444 Specification for Copper Wire Rod ASTM B-49
IS-3347 Specification for Porcelain Transformer Bushing DIN 42531,23,3
IS-335 Specification for Transformer Oil BS 148, D-1473, D-1533-
1934 IEC Pub 296
IS 5 Specification for Colours for Ready Mixed Paints
IS-2099 Specification for High Voltage Porcelain Bushings
IS-7421 Specification for Low Voltage Bushings
IS-3347 Specification for Outdoor Bushings DIN 42531 to 33
IS-5484 Specification for Al Wire Rods ASTM B-233
IS - 9335 Specification for Insulating Kraft Paper IEC 60554
IS- 1576 Specification for Insulating Press Board IEC 60641
IS/6600 2026-7 Guide for Loading of Oil Immersed Transformers IEC 60076
Refer Appendix II of the Manual for List of Standards.
3.0 SERVICE CONDITIONS
The Distribution Transformers to be supplied against this Specification shall be suitable for
satisfactory continuous operation under the climatic conditions prevailing at site and to be
specified by the purchaser as follows, as per IS 2026 (Part -1) Latest Revision/International
43
Standards tabulated above :

(i) Location
(ii) Max ambient air temperature (deg.C) :
(iii) Min. ambient air temperature (deg.C) :
(iv) Max average daily ambient air temperature (deg.C) :
(v) Max. yearly weighted average ambient temperature(deg.C) :
(vi) Max. altitude above mean sea level (meters) :
4.0 STANDARD RATINGS
Transformers shall be suitable for outdoor installation with three phase, 50 Hz, 11 kV system in
which the neutral is effectively earthed and these should be suitable for service under fluctuations
in supply voltage upto plus 10% to minus 15%.
The transformer shall conform to the following specific parameters:
SL. No Item Specification

1. Continuous rated 16kVA 25 kVA 63kVA 100 kVA
capacity
2. System highest Voltage 12 kV 12 kV 12 kV 12 kV
3. Rated Voltage HV 11 kV 11 kV 11 kV 11 kV
4. Rated Voltage LV 433 V 433 V 433 V 433 V
5. BIL 95 kV Peak 95 kV Peak 95 kV Peak 95 kV Peak
6. Frequency 50Hz +/- 5% 50Hz +/- 5% 50Hz +/- 5% 50Hz +/- 5%
7. No. of phases Three Three Three Three
8. Connection HV Delta Delta Delta Delta
9. Connection LV Star (neutral Star (neutral Star (neutral Star (neutral
brought out and brought out and brought out and brought out and
directly earthed directly earthed directly earthed directly earthed
10. Vector group Dyn-11 Dyn-11 Dyn-11 Dyn-11
11. Type of cooling ONAN ONAN ONAN ONAN
12. Percentage impedance at 4.5 4.5 4.5 4.5
75°C
13. Permissible temperature
rise over ambient
(i) Of top oil measured 35 35 35 35
by thermometer
(ii) Of winding
measured by resistance 40 40 40 40
14. Minimum clearances in
air As per IS-1180 As per IS-1180 As per IS-1180 As per IS-1180
(a) HV phase to phase / latest latest latest latest
phase to earth (mm) 255/ 140 255/ 140 255/ 140 255/ 140
(b) LV phase to phase / 75/40 75/40 75/40 75/40
phase to earth (mm)
15. Tap changer Not applicable Not applicable Not applicable Not applicable
Specifications for Outdoor type, Completely Self Protected, 3 Phase Distribution Transformers (upto 45
5.0 TECHNICAL REQUIREMENTS
5.1 Core
5.1.1 Material - Cold Rolled Grain Oriented (CRGO) /Amorphous Metal

(a) Material- CRGO
5.1.2 (a) The core shall be stacked / wound type, of high grade cold rolled grain oriented
steel laminations having low loss and good grain properties, coated with hot oil proof
insulation, bolted / banded together and to the frames firmly to prevent vibration or noise.
The complete design of core must ensure permanency of the core losses with continuous working
of the transformers. The value of the maximum flux density allowed in the design and grade of
lamination used shall be clearly stated in the offer.
The manufacturer should offer the core for inspection and approval by the purchaser during
manufacturing stage. Manufacturer's shall give notice for inspection with the following
documents as applicable as a proof towards use of prime core material
• Invoice of the Supplier

• Mills Test Certificate
• Packing List
• Bill of Lading
• Bill of Entry Certificate to Customs
5.1.3 (a) Core Clamping for CRGO Stacked Core
• MS Channel shall be used on top and bottom

• Core Channel on LV side to be reinforced at equidistance, if holes / cutting is done for
LT lead in order to avoid bending of channel.
• MS Channels shall be painted with varnish or oil-resistant paint.
• Clamping & Tie-rods shall be made of HT steel and shall be parkarised
5.1.4 (a) Core Clamping for CRGO Wound Core
• Core clamping shall be with top and bottom U-shaped core clamps made of sheet steel
clamped with HT steel tie rods for efficient clamping.
• MS core clamps shall be painted with varnish or oil-resistant paint.
• MS rods shall be used as tie rods.
• Suitable provision shall be made in the bottom core clamp / bottom plate of the
transformer to arrest movement of the active part.
5.1.5 (a) The transformers core shall be suitable for over fluxing (due to combined effect
of voltage and frequency) upto 12.5% without injurious heating at full load conditions and
shall not get saturated. The Manufacturer shall furnish necessary design data in support of this
situation.
5.1.6 (a) No load current shall not exceed 1% of full load current and will be measured by
energising the transformer at 433 volts, 50 c/s on the secondary. Increase of voltage of 433 volts
by 12.5% shall not increase the no load current beyond 6% of full load current.
(b) Material - Amorphous Metal
5.1.8 (b) The core shall be high quality Amorphous ribbons having very low loss formed into
wound cores of rectangular shape, bolted together to the frames firmly to prevent vibration or
noise. The complete design of core must ensure permanency of the core loss with continuous
working of the transformers. The value of the flux density allowed in the design shall be clearly
stated in the offer. Curve showing the properties of the metal shall be attached with the offer.
5.1.7 (b) Core Clamping for Amorphous Metal Transformers

• Core clamping shall be with top and bottom U-shaped core clamps made of sheet steel
clamped HT steel tie rods for efficient clamping.
• MS core clamps shall be painted with varnish or oil-resistant paint.
• MS rods shall be used as tie rods.
• Suitable provision shall be made in the bottom core clamp / bottom plate of the
transformer to arrest movement of the active part.
5.1.9 (b) The transformers core shall be suitable for over fluxing (due to combined effect
of voltage and frequency) upto 12.5% without injurious heating at full load conditions and
shall not get saturated. The Manufacturer shall furnish necessary design data in support of this
situation.
5.1.10 (b) No load current shall not exceed 1% of full load current and will be measured by
energising the transformer at 433 volts, 50c/s on the secondary. Increase of voltage of 433 volts
by 12.5% shall not increase the no load current beyond 5% of full load current.
Note : "Equal weightage shall be given to the transformers with Amorphous metal core and CRGO".
5.2 Windings
5.2.1 Material: Super enamel covered copper conductor / double paper covered copper
conductor. Aluminium conductors can also be used with same loss levels as of copper wound
transformers.
5.2.2 LV winding shall be in even layers so that neutral formation is at top.

5.2.3 The winding construction of single HV coil preferred to crossover coil over LV coil
5.2.4 Inter layer insulation shall be electrical grade Epoxy dotted kraft Paper for rectangular
coils.
5.2.5 Proper bonding of inter layer insulation with the conductor shall be ensured.
5.2.6 Dimensions of winding coils are very critical. Dimensional tolerances for winding coils
shall be with in limits as specified in GTP.
5.3 Oil
The insulating oil shall comply with the requirements of relevant standards IS 335 / IEC 60296
5.4 Insulation Material
5.4.1 Material: Electrical Grade Epoxy Dotted Kraft Paper shall he used for Rectangular
Coil
5.4.2 All spacers, axial wedges / runners used in windings shall be made of pre-compressed
solid press board, conforming to type B 3.1 of IEC 641-3-2. In case of cross-over coil winding
of HV all spacers shall be properly sheared and dovetail punched to ensure proper locking. All
axial wedges / runners shall be properly milled to dovetail shape so that they pass through the
designed spacers freely. Insulation shearing, cutting, milling and punching operations shall be
carried out in such a way, that there is no burr or dimensional variations.
5.5 Losses : The maximum losses at rated voltage and rated frequency permitted at 75 Deg.
C. are indicated below:
Voltage Ratio kVA Rating No load losses in watts Full load losses in watts (Max)
(Max) at 75 Deg C
11000/433-250 V 16 65 425
11000/433-250 V 25 80 615
11000/433-250 V 63 150 1100
11000/433-250 V 100 220 1575
Note: The losses mentioned above are under discussion and finalisation by BIS to revise IS:1180. The above losses
eventually may get revised if any, after said revision.
The above losses are maximum allowable and there would not be any positive tolerance.
Transformers with higher losses than the above specified values would be treated as Non-
responsive.
Transformers with losses less than those specified above will be capitalized during transformer
evaluation as indicated below. (Refer to Loss Capitalisation formula, Section AA, Loss
Capitalization factors:
A. Iron Losses - Rs. 89.67 X Ec / Watt
B. Copper Losses - Rs. 26.9 X Ec / Watt
Where Ec is the cost of energy ( in Rupees per unit at 11 kV feeder level). In case of non
availability of Ec (Energy cost per unit) at 11 kV feeder level, utility should consider the Bulk
Rate Tariff plus 5% as the cost of energy at 11 kV feeder level
• PRICE SCHEDULE
The following format shall be filled by the manufacturer for evaluating TOC (TOC) price.
SL. Price Component Rating 1 Rating 2 Rating 3 Rating 4

No
1. Unit ex-works price
2. Freight & Insurance
3. (i) Excise duty
(ii) Educational cess on Ex
cise duty
4. Sales Tax
5. Total Cost per Unit without
Capitalization (1+2+3+4)
6. NLL
7. Cost of NLL/Watt
8. Cost of Total NLL ( 6 x 7 )
9. LL
10. CostofLL/Watt
11. Costoftotal LL(9x 10)
12. TOC price per Unit with
Capitalization (5+8+11)
13. No. of Transformers
14. Type test charges
15. TOC price((12xl3)+14)
5.6 Percentage Impedance
The value of impedance of transformers at 75 Deg. C shall be 4.5% subject to the tolerance
specified in the standard IS:2026.
5.7 Temperature Rise : The temperature rise over ambient of 50 deg. C shall not exceed the
limits given below:
Top oil temperature rise measured by thermometer : 35 Deg.C

Winding temperature rise measured by resistance : 40 Deg.C
Transformers not meeting the above limits of temperature rise shall not be accepted.
5.8 Penalty for Non Performance
5.8.1 During testing, if it is found that the actual measured losses are more than the values
quoted by the manufacturer penalty shall be recovered from the manufacturer at double the
loss capitalization rate arrived at clause 5.5. For fraction of a kW, proportionate penalty will be
recovered.
5.8.2 Transformers with temperature rise and impedance beyond guaranteed values:
5.8.2.1 Purchaser reserves the right to reject any transformer during the test at supplier's works,
if the temperature rise exceeds the guaranteed values.
5.8.2.2 Purchaser reserves the right to reject any transformer during the test at supplier's works,
if the impedance values differ from the guaranteed values including tolerance.
5.8.2.3 Purchaser also reserves the right to retain the rejected transformer and take it into service
until the manufacturer replaces it with a new transformer at no extra cost. The delivery as per
contract will be counted when the new transformer as per specification is provided by the
manufacture.
5.9 Tank
The transformer tank can be with radiator fins/ rounded or elliptical cooling tubes or made of
corrugated panels.
5.9.1 For Rectangular / Octogonal Plain Tank
The transformer tank shall be of robust construction rectangular /octogonal in shape and shall
be built up of tested MS sheets.
The internal clearance of tank shall be such that, it shall facilitate easy lifting of core with coils
from the tank without dismantling LV bushings.
All joints of tank and fittings shall be oil tight and no bulging should occur during service.
The tank design shall be such that the core and windings can be lifted freely. The tank plate shall
be of such strength that the complete transformers when filled with oil may be lifted bodily by
means of lifting lugs. Inside of tank shall be painted with varnish/hot oil resistant paint.
The four walls of the tank shall be made of Two "L" shaped sheets (without joints) fully welded
at the corners from inside and outside of the tank for withstanding a pressure of 0.8 kg/cm2 for
10 minutes.
The tank shall be reinforced by angle welded on all the outside walls on the edge of the tank to
form two equal compartments. Permanent deflection when the tank without oil is subject to a
vacuum of 525 mm of mercury for octogonal tank and 760 mm of mercury for round tank, shall
not be more than 5 mm upto 750 mm length and 6.5 mm upto 1250 mm length. The tank shall
further be capable of withstanding a pressure of 0.8 kg/sq cm (g) and a vacuum of 0.3 kg/sq cm
(g) without any deformation.
The radiators can be tube type or fin type or pressed steel type to achieve the desired cooling
and the same shall be capable of giving continuous rated output without exceeding the specified
temperature rise. 4 Nos. welded heavy duty lifting lugs of MS plate 8 mm thick (min) suitably
reinforced by vertical supporting flat welded edgewise below the lug shall be provided on the
side wall.
4 Nos. of welded heavy duty pulling lugs of MS plate 8 mm thick (min) shall be provided to pull
the transformer horizontally.
Top cover fixing bolts of Galvanised Iron adequately spaced and 6 mm Neoprene bonded cork
gaskets conforming to IS 4253 part-II shall be placed between tank and cover. The bolts outside
tank shall have 2 flat washers and one spring washer.
5.9.2 Corrugated Tank
Corrugated tanks may be offered for 63 kVA and 100 kVA.
The transformer tank shall be of robust construction corrugation in shape and shall be built up
of CRCA sheets of 1.2 mm thick.
from the tank, with CCA (core-coil assembly), HV & LV bushings mounted on Top cover.
All joints of tank and fittings shall be oil tight and no bulging should occur during service.
The tank design shall be such that the core and windings can be lifted freely. The tank plate shall
means of lifting lugs. Inside of tank shall be painted with varnish / hot oil resistant paint.
Corrugation panel shall be used for cooling. The transformer shall be capable of giving
continuous rated output without exceeding the specified temperature rise.
2 Nos. welded heavy duty lifting lugs of MS plate 8 mm thick (min) suitably reinforced are to
be provided.
Top cover fixing bolts of galvanized iron and 6 mm Neoprene bonded cork gaskets conforming
to IS 4253 part-II / nitrile rubber shall be placed between tank and cover. The bolts outside tank
shall have 2 flat washers and one spring washer.
Tanks with corrugations and without conservator shall be tested for leakage test at a pressure of
0.15kg/sq cm measured at the top of the tank
5.9.3 Sealed Transformer with Radiators
In this type of construction tank is designed to have cover welded to the curb of tank.
Space is provided above the core coil assembly where inert gas cushion system accommodates
the oil expansion under variable pressure. The tank should be of stiff construction able to
withstand pressure of 2 atmospheres.
5.10 Conservator
On Transformers of 100 kVA rating with rectangular plain tank the provision of conservators is
obligatory. For other ratings manufacturer may adopt their standard practice. Conservator is not
required in transformers with corrugated tank.
When a conservator is provided, oil gauge and the plain or dehydrating breathing devise shall be
fixed to the conservator which shall also be provided with a drain plug and a filling hole (M30
normal size thread) with cover. The capacity of a conservator tank shall be designed keeping in
view the total quantity of oil and its contraction and expansion due to temperature variations. In
addition the cover of main tank shall be provided with an air release plug to enable air trapped
within to be released, unless the conservator is so located as to eliminate the possibility of air
being trapped within the main tank.
The inside diameter of the pipe connecting the conservator to the main tank should be within20
to 50 mm and it should be projected into the conservator so that its end is approximately 20
mm above the bottom of the conservator so as to create a sump for collection of impurities. The
minimum oil level (corresponding to -5 deg C) should be above the sump level.
5.11 Surface Preparation and Painting
5.11.1 For Surface Preparation refer to section A of this Manual
5.12 Bushings
The bushings shall conform to the relevant standards specified and shall be outdoor type.
The bushing rods and nuts shall be made of brass material 12 mm diameter for both HT &
LT. The bushings shall be fixed to the transformers on side with straight pockets and in the
same plane or on the top cover. Arcing horns or lightning arrestors shall be provided on HV
bushings.
For 11 kV, 17.5 kV class bushings and for 0.433 kV, 1.1 kV class bushings shall be used. Bushings
with plain sheds as per IS-3347 shall be mounted on the side of the Tank and not on top cover.
A minimum phase to phase clearance of 75 mm for LV (upto 1.1 kV bushings) and 255 mm for
HV bushings shall be obtained with the bushing mounted on the transformer.
The terminal arrangement shall not require a separate oil chamber not connected to oil in the
main tank.
5.13 Terminal Connectors
The LV bushing and HV bushing stems shall be provided with suitable terminal connectors so
as to connect the jumper without disturbing the bushing stem. Connectors shall be with eye bolts
so as to receive 55 sq mm conductor for HV.
5.14 Terminal Markings
High voltage phase windings shall be marked both in the terminal boards inside the tank and on
the outside with capital letter 1U, IV, 1W and low voltage winding for the same phase marked
by corresponding small letter 2U, 2V, 2W. The neutral point terminal shall be indicated by the
letter 2N. Neutral terminal to be brought out and connected to local grounding terminal by an
Earthing strip.
5.15 Current Transformers (for 63 and 100 kVA ratings only)
• CT's shall be provided if required on secondary side.

• Current transformer shall be mounted inside the tank on LV side of the transformer. Ring
Type CTs in air, mounted in LV cable boxes are also accepted
• The current transformers shall be comply with IS: 2705.
• All secondary leads of bushing mounted CT's shall be brought to a terminal box near
each bushing. The CT terminals shall have shorting facility.
CT should not get saturated upto 200% of rated current.
Transformer Rating 63 kVA 100 kVA

Current Ratio 100/5 A 150/5 A
Class 0.5 0.5
Burden 20 VA 20 VA
Application Metering Metering
ISF 5 5
5.16 Lightning Arresters
9 kV, 5 kA Metal Oxide Lightning Arresters as per relevant standard, one number per phase
shall be fitted under the HV bushings with GI earth strip 25x4 mm connected to the body of the
transformer with necessary clamping arrangements. The metal oxide lightning arresters shall be
of reputed make.
5.17 Protection
The transformers shall have the following Completely Self Protection (CSP) features:
(i) Internal HV fuse on the HT side of transformer
Specification for the HV fuses: Expulsion/any other suitable type of fuse placed in series with
the primary winding. This fuse is mounted normally inside of the primary bushing for the three
phases and is connected to the high voltage winding through a terminal block. This has to protect
that part of the electrical distribution system which is ahead of the distribution transformers from
faults which occur inside the distribution transformer i.e., either in the windings or some other
part of the transformer. It shall be ensured that this fuse does not blow for faults on the secondary
side (LT side) of the transformer i.e., the blowing characteristics of the fuse and LT breaker shall
be so coordinated such that the fuse shall not blow for any faults on the secondary side of the
transformer beyond LT breakers and those faults shall be cleared by the LT breaker only.
(ii) 3 Pole LT circuit breaker
(a) Internally mounted oil immersed LT breaker on the LV side of the transformer:
All LT faults after the breaker shall be cleared by this breaker. As such it shall be designed for
perfect coordination with the HT fuse link. The Manufacturer shall furnish the time / current
characteristics of LT circuit breaker and 11 kV fuses for various current multiples.
The two characteristics shall be drawn on the same sheet to indicate coordination between the
circuit breaker and fuse. The Manufacturer shall carry out coordination test as indicated above
and this forms one of the tests for acceptance test.
The breaker shall be coordinated thermally with the transformer design to follow closely the
variations of coil temperature due to fluctuating loads and ambient temperatures.
This is to be accomplished by connecting the breaker in series between the secondary winding
and the secondary bushings. The breaker shall be located in the same oil as the core and coil
assembly so that the bimetal are sensitive to the temperature of oil as well as the load current
The circuit breaker shall also be closed and opened manually standing on ground. The current
carrying parts of breakers shall be copper plus a set of copper tungsten current interrupting
contacts.
The cross-section of the current carrying parts of the breaker shall withstand the full load current
at a current density not more than 2.5A/sq. mm (for additional mechanical strength the area
should be more).
(b) MCCB
3 pole MCCB (confirming to IS 13947) from reputed manufacturers of appropriate rating with
inverse time characteristics for overload & instantaneous magnetic trip (trip time less than 10
mS at 0.4 lagging p.f.) for short circuits shall be provided after the LT bushing in the distribution
box. All plastic material shall comply to glow wire test as per relevant IS. Type test report from
NABL accredited laboratory shall be submitted.
A distribution box (made of MS or SMC or FRP) shall be provided as an integral part of the
transformer to be mounted on the tank before installation on the pole. LT bushing shall be inside
the distribution box and a facility for sufficient number of outgoing feeders through cable glands
shall be provided. Distribution box shall also have provision for installation of energy meter.
Distribution box shall be designed for out-door duty with minimum IP - 55 protection. It shall
have pad-locking arrangement.
(iii) Load Management Signal Light
A signal light shall be provided to give information about the loading condition of the transformer.
It shall forewarn any overloading problem at the installation such that a change out of the existing
transformer with a higher capacity transformer can be planned. The signal light mechanism shall
not reset itself when the load drops from the overloaded condition. The signal light shall remain
lighted once the signal light contacts close due to overload and can be turned off by manual
operation. (The signal light shall not give indication for momentary overloading).
5.18 Fittings
The following standard fittings shall be provided:

(a) Rating and terminal marking plates non-detachable
(b) Earthing terminals with lugs - 2 Nos.
(c) Lifting lugs for main tank & top cover
(d) Pulling lugs - 4 Nos
(e) HV bushings - 3 Nos.
(f) LV bushings - 3 Nos.
(g) Neutral bushings-1 No.
(h) Terminal connectors on the HV/LV bushings
(i) 9 kV 5 kA lightning arrestors on HT side - 3 no.
(j) Thermometer pocket with cap -1 No.
(k) Air release device
(1) Stiffener angle 40 x 40 x 5 mm and vertical strip of 50 x 5 mm flat
(m) Radiators
(n) Prismatic oil level guage
(o) Drain cum sampling valve
(p) Oil filling hole having M30 thread with plug and drain valve on the conservator
(q) Silicagel breather
(r) Pressure relief device or explosion vent.
(s) Base channel 75 x 40 mm
(t) MCCB or Oil immersed LT circuit breaker along with operating rod
(u) HV fuse links
(v) Signal light
5.19 Fasteners
All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the appropriate
Indian Standards for metric threads, or the technical equivalent.
Bolts or studs shall not be less than 6 mm in diameter except when used for small wiring
terminals.
All nuts and pins shall be adequately locked.
Wherever possible bolts shall be fitted in such a manner that in the event of failure of locking
resulting in the nuts working loose and falling off, the bolt will remain in position.
All ferrous bolts, nuts and washers placed in outdoor positions shall be treated to prevent
corrosion, by hot dip galvanising, except high tensile steel bolts and spring washers which shall
be electro galvanised/ plated. Appropriate precautions shall be taken to prevent electrolytic
action between dissimilar metals.
Each bolt or stud shall project at least one thread but not more than three threads through the
nut, except when otherwise approved for terminal board studs or relay stems. If bolts nuts are
placed so that they are inaccessible by means of ordinary spanners, special spanners shall be
provided.
Taper washers shall be provided wherever necessary.
5.20 Mounting Arrangement
The under base of all transformers shall be provided with two 75 x 40 mm channels 460 mm
long with holes to make them suitable for fixing on a platform or plinth
5.21 Overload Capacity
The transformers shall be suitable for loading as per IS: 6600 / 2026-7.
6.0 TESTS
6.1 Routine Tests
• Ratio, polarity and phase sequence.

• Insulation Resistance (IR) & Polarisation Index (PI)
• Magnetic Balance Test
• No load current and losses at rated frequency, rated voltage and at 90% & 110%
voltage.
• Load loss at rated current and normal frequency
• Impedance voltage test
• Resistance of windings
• Induced over voltage withstand test.
• Separate source voltage withstand test.
• LT Circuit Breaker coordination test.
• Efficiency & regulation tests as per cl. 19 of IS 1180.

• Air pressure test on assembled transformer at 0.35 kg/cm2 for 10 min.
6.2 Special Tests
Lightning impulse with chopped on the tail.

Impulse voltage test: As per clause no. 13 (with chopped wave) of IS-2026 part-III as per latest
version. BIL for 11 kV shall be 95 kV peak.
Short circuit test.
Short Circuit Withstand Test: Thermal and dynamic ability including test as per IS 2026
part-V.
6.3 Additional Tests

• Neutral current measurement
• Air pressure test: As per Cl.22.5 of IS -1180 / part-I
• Transformer tank shall be subjected to specified vacuum. The tank designed for vacuum
shall be tested at an internal pressure of 0.35 kg/cm2 absolute (250 mm of Hg) for one
hour. The permanent deflection of flat plates after the vacuum has been released shall not
exceed the values specified below:
Horizontal length of flat plate (in mm) Permanent deflection (in mm)
Upto & including 750 5.0
751 to 1250 6.5
• Transformer tank together with its radiator and other fittings shall be subjected to
pressure corresponding to twice the normal pressure or 0.35 kg/cm2 whichever is lower,
measured at the base of the tank and maintained for an hour. The permanent deflection
of tie flat plates after the excess pressure has been released, shall not exceed the figures
for vacuum test.
• The pressure relief device shall be subject to increasing fluid/air pressure. It shall operate
before reaching the test pressure as specified in the above clause. The operating pressure
shall be recorded. The device shall seal-off after the excess pressure has been released.
• Oil samples (one sample per lot) to comply with IS 1866.
• Single phase LV excitation current at all three phases (for reference)
6.4 Type Tests to be Conducted on one Unit
In addition to the tests mentioned above the following tests shall be conducted.
• Temperature rise test.
• Lightning impulse withstand voltage test:
Oil samples (before and after short-circuit and temperatures rise test) for each tested
transformer.
SECTION C
Specifications for Outdoor Type, Completely Self

Protected, Single Phase Distribution Transformers
(Single Phase 11 kV/250 V & 11/√3 kV/250V, 5, 10,
16 & 25 KVA Ratings)
SECTION C
Specifications for Outdoor Type, Completely Self Protected, Single
Phase Distribution Transformers (Single Phase 11 kV/250 V & 11/√3
kV/250V, 5, 10, 16 & 25 KVA Ratings)
1.0 SCOPE
1.1 This section covers oil immersed naturally cooled 11 kV / 250V* and 11 kV/√3 / 250V*
single phase Completely Self Protected distribution transformers, but does not purport to include
all the necessary provisions of a contract. For general requirements and tests, reference shall be
made to sections A to BB of the Manual.
The Standard Ratings of 1- Phase Transformers shall be 5, 10, 16 & 25 kVA.
2.0 STANDARDS
2.1 The materials shall conform in all respects to the relevant Indian Standard Specifications
with latest amendments/edition thereof:
Note : * REC Specification mention 230 V
Indian Standard Title International and Internationally

recognized standard
IS-2026 (Part-I to IV) Specification for Power Transformer IEC-60076
IS-1180 (Part l& 2) Outdoor Three Phase Distribution Transformer
IS-3347 Specification for Porcelain Transformer Bushings DIN 42531,2,3
IS-7421 Specification for Low Voltage Bushings

IS - 12444 Specification for Copper Wire Rods ASTM B - 49
IS-335 Specification for Transformer Oil BS 148/ASTM DI275, DI533, ILC
Pub 296
1S-3070 Specification for Lightning Arresters 1HC99-1

1S-6600/ Guide for Loading of Oil Immersed Transformers 1EC 60076-7 (ILC 354)
2026-7
1S-2099 High Voltage Porcelain Bushings IEC 60137
IS 9335 Specification for Insulating Kraft Paper IEC 60554
IS 1576 Specification for Insulating Press Board IEC 60641
IS 5 Specification for Colours for Ready Mixed
Paints
59
The Distribution Transformers to be supplied against this Specification shall be suitable for
satisfactory continuous operation under the climatic conditions prevailing at site and to be
specified by the purchaser as follows as per IS 2026 (Part-I) latest revision. International
Standards tabulated above.
(i) Location :
(ii) Max ambient air temperature (Deg.C) :
(iii) Min. ambient air temperature (Deg.C) :
(iv) Max. average daily ambient air temperature (Deg.C) :
(v) Max. yearly weighed average ambient temperature (Deg.C) :
(vi) Max. altitude above mean sea level (m) :
The transformers shall be suitable for outdoor installation with Single phase, 50 c/s 11 kV
systems in which the neutral is effectively earthed and they should be suitable for service under
fluctuations in supply voltage upto plus 10% to minus 15%.
The transformer shall conform to the following specific parameters.
Rated HV side value (11/√3 or 11 kV) shall be specified in the detailed Guaranteed Technical
Particulars by Purchaser
Table 1
SI. ITEM SPECIFICATION

No
1. Continuous rated capacity 5kVA 10 kVA 16kVA 25 kVA
2. System Voltage (Max) 12 kV 12 kV 12 kV 12 kV
3. Rated Voltage HV 11 kV/√3 or 11 kV 11 kV/√3 or 11 kV 11 kV/√3 or 11 kV 11 kV/√3 or 11

kV
4. Rated Voltage I.V 230 V (250 V Max) 230 V (250 V Max) 230 V(250 V Max) 230 V(250 V
Max)
5. BIL 95 kV Peak 95 kV Peak 95 kV Peak 95 kV Peak
6. Frequency 50 Hz ± 3% 50 Hz ± 3% 50 Hz ± 3% 50 Hz ± 3%
7. No of phases Single Single Single Single
8. Type of cooling ONAN ONAN ONAN ONAN
9. Tap changing arrangement Not provided Not provided Not provided Not provided
10. Percentage impedance at 2.5% (Tolerance as 4 % (Tolerance as 4 % (Tolerance 4% (Tolerance
11. Rated frequency and 75" C per IS: 2026) per IS: 2026) as per IS: 2026) as per IS: 2026)
Permissible temperature rise
over ambient
Specifications for Outdoor Type, Completely Self Protected, Single Phase Distribution Transformers 61
(Single Phase 11 kV/250 V & 11/√3 kV/250V, 5, 10, 16 & 25 KVA Ratings)
(i) of top oil measured by 35 "C 35 "C 35 "C 35 ' C

thermometer
(ii) of winding measured by 40 "C 40 "C 40 "C 40 "C
resistance
12. Minimum clearances in air
(a) HV phase to phase / 255/ 140 255/140 255/ 140 255/ 140
phase to earth (mm)
(b) LV phase to phase / 75/40 75/40 75/40 75/40
phase to earth (mm)
5.1 Winding Connection and Terminal Arrangements
For 11 kV transformers both ends of primary winding shall be brought out through HV
bushings. For 11 kV/ √3 transformers, neutral end of the primary HV winding shall be bought
out for connecting to ‘Neutral’ supply wire through 1.1 kV bushing. There shall be provision for
connecting ‘Neutral’ terminal, to local ‘Earth’ by way of a tinned Copper strip, of adequate size
and dimension. The secondary winding shall be connected to two LV bushings.
5.2 Core
5.2.1 Core Material
Transformer core shall have wound core construction using new and high quality CRGO steel with
heat resistant insulating coating or Amorphous Metal. The laminations shall be free from burrs
& edge bends. Air gap in the core assembly shall be avoided. The core shall be properly stress
relieved by annealing in inert atmosphere as per core material manufacturer’s recommendations.
Amorphous metal core shall be annealed under magnetic field. The transformer shall be suitable
for over fluxing (due to combined effect of voltage and frequency) upto 12.5% without injurious
heating. The operating flux density shall be such that there is a clear safe margin over the over-
fluxing limit of 12.5%.
Following documents as applicable shall be submitted during inspection as a proof towards use
of prime core material
• Invoice of the supplier

• Mills Test Certificate
• Packing List
• Bill of Lading
• Bill of entry certificate to customs
5.3 Winding
HV and LV windings shall be wound from copper conductors.Aluminium conductors can also
be used with same loss levels as of copper wound transformers. The HV winding conductor
shall be covered with Super enamel & LV winding with DPC / Super Enamel. The inter layer
insulation shall consist of epoxy resin coated paper or epoxy resin dotted paper. The windings
shall be progressively wound in LV - HV coil design for better voltage regulation and mechanical
strength. Compression bonding of the windings shall be ensured by deploying suitable press in
the winding process or by curing of epoxy paper insulation in a suitable press. The core coil
assembly shall be dried in an oven. The type of winding shall be indicated, whether LV windings
are of conventional to type or foil wound.
Joints in the winding shall be avoided. However if joining is necessary, the joints shall be
properly brazed & finished.
5.4 Oil
5.4.1 The insulating oil shall be new and shall comply with the requirements of IS 335. Use
of recycled oil is not acceptable.
5.4.2 Oil shall be filtered & tested for BDV & moisture content before filling. Oil filling shall
be carried under vacuum of 5 torrMin.
5.4.3 Testing of oil after filling
Testing of oil sample for BDV & moisture content from assembled transformers shall be carried
out as acceptance test in line with IS 1866.
5.4.4 Insulation Material
The inter layer insulation shall be of epoxy resin bond paper. The core/coil assembly shall be securely held
in position to avoid any movement under short circuit conditions.
5.5 Losses : The maximum losses at rated voltage and rated frequency permitted at 75 Deg.C. are
indicated below:
No load losses (Max) - CRGO No load losses (Max) Full load losses in watts
KVA Rating watts Amorphous watts (Max) at 75 Deg C watts
5 25 8 135
10 30 12 180
16 45 17 230
25 55 25 310
Note: The losses mentioned above are under discussion and finalisation by BIS to revise IS: 1180. The above losses
eventually may get revised if any, after said revision.
The above losses are maximum allowable and there would not be any positive tolerance. Transformers
with higher losses than the above specified values would be rejected.
Transformers with losses less than those specified above will be capitalized during bid evaluation as per
loss capitalization formula as given below.
Total Ownership Cost (TOC) after loss capitalization = Quoted Price + NLL X A + LLxB
Transformers with losses less than those specified above will be capitalised during evaluation as
indicated below. (Refer to Loss Capitalisation formula, SectionAA).
Loss Capitalization factors:

A. Iron Losses - Rs. 89.67 x Ec / Watt
B. Copper Losses - Rs. 26.9 x Ec / Watt
Where Ec is the cost of energy ( in Rupees per unit at 11 kV feeder level). In case of non availability of Ec
(Energy cost per unit) at 11 kV feeder level, utility should consider the Bulk Rate Tariff plus 5% as the cost
of energy at 11 kV feeder level.
Price schedule:
The following format shall be filled by the manufacturer for evaluating TOC.
SI. No Price Component

1 Unit ex-works price (Rupees)
2 Freight & Insurance (Rupees)
3 Excise duty (Rupees) (2) Educational cess on Excise duty (Rupees)
4 Sales Tax (Rupees)

5 Total Cost per Unit without Capitalization (1+2+3+4) (Rupees)
6 NLL (Watts)
7 Cost of NLUWatt (Rupees) (A)
8 Cost of Total NLL (6 X 7) (Rupees)
9. LL (Watts)
10. Cost of LL/Watt (Rupees) (B)
11. Cost of total LL(9 x 10) (Rupees)
12. TOC price per Unit with Capitalization (5+8+11) (Rupees)
5.6 Penalty for Non-Performance
5.6.1 Loss values beyond guaranteed values, but less than Max. losses specified at cl. 5.5
-During testing, if it is found that the actual measured losses are more than the values quoted,
penalty shall be recovered from the manufacturer at double the loss capitalization rate arrived at
clause 5.5. For fraction of a Watt, proportionate penalty will be recovered.
5.6.2 Transformers with temperature rise and impedance beyond guaranteed values:
5.6.2.1 Purchaser reserves the right to reject any transformer during the test at supplier’s works,
if the temperature rise exceeds the guaranteed values.
5.6.2.2 Purchaser reserves the right to reject any transformer during the test at supplier’s works,
if the impedance values differ from the guaranteed values including tolerance.
5.6.2.3 Purchaser also reserves the right to retain the rejected transformer and take it into
service until the Manufacturer replaces it with a new transformer at no extra cost. The delivery
as per contract will be counted when the manufacturer provides the new transformer as per
specification.
5.6.2.4 Transformers having losses above the values specified in the clause 5.5 shall be
rejected.
5.7 Tank
The oil volume inside the tank shall be such that even under the extreme operating conditions,
the pressure generated inside the tank does not exceed 0.4 kg/cm2 positive or negative. There
must be sufficient space from the core to the top cover to take care of oil expansion.
The tank cover shall have plasticised surface at the top to guard against bird faults. Alternately,
suitable insulating shrouds shall be provided on the bushing terminals.
The Transformer tank shall be of robust construction round in shape and shall be built up of
tested CRCA / MS sheet. The tank shall be capable of withstanding a pressure of 1 kg/cm2 (g)
and a vacuum of 760 mm of Hg for 30 minutes without any permanent deflection (Air pressure
test shall be conducted as per IS -1180)
The L - seam joint, C - seam joint and all fittings and accessories shall be oil tight and no
deflection / bulging should occur during service.
The circular base plate edges of the tank should be folded upward, for at least 25 mm, to have
sufficient overlap with vertical sidewall of the transformer.
Tank shall have permanent lugs for lifting the transformer bodily and there shall be facilities for
lifting the core coil assembly separately.
The transformer tank and the top cover shall be designed in such a manner as to leave no
external pockets in which water can lodge.
The transformer shall be provided with two mounting lugs suitable for fixing the transformer to
a single pole by means of 2 bolts of 20 mm diameter as per ANSI C 57.12.20.
• Both mounting lugs are made with steel of min. 5 mm thickness.
• Minimum Oil level mark shall be embossed inside the tank.
• Jump proof lips shall be provided for upper mounting lug.
• Mounting lugs faces shall be in one plane.

• The top cover shall be fixed to the tank through clamping only.
• HV bushing pocket shall be embossed to top side of the top cover so as to eliminate
ingressing of moisture and water.
• The edges of the top cover shall be formed, so as to cover the top end of the tank and
gasket.
Sealing gaskets - Continuous (without joint) oil resistant high quality Nitrile / neoprene /
Polyurethane rubber gaskets conforming to Type-III as per latest IS-11149 shall be provided
between tank & top cover and for fixing the bushings.
Tank sealing - The transformer shall be of sealed tank construction with welded or bolted
cover which seals the interior of the tank from atmosphere and in which gas volume plus oil
volume remains constant. The space on the top of the oil shall be filled with dry air or nitrogen.
The nitrogen plus oil volume inside the tank shall be such that even under extreme operating
conditions, the pressure generated inside the tank does not exceed 0.4 kg/cm2 positive or
negative. The nitrogen shall conform to commercial grade of the relevant Standard.
For surface preparation refer to section ‘A’ of this Manual.
5.9 Winding Connection & Bushing Terminal Arrangements
For 11/√3 kV Transformers, Neutral end of the primary HV winding shall be brought out
for connection to ‘Neutral’ supply wife through 1.1 kV bushings. ‘Neutral’ terminal shall be
connected to transformer tank by way of a tinned Copper strip of adequate size and dimension.
The secondary winding shall be connected to two LV bushings. HV terminal shall be designed to
directly receive ACSR conductor upto 7/2 59 mm (without requiring the use of lug) and the LV
terminals shall be suitable for directly receiving LT cables (aluminium) ranging from 10 sq mm
to 25 sq mm both in vertical and horizontal position and the arrangements should be such as to
avoid bimetallic corrosion. Terminal connectors must comply as per IS : 5561.
5.10 Bushings
The bushings shall conform to the relevant standards specified.
For HV, 12 kV class bushings shall be used and for LV, 1.1 kV class bushings shall be used.
The HV bushings shall be fixed to the top cover of the transformer and the LV bushings shall
be fixed to transformer on sides and in the same plane. The bushing rods and nuts shall be of
brass.
The terminal arrangement shall not require a separate oil chamber not connected to oil in the
main tank.
The HV bushings shall not have arcing horns.

5.11 Rating and Terminal Plates
There shall be a rating plate on the transformer containing the information given in the relevant
Indian Standard. The HV winding terminals shall be marked 1.1 and 1.2 for 11 kV/√3 HV
winding. 1.2 terminal will be connected to neutral. In case of 11 kV HV winding the terminal
shall be marked as 1.1 - 1.2. The corresponding secondary terminal shall be marked as 2.1 and
2.2.
5.12 Protection
The transformer shall have the following CSP features:
5.12.1 Internal HV Fuse on the HT Side of Transformer
Suitable replaceable fuse shall be placed inside the transformer, in series with the primary
winding. The fuse on primary side of the distribution transformer shall take care of any fault
occurring inside the transformer itself. The characteristic of the fuse and LT breaker shall be
well coordinated so that the fuse shall not blow for any faults on the secondary side of the
transformer beyond LT Breaker and those faults shall be cleared by LT breaker only. The fuse
shall confirm to IS 9385 and shall be tested for short circuit current.
5.12.2 LT Circuit Breaker
This breaker shall clear all LT faults after the breaker. As such it shall be designed for perfect
coordination with the HT fuse for various current multiples. The two characteristics shall be
drawn on the same sheet to indicate coordination between the circuit breaker and HV fuse. The
manufacturer shall carry out coordination test as indicated above, and this forms one of the tests
for acceptance. The LT breaker shall also be coordinated with overload characteristics of the
transformer. The reference temperature for calibration shall be 40 Deg C.
Arrangement shall be made so that the circuit breaker can be closed and opened manually
standing on ground.
The cross section of the current carrying parts of the breaker shall withstand the full load current
at a current density not more than 2.5 A/sq.mm (for additional mechanical strength the area
should be more). Rated short circuit breaking capacity of the breaker shall not be less than 2.5
kA. The circuit breaker shall confirm to IS-13947 with power factor 0.4 lagging. Time current
characteristics & other requirements shall be in line with IS 13947 (latest version).
Time current characteristics of LT CB
SL. No. Test current Initial test conditions Time limits of tripping/ no Remarks
tripping
1. 1.05 In Cold l ≥ 2.5h No tripping
2. 1.20 In Immediately after Sl.no. 1 I0 min ≤ t ≥ 2h Tripping
3. 1.30 In Cold t ≤ 30 min Tripping
4. 1.40 In Cold t≤10 min Tripping

5. 2.50 In Cold t ≤ 1 min Tripping
6. 4.00 In Cold t ≥ 5S Tripping
7. 6.00 In Cold t≤5S Tripping
8. 12.00 In Cold t ≥ 40mS Tripping
Where In is full load LV current of the transformer.
Manufacturer shall submit the coordination of time-current characteristics of LT & HT side

plotted on the same sheet of paper for approval of the owner.
Manufacturer shall offer either internally mounted oil immersed circuit breaker or MCCB as
specified below. (Utilities may specify any one option).
(a) Internally mounted, Oil immersed ‘LT’ Breaker
The breaker shall be located in the same oil as the core and coil assembly so that the bimetal is
sensitive to the temperature of oil as well as the load.
(b) MCCB
Double pole MCCB (confirming to IS 13947) from reputed manufacturers of appropriate rating
with inverse time characteristics for overload & instantaneous magnetic trip (trip time less
than 10 mS at 0.4 lagging p.f.) for short circuits shall be provided after the LT bushing in the
distribution box. All plastic material shall comply to glow wire test as per relevant IS. Type test
report from NABL accredited laboratory shall be submitted.
A distribution box (made of MS or SMC or FRP) shall be provided as an integral part of the
transformer to be mounted on the tank before installation on the pole. LT bushing shall be inside
the distribution box and a facility for sufficient number of outgoing feeders through cable glands
shall be provided. Distribution box shall also have provision for installation of energy meter.
Distribution box shall be designed for out-door duty with minimum IP - 55 protection. It shall
have pad-locking arrangement.
5.12.3 Signal Light for Tripping of LT Breaker
The distribution box shall be equipped with an LED to indicate tripping of LTCB. On resetting
of LTCB the LED shall be automatically switched off.
5.12.4 11 kV Lightening Arresters
High surge capacity 9 kV, 5 kA metal oxide lightening arrester conforming to 1S-3070 (Pt-III)
shall be mounted on the transformer & clamped securely to the lank, to protect the transformer
and associated line equipment from the occasional high voltage surges resulting from lightning
or switching operations. The Earthing terminal of the lightning arresters shall be connected
solidly to the Earthing terminal on the tank body. Lightning arrestors with polymer insulators in
line with relevant IEC shall also be acceptable.
5.12.5 Pressure Release Device
The transformer shall be equipped with a self-sealing pressure release device, designed to
operate at a minimum pressure of 8 psi (0.564 kg/ cm2). The PRD shall be provided in the low-
voltage terminating portion of the tank above top oil level. Inlet port shall be V4 inch or longer
NPT. Resealing pressure shall be 0.3 kg/cm2
5.13 Fittings
The following standard fittings shall be provided:

(i) Rating and Terminal marking plates.
(ii) Earthing terminals - 2 Nos.
(iii) Lifting lugs - 2 Nos.
(iv) HV bushings.
(v) LV bushings.
(vi) Bird guard.
(vii) HV & LV Terminal connectors.
(viii) HV side Neutral ‘Earthing’ strip;
(ix) LV earthing arrangement.
(x) Metal oxide lightning arrestors (9kV, 5kA)
(xi) MCCB or Oil immersed LT circuit breaker along with operating rod
a. (make, type and technical details to be provided.)
(xii) HV fuse links
(xiii) Signal light
(xiv) Oil level indicator
(xv) Top cover fixing clamps.
(xvi) Pressure relief device.
(xvii) Mounting lugs - 2 Nos.
(xviii) 5 year guarantee plate
(xix) Any other fitting necessary for satisfactory performance of the manufacture.
5.14 Fasteners
All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the appropriate
Indian Standards for metric threads, or the technical equivalent.
Bolts or studs shall not be less than 6 mm in diameter except when used for small wiring
terminals.
All nuts and pins shall be adequately locked.
Wherever possible bolts shall be fitted in such a manner that in the event of failure of locking
corrosion, by hot dip galvanising, except high tensile steel bolts and spring washers which shall
be electro-galvanised/ plated. Appropriate precautions shall be taken to prevent electrolytic
Each bolt or stud shall project at least one thread but not more than three threads through the nut,
except when otherwise approved for terminal board studs or relay stems. If bolts nuts are placed
so that they are inaccessible by means of ordinary spanners, special spanners shall be provided.
Taper washers shall be provided where necessary.
6.0 TESTS
6.1 Routine Tests
• Ratio, polarity tests.

• No load current and loss at rated voltage and frequency.
• Load loss at rated current and normal frequency.
• Impedance voltage test.
• Resistance of windings.
• Insulation Resistance (IR) & Polarisation Index (PI).
• Induced over voltage withstand test.
• Separate source voltage withstand test.
• LT Circuit Breaker coordination test.
• Efficiency & regulation tests as per cl. 19 of IS 1180.
• Air pressure test on assembled transformer at 0.35 kg/cm2 for 10 min.
6.2 Special Tests
Lightning impulse with chopped on the tail.
Impulse voltage test: As per clause no. 13 (with chopped wave) of IS-2026 part-III as per latest
version. BIL for 11 kV shall be 95 kV peak
Short circuit test
Short Circuit Withstand Test: Thermal and dynamic ability including test as per IS 2026
part-V.
6.3 Additional Tests
• Oil samples test (one sample / lot) to comply with IS 1866

• Air pressure Test: As per clause 24.5.1 of IS-1180/ Part-II.
6.4 Type Tests to be Conducted on one Unit
In addition to the tests mentioned above the following tests shall be conducted.
• Temperature rise test.

• Lightning/Impulse withstand voltage test.
• Oil samples (before and after short circuit and temperature rise test).
SECTION D
Specifications for Three Phase Distribution

Transformers (above 100 kVA and upto 33 kV class)
SECTION D
Specifications for Three Phase Distribution Transformers (above 100
kVA and upto 33 kV class)
1.0 SCOPE
1.1 This section covers, Three phase distribution transformers of above 100 kVA to 3150
kVA, 11 & 33 kV (outdoor & indoor use) but does not purport to include all the necessary
provisions of a contract. For general requirements and tests, reference shall be made to sections
A and BB respectively of the Manual.
kVA Voltage Ratio
160
200
250
315
400
500
630
800 11000/433V
1000
1250
1600
2000
2500
3000
3150
315
400
500
630
800
1000
33000/433V
1250
1600
2000
2500
3000
3150
The above ratings are also applicable for 22 /0.433 kV transformers.
2.0 STANDARDS
2.1 The materials shall conform in all respects to the relevant Indian / International Standard
73
Specification, with latest amendments thereof, some of them are listed below: However, prior
agreement with customer is necessary for standard to be followed.
Indian Standard Title International & Internationally
recognised standard
IS -2026 Specification for Power Transformer Outdoor IEC 60076
IS- 1180 Distribution Transformer upto and including 100
IS 12444 kVA Specification for Copper Wire Rod ASTM B-49
IS-3347 Specification for Porcelain Transformer Bushing

IS-335 Specification for Transformer Oil DIN 42531,23,3
IS -5 Specification for Colours for Ready Mixed Paints BS 148, D-1473, D-1533- 1934
IS-2099 Specification for High Voltage Porcelain Bushings IEC Pub 296
IS – 7421 Specification for Low Voltage Bushings DIN 42531 to 33
IS– 3347 Specification for Outdoor Bushings ASTM B - 233
IS - 5484 Specification for Al Wire Rods IEC 60137
IS -9335/IS- 1576 Specification for Insulating Kraft Paper
IS – 6600 / Specification for Insulating Press Board
IS 2026-7 Guide forLoading of Oil Immersed Transformers

3.1 The Distribution Transformers to be supplied against this Specification shall be suitable
for satisfactory continuous operation under the climatic conditions prevailing at site and to
be specified by the purchaser as follows as per IS 2026 (Part-I) Latest Revision/International
Standards tabulated above :
(i) Location : ----
(ii) Max ambient air temperature (Deg.C) : ----
(iii) Min. ambient air temperature (Deg.C.) : ----
(iv) Max average daily ambient
air temperature (Deg.C) : ----
(v) Max. yearly weighted average
ambient temperature (Deg.C) : ----
(vi) Max. altitude above mean sea level (m) : ----
4.0 TAPPINGS AND TAP CHANGING
4.1 Tappings shall be provided on the higher voltage winding for variation of HV Voltage
from plus 5% to minus 10% in steps of 2.5%. However no. of taps & steps to be decided as per
requirement of the customer. Preference shall be given for off-circuit tap link arrangement. Tap
change arrangement is not preferred in an ideal case.
4.2 Tap changing, if at all provided shall be carried out by means of an off circuit externally
operated self positioning tap switch when the transformer is in de-energised condition. Switch
position No. 1 shall correspond to the maximum voltage tapping. Each tap change shall result in
variation of 2.5% in voltage. Provision shall be made for locking the tap changing switch handle in
position.
Specifications for Three Phase Distribution Transformers (above 100 kVA and upto 33 kV class) 75
4.3 For ratings greater than 500 kVA On-load tapchanger may be provided for variation of
HV voltage from plus 5% to minus 15% in steps of 1.25%.
5.0 TYPE OF COOLING

The transformers shall be oil immersed with natural oil circulation type-ONAN.
6.0 INSULATION LEVELS

Voltage Impulse voltage (kV Peak) Power frequency (kV)
433 — 3
11000 75 28
33000 170 70
7.0 WINDING CONNECTIONS

HV------Delta. LV------Star
Vector Symbol.......Dyn11
8.0 LOSSES AND IMPEDANCE

Losses and Impedance shall be guided as per recommendations of BEE star rating plan.
Note: 1. Note: The losses mentioned above are under discussion and finalisation by BIS to revise
IS:1180. The above losses eventually may get revised if any, after said revision.
2. For 22/0.433 kV transformers losses of33/0.433 kV shall be applicable.
9.1 Core
9.1.1 Material - CRGO
The core shall be stacked type generally of high grade cold rolled grain annealed steel
lamination having low loss and good grain properties, coated with hot oil proof insulation,
bolted together and to the frames firmly to prevent vibration or noise. The complete
design of core must ensure permanency of the core losses with continuous working of the
transformers.
9.1.2 Core Clamping for CRGO Stacked Core
MS channel or plate shall be used on top and bottom.
Channel frames on LV side to be reinforced at equidistance, if holes / cutting is done for LT lead
in order to avoid bending of channel.
MS channels/plate frames shall be painted with hot oil-resistant varnish or paint.
9.1.3 The transformers core shall be suitable for over fluxing (due to combined effect of
voltage and frequency) upto 10% without injurious heating at full load conditions and shall not
get saturated.
9.1.4 No load current shall not exceed 1% of full load current for all ratings covered under this
section Increase in secondary voltage of 433 volts by 10% shall not increase the no load current
beyond 6% of full load current for ratings below 315 kVA and 4% of full load current for ratings
above 315 kVA.
9.2 Windings
9.2.1 Material: Super enamel covered/Double paper covered (DPC) Copper / Aluminium
round/strip conductor.
9.2.2 LV winding shall be of strip type copper / Aluminium conductor or copper / aluminium
foil type.
9.2.3 HV coil is wound over LV coil as crossover coils or continuous disc coils.
The choice of copper / aluminium as winding material should be left to customer at the time of
tendering.
9.2.4 Inter layer insulation shall be Kraft paper/Epoxy dotted paper. Proper bonding of inner
layer insulation with the conductor shall be ensured.
9.3 Oil
The insulating oil shall comply with the requirements of relevant standards IS 335 / IEC:60296
9.4 Temperature Rise
The temperature rise over ambient of 50 deg C shall not exceed the limits described below:
Top oil temperature rise measured by thermometer : 35 Deg.C
Winding temperature rise measured by resistance : 40 Deg.C
9.5 Insulation Material
Material: Electrical grade insulation Kraft paper.
All spacers, axial wedges / runners used in windings shall be made of pre-compressed Pressboard—
solid, conforming to type B 3.1 of IEC 641-3-2. In case of cross-over coil/continuous disc winding
of HV all spacers shall be properly sheared and dovetail punched to ensure proper locking. All axial
wedges / runners shall be properly milled to dovetail shape so that they pass through the designed
spacers freely. Insulation shearing, cutting, milling and punching operations shall be carried out in such
a way, that there is no burr or dimensional variations.
10.0 TANK
10.1 Rectangular Plain Tank
The transformer tank shall be of robust construction rectangular in shape and shall be built up
of tested MS sheet.
The internal clearance of tank shall be such that it shall facilitate easy lifting of core with coils
from the tank without dismantling LV bushings.
All joints of tank and fittings shall be oil tight and no bulging should occur during service. The
tank design shall be such that the core and windings can be lifted freely. The tank plate shall
The four walls of the tank shall be made of two “L” shaped sheets (without joints) fully welded
at the corners from inside and outside of the tank for withstanding a pressure of 0.8 kg/cm2 for
10 minutes.
The tank shall be reinforced by welded angle on all the outside walls on the edge of the tank to
form two equal compartments. Permanent deflection when the tank without oil is subject to a
vacuum of 525 mm of mercury for rectangular tank and 760 mm of mercury for round tank shall
not be more than 5 mm upto 750 mm length and 6 mm upto 1250 mm length. The tank shall
further be capable of withstanding a pressure of 0.8 kg/sq cm (g) and a vacuum of 0.3 kg/sq cm
(g) without any deformation.
Only Pressed steel radiators shall be used for cooling. The transformer shall be capable of
giving continuous rated output without exceeding the specified temperature rise. 4 Nos. welded
heavy duty lifting lugs of MS plate 8 mm thick (min) suitably reinforced by vertical supporting
flat welded edgewise below the lug shall be provided on the side wall.
Top cover fixing shall be with galvanised iron bolts and 6 mm Synthetic resin bonded cork sheet
gasket (type RC 70C) conforming to IS 4253 part-II shall be placed between tank and cover. The
bolts outside tank shall have 2 flat washers & one spring washer.
10.2 Corrugated Tank
The transformer tank shall be of robust construction corrugated in shape and shall be built
up of CRCA sheets of thickness. Thickness of corrugated CRCA sheet shall be decided by
manufacturer & customer jointly.
from the tank with CCA (core-coil assembly), HV & LV bushings mounted on Top cover.
All joints of tank and fittings shall be oil tight and no bulging should occur during service. The
tank design shall be such that the core and windings can be lifted freely. The tank plate shall
Corrugated panel shall be used for cooling. The transformer shall be capable of giving continuous
rated output without exceeding the specified temperature rise.
2 Nos. welded heavy duty lifting lugs of MS plate 8 mm thick (min) suitably reinforced shall
be provided.
Top cover fixing shall be with GI (Galvanised Iron) bolts and 6 mm Synthetic resin bonded cork
sheet gasket (type RC 70C) bonded cork gaskets conforming to IS 4253 part-II shall be placed
between tank and cover. The bolts outside tank shall have 2 flat washers & one spring washer.
Tanks with corrugations and without conservator shall be tested for leakage test at a pressure of
0.15kg/cm2 measured at the top of the tank.
10.3 Sealed Transformer with Radiators
In this type of construction, tank is designed to have cover welded to the curb of tank. Space is
provided above the core coil assembly where inert gas cushion system accommodates the oil
expansion under variable pressure. The tank should be of stiff construction, able to withstand
pressure of 2 atmospheres.
10.4 Conservator
The provision of conservator is obligatory for plain Tanks mentioned in clause 10.1 above
i.e., where pressed steel radiators are used for oil circulation. Conservator is not required for
corrugated tanks.
When a conservator is provided, oil gauge and the plain or dehy drating breathing devise shall be
fixed to the conservator, which shall also be provided with a drain plug and a filling hole (M30
normal size thread) with cover. The capacity of a conservator tank shall be designed keeping in
view the total quantity of oil and its contraction and expansion due to temperature variations.
In addition, the cover of main tank shall be provided with an air release plug to enable air
trapped within to be released, unless the conservator is so located as to eliminate the possibility
of air being trapped within the main tank.
The inside diameter of the pipe, connecting the conservator to the main tank, should be within
20 to 50 mm and it should be projected into the conservator so that its end is approximately 20
mm above the bottom of the conservator so as to create a sump forcollection of impurities. The
minimum oil level (corresponding to -5 deg.C.) should be above the sump level.
For surface preparation refer to section A of this Manual.
11.0 TERMINALS
The terminals arrangement alternatives are given below:
kVA Voltage Details of Terminals
All ratings 11000 17.5 kV porcelain Bushings as per IS 3347 for normally polluted atmosphere, or 3p 1G
air or compound filled cable box suitable for 3core XLPE /PILC aluminium cables.
All ratings 33000 36 kV porcelain Bushings as per IS3347 for normally polluted atmosphere, or 3p 1G
air or compound filled cable box suitable for 3core XLPE /PILC aluminium cables.
160/200 433 4plG air filled cable box suitable for3 l/2 core 135mm2 PVC aluminium cable
250 433 4plG air filled cable box suitable for3 l/2core 400mm2 PVC aluminium cable
315, 400, 500
433 4p2G air filled cable box suitable for3 l/2core 400mm2 PVC aluminium cable
630.800 433 4p4G air filled cable box suitable for3 l/2core 400mm2 PVC aluminium cable
1000,1250 433 4p6G air filled cable box suitable for3 l/2core 400mm2 PVC aluminium cable
1600 433 4p21G air filled cable box suitable for 1 core 1000mm2 PVC aluminium cable
2000, 2500 433 4p28G air filled cable box suitable for 1 core 1000mm2 PVC aluminium cable
3000
Note: (a) Alternatively 433V terminal could be provided with 1.1 kV bushings as per 1S.3347 for normally polluted
atmosphere.
(b) Alternatively 433 V terminal could be provided with 1.1 kV bushing suitable for bus duct connections.
(c) Alternatively 433 V terminal could be provided with1.1 kV epoxy bushings in cable box or bus duct.
(d) P & G denote ‘Pole’ and ‘Gland’ respectively.
(e) Epoxy may be used as the filling medium instead of bitumen compound.
(i) The bushings shall conform to the relevant standards specified and shall be outdoor type.
The bushing rods and nuts shall be made of brass material 12 mm diameter for both HT
& LT. The bushings shall be fixed to the transformers on side with straight pockets and in
the same plane or on the top cover. The tests as per IS 2099 / IS 7421 shall be conducted
on the transformer bushings.
(ii) For 0.433/11 kV/33 kV service voltage, 1.1/17.5/36 kV class bushings shall be used.
Bushings of plain sheds as per IS-3347 shall be mounted on the tank/cover. For 1.1 kV
class indoor transformers, 1.1 kV class epoxy busbar bushings /porcelain bushings can be
used. Bushings in HV cable box as per BS2562 may be used for compound filled cable
box or termination in air with boots covering the live terminals.
(iii) Dimensions of the bushings shall conform to the Standards specified.
(iv) A minimum phase to phase clearance of 75 mm for LV (upto 1.1 kV bushings) and 255
mm for HV bushings shall be obtained with the bushings mounted on the transformer.
(v) The bushings shall be fixed on the sides with pockets in the same plane or on the top
cover.
(vi) Brazing of all inter connections, jumpers from winding to bushing shall have cross-section
larger than the winding conductor.
(vii) The design of the cable box internal bushing for LV shall be such as to provide adequate
earth clearance and creepage distance as stipulated in the standards specified. All other
tests as per relevant standards shall be applicable.
(viii) The terminal arrangement shall not require a separate oil chamber not connected to oil in
the main tank.
(ix) HV and LV bushings shall be mounted on top cover in case of corrugated tank.
11.1 Terminal Clearances
The minimum clearance shall be as under:
Voltage Medium Clearance phase to Clearance phase to
phase (mm) terminal earth (mm) terminal
chamber Open Closed chamber Open Closed
433 Air 40 25 40 20
11000 Air 280 165 140 102
*Compound — 60
— 75
33000 Air 351 351 320 222
*Compound — 125 — 100
* Clearances given against compound filled cable box are applicable for same cable box in air if terminals insulated
with boots are used and cable is ofXLPE type.
For outdoor bare bushings the LV and HV bushing stems shall be provided with suitable terminal
connectors so as to connect the jumper without disturbing the bushing stem.
11.2 Terminal Markings
High voltage and low voltage phase windings shall be marked both in the terminal boards inside
the tank and on the outside with capital letter 1U, IV, 1W and low voltage winding for the same
phase marked by corresponding letter 2U, 2V, 2W. The neutral point terminal shall be indicated
by the letter 2N.
11.3 Fittings to be provided
The following fittings shall be provided for transformers with conservator:
(a) Rating and terminal marking plates.
(b) Two earthing terminals (studs and bolts should be properly galvanized and conform to
IS: 1363 and IS: 1367.
(c) Two lifting lugs to lift core assembly.
(d) Two lifting lugs to lift complete transformer
(e) Lifting lugs for tank cover.
(f) Thermometer pocket in accordance with IS: 3580.
(g) Air release plug on the transformer tank to release air trapped inside the tank when filling
oil through conservator.
(h) Conservator tank shall have inter connection pipe projection, 20 mm above bottom of the
conservator so as to create a sump for collection of impurities. It shall have 30 mm dia
drain valve, oil filling hole with cap on the top of the conservator.
(i) Oil level gauge with toughened glass with “minimum” marking.
(j) De-hydrating breather.
(k) One drain cum sampling valve.
(1) One filter valve on the upper side of the tank
(m) Unidirectional flat rollers.
(n) Inspection hole
For sealed transformers with radiators and nitrogen cushion, the following accessories are
recommended:
(a) Oil level guage
(b) Pressure guage
(c) Oil temperature indicator and winding temperature indicator (optional).
(d) One drain cum sampling valve
(c) One filter valve on upper side of tank.
11.4 Fasteners
Bolts or studs shall not be less than 6 mm in diameter except when used for small wiring terminals.
Wherever possible, bolts shall be fitted in such a manner that in the event of failure of locking,
corrosion, by hot dip galvanizing, except high tensile steel bolts and spring washers which shall
be electro-galvanized/ plated. Appropriate precautions shall be taken to prevent electrolytic
Each bolt or stud shall project at least one thread but not more than three threads through the
nut, except when otherwise approved for terminal board studs or relay stems. If bolts, nuts are
placed so that they are inaccessible by means of ordinary spanners, special spanners shall be
provided.
Taper washers shall be provided where necessary.

SECTION E
Specifications for Power Transformers of Voltage

Class Below 145 kV
SECTION E
Specifications for Power Transformers of
Voltage Class Below 145 kV
1.0 SCOPE
1.1 This section covers technical requirements/parameters for power transformers for volt-
age below 132 kV. This part specification does not purport to include all the necessary provi-
sions of a contract. For general requirements, loss capitalization and tests, reference shall be
made to Section ‘A’, ‘AA’ and ‘BB’ respectively of this Manual.
For 110 kV / 100 kV class transformers reference can be drawn from section F for appropriate
rating of transformer.
1.2 Standard Rating
1.2.1 66 kV Class Transformers

Three-phase Voltage ratio Cooling
power rating kV
MVA
6.3 66/11 ONAN
8.0 66/11 ONAN
10.0 66/11 ONAN
12.5 66/11 ONAN/ONAF
20.0 66/11 ONAN/ONAF
ONAN rating-60 percent of ONAF.

Three-phase Voltage Cooling
power rating ratio
MVA kV
1.0 33/11 ONAN
1.6 33/11 ONAN
3.15 33/11 ONAN
4.0 33/11 ONAN
5.0 33/11 ONAN
6.3 33/11 ONAN
8.0 33/11 ONAN
10.00 33/11 ONAN
85
Rating MVA Voltage Impedance Cooling

ratio voltage
kV percent
(A) 3.15 11/6.6 6.25 ONAN

4 11/6.6 7.15 ONAN
(B) 3.15 11/3.3 6.25 ONAN

4 11/3.3 7.15 ONAN
5 11/3.3 7.15 ONAN
6.3 11/3.3 7.15 ONAN
2.0 WINDING CONNECTIONS AND VECTOR GROUP
2.1 Transformers of 11 kV and 33 kV Class
HV — Delta
LV — Star
Vector Group — Dy n11
2.2 Transformers of 66 kV Class
HV — Star or Delta
LV — Star
Vector Group — YNyn0 or Dyn 11
Note: No Tertiary Winding is required for 66 kV Class Transformers.
3.0 TAPPINGS
3.1 OLTC is not recommended for 11 kV and below 5 MVA. For other kV class transformers,
this may be provided for higher ratings, if required. In case of off-circuit tap changer, the
tappings shall be such as to provide for a voltage adjustment on the high voltage of + 3 percent
to - 9 percent in steps of 3 percent, the tappings being located on the high voltage winding. In
case of on-load tap changer, the tappings shall also be on the high voltage winding. A voltage
adjustment of high voltage of + 5 to - 15 percent in 16 equal steps is recommended.
With transformers having OLTC, these tappings may be used to get 10 percent over-voltage
on low voltage ‑side at no-load. When under this condition the high voltage side experiences
Specifications for Power Transformers of Voltage Class below 145 kV 87
an over-voltage, the tappings shall be changed so that the over-excitation is limited to 10

percent only.
Highest Rated lighting Rated Short

Voltage impulse with-stand duration power
for voltage frequency with-
equipment kV peak stand voltage
kV rms kVrms
3.6 40 10
7.2 60 20
12 75 28
36 170 70
72.5 325 140
Note:
(i) 66 kV Windings should be with graded insulation.
(ii) Some utilities are specifying higher lightning impulse level of 350 kVp for 72.5 kV non-uniform winding.
4.1 Clearances of Line Terminals in Air
The minimum clearances in air between live conductive parts and conductive parts to earthed
structure shall be as follows:
Highest System Basic Insulation Minimum clearances

Voltage level
Phase to Phase to
kV kV peak Phase (mm) Earth (mm)
12 75 280 140
24 125 330 230
36 170 350 320
52 250 530 480
72.5 325 700 660
145 550 1220 1050
5.0 TEMPERATURE RISE
For the purpose of standardization of maximum temperature rises of oil and windings, the fol-
lowing ambient temperatures are assumed:
Cooling medium : Air

Maximum ambient temperature : 50°C
Maximum daily average ambient temperature : 40°C
Maximum yearly weighted average temperature : 32°C
With the above ambient temperature condition the temperature rises are as given below:
Oil oC Winding oC
50 55
6.0 TERMINALS
• 3.3 kV-3.6 kV porcelain bushings with plain sheds as per IS: 3347.
• 6.6 and 11 kV-17.5 kV porcelain bushings with plain sheds as per IS: 3347.
• 33 kV-36 kV porcelain bushings with plain sheds as per IS: 3347.
• 66 kV-72.5 kV condenser bushings as per section II.
• Transformers shall be fitted either with bushing insulators or cable boxes as required by
the purchaser.
7.0 FITTINGS AND ACCESSORIES
(a) Rating and diagram plate.

(b) 2 Nos. earthing terminals.
(c) Cover lifting lugs.
(d) Lifting lugs.
(e) Skids and pulling eyes on both directions.
(f) Oil-filling hole and cap.
(g) Jacking pads.
(h) Pocket on tank cover for thermometer.
(i) Air release devices.
(j) Conservator with oil filling hole, cap and drain plug-size 19 mm nominal pipe (3/4 in.
BSJ/M 20).
(k) (i) Prismatic oil level gauge for all transformers up to and including 1.6 MVA.
(ii) Magnetic type oil gauge for transformers above 1.6 MVA, with low oil level
alarm contact.
(1) Silica gel breather with oil seal.
(m) Pressure relief device (16 MVA & above)
(n) Valves:
(i) Drain valve with plug or blanking flanges. The same can be used for filtering purpose.
(ii) A sampling valve.
(iii) 1 No. Top & 1 No. Bottom Filter Valve.
(o) Buchholz relay with alarm and trip contacts with one shut-off valve on conservator side
(i) Size of Buchholz relay up to 10 MVA-50 mm
(ii) 10 MVA and above-80 mm
Specifications for Power Transformers of Voltage Class below 145 kV 89
(p) Oil temperature indicator with one electrical contact shall be provided with anti-vibration
mounting.
(q) Winding temperature indicator with two electrical contacts for alarm and trip purposes.
Switching of fans shall be done by winding temperature indicator for all transformers
having ONAF rating. The winding temperature indicator shall be provided with anti-
vibration mounting.
(r) Tank mounted weather-proof marshalling box for housing control equipment and terminal
connectors. Wiring up to marshalling box with PVC SWA PVC copper cables 660/1100
volts grade.
(s) Air cell (7.5 MVA & above)
(t) Rollers-4 Nos.
Sl. Gauge
Rating Type
No. Shorter axis Longer axis
1 Up to 5 MVA Flat, uni-directional As per manufacturer’s practice,
however, not to exceed 1000 mm
2 6.3 MVA Flanged, bi-directional 1435 mm 1435 mm
3 10 MVA and above Flanged, bi-directional 1676 mm 1676 mm
(v) Cooling accessories

ONAN/ONAF cooling
(i) Radiators with shut-off valves and air release plugs.
(ii) Fans.
(iii) Filter valves.
(iv) Drain and sampling device.
(v) Air release device.
SECTION F
Specifications for 145 kV Class Power Transformers

SECTION F
1.0 SCOPE
1.1 This section covers technical requirements/parameters for power transformers of 145
kV class. This part specification does not purport to include all the necessary provisions of a
contract. For general requirements, loss capitalization and tests, reference shall be made to
Sections ‘A’, ‘AA’ and ‘BB’ respectively of this Manual.
For 100/110 kV class transformers, reference can be drawn from this section for appropriate
rating of the transformers.
1.2.1 Two Winding Transformers
Three-phase Voltage Impedance

power rating ratio voltage Cooling
MVA kV per cent
(a) 16 132/33 10 ONAN/ONAF
16 132/33 10 ONAN/ONAF
16 132/33 12.5 ONAN/ONAF
(b) 16 132/11 10 ONAN/ONAF
25 132/11 10 ONAN/ONAF
31.5 132/11 12.5 ONAN/ONAF
(i) Connections : HV-Star with neutral directly earthed

LV-Star with neutral directly earthed
Vector Group : YNyn0
Alternatively
HV-Star with neutral directly earthed
LV-Delta Vector Group : YNd 11
(ii) Tappings : On-load tappings at the neutral end of HV winding for

HV variation. Tapping
Range : + 5 to -15 per cent in 16 equal steps.
(iii) ONAN rating for 16 MVA, 25 MVA and 31.5 MVA transformers shall be 10, 16 and 20
MVA respectively.
93
1.2.2 Interconnecting Auto-Transformers

Three-phase Impedance
Voltage
power rating voltage per Cooling
ratio kV
MVA cent
50 132/66 10 ONAN/ONAF
63 132/66 10 ONAN/ONAF
(i) Connections : HV and LV

- Star auto with neutral directly earthed.
Vector Group : YNao
Note : (i) No stabilizing winding up to 100 MVA for 3-Phase, 3 limbed core type construction.
ii) Tappings: On-load for the variation of 66 kV voltages from - 5 to + 15 per cent in 16 steps.
iii) ONAN rating shall be 60 per cent of ONAF rating.
1.2.3 Generator Transformers
Three-Phase Impedance
Voltage
Power Rating voltage Cooling
ratio
MVA per cent
140 11/138 12.5 ONAN/ONAF or
ONAN/OFAF or
ODAF or
OFWF/ODWF
140 13.8/138 12.5 -do-
250 15.75/138 14.5 ONAN/ONAF or
ONAN/OFAF or
ODAF or
OFWF/ODWF
(i) Connection : HV-Star with neutral directly earthed LV-Delta
Vector Group : YNd11/ YNd1/ YNd7 /YNd5 (As per User’s requirement)
(ii) Tappings : Off-circuit taps on HV for HV variation from +2½ to -7½ percent
in 2½ per cent steps or On-load tap changer on HV for HV variation from + 5 per cent
to -10 per cent in 1.25 per cent steps.
(iii) ONAN rating in case of ONAN/ONAF, ONAN/OFAF, cooling shall be 60 per cent of
OFAF rating. OFAF/ODAF = 100 per cent.
(iv) The standardized ratings are for three-phase units only. If single phase units are required
due to transport limitations, then these ratings will be one-third of the three-phase
unit.
Specifications for 145 kV Class Power Transformers 95

Rated lightning Rated short duration
Highest voltage for impulse withstand power frequency with-
equipment kVrms voltage kV peak stand voltage kVrms
12 75 28
17.5 95 38
36 170 70
72.5 325* 140
145 550** 230**
* Some utilities specify lightning impulse level of 350 kVp

** Some utilities specify 650 kVp lightning impulse and 275 kVrms power frequency voltage level.
Highest System Voltage Basic Insulation level Minimum clearances
kV kV peak Phase to Phase to

phase (mm) earth (mm)
12 75 280 140
24 125 330 230
36 170 350 320
52 250 530 480
72.5 325 700 660
145 550 1220 1050
145 650 1430 1270
3.0 COOLING EQUIPMENT
(a) ONAN/ONAF 1-100 per cent tank or separately mounted cooling system
consisting of radiators and fans and one standby fan 2-50 per
cent group and 2 standby fans, one in each 50 per cent group
(b) ONAN/OFAF or ODAF 2-50 per cent groups

2-100 per cent pumps per group, one of which will be standby
for each 50 per cent bank
2-standby fans one in each 50 per cent group
3-50 per cent group with independent pump and fans out of
which one group to act as standby,
(c) OFWF or ODWF 2-100 per cent heat exchangers out of which one is standby.
For the purpose of standardization of maximum temperature rises of oil and winding the
following ambient temperatures considering the transformer to be operating at extreme tap
position incurring extra copper losses
Cooling medium Air Water
Maximum ambient temperature 50°C 30°C
Maximum daily average ambient temp. 40°C 25°C
Maximum yearly weighted average temp. 32°C –
With the above ambient temperature conditions temperature rises considering the transformer to
be operating at extreme tap position incurring extra copper losses are as given below :
External Cooling Medium

Part
Air Water
Winding (measured 55. when the oil circulation 60, when the oil circulation is
by resistance) °C is natural or forced non- natural or forced non-directed.
directed. 60, when the oil 65, when the oil circulation is
circulation is forced directed. forced directed.
Top oil (measured by 50 55

thermometer) °C
5.0 TERMINAL BUSHINGS
(a) Two-winding and auto-transformers

The terminal bushings shall be as per Section II of the manual.
(b) Generator transformer
LV side : LV bushings shall be mounted on turrets suitable for
connection to busbars in isolated phase bus ducts.
HV side : As per Section II.

(c) Lifting bollards.
(d) Jacking pads.
(e) Haulage lugs.
(f) Pocket on tank cover for thermometer.
(g) Air release devices.
(h) Conservator with oil filling hole, cap and drain valve, aircell (above 7.5 MVA).
(i) Magnetic type oil level gauge with low oil level alarm contacts of 0.5 A, 220 V DC rating.
(j) Silica gel breather with oil seal-2 Nos. of 100 per cent for 140 and 250 MVA ratings.
(k) Pressure relief device.
(1) Valves
(i) Oil valve between each cooler and main tank.
(ii) Drain valve.
(iii) 2 Nos. filter valves, one on top and another at bottom on diagonally opposite corners.
(iv) 2 Nos. sampling valves at top and bottom of main tank.
The sampling valve shall be provided with provision for fixing PVC pipe.
(m) Valve schedule plate for transformers above 31.5 MVA.
(n) Buchholz relay with alarm and trip contacts of 0.5A, 220 V DC rating and one shut-off
valve size 80 mm.
(o) (i) Oil temperature indicator with maximum-pointer and one electrical contact.
(ii) Oil temperature indicator with maximum pointer and two sets of contacts for above
31.5 MVA.
(p) Winding temperature indicator with ‘maximum pointer and 3 sets of contacts for ONAN/
ONAF and 4 sets of contacts for ONAF/OFAF or ODAF and 2 sets of contacts for OFWF/
ODWF.
(q) Repeater dial of winding temperature indicator for remote indication for transformers
above 16 MVA. For transformer above 50 MVA, the remote indication shall be a separate
measuring system.
(r) Rollers.
Gauge
Rating Type Shorter Longer
axis axis
1. Two winding Flanged bi-directional 1676 mm 1676 mm
and auto with locking and bolting
transformers device.
2. Generator Flanged, bi-directional 2 rails with 2 rails with
transformers with locking and bolting 1676mm gauge 1676mm gauge
device.
Alternatively 3 rails with
1676 mm gauge between
adjacent rails. Alternatively
4 rails in two pairs with 1676
mm gauge for each pair and
centre distance between pair
3486 mm.
(s) Inspection cover.

(t) Wiring up to marshalling box with PVC copper cables, 660/1100 volts grade.
(u) Tank mounted/floor mounted weather-proof marshalling box for housing control
equipment and terminal connections.
(v) On-load tap changing gear with remote control panel as required.
(w) Cooling accessories:

(I) ONAN/ONAF Cooling
(i) Requisite number of radiators with top and bottom shut-off-valves, air release
plug and drain plug.
(ii) Fans.
(iii) For header mounted radiator 2 Nos. valves, one at top header and other at
bottom header to be used for filtration and oil filling. Bottom valve to be used
as drain valve also.
(iv) Drain and sampling device.
(v) Air release device.
(II) ONAN/ONAF-OFAF/ODAF Cooling
(i) Requisite number of radiators with shut-off-valves.
(ii) Fans.
(iii) Oil pumps.
(iv) Oil flow indicator with one alarm contact.
(v) For header mounted radiators 2 Nos. valves, one at top header and other at
bottom header to be used for filtration and oil filling. Bottom valve to be used
as drain valve also.
(vi) Drain-cum-filter valve for cooling system.
(vii) Air release plug.
(III) OFAF/ODAF Cooling
(i) OFAF coolers with integral fans.
(ii) Oil pumps.
(iii) Oil flow indicator with one alarm contact.
(iv) Brass encased thermometers.
(v) Drain plug and air release devices.
(TV) OFWF/ODWF Cooling.
(i) Oil/Water heat exchangers.
(ii) Oil pumps.
(iv) Water flow indicator with one alarm contact.
(v) Pressure gauges.
(vi) Brass encased thermometers.
(vii) Differential pressure gauge with one alarm contact.
(viii) Reflux valves (Non-return).
(ix) Drain-cum-filter valve for cooling system.
SECTION G
Specifications for 245 kV Class Power

Transformers
SECTION G
1.0 SCOPE
kV voltage class but does not purport to include all the necessary provisions of contract. For
general requirements, loss capitalization and tests, reference shall be made to Sections ‘A’, ‘AA’
and ‘BB’ respectively of this Manual.
1.2.1 Two Winding Transformers
(A)
Three-phase Voltage Impedance Cooling
power rating ratio voltage
MVA kV percent
50 220/66 12.5 ONAN/OFAF or
ONAN/ODAF
100 220/66 12.5 ONAN/OFAF or
ONAN/ODAF
(i) Connections : HV—Star with neutral effectively earthed.

LV—Star with neutral effectively earthed.
Stabilizing
winding : No stabilizing winding up to 100 MVA for 3-phase, 3 limbed
core type construction.
(ii) Vector Group : YNyn0.
(iii) Tapping : On-load tappings at the neutral end of HV for HV
±10 per cent in 16 equal steps.
(iv) Cooling : ONAN : 60 per cent
OFAF : 100 per cent
ODAF : 100 per cent
The rating under ONAF condition although not guaranteed should
be about 80 percent.
(B)
Three-phase Voltage Impedance Cooling
power rating ratio kV voltage per-
MVA cent
50 220/33 12.5 ONAN/OFAF or
ONAN/ODAF
100 220/33 15.0 ONAN/OFAF or
ONAN/ODAF
101
(i) Connections : HV—Star with neutral effectively earthed.

LV—Delta. Alternatively star with neutral effectively earthed.
Vector Group : Yd11. Alternatively YNyno.
Stabilizing : No stabilizing winding for YNyn0 up to 100 MVA for 3-phase,
3 limbed core type construction.
(ii) Tappings : On load tappings at the neutral end of HV for HV variation from
+10 to -10 per cent in 16 equal steps.
(iii) Cooling : ONAN : 60 per cent
OFAF : 100 per cent
ODAF : 100 per cent
Note : The rating under ONAF condition although not guaranteed shall be about 80 per cent.
1.2.2 Auto-Transformers
Three-phase Voltage Percentage Cooling
power rating ratio impedance
MVA voltage
ONAN/OFAF or
100 220/132 12.5 ONAN/ODAF
ONAN/OFAF or
160 220/132/11 12.5 ONAN/ODAF
ONAN/OFAF or
200 220/132/11 12.5 ONAN/ODAF
ONAN/ONAF cooling can also be specified for above transformers.

(i) Connections : HV and LV — Star auto with neutral effectively earthed.
(ii) Stabilizing
winding : Delta. (No stabilizing winding for 100 MVA 3 phase 3
limbed Core type construction)
(iii) Vector Group : YNa0dl
(iv) Tappings : On-load for the variation of 132 kV voltage from-5 to
+15 per cent in 16 equal steps.
(v) Cooling ONAN : 60 per cent
OFAF/ODAF : 100 per cent.
Note :
(1) In case auto-transformers are provided with L. V. winding (Tertiary Winding) for loading purpose then the MVA
rating, voltage rating, percentage impedance between HV winding to L. V. winding and IV winding to L.V. winding
shall be specified by the customer. The minimum rated lightning impulse withstand voltage level shall be 170 kV
peak. Rated short duration power frequency voltage shall be 70 kV.
(2) Rating under ONAF condition although not guaranteed shall be about 80 per cent.
1.2.3 Generator Transformers for Thermal Stations
Three-phase power Voltage Percentage

Cooling
rating MVA Ratio impedance voltage
140 11/235 12.5 ONAN/OFAF or ODAF or
OFWF/ ODWF
140 13.8/235 12.5 ONAN/OFAF or ODAF or
OFWF
250 15.75/235 14.0 ONAN/OFAF or ODAF or
OFWF/ODWF
315 15.75/235 14.0 -do-
(i) Connection : HV — Star with neutral effectively earthed.

LV — Delta.
(ii) Vector Group : YNd11/ YNd1/ YNd5/ YNd7 (As per User’s requirement)
(iii) Tappings : Off-circuit taps on HV for HV variation from + 2½ to -7½ percent
in 2½ per cent steps or On-load tap changer on HV for HV variation
from + 5 percent to -10 per cent in 1.25 per cent steps.
(iv) The standardized ratings are for three phase units only. If single phase units are required
due to transport limitations then these ratings will be one-third of the three-phase unit.
(v) Cooling : ONAN : 60 per cent
OFAF/ODAF : 100 per cent.
Two 50% cooling radiator banks shall be provided. Each bank shall have one stand by fan and
one stand by pump.
Highest voltage Rated lightning Power frequency rated
for equipment impulse withstand short duration withstand
kV rms voltage kV peak voltage kV rms
12.0 75 28
17.5 95 38
36 170 70
72.5 325* 140
145 550** 230**
245 950*** 395***

** Some utilities specify 650 kVp lightning impulse and 275 kVrms power frequency voltage level.
*** Some utilities specify 1050 kVp lightning impulse and 460 kVrms power frequency voltage level.
Highest Minimum clearances

Basic Insulation
System level
Voltage Phase to Phase to
kV kV peak phase (mm) earth (mm)
12 75 280 140
24 125 330 230
36 170 350 320
52 250 530 480
72.5 325 700 660
145 550 1220 1050
145 650 1430 1270
245 950 2000 1800
245 1050 2350 2150
3.0 COOLING EQUIPMENT
(a) ONAN/OFAF - 2-50 per cent groups

or ODAF 2-100 per cent pumps for each 50 per cent bank,
One of which will be standby.
2-Standby fans one in each 50 per cent group, or
3-50 per cent groups with independent pumps and
fans out of which one group to act as standby
(b) OFWF or ODWF - 2-100 per cent heat exchangers out of which one is
standby.
For the purpose of standardization of maximum temperature rises of oil and winding, the
following ambient temperatures are assumed:
Cooling medium Air Water

Maximum ambient temperature 50°C 30°C
Maximum daily average ambient temperature 40°C 25°C
Maximum yearly weighted average temperature 32°C -
With the above ambient temperature conditions, temperature rises are as given below:
External cooling-medium
Part
Air Water
°C °C
Windings (measured by 55, when the oil circulation is 60, when the oil circulation is
resistance) natural or forced non-directed. natural or forced non directed.
60, when the oil circulation is 65, when the circulation is
forced directed. forced directed.
Top oil 50 55
(measured)
by thermometer)
5.0 TERMINAL BUSHINGS
(a) Two windings and Auto-Transformers. The terminal bushings shall be as per Section II.
(b) Generator Transformer
LV Side : LV bushings shall be mounted on turrets suitable for connection to bus
bars in isolated phase bus ducts.
HV Side : As per Section II.

(d) Jacking pads.
(e) Haulage lugs.
(h) Conservator with oil filling hole, cap drain valve.
(i) Magnetic type oil gauge with low oil level alarm contacts of 0.5 A, 220 V DC.
(j) Silicagel breather with oil seal-2 Nos.
Note: In addition to the silicagel breather more advanced oil preservation system like air dryers, molecular sieve
flexible membrane can also be considered.
(k) Required Nos. of pressure relief vents or spring operated pressure relief devices. For
transformer above 50 MVA, the remote indication shall be a separate measuring system.
(1) Valves
(i) Oil valve between each cooler and main tank.
(ii) Drain valve
(iii) 2 Nos. filter valves on diagonally opposite corners.
(iv) 2 Nos. sampling valves at top and bottom of main tank. The sampling valve shall be
provided with provision for fixing PVC pipe.
Rating Type Gauge
Shorter axis Longer axis
1 2 3 4 5
1. Two winding and Flanged 1676 mm 1676 mm
auto-transformers bidirectional with
locking and bolting
device.
Generator Flanged 2 rails with 2 rails with

2. Transformers bidirectional With 1676 mm 1676 mm
locking and Bolting gauge gauge
device.
Alternatively 3
rails with 1676
mm gauge between
adjacent rails.
Alternatively 4
rails in two pairs
with 1676 mm
gauge for each pair
and centre distance
between pair 3486
mm.
(m) Valve schedule plate.
(n) Buchholz relay with alarm and trip contacts of 0.5A, 220 V DC and one shut-off valve on
conservator side, size 80 mm.
(o) Oil temperature indicator with maximum-pointer and two sets of contacts.
(p) Winding temperature indicator with maximum pointer and 3 sets of contacts of ONAN/
ONAF and 4 sets of contacts for ONAF/OFAN or ODAF and 2 sets of contacts for OFWF/
ODWF.
(q) Repeater dial of winding temperature indicator for remote indication.
(r) Rollers.
(s) Inspection cover.
(t) Wiring up to marshalling box with PVC copper cables, 660/1100 volts grade.
(u) Tank mounted/floor mounted weather-proof marshalling box for housing control equip-
ment and terminal connections.
(v) On-load tap changing gear with remote control panels as required.
(w) Cooling accessories.
(I) ONAN/OFAF or ODAF Cooling
(i) Requisite number of radiators with shut-off-valves.
(ii) Fans.
(iii) Oil pumps.
(iv) Oil flow indicator with one alarm contact.
(v) For header mounted radiators 2 Nos. valves, one at top header and other at bo tom
header to be used for filtration and oil filling. Bottom valve to be used as drain
valve also.
(vi) Drain-cum-filter valve for cooling system size.
(vii) Air release plug of size 19 mm nominal pipe (3/4in. BSP).
(II) OFAF/ODAF Cooling
(i) OFAF/Coolers with integral fans.
(ii) Oil pumps.
(iv) Brass encased thermometers.
(v) Drain plug and air release devices.
(III) OFWF/ODWF Cooling
(i) Oil / Water heat exchangers
(ii) Oil pumps.
(iv) Water flow indicator with one alarm contact.
(vi) Brass encased thermometers.
(vii) Differential pressure gauge with one alarm contact.
(viii) Reflux valves (Non-return)
(ix) Drain-cum-filter valve for cooling system.
SECTION H

Transformers
SECTION H
1.0 SCOPE
kV class but does not purport to include all the necessary provisions of a contract. For general
requirements, loss capitalization and tests reference shall be made to Sections ‘A’, ‘AA’ & ‘BB’
respectively of this Manual.
Three Voltage Tapping Percent Cooling

phase ratio range impedance
rating MVA per cent voltage
250 15.75 A-Off circuit taps
or
315 or 16.5 + 2.5% to- 7.5% 14.5 ONAN/OFAF
or OFAF or
/420 B-On-load taps OFWF or
+ 5% to -10% ONAN/ ODAF or
ODAF or ODWF
600 or 780 20 to 27 kV A-Off circuit taps

or 945MVA /420
Bank
B - On load taps 13.5 to 16.0 ONAN/
OFAF or
OFAF or
OFWF or
ONAN/
ODAF
or ODAF
or ODWF
Note : The ratings of generator transformers for hydro generating sets have not been standardized as the sizes of
these sets depend upon site characteristics.
The purchaser shall specify the type of cooling required.
Other Parameters
(i) Connections HV Star neutral effectively earthed, LV delta

(ii) Connections symbol YNd11/YNd1/ YNd5/ YNd7 (As per User’s requirement)
(iii) Tappings
Full power tappings on HV winding for HV voltage variation. Tap changing shall be by:
(a) Off-circuit tap changer, tapping range + 2.5% to - 7.5% in steps of 2.5 per cent alternatively
(b) On-load tap changer, tapping range + 5% to - 10% in steps of 1.25 per cent
109
(iv) Three-phase rating should be understood as three phase bank rating and not necessarily
three-phase unit rating. Wherever transport restrictions impose, single phase ratings equal
to one-third of the three phase bank rating may be specified.
(v) ONAN rating shall be guaranteed at 60 per cent of the OFAF, or ODAF rating. Rating
under ONAF condition shall be about 80 per cent. Two 50% cooling radiator banks shall
be provided. Each bank shall have one stand by fan and one stand by pump.
(vi) Air core reactance of HV winding shall not be less than 20 per cent and knee point voltage
shall not be less than 1.1 pu.
(vii) Short circuit level Transformer shall be suitable for connection to
for 420 kV system the system having the following short circuit
and duration levels and duration: 40,50 and 63 kA for one
second.
(viii) Terminal Bushings
(a) LV Terminals: Oil - sealed / Oil communicating Condenser type bushings mounted on
turrets suitable for connections to busbars in isolated phase busducts which shall have
spacing of 1250 mm for 250 MVA three-phase unit and 1500 mm for each 200 MVA
single-phase unit of a 600 MVA three-phase bank.
(b) HV Terminals-Line End: 420 kV oil filled condenser bushing. No arcing horns shall be
provided. For details refer Section II.
Neutral End: 17.5 kV porcelain bushing. No arcing horns shall be provided.
1.2.2 Auto - Transformers
The purchaser may specify auto-transformer with constant ohmic value of impedance or constant
percentage impedance as given below:
Standard Ratings
(a) Auto - Transformers (Constant Percentage Impedance)
Three-phase Voltage Tapping range Percent impedance voltage Cooling

ratio
HV/IV/LV per cent
MVA HV-1V HV-LV IV-LV
100/100/33.3 400/132/33 + 10% to-10% 16 12.5 27 12 ONAN/OFAF
steps of 1.25%
200/200/66.7 400/132/33 + 10% to -10% 12.5 36 22 ONAN/OFAF or
16 steps of 1.25% ONAN/ODAF
250/250/83.3 400/220/33 + 10% to-10% 16 12.5 45 30 ONAN/OFAF or
steps of 1.25% ONAN/ODAF
315/315/105 400/220/33 + 10% to-10% 16 12.5 45 30 ONAN/OFAF or
500/500/166.7 400/220/33 + 10% to-10% 16 12.5 45 30 ONAN/OFAF or
630/630/210 400/220/33 + 10% to-10% 12.5 45 30 ONAN/OFAF or
16 steps of 1.25% ONAN/ODAF
(b) Auto-Transformers (Constant Ohmic Impedance)
Three-Phase HV/ Voltage Ratio Tapping Range Per cent impedance Cooling
IV/LV per cent voltage
MVA HV-IV HV-LV IV-LV
(min)*
+ 10 to-10% ONAN/OFAF
100/100/33.3 400/132/33 12.5 45 30
16 steps of 1.25% ONAN/OFAF
+ 10 to-10% ONAN/ODAF
200/200/66.7 400/132/33 12.5 45 30
250/250/83.3 400/220/33 12.5 60 45
315/315/105 400/220/33 12.5 60 45
+ 10 to - 10% ONAN/ODAF
500/500/166.7 400/220/33 12.5 60 45
+ 10 to-10%
630/630/210 400/220/33 12.5 60 45 ONAN/ODAF
16 steps of 1.25%
* No limit is specified on higher side.
ONAN/ONAF cooling can also be specified for 100,200,260 1nd 315 MVA ratings.
Other Parameters
(i) Connections HV Star auto with neutral

IV effectively earthed
LV Delta
(ii) Connection symbol YNa0d11
(iii) Full power tappings shall be provided on series winding for the variation of voltage on
HV side. The tap changers shall be suitable for bi-directional flow of rated power. The tap
changers shall be in accordance with Section GG.
three phase unit rating. Wherever transport restrictions impose, single phase ratings equal
to one third of the three phase bank ratings may be specified.
(v) ONAN rating shall be guaranteed at 60 per cent of the OFAF or ODAF rating. Rating
under ONAF condition although not guaranteed shall be about 80 per cent.
(vi) For these transformers the temperature rise of the top oil refers to the specified loading
combination for which the total losses are highest. Individual winding temperature rises
shall be considered relative to that specified loading combination which is the most severe
for the particular winding under consideration.
(vii) Air core reactance of HV winding shall not be less than 20 per cent and knee point voltage
(viii) The specified percentage impedance voltage is at principal tapping and on the MVA base
corresponding to HV/TV rating. Tolerance on percentage impedance voltage shall be as under:

Pairs of windings Tolerance
HV-IV (normal tap) ±10 per cent
HV-IV (max & min tap) ±15 per cent
For constant percentage impedance auto-transformer

HV-LV ±15 percent
IV-LV ± 15 per cent
1.2.3 Short Circuit Level

Transformer shall be suitable for connection to the system having the following short circuit level:
• 420 kV 40,50 and 63 kA (rms), 1 second
• 245 kV 40 kA (rms), 1 second
• 145 kV 31.5/40 kA (rms), 1 second

1.2.4 Terminals
(a) LV Terminals: 52 kV oil-filled condenser bushings. The bushing shall be arranged in a
line with 1000 mm spacing to allow mounting of phase to phase barriers.
No arcing horns shall be provided.
(b) IV Terminals: 145/245 kV oil-filled condenser bushings with test taps. No arcing horns
shall be provided.
(c) HV Terminals - Line End: 420 kV oil-filled condenser bushing. No arcing horns shall be
provided.
For details refer Section II.
Neutral End: 17.5 kV porcelain bushing. No arcing horns shall be provided.
1.2.5 Insulation Levels
1.2.5.1 Lightning Impulse And Power Frequency Voltage Test Level
Highest voltage Rated lightning Rated power

for equipment impulse withstand frequency, short
kV (rms) voltage kV (peak) duration withstand
voltage kV (rms)
12 75 28
17.5 95 38
24 125 50
145 550* -
245 950** -
420 1300*** -
** Some utilities specify lightning impulse level of 1050 kVp.
*** Some utilities specify lightning impulse level of 1425 kVp.
1.2.5.2 Rated Switching Surge kV (Peak) 1050 Or 1175 Withstand Voltage

For 400 Kv Terminal.
1.2.5.3 Partial Discharge At 1.5 Um/√3 Shall Be Limited To 500 Pc.

Notes :
(i) Insulation of tertiary winding of auto-transformer should be adequate to withstand the transferred surge voltage
appearing across them due to an impulse striking on HV or IV terminals. Therefore, 33 kV LV winding shall be
designed for a minimum lightning impulse withstand voltage of 250 kV (peak) and short duration power frequency
withstand voltage of 95 kV (rms).
(ii) The shunt reactor or capacitors connected to the LV side would be required to be frequently switched on and off.
The LV winding should be capable of withstanding the stresses as may be caused by frequent switching.
1.2.5.4 TEMPERATURE RISES

Air - cooled Water-cooled
transformers transformers
(a) Temperature rise of top oil 50°C 55°C
(b) Measured by thermometer
Temperature rise of winding
Measured by resistance:
- When oil circulation 55°C 60°C
Natural or forced non-directed
- When oil circulation is 55°C 65°C
Forced directed
Notes :
(i) For the purpose of standardization of maximum temperature rises of oil and winding as measured by resistance,
the following ambient temperatures are assumed :
Air Water
Cooling medium ambient temperature 50°C 30°C
Maximum daily average ambient temperature 40°C 25 °C
(ii) Maximum yearly weighted temperature is based on ambient temperature cycle and its duration.
(iii) Wherever ambient temperatures are higher than those specified above, the temperature rises, reduced by
corresponding amount, shall be specified.
(iv) Guaranteed temperature rise limits are valid for all the tappings.
(v) The above temperature rises are applicable to transformers required for operation at an altitude notexceeding
1000 metres above sea level.
1.3 Cooling
1.3.1 ONAN/OFAF or ONAN/ODAF Two 50 per cent banks. One number of pump
and one standby pump in each bank. Adequate
number of fans and one standby fan in each 50
per cent bank.
1.3.2 OFAF or OD AF Adequate number of coolers with one cooler as

standby (6x 20% OFAF coolers or 4x33%
OFAF coolers can be adopted).
1.3.3 OFWF or ODWF Two 100 per cent coolers.
Notes :
(i) The transformer shall be filled up with mineral oil, conforming to IS: 335 or IEC 60296.
(ii) For auto transformers 100 per cent cooling equipment should be capable of dissipating losses occurring in all the
three windings, at any tap. It is required only in case specifically called fort.
1.4 Bushings
1.4.1 The voltage and current ratings, basic insulation level and creepage distances of the
bushings shall be in accordance with the following table:
SI. Voltage rating Current Creepage Basic
No. kV (rms) rating distance insulation
(Amps) (mm) level (kVP)
1. 420 1250 10500 1425
1250
2. 245 2000 6125 1050
3. 145 800 3625 650
4. 52 1250 1300 250
3150
1.4.2 The Dimensions of Bushings are as per Section II.
Clearances in air between live parts and to earthed structures for LV terminals of generator
transformers and auto-transformers shall be determined as per spacing given in clause 1.1.1 (viii)
and 1.2.1.4 respectively. The clearances for HV and IV terminals shall be as tabulated below:
Clearances
Highest voltage for equipment kV
(rms) Phase to phase Phase to
earth (mm) (mm)
12 280 140
24 330 230
36 350 320
52 530 480
72.5 700 660
145 1220 1050
145 1430 1270
245 2000 1800
245 2350 2150
420 4000 3500
Air clearances of 3500 mm between phase to earth can be relaxed to the extent of maximum of
200 mm so far as air release pipe emanating from bushing turret is concerned.
1.6 Fittings and Accessories

(b) Two earthing terminals.
(d) Jacking pads.
(e) Haulage lugs.
(g) Air release devices,
(h) Sudden/Rapid Pressure Rise Relay (Optional)
(i) Conservator with oil- filling hole, cap and drain valve (size: 25 mm.)
(j) Magnetic type oil gauge with low oil level alarm contacts (ratings: 0.5 Amp, 220 Volts
DC.) Dial size 250 mm.
(k) Silica gel breather with oil seal.
(l) Air cell type oil preservation system.
(m) Pressure relief device (atleast 2 Nos) capable of resealing after release of pressure.
(n) Valves
• Oil valves between cooler and main tank
• Drain valve preferably with padlocking arrangement (size 100 mm).
• Two filter valves (size: 50 mm) on diagonally opposite ends - one at top and
other at bottom preferably with padlocking arrangement on bottom valve.
• Two sampling valves (size: 15 mm) at top and bottom of main tank.
(o) Oil flow indicator with alarm contacts (ratings, 0.5 Amps, 220 Volts DC) with each
pump.
(p) Valve schedule plate.
(q) Buchholz relay with alarm and trip contacts (Ratings: 1.0 Amp 220 Volts DC) shall
have:
• One number shut-off valve (Size: 80 mm) on conservator side
• Test cock
• Gas collection box and gas check valve at ground level. Copper tube interconnection
between gas collection box and relay shall also be provided. In transformers, for
installation in areas subject to high seismic forces, i.e., horizontal acceleration of 0.3
g or more at and above a frequency of 8 Hz pitot type or reed type of gas and oil relay
shall be used.
(r) Dial type oil temperature indicator with ‘maximum-reading’ pointer and two sets of
contacts (ratings, 5 Amps, 220 Volts DC).
(s) 1 No. dial type winding temperature indicator for a two winding transformer and
one dial type windings temperature indicator for each winding of a multi winding
transformer with ‘maximum-reading’ pointer and two sets of contacts rating : 5 Amps,
220 Volts DC (for OFAF/ODAF and OFWF/ODWF) and four sets of contacts (for
ONAN/OD AF/OFAF).
(t) Remote indication for each winding temperature shall be through a separate
measuring system.
(u) Cover lifting lugs.
(v) Provision for mounting bi-directional flanged rollers with locking and bolting device for
rail gauge specified below:
Type of construction Shorter axis Longer axis
Single-phase Two rails with 1676 mm gauge Two rails with 1676 mm gauge
Three-phase 2/3/4 rail combination according to Two rails with 1676 mm gauge
layout and size of the transformer
(w) Weather proof marshalling box for housing control equipment and terminal
connections.
(x) Wiring up to marshalling box with PVC SWA copper cables of 650/1100 volt grade.
(y) Cooling accessories.
I ONAN/OFAF or ONAN/ODAF cooling
(i) Requisite number of radiators provided with:
- One shut off valve on top (size: 80 mm)
- One shut off valve at bottom (size: 80 mm)
- Air release device on top
- Drain and sampling device at bottom
- Lifting lugs
(ii) Fans
(iii) Oil pumps with shut off valve on both sides (if required for ONAN cooling
pumps can be by-passed using by-pass pipes and valves).
(iv) Expansion joints, one each on top and bottom cooler pipe connections.
(v) Air release device and oil drain plug on oil pipe connections.
II OFAF or ODAF cooling
(i) OFAF coolers with integral fans
(ii) Oil pumps with shut-off valves on both sides.
(iii) Brass encased thermometers.
(iv) Air release devices and oil pipe connections.
(v) Lifting lugs.
III OFWF or ODWF Cooling
(i) Oil/water heat exchangers with segregated oil and water headers

(iii) Water flow indicator with alarm contacts (ratings: 0.5 Amp, 220 Volts DC).
(iv) Brass encased thermometer.
(vi) Differential pressure gauge with alarm contacts, operating when difference
between oil outlet pressure and water inlet pressure is less than 0.2 kg./cm2
(vii) Reflux valve if required as per scheme.
(viii) Drain and sampling device on cooler pipe connection.
(z) Online DGA
(aa) Online Moisture Removal (for GT).
SECTION I

Transformers
SECTION I
1.0 SCOPE
1.1 This section covers power transformers of 800 kV class but does not purport to include
all the necessary provisions of a contract. For general requirements, capitalization and tests
reference shall be made to Sections ‘A’, ‘AA’&‘BB’respectively of this Manual.
Single Voltage Tapping Percent Cooling
phase ratio range impedance
rating MVA kV Voltage
OFAF/OFWF
200 21/765√3 ± 5% in 8 15-16% (with ODAF/ODWF
steps with ±5% tolerance) at principal
off circuit tap
260 24/765√3 taps/ links
315 27/765√3
Three single-phase units will form a bank of 3-phase.

Note : The purchaser shall specify the type of cooling required before purchase.
Above mentioned Transformer rating (in Table) shall be decided by the Utility based on generator rating,
power factor & system requirement.
Other Parameters
(i) Connections - HV star neutral effectively earthed, LV delta
(ii) Connections symbol – YNd11 / YNd1/ YNd5/ YNd7(As per User’s requirement)in
3-phase bank.
(iii) Tappings - Full power tappings on HV winding for HV voltage variation.
(iv) Air core reactance of HV winding shall not be less than 20 per cent and knee point voltage
(v) Short circuit level
Transformer shall be suitable for connection to the system having the following short
circuit level:
800 kV - 40 kA or 50 kA (rms) for 1 second as required.
(vi) Terminal bushings
(a) LV Terminals: 36 kV, 12500 Amps. Oil filled condenser type bushings mounted
on turrets, suitable for connections to bus bars in isolated phase bus ducts which
shall have spacing of 1500 mm for each 200 MVA single-phase unit of a 600 MVA
three-phase bank.
121
For 260 MVA single-phase unit of a 780 MVA three-phase bank, 1 no. 36 kV,
16000 Amps, rating.
(b) HV Terminals-Line End: 800 kV, 1250/2000/2500 Amps,oil filled condenser
Bushing with test tap. No arcing horns shall be provided. For details refer
Section II.
(c) Neutral End: 36 kV porcelain bushing. No arcing horns shall be provided. (vii)
Temperature rises
(a) Top oil measured by Thermometer - 40°C
(b) Winding rise measured by Resistance method - 45°C
(c) Maximum design ambient temperature - 50°C
(also refer para 1.4 note i)
Total capacity of coolers for each transformer shall be minimum 120% of actual requirements.
1.2.2 Auto - Transformers
Single-phase rating Voltage ratio Tapping range Per cent impedance voltage at Cooling
HV/TV/LV principal tap
MVA kV HV-IV HV-LV IV-LV
333.33/333.33/111.1 765/400/33 ± 5.5% in 22 14.0 60 45 ONAN/ONAF/
√3 √3 steps OFAF or ODAF
Alternatively
ONAN/ONAF1/
ONAF2
500/500/167.67 765/400/33 ± 5.5% in 22 14.0 195 180 -do-

√3 V3 steps
tolerance tolerance tolerance
±10% ±15% ±15%
Note : Three single-phase units will form a bank of 3-phase. Rating of stabilizing LV winding may be of 1/3rd
reactive rating. However, continuous thermal rating shall be at least 5 MVA Active loading.
Other Parameters
(i) Connections - HV/IV Star auto with neutral effectively earthed LV Delta
(ii) Connection symbol - YNa0d11(3-phase)
(iii) ONAN rating shall be guaranteed at 60 per cent of the OFAF or ODAF rating. Rating
under ONAF condition although not guaranteed shall be about 80 per cent. Alternatively
ONAN/ONAF 1/ONAF2 (60%/ 80%/ 100%) cooling with 2 x 50% or with radiator banks
or 4x33.3% unit coolers can be used.
(iv) For these transformers the temperature rise of the top oil refers to the specified loading
combination for which the total losses are highest. Individual winding temperature rises
shall be considered relative to that specified loading combination which is the most severe
for the particular winding under consideration.
(v) Air core reactance of HV winding shall not be less than 20 per cent and knee point voltage
(vi) Short circuit Level
Transformer shall be suitable for connection to the system having the following short
circuit level:
800 kV – 40, 50 kA (rms) for 1 second
420 kV – 40,50 and 63 kA (rms) for 1 second
(vii) Terminals
(a) LV Terminals: 52 kV oil-filled condenser bushings. The bushing shall be arranged

in a line with 1000 mm spacing. No arcing horns shall be provided.
(b) IV Terminals: 420 kV oil-filled condenser bushings with test taps. No arcing horns
shall be provided.
(c) HV Terminals: 800 kV oil-filled condenser bushing with test tap. No arcing horns
shall be provided.
Neutral End: 36 kV porcelain bushing. No arcing horns shall be provided.
(viii) Temperature Rises:
(a) Top oil measured by thermometer - 40°C
(b) Winding rise measured by resistance method - 45°C
(c) Maximum design ambient temperature - 50°C

(Also refer to Notes under clause 1-4)
1.3 Insulation Levels
1.3.1 Impulse and Power Frequency Voltage Test Level for Transformer Windings.
Highest voltage Rated lightning impulse Rated switching impulse Rated power frequency
for equipment withstand voltage withstand voltage short duration withstand
Urn kV (rms) kV (peak) kV (peak) voltage kV (rms)
17.5 (Neutral) 95 — 38
24 125 — 50
52 (LV of Auto 250 — 95
Transformer)
420 1300 1050 —
800 1950 1550 —
1.3.2 Partial discharge at 1.5 Um/√3 shall be limited to 500 pC

Notes
(i) Insulation of tertiary winding of Auto-transformer should be adequate to withstand the transferred surge
voltage appearing across it due to an impulse striking on HV or IV terminals. Therefore, 33 kV LVwinding shall
be designed for a minimum lightning impulse withstand voltage of 250 kV (peak) andshort duration power
frequency withstand voltage of 95 kV (rms).Surge Absorbers may be adopted between Tertiary winding Terminals
to limit transferred surge value to 250 kVp and is a discretion between purchaser and manufacturer.
(ii) The shunt reactor or capacitors connected to the LV side would required to be frequently switched onand off.
The LV winding should be capable of withstanding the stresses as may be caused by frequentswitching.
1.4 Temperature Rises

Notes
(i) For the purpose of standardization of maximum temperature rises of oil and winding as measured by resistance,
the following ambient temperatures are assumed.
Air Water
Cooling medium ambient temperature 50°C 30”C
Maximum daily average ambient temperature 40ºC 25°C
(iii) Wherever ambient temperature is higher than those specified above, the temperature rises, reduced by
(iv) Guaranteed temperature rise limits are valid for all the tapping.
(v) The above temperature rises are applicable to transformers required for operation at an altitude not exceeding
1000 meters above sea level.
1.5 Cooling
1.5.1 ONAN/OFAF or ONAN/ODAF Two 50 percent banks. One number of pump
and one standby pump in each bank. Adequate
number of fans and one standby fan in each 50
per cent bank.
1.5.2 ONAN/ONAF1/ONAF2 Two 50 percent banks or four 33.3% unit coolers.
Adequate number of fans and one standby fan in
each 50 per cent bank or in each 33.3% bank.
1.5.3 OFAF or ODAF Adequate number of coolers with one cooler as
standby.
1.5.4 OFWF or ODWF Two 100 per cent coolers.
Note:-
(i) The transformer shall be filled up with mineral oil, conforming toIS: 335 or IEC 60296.
(ii) Tor auto transformers 100 per cent cooling equipment should be capable of dissipating losses occurring in all
the three windings, at any tap.
1.6 Bushings
1.6.1 The voltage and current ratings, basic insulation level and creepage distances of the
bushings shall be in accordance with the following table:
Voltage rating Current rating Creepage distance Basic impulse Switching impulse
kV (rms) (Amps) (mm) level (kVp) level (kVp)
800 2500 16,000 2100 1550
420 1250 / 2000 10500 1425 1050
52 3150 / 5000 1300 250 --
1.6.2 Partial Disc/large Level Pico-Coulombs :as per IEC 60137.500 at 1.5 p.u.
Clearances in air between live parts and to earthed structures for LV terminals of generator
transformers and auto - transformers shall be determined as per spacing given in clause 1.1.1
(ix) and 1.2.1 (x) respectively.
The clearances for HV and IV terminals shall be as tabulated below:
Highest voltage for equipment kV Clearances

(rms)
Phase to phase Phase to earth
(mm) (mm)
12 280 140
24 330 230
36 350 320
52 530 480
72.5 700 660
145 1220 1050
145 1430 1270
245 2000 1800
245 2350 2150
420 4000 3500
800 5800* / 6700* 5000* / 5800*
* depending upon lightening & switching impulse level.
Airclearances between phase to earth can be relaxed to the extent of maximum of 200 mm so far
as air release pipe emanating from bushing turret is concerned.
(b) Two earthing terminals,
(d) Jacking pads.
(e) Haulage lugs.

(h) Conservator with oil- filling hole, cap and drain valve (size: 25 mm )
(i) Magnetic type oil gauge with low oil level alarm contacts (ratings: 0.5 Amp, 220 Volts
DC.) Dial size 250 mm.
(j) Silicagel breather with oil seal.
(k) Air cell type oil preservation system. Aircell rupture detector may be provided.
• In addition to provision of air cell in conservators for sealing of the oil system against
the atmosphere, an on line insulating oil drying system shall be provided. This on line
insulating oil drying system shall be designed for very slow removal of moisture that may
enter the oil system or generated during cellulose decomposition.
(1) Required number of pressure relief device capable of resealing after release of pressure.
(m) Valves
• Oil valves between cooler and main tank
• Drain valve preferably with padlocking arrangement (minimum size 80 mm).
• Two filter valves (size: 50 mm) on diagonally opposite ends - one at top and other at
bottom preferably with padlocking arrangement on bottom valve.
• Two sampling valves (size: 15 mm) at top and bottom of main tank.
(n) Oil flow indicator with alarm contacts (ratings, 0.5 Amps, 220 Volts D.C.) with each
pump.
(o) Valve schedule plate.
(p) Buchholz relay with alarm and trip contacts (Ratings: 1.0 Amp. 220 Volts D.C.) shall
have
• One number shut-off valve (Size: 80 mm) on conservator side
• Test cock
• Gas collection box and gas check valve at ground level. Copper tube interconnection
between gas collection box and relay shall also be provided. In transformers, for installation
in areas subject to high seismic forces, i.e., horizontal acceleration of 0.3 g or more at and
above a frequency of 8 Hz pitot type or reed type of gas and oil relay shall be used.
(q) Online dissolved gas monitoring device.
(r) Dial type oil temperature indicator with maximum reading pointer and two sets of contacts
(ratings, 0.5 Amps, 220 Volts D.C).
(s) 1 No. dial type winding temperature indicator for a two winding transformer and one dial
type windings temperature indicator for each winding of a multi winding transformer with
‘maximum reading’ pointer and two sets of contact ratings: 5 Amps, 220 Volts D.C. (for
OFAF/ODAF and OFWF/ODWF) and four sets of contacts (for ONAN/ODAF/OFAF).
(t) Remote indication for each winding temperature shall be through a separate measuring
system.
(u) Cover lifting lugs.
(v) Provision for mounting bi-directional flanged rollers with locking and bolting device for
rail gauge specified below:
Type of construction Shorter axis Longer axis

Single-phase 2/3 rail combination with 1676 Two rails with
mm gauge according to layout 1676 mm gauge
and size of Transformer
(w) Weather proof marshalling box for housing control equipment and terminal connections.
(x) Wiring up to marshalling box with PVC SWA copper cables of 650/1100 Volt grade.
(y) Cooling accessories.
(I) ONAN/OFAF or ONAN/ODAF cooling
(i) Requisite number of radiators provided with:
- One shut off valve on top (minimum size: 80 mm)
- One shut off valve at bottom (minimum size: 80 mm)
- Air release device on top
- Drain and sampling device at bottom
- Lifting lugs
(ii) Fans
(iii) Oil pumps with shut off valve on both sides (if required for ONAN cooling pumps
can be by-passed using by-pass pipes and valves).
(iv) Expansion joints, one each on top and bottom cooler pipe connections.
(v) Air release device and oil drain plug on oil pipe connections.
(II) OFAF or ODAF cooling

(i) OFAF coolers with integral fans
(iii) Brass encased thermometers.
(iv) Air release devices and oil pipe connections.
(v) Lifting lugs.
(III) OFWF or ODWF cooling
(i) Oil/water heat exchangers with segregated oil and water headers
(iii) Water flow indicator with alarm contacts (ratings: 0.5 Amp, 220 Volts DC).
(iv) Brass encased thermometer.
(vi) Differential pressure gauge with alarm contacts, operating when difference between
oil outlet pressure and water inlet pressure is less than 0.2 kg/cm2
(vii) Reflux valve if required as per scheme.
(viii) Drain and sampling device on cooler pipe connection.

SECTION J
Specification for 420 kV Class Shunt Reactors &

Associated
145 kV Class Neutral Grounding Reactors
SECTION J
Specification for 420 kV Class Shunt Reactors & Associated
A. Specifications for 420 kV Class Shunt Reactors
1.0 Scope
1.1 This section covers technical requirements/parameters for Shunt Reactors of 420 kV
class but does not purport to include all the necessary provisions of a contract. For general
requirements, loss capitalization and tests, reference shall be made to Sections ‘A’, ‘AA’ & ‘BB’
1.2 Introduction
The AC power system networks are operated as voltage source networks. One essential
requirement, therefore is that under all operating conditions of load the voltage, profile of entire
network should be maintained nearly flat, regulating the voltage of each bus within narrow band
of permitted tolerance. No special compensation facilities are needed when the Power transfer
is over small distances. With increase in power network and generating station connected to
load centers employing long transmission lines, this requirement becomes difficult to meet. The
need, thus arises to compensate these long transmission lines (generally above 200 km).
1.3 Problem Associated with- Reactive Power
Power transmission lines are characterised by their line inductance and shunt capacitance. For
shorter lines their inductive reactance dominates. As a result, when they carry load current,
which normally is inductive in nature, the receiving end voltage reduces in magnitude and hence
shunt reactors are not required for such lines. Long transmission lines present a problem of a
different kind; once energised the line charging becomes a source of reactive power. Under light
load conditions the VAR generation exceeds the VAR consumption which causes excessive
voltage at mid-point. The consumed reactive power is equal to generated power for a certain
transmitted load. This transmitted load is called surge impedance or natural load of the line.
Voltage profile under these conditions becomes flat. Under Heavy load condition, generation of
reactive power in lines reduces while its consumption increases substantially.
1.4 Function of Shunt Reactor
In practice, on account of the transient stability considerations, the permissible loading of long
-lines is kept below surge impedance loading and therefore one faces the challenge to restrict
over voltage along the length of the line. This is accomplished by the connection of shunt reactor
at intermediate buses. This solution is satisfactory but, when used, the total transmission capacity
of the line is reduced. Mid-point shunt compensation not only improves the voltage profile but
also enhances the power transfer capacity of a long line. Shunt Reactors are, thus, important
components-for better utilization of existing and new lines since they compensate for large
capacitive currents generated by HV transmission lines over long distances, restricting optimum
system operation under low load conditions.
131
Capacitive energy is thus balanced with reactive energy and the shunt reactors:
• Maintain grid voltage within limits compatible with the systems insulation level under
normal service conditions. (Lightly loaded condition.)
• Control dynamic over voltage under abnormal conditions (loss of system, interconnections.
resulting from load shedding operations. or from a line-ground fault)
• Take care of switching transients.
1.5 Reactors may be permanently connected, or switched in and off type, depending upon
voltage variations.
1.6 Connection In The System
The reactor is connected either directly on the line and or HV bus or connected to a low-voltage
tertiary winding of a large transformer.
1.7 Applicable Standard
Except otherwise specified or implied herein, the Reactors shall comply with latest edition of
International Standard IEC 60076-6.
Based on length of transmission lines & reactive power compensation in India following three
phase ratings of Shunt Reactor have been standardised for 400 kV lines –
1. 50 MVAR
2. 63 MVAR
3. 80 MVAR
4. 125 MVAR
Note: Single Phase Rating option also possible for specific requirement.
1.9 Major Technical Parameters
1.9.1 Type: Gapped Core or Magnetically Shielded Air Core type Construction
1.9.2 Application & Operation: Shunt Reactors will be connected to the 400kV transmission
system for Reactive Power Compensation and shall be capable of controlling the dynamic over
voltages occurring in the system due to load rejection.
1.9.3 Shunt Reactors shall be capable of operating continuously at a voltage 5% higher than
their rated voltage without exceeding hot spot temperature of 140°C at any part of the reactor.
1.9.4 The Neutral Grounding Reactors(NGR) are required for grounding of the neutral point
Specification for 420kV Class Shunt Reactors & Associated 133
of Shunt Reactors to limit the secondary arc current & recovery voltage to a minimum value
in case Shunt Reactor is connected in the line termed as “Line Reactor”. The Reactor directly
connected to the bus termed as “Bus Reactor” and shall have its neutral directly earthed without
NGR. In such cases utility may decide to have BIL for Neutral of Shunt Reactor as 95 kVp &
38kVrms with 36 kV Neutral Bushing.
1.9.5 The Reactor shall be capable of withstanding Switching Surge Overvoltage of 2.5 p.u
and temporary overvoltage of the order of 2.3 p.u for few cycles followed by power frequency
overvoltage upto 1.5 p.u.
1.9.6 Rating (MVAR) 50/63/80/125
(a) Rated voltage 420kV (1.0 pu)

(b) System Fault Level 40/50/63 kA as per System Requirement
(c) Connection Star with Neutral brought Out
(d) Tolerance on Impedance -0 to +5%
(e) Ratio of Zero sequence Reactance to positive 0.9 to 1.0
Reactance (X0/X1)
(f ) Range of Constant Impedance (Linearity) Up to 1.5 pu
(g) Harmonic Content in Phase Current The crest value of the third harmonic component in
phase current not to exceed 3% of the crest value at
rated voltage
(h) Permissible unbalance current among different phase ±2%
(i ) Vibration Level at rated voltage & frequency 200 microns p-p, 60 microns average
(j) Stress on tank wall 2 kg/mm2 maximum
(k) Noise Level 80 dB
(l) ONAN with separate/tank mounted radiator bank*
*OFWF/OFAF due to space constraint/ customer
specific requirement
ONAN - One 100% bank
Cooling OFAF - Adequate number of coolers with one cooler
as standby
OFWF - Two 100 per cent coolers
Radiator bank/ Cooler can be tank or separately
mounted
(m) Maximum Partial Discharge level 500 pico coulomb at 1.5 pu (as per IEC 60076-3)
(n) Temperature Rises*
Temperature rise of top oil measured by 40oC
thermometer
Temperature rise of winding measured by resistance 45oC
Notes:
(i) For the purpose of standardization of maximum temperature rises of oil and winding as measured by resistance, the
following ambient temperatures are assumed :
Cooling medium ambient temperature Air at 50°C, Water at 30°C
Maximum daily average ambient temperature Air at 40°C, Water at 25°C
Maximum yearly weighted average temperature Air at 32°C
(iii) Wherever ambient temperatures are higher than those specified above, the temperature rises, reduced by
(iv) The above temperature rises are applicable to transformer reactors required for operation at an altitude not
exceeding 1000 metres above sea level.
1.10 Terminals
Line Terminals: 420 kV oil-filled condenser bushings with test taps. No arcing horns shall be
provided.
Neutral Terminal: 145 kV oil-filled condenser bushings with test taps. No arcing horns shall be
provided.
1.10.1 Technical Parameters Bushings
Parameter Bushing Bushing

Line Terminal Neutral Terminal
(a) Rated Voltage (kV) 420 145
(b) Rated Current (A) 1250 1250
(c) Creepage distance (mm) 10,500 3625
(d) Mounting Tank Cover Tank Cover
(e) Rated Lightning Impulse withstand voltage (kVp) 1425 650
(f ) Rated Switching Impulse withstand voltage (kVp) 1050 -
(g) One minute Power frequency withstand voltage (kVrms) 695 305
Notes-
(i) The 1250 amps bushings shall be suitable for draw lead type assembly
(ii) The Dimensions of Bushings are as per Section II.
(iii) In case of GIS termination, bushing to meet the requirements as per IEC 61639.
1.11 INSULATION LEVEL WINDINGS
Parameter Line End Neutral End

(a) Lightning Impulse withstand voltage (kVp) 1300 550
(b) Switching Impulse withstand voltage (kVp) 1050 -
(c) Power frequency withstand voltage (kVrms) - 230
1.12 Clearances of Line Terminals in Air Clearances
(a) Highest voltage for equipment kV (rms) Phase to Phase Phase to Earth
420 4000 mm (Min) 3500 mm (Min)
145 NA 1050 mm (Min)
Note - Air clearances of 3500 mm between phases to earth can be relaxed to the extent of maximum of 200 mm so far
as air release pipe emanating from bushing turret is concerned.
1.13 TESTS
1.13.1 Routine Tests
(a) Measurement of winding resistance.

(b) Measurement of insulation resistance between winding & earth by 5 kV megger.
(c) Measurement of impedance by bridge method.

(d) Measurement of loss and current by bridge method at rated voltage and ambient
temperature. Correction factor per degree centigrade shall be established for each rating of
reactor by measuring losses at ambient temperature and elevated temperature. Correction
factor thus established shall be applied for computation of losses at 75oC. Loss value thus
obtained shall be corrected to rated current.
For purpose of similarity for applying this coefficient the shunt reactor under test shall
have identical rating & guaranteed losses within ±5%.
(e) Measurement of Capacitance and Tan delta
(f) Jacking test on reactor tank without fitting & accessories.
(g) Frequency response analysis test.
(h) Measurement of vibration & stress.
(i) Isolation test between Core-End Frame, End-frame-tank and Core-Tank by 2.5kV AC for
one minute.
(j) Dielectric Test
(i) Separate source voltage withstand test at 230 kV AC for one minute.
(ii) Induced over voltage withstand test with P.D. indication at 412 kV AC (1.7pu/√3)
for 5 minutes and at 364 kV AC (1.5pu//√3) for one hour.
Note: Large value of reactive compensation is required during induced over voltage test on reactors. Considering
the test plant limitations level of 1.7pu can be omitted for larger ratings of Shunt Reactors as per the agreement
between the manufacturer and customer. This is permitted by IEC.
(iii) Full wave lightning impulse voltage withstand test at 1300 kVp on line terminals.
(iv) Switching impulse voltage withstand test at 1050 kVp on line terminals.
1.13.2 Type Test (On One Unit Only)
(a) Temperature rise test as per IEC 60076-2 along with DGA before and after
temperature rise test.
(b) Measurement of acoustic noise level
1.13.3 Special Test (On One Unit Only)
(a) Measurement of zero sequence reactance.(for three phase reactors only)

(b) Full wave lightning impulse voltage withstand test at 550 kVp on neutral terminal.
(c) Magnetization curve test/ knee point voltage measurement.
(d) Measurement of Harmonics
(e) Measurement of Mutual Reactance (for three phase reactors only)
1.13.4 Test on Reactor Tank
(a) As per requirements of GENERAL section

1.13.5 Reactor Oil Testing
The following tests are to be conducted on oil samples for the reactor tank assembled for testing.
Acceptance norms for insulating oil after filling into reactor shall be as given below –
Characteristic Permissible limit ( IEC 60422)
Electrical strength 60 kV (min.)
Water content 10 ppm (max.)
Ten Delta at 90oC 0.01 (max.)
Resistivity at 90 C
o
6 x 1012 ohm-cm (min.)
Interfacial tension 0.035 N/m (min.)
1.14 GUARANTEED TECHNICAL PARTICULARS
1. Manufacture name & country

2. Type of reactor (Gapped/ Air core)
3. Standards applicable
4. Rated MVAr capacity
5. Rated voltage (kV)
6. Type of cooling
7. Thermal data
a) Temperature rise in oil above ambient temperature (Deg C)
b) Temperature rise of winding by resistance above ambient temperature
(Deg C)
c) Rated frequency (Hz)
8. Number of phases
9. Guaranteed max. losses at rated voltage and frequency at rated output
at 75 Deg C (kW)
10. Noise level & reference (dB)
11. Insulation level (winding & bushing) Winding Bushing Line/ Neutral
Line/ Neutral
a) Lightning impulse (1.2/50 microsecs.) withstand voltage (kVp)
b) Power frequency withstand voltage (kVrms)
c) Switching surge withstand voltage (kVp)
12. Range of voltage upto which impedance will be constant (p.u.)
a)
b) Impedance value at 1.0 pu (ohms)
c) Impedance value at 1.5 pu (ohms)
13. X0/X1
14. Vibration & maximum stress on the tank
a)
b) Vacuum withstand capacity of tank
15. Harmonic content in phase current

16. Shipping weights & Dimensions
(a) Size of largest package (mm)x(mm)x(mm)
(b) Weight of largest package (kg)
(c) Gross weight to be handled (kg)
(d) Gross volume to be handled (cu.m)
(e) Approx. overall dimension (lxbxh) (mm)
(f) Approx. quantity of oil required for first filling
(g) Un tanking height
17. Proposed method of transportation
18. Compliance to technical specification w.r.t. parameter specified for
(a) Oil
(b) Bushing CT
(c) Bushings
(d) Terminal connectors
19. Whether similar equipment are type tested & are in successful
operation for at least two years (If yes, furnish type test reports)
20. Overall general arrangement drawing of Shunt Reactor with all
accessories to be enclosed
21. Additional Data
1. System Fault Level
2. Connection
3. Amount of unbalanced current in each phase when connected to
symmetrical voltages
4. Tolerance on Current
5. Capacitance Value (Phase to ground)
6. Clearances from 400 kV terminal
(a) Phase to phase
(b) Phase to ground
(c) Neutral to ground
7. Tank
(a) Type
(b) Material
(c) Thickness
8. Gasket Details
(a) Material
(b) Temperature withstand capability
9. Conservator
(a) Total Volume
(b) Volume between highest & lowest visible oil level

(c) Type of Conservator
10. No. of Pressure Relief device provided
(a) Operating Pressure
11. Temperature Indicators
(a) OTI/WTI
(i) Make
(ii) Range (oC)
(iii) Accuracy (%)
(b) RWTI
(i) Make
(ii) Range (oC)
(iii) Accuracy (%)
(iv) Auxiliary Supply required
12 Winding
(a) Material
(b) Cross-sectional area of conductor
(c) Current density
13. Core
(a) Type of Core
(b) Justification for type of Core adopted
(c) Technical details of the core (No. of limbs)
(d) Material of Core, its grade & thickness
14. Bushings Line (400 kV) Neutral(145 kV)
(a) Type
(b) Maker’s Name
(c) Standard Applicable
(d) Visible discharge voltage for falling power frequency voltage
(e) One minute power frequency withstand voltage
(i) Dry
(ii) Wet
(f) Full wave Impulse withstand voltage
(g) Switching Impulse withstand voltage
(h) Total Creepage distance in air (Approx.)
(i) Weight of assembled bushing (Approx.)
(j) Cantilever Strength (Approx.)
(k) Rated Current
15. Radiator
(a) Make
(b) Material
(c) Thickness
(d) Pressure Withstand Capability
(e) Vacuum Withstand Capability
16. Marshalling box
(a) Type of Mounting
(b) Degree of Protection
17. Bushing Current Transformer
(a) Line Side
(i) Type or voltage class
(ii) Ratio
(iii) Accuracy class
(iv) Burden (VA)
(vi) Knee point voltage (Volts) (Minimum)
(vii) Maximum resistance of secondary winding (ohms)
(viii) Maximum exciting (mA) current
(b) Neutral Side (Before/ After Neutral formation)
(ii) Ratio
(iv) Burden (VA)
B. SPECIFICATION FOR NEUTRAL GROUNDING REACTORS
1.0 Scope
1.1 This section covering specification for Neutral Grounding Reactors, does not purport to
include all the necessary provisions of a contract. For general requirements and tests, reference
shall be made to other Sections ‘A’ and ‘BB’ of the Transformer Manual.
2.0 General
2.1 Unless otherwise modified in this section the earthling transformers shall comply with
latest versions of IEC 60076
2.2 Single phase Neutral Grounding Reactors are connected between neutral point of 400
kV Shunt Reactors and earth, where neutral of Shunt Reactor is designed for 145 kV class
insulation.
2.3 In the high voltage transmission system installed with shunt reactor and when single
pole reclosing is envisaged, a small inductor called neutral grounding reactor is required to be
put between neutral of shunt reactor and earth to compensate the capacitive current during single
line to earth fault.
2.4 Thus NGR is required to carry high current for a very short time.
2.5 In a shunt reactor maximum permissible unbalance current among different phases is
2%, which implies that for 125 MVAR shunt reactor current of 3.5Amp may flow through
continuously.
2.6 Based on above consideration NGR is designed for continuous current of 10 Amp & 60
Amp for 10 seconds (time during which the fault would be definitely cleared).
2.7 NGR consists of air core coil of suitable impedance (as specified in the contract based
on system requirement) immersed in oil filled tank. The Line terminal is brought out through
145kV OIP condenser Bushing which is connected to neutral terminal of shunt reactor. Neutral
terminal is brought out through 36 kV porcelain bushing.
2.8 As continuous losses of NGR are negligible, reactor tank surface is adequate for
dissipation of these losses & therefore no cooling equipment is required.
3.0 TECHNICAL PARAMETERS
(a) Rated Voltage from insulation strength 145 kV

consideration
(b) Rated frequency 50 Hz
(c) No. of Phases 1
(d) Type Outdoor
(e) Insulation Graded
(f ) Max. Continuous Current 10A(rms)
(g) Rated Short time current for 10 seconds 60A(rms)
(h) Rated Impedance at rated Short time current 400 to 2500 ohm (actual value to be defined by
Customer)
(i) Cooling System Natural Oil Cooling(ONAN)
(j ) Max Temperature rises over 50°C ambient Winding measured by resistance : 50°C
Top Oil measured by Thermometer: 45°C
(k ) Connection Between neutral of Shunt Reactor and Ground
(l) Line Terminal 145 kV oil-filled condenser bushings with test taps. No
arcing horns shall be provided
(m) Neutral Terminal 36 kV Porcelain bushing. No arcing horns shall be

provided.
3.1 Technical Parameters of Bushings

(c) Creepage distance (mm) 3625 600
(e) Rated Lightning Impulse withstand voltage (kVp) 650 170
(f ) One minute Power frequency withstand voltage 270 305 75 77
(kVrms)
Notes:
(i) The 1250 amps bushings shall be suitable for draw lead type assembly.
(ii) The Dimensions of condenser Bushings are as per Section II.
(iii) In case of GIS termination, bushing to meet the requirements as per IEC 61639
3.2 Insulation Level Windings
Line End Neutral End

Lightning Impulse withstand voltage (kVp) 550 95
Power frequency withstand voltage (kVrms) 230 38
Voltage Level Phase to Earth

145 1050
24 230
3.4 Method of Grounding : Solidly
3.5 Tests

(c) Measurement of impedance by V/I method at 10A & 60A.
(d) Separate source voltage withstand test at 38 kV AC for one minute.
(e) Full wave lightning impulse voltage withstand test at 550 kVp on line terminals.
3.6 Tests on Reactor Tank
3.6.1 As per requirements of GENERAL section
3.7 Guaranteed Technical Data
1. Manufacture name & country of manufacture

2. Type of reactor (gapped/ air core)
4. Type of cooling
6. Max. continuous current (Amps)
7. Rated short time current at 10 sec. (Amps)
8. Ohmic value (ohms)
Rated reactive capacity for continuous operation at rated voltage (MVAR)
9. Thermal data:
(a) Temperature rise in oil at rated current above ambient temperature of 500C (Deg C)
(b) Temperature rise of winding over ambient temperature of 500C (Deg C)
10. Rated frequency (Hz)
11. Guaranteed max. losses at rated voltage and frequency at rated output (kW)
12. Insulation level (winding & bushing)
(a) Lightning impulse (kVp)
(b) Power frequency (kVrms)
(c) Neutral brought out at (kV)
13. Type of insulation (Graded or Uniform)
14. Overall dimensions & weights
(a) Length with coolers (mm)
(b) Breadth with coolers (mm)
(c) Height with bushing (mm)
(d) Quantity of oil (kl)
(e) Un tanking heights (mm)
15. Shipping data
(a) Oil
(b) Bushing CT
(c) Bushings
(d) Terminal connectors

17. Whether similar equipment are type tested & are in successful operation for at least two years (If yes, furnish
type test reports)
18. Overall general arrangement drawing of Neutral Grounding Reactor with all accessories to be enclosed
(a) Line Side
(ii) Ratio
(iv) Burden (VA)
(v) Accuracy limit factor
(b) Neutral Side
(ii) Ratio
(iv) Burden (VA)
SECTION K
Specifications for 800 kV Class Shunt Reactors &

Associated
145 kV Neutral Grounding Reactor
SECTION K
Specifications for 800 kV Class Shunt Reactors & Associated
A. Specifications for 800 kV Class Shunt Reactors
1.0 Scope
1.1 This section covers technical requirements/parameters for Shunt Reactors of 800 kV
class but does not purport to include all the necessary provisions of a contract. For general
requirements, loss capitalisation and tests, reference shall be made to Sections ‘A’, ‘AA’ & ‘BB’
1.2 Refer clause no. 1.2 ,1.3, 1.4, 1.5, 1.6, 1.7 of Section J “Specifications for 420 kV Class
Shunt Reactors” for general information , functions & application.
Based on length of transmission lines & reactive power compensation in India ,following single
phase ratings of Shunt Reactor have been standardised for 800kV lines –
1. 80 MVAR - 765kV
2. 110 MVAR - 765kV
1.4 Major Technical Parameters
1.4.1 Type: Gapped Core or Magnetically Shielded Air Core type Construction
1.4.2 Application & Operation: Shunt Reactors will be connected to the 800 kV transmission
system for Reactive Power Compensation and shall be capable of controlling the dynamic over
voltage occurring in the system due to load rejection.
1.4.3 Shunt Reactors shall be capable of operating continuously at a voltage 5% higher than
their rated voltage and thermal and cooling system shall be designed accordingly.
1.4.4 The Neutral Grounding Reactors are required for grounding of the neutral point of Shunt
Reactors to limit the secondary arc current & recovery voltage to a minimum value in case
Reactor is connected in the line termed as “Line Reactor”. The Reactor directly connected to the
bus termed as “Bus Reactor” and its neutral is directly earthed.
1.4.5 The Reactor shall be capable of withstanding Switching Surge Overvoltage of 1.9
p.u and temporary overvoltage of the order of 1.4 p.u for about 10 cycles followed by power
frequency overvoltage upto 1.8 p.u.
147
1.4.6
(a) Rating (MVAr) 80/110 single phase at 765/√3 kV

(b) (i) Rated voltage 765/√3 kV
(ii) Max. continuous operating voltage(Um) 800/√3 kV
(c) System Fault Level 40/50/63 kA as per System requirement
(d) Connection Star after 3 phase bank formation
(e) Tolerance on Impedance -0 +5 %
(f) Ratio of Zero sequence Reactance to positive 0.9 to 1.0
Reactance (X0/X1)
(g) Range of Constant Impedance (Linearity) Up to 1.25 pu
(h) Harmonic Content in Phase Current The crest value of the third harmonic component in
phase current not to exceed 3% of the crest value
of the crest value of fundamental when reactor is
energized at rated voltage with sinusoidal wave form
(i) Permissible unbalance current among different phases +/- 1%
of a bank
(j) Vibration Level at 800√3 kV voltage & 50Hz 200 microns p-p, 60 microns average
(k) Stress on tank wall at 800√3kV 2 kg/mm2 max.
(l) Noise Level at 800/√3kV 80 dBA
(m) Cooling ONAN with separate radiator bank
(n) Maximum Partial Discharge level 500 pico coulomb at 1.5 pu (as per IEC 60076-3)
(o) Temperature Rises over an ambient temp. of 50 Deg.
Cent. And at 800/√3kV
Temperature rise of top oil measured by thermometer 400C
Temperature rise of winding measured by resistance 450C
The above temperature rises are applicable to reactors required for operation at an altitude not exceeding 1000
metres above sea level.
1.5 Terminals
Line Terminals : 800 kV oil-filled condenser bushings with test taps.
Neutral Terminal: 145 kV oil-filled condenser bushings with test taps. No arcing horns shall be
provided.
1.5.1 Technical Parameters Bushings
Parameter Line Terminal Neutral Terminal

(b) Rated Current (A) 1600/2500 1250
Specifications for 800kV Class Shunt Reactors & Associated 149
(e) Rated Lightning Impulse withstand 2100 650

voltage (kVp)
(f) Rated Switching Impulse withstand 1550 -
voltage (kVp)
(g) One minute Power frequency withstand 970 275 305
voltage (kVrms)
Notes:
(a) The bushings shall be suitable for draw lead type or draw rod type assembly
(b) The Dimensions of Bushings are as per Section II.
(c) In case of GIS termination, bushing shall meet the requirements as per IEC 61639.

Parameter Line End Neutral End
(a) Lightning Impulse withstand 1950 550
voltage (kVp)
(b) Switching Impulse withstand 1550 -
voltage (kVp)
(c) Power frequency withstand - 230
voltage (kVrms)
(a) Highest voltage for Phase to earth

equipment kV (rms) Clearance (mm)
800 5800 mm (Min)
145 1050 mm (Min)
1.8 TESTS
1.8.1 Routine Tests

(c) Measurement of reactance by bridge method.
(d) Measurement of loss and current by bridge method at rated voltage and ambient
temperature. Correction factor per degree centigrade shall be established for each rating of
reactor by measuring losses at ambient temperature and elevated temperature. Correction
factor thus established shall be applied for computation of losses at 75ºC. Loss value thus
obtained shall be corrected to rated current.
(e) Measurement of Capacitance and Tan delta
(g) Frequency response analysis test.
(h) Measurement of vibration & stress.
(i) Isolation test between Core-End Frame, End-frame-tank and Core-Tank by 2.5kV AC for
one minute.
(j) Dielectric Test
(i) eparate source voltage withstand test at 230 kV AC for one minute.
(ii) Induced over voltage withstand test with P.D. indication at 785 kV AC (1.7pu/√3)
for 30 seconds and at 693kV AC (1.5pu/√3) for one hour.
Note: Large value of reactive compensation is required during induced over voltage test on reactors. Considering the
test plant limitations level of 1.7pu can be omitted for larger ratings of Shunt Reactors as per the agreement
between the manufacturer and customer. This is permitted by IEC.
(iii) Full wave lightning impulse voltage withstand test at 1950 kVp on line terminals.
(iv) Switching impulse voltage withstand test at 1550 kVp on line terminals.
1.8.2 Type Test (On One Unit Only)
(a) Temperature rise test as per IEC 60076-2 & DGA before and after temperature rise test.
(b) Measurement of acoustic noise level at 800/√3kV
1.8.3 Special Test (On One Unit Only)
(a) Full wave lightning impulse voltage withstand test at 550 kVp on neutral terminal.
(b) Magnetization curve test/ knee point voltage measurement.
(c) Measurement of Harmonic content of current
1.8.4 Test on Reactor Tank
(a) As per requirements of GENERAL section
1.8.5 Reactor Oil Testing
The following tests are to be conducted on oil samples for the reactor tank assembled for testing.
Acceptance norms for insulating oil after filling into reactor shall be as given below –
Characteristic Permissible limit ( IEC 60422)

Electrical strength 70 kV (min.)
Water content 10 ppm (max.)
Ten Delta at 900C 0.01 (max.)
Resistivity at 900C 6 x 1012 ohm-cm (min.)
Interfacial tension 0.035 N/m (min.)
1.9 Guaranteed Technical Particulars
Refer Clause no 1.14 of Section J “Specification of 420 kV Class Shunt Reactors”

B. SPECIFICATION FOR NEUTRAL GROUNDING REACTORS
1.0 Scope
This section covering specification for Neutral Grounding Reactors, does not purport to include
all the necessary provisions of a contract. For general requirements and tests, reference shall be
made to other Sections ‘A’ and ‘BB’ of the Transformer Manual.
2.0 General
2.1 Unless otherwise modified in this section the Neutral Grounding Reactors shall comply
with latest versions of IEC 60076
2.2 Single phase Neutral Grounding Reactors are connected between neutral point of 800
kV Shunt Reactors and earth, where neutral of Shunt Reactor is designed for 145 kV class
insulation.
2.3 In the high voltage transmission system installed with shunt reactor and when single
pole reclosing is envisaged, a small inductor called neutral grounding reactor is required to be
put between neutral of shunt reactor and earth to compensate the capacitive current during
single line to earth fault.
2.4 Thus NGR is required to carry high current for a very short time.
3.0 Technical Parameters

(a) Rated Voltage from insulation strength 145 kV
consideration
(b) Rated frequency 50 Hz
(c) No. of Phases 1
(d) Type Dry type air core for outdoor application
(e) Insulation Graded
(f ) Max. Continuous Current 20A (rms)
(g) Rated Short time current for 60 seconds 240A (rms) (However the NGR shall be
designed for a current rating of 600A(rms) short
time current to ensure mechanical robustness)
(h) Rated Impedance at rated Short time current Actual value to be defined by Customer
(Ohms)
(i ) Cooling System Natural Air Cooled
(k) Connection Between neutral of Shunt Reactor and Ground
(l) Line Terminal 145 kV oil-filled condenser bushings with test
taps. No arcing horns shall be provided
(m) Neutral Terminal 36 kV Porcelain bushing. No arcing horns shall
be provided.
3.1 Technical Parameters of Bushings

(e) Rated Lightning Impulse 650 170
withstand voltage (kVp)
(f) One minute Power 305 77
frequency withstand
voltage (kVrms)
Notes
(i) The 1250 amps bushings shall be suitable for draw lead type assembly.
(ii) The Dimensions of condenser Bushings are as per Section P.
(iii) In case of GIS termination, bushing to meet the requirements as per IEC 61639

Line End Neutral End
(a) Lightning Impulse withstand voltage (kVp) 550 95
(b) Power frequency withstand voltage (kVrms)
230 38
Phase to Earth
(a) 145 1050
(b) 36 230
3.4 Method of Grounding: Solidly

3.5 Mounting of NGR : On Pedestal Insulator
3.5.1 Requirement of Pedestal Insulator
Type Porcelain/ Silicon rubber
(a) Minimum Creepage 438 mm
(b) One minute Power frequency 55 kVrms
withstand voltage
(c) Lightning Impulse Withstand 125 kVp
voltage
(d) Mounting Structure Non magnetic material
3.6 Tests

(c) Measurement of impedance by V/I method

(d) Separate source voltage withstand test at 38 kV AC for one minute.
(e) Full wave lightning impulse voltage withstand test at 550 kVp on line terminal.
3.7 Test on Reactor Tank
3.7.1 As per requirements of Section A
3.8 Guaranteed Technical Data
1. Manufacture’s name & country of manufacture

2. Type of reactor
4. Type of cooling
6. Max. continuous current (Amps)
7. Rated short time current for 10 sec. (Amps)
8. Ohmic value (ohms)
Rated reactive capacity for continuous operation at rated voltage (MVAR)
9. Rated frequency (Hz)
10. Guaranteed max. losses at rated voltage and frequency at rated output (kW)
11. Insulation level (winding & bushing)
(a) Lightning impulse (kVp)
(b) Power frequency (kVrms)
(c) Neutral brought out at (kV)
12. Type of insulation (Graded or Uniform)
13. Overall dimensions & weights
(a) Length (mm)
(b) Breadth (mm)
(c) Height (mm)
(d) Un tanking heights (mm)
14. Shipping data
(a) Bushing CT
(b) Bushings
(c) Terminal connectors
16. Whether similar equipment are type tested & are in successful operation for at least two
years (If yes, furnish type test reports)
17. Overall general arrangement drawing of Neutral Grounding Reactor with all accessories
to be enclosed
(a) Line Side
(ii) Ratio
(iv) Burden (VA)
(b) Neutral Side
(ii) Ratio
(iv) Burden (VA)
SECTION L
Specifications for Earthing Transformers

SECTION L
Specifications for Earthing Transformers
1.0 SCOPE
1.1 This section covering specification for earthing transformers, does not purport to include
all the necessary provisions of a contract. For general requirements,loss capitalization and tests,
reference shall be made to Sections ‘A’, ‘AA’ and ‘BB’ of the Transformer Manual.
2.0 GENERAL
2.1 Unless otherwise modified in this section the earthling transformers shall comply with
latest versions of IS 5553 (Part 6) and IS 2026.
2.2 Three phase earthing transformers provide an artificial neutral and are used for the
following purposes :
(a) to earth an otherwise unearthed system.

(b) to connect single phase loads between lines and neutral.
(c) to connect an arc suppression coil.
(d) to limit fault current during a line to earth fault determined by the zero sequence
impedance of earthing transformers and also by the possible addition of resistors and
thereby permitting selective protection.
*Note : The provision of the earthing transformer does not necessarily make the system effectively earthed.
(e) Earthing transformers with zigzag (inter-star) connected winding can have a star connected
secondary winding to provide an auxiliary supply.
2.3 Construction of earthing transformer is similar to conventional oil filled transformer.
Usually cooling specified is ONAN type.
3.0 WINDING CONNECTIONS
Earthing transformers are usually connected either in zigzag (inter-star) or star-delta. For star-
delta transformer the secondary delta winding shall always be connected in closed delta. The
neutral of star connected main winding is earthed. Earthing transformer which consists of a
single winding connected in inter-star may also be provided with, an auxiliary (secondary)
winding. This secondary winding when provided shall be connected in star.
(a) Primary - Zigzag (inter-star), Secondary - Star

(b) Primary - Star Secondary - Delta
(c) Primary - Zigzag (inter-star)
3.1 For the purpose of fault current limitation resistors/reactors can be inserted either
between primary neutral point and earth or in series with primary terminals of inter-star or star
connected primary windings to adjust the zero sequence impedance (Figs. 1 and 2).
157
For star-delta connected earthing transformer the delta connected winding may be of the
open type in order to permit the insertion of a resistor or reactor to adjust the zero sequence
impedance.
3.2 Also connecting the resistor/reactors at the neutral end would be preferable.
4.1 For zigzag connected earthing transformer having auxiliary winding if tappings are
required for voltage variation, it shall be provided on zigzag connected main winding. Equal and
uniform number of tappings shall be provided on both zig and zag windings of main windings.

Fig. 1 Interconnected star (zigzag) neutral earthing transformer
Fig. 2 3 phase star-delta neutral earthing transformer
Rangeof variation: +5 to -5% in steps of 2.5%

Specifications for Earthing Transformers 159
4.2 Tap changing shall be carried out by means of an off circuit externally operated self-
positioning switch (when the transformer is in de-energised condition. Position No. 1 shall
correspond to maximum plus tappings. Provisions shall be made for locking the tap changing
switch handle in position.
4.3 However, tappings are not preferred for earthing transformer.
5.0 INSULATION LEVEL
The insulation level for the line terminals of an earthing transformer shall correspond to those
specified for transformers as per IS: 2026 (Part 3).
6.1 Losses
6.1.1 Only no-load losses should be specified for earthing transformer not provided with
additional auxiliary windings. The tolerance on specified no. load losses will be subject to limits
specified in IS: 2026.
6.1.2 Both no-load and load losses will be specified for earthing transformers provided with
windings’ suitable for supplying auxiliary loads. The load losses specified should be based on the
rating of the auxiliary winding. These losses are also subject to tolerance in accordance with IS :
2026.
6.2 Impedance
6.2.1 Zero sequence impedance of each earthing transformer shall be specified in ohms per
phase and this impedance will be subject to a tolerance of +20%. -0%.
6.2.2 When earthing transformers are provided with auxiliary winding impedance between the
auxiliary winding and the main inter-star (zigzag) winding must be specified and this impedance
shall be subject to tolerance as per IS : 2026.
However, if any difficulty arises to achieve both the specified zero sequence impedance of main
winding and the percentage impedance between the main winding and auxiliary winding, in
such cases either external resistors/reactors may be provided on main windings to adjust the zero
sequence impedance or current limiting resistors/reactors may be provided on auxiliary side to
limit the fault current on auxiliary side to the specified value.
7.0 CONTINUOUS AND SHORT TIME CURRENT RATING
7.1 Continuous Current

7.1.1 Rated Neutral Continuous Current
Continuous neutral current is specified either in the case where phase unbalance of the system
exists or when the earthing transformer is to be designed for connection of single phase loads
between line and the neutral.
7.1.2 Rated Continuous Current
The current flowing through the line terminals continuously when a rated power of a secondary
winding is specified.
Note : The earthing transformer shall carry the specified neutral or rated continuous current and comply as regards
the temperature rise with appropriate requirements of IS : 2026 when it is energised at rated voltage and frequency
7.2 Rated Short Time Current in the Neutral
The earthing transformer shall carry the specified neutral fault current for the specified duration
without exceeding the winding temperature of 250°C for copper and a temperature of 200°C
for aluminium.
When an earthing transformer is designed for the neutral point to be connected to a current
limiting impedance in the connection to earth, it should also be capable of withstanding, for
a period of 5 seconds, the maximum earth fault current that can flow without the additional
impedance in circuit. This safe guard is necessary should, for instance, the bushing of an earth
resistor flash over.
When earthing transformer are operated without external resistor, the rated short time current
and zero sequence impedance shall have the following relationship :
3. Vph
Ish =
Zo

Vph is the maximum permissible operating phase voltage
Zo is the zero sequence impedance per limb of earthing transformer
Ish is the short time neutral current of the transformer
7.3 Ability to Withstand Rated Short Time Current
7.3.1 The earthing transformers shall be capable of withstanding the mechanical and thermal
stresses caused by the rated short time current flowing for the specified duration.
The thermal ability can be demonstrated by calculation using the following formula as per clause
9.1 of IS 2026 (Part 5)
θ1 = θ0 + a J2t x 103 °C
where
Q1 is the highest average temperature attained by the winding due to short time current
maintained over the specified duration and shall not exceed 250°C for copper winding and
200°C for aluminium winding.
θo is the initial temperature in degree Celsius
J is the short time current density in ampere per square millimetre
t is the duration in seconds
a is a function of 1/2 (θ2 + θ0), in accordance with Table 1.
θ2 is the maximum permissible average winding temperature, 250°C for copper and 200°C for
aluminium.
7.3.1.1 Where earthing transformers are used with external resistor/reactors to limit the earth
fault current, the earthing transformer should also be able to withstand dynamically and thermally
the maximum earth fault current without external resister/reactors for a period of 5 seconds.
7.3.1.2 For earthing transformers without secondary winding θ0 shall be taken as the sum of the
maximum ambient temperature and manufacturers guaranteed average oil temperature rise of
the earthing transformer under normal operating conditions.
7.3.2 For earthing transformer with loaded secondary windings θ0 shall be the sum of the
appropriate maximum ambient temperature and the relevant temperature is specified inIS : 2026
measures by change in resistance.
Table 1
a - function of 1/2(Ө1 + Ө2) °C

1/2(Ө0 + Ө2)
Copper windings Aluminium windings
140 7.41 16.5
160 7.80 17.4
180 8.20 18.3

200 8.59 19.1
220 8.99 -
240 9.38 -
7.3.3 Ability of earthing transformer to withstand mechanical stresses due to the rated short time
current flowing in the windings under fault conditions shall be determined by tests described as
per clause 8.6 of IS 5553 (part 6).
8.0 TESTS
8.1 Type Test
• Impulse Voltage Withstand Test (IS : 2026 (Part 3)).

• Heat run test (IS : 2026 (Part 2)).
Applicable only in the case of earthing transformers having auxiliary winding.
8.2 Special test

• Short circuit withstand test.
Clause 8.6 of IS : 5553 (Part 6).
8.3 Routine Test
• Measurement of winding resistance IS : 2026 (Part 1).
• Measurement of insulation resistance IS : 2026 (Part I).
• Measurement of zero sequence impedance IS : 2026 (Part I).
Note : Zero sequence impedance may be measured at any current between 25 per cent to 100 per cent rated short time
neutral current and is expressed in ohms per phase. It shall be ensured that the applied current shall not exceed
the current carrying capability of the winding or metallic constructional parts.
• Measurement of no load loss and no load current IS : 2026 (Part I).

• Measurement of impedance voltage and loss (in case of auxiliary winding)
• Dielectric tests (IS: 2026 (Part 3).
• Separate source voltage withstand Test IS : 2026 (Part 3).
• Induced over voltage test IS : 2026 (Part 3).Applicable only in the case of earthing
transformer with a secondary winding.
• Check of voltage vector relationship and polarity IS : 2026 (Part 1).
• Measurement of voltage ratio IS : 2026 (Part 1). Applicable only in the case of earthing
transformer with a secondary (auxiliary) winding.
• Ratio measurement of zigzag connected earthing transformer with star connected auxiliary winding.
For a zigzag connected earthing transformer the zig and zag windings constituting one phase arc
physically wound on two different limbs of the core. Hence if a single phase supply is applied
between line and neutral of inter-star (zigzag) connected winding, the voltage induced in zig
and zag winding, will be different. Due to this, voltage induced on secondary winding of same
phase will not be the same as that defined by the per phase voltage ratio of the transformer.
Thus voltage ratio measurement with single phase application will give misleading results if
application and measurement is made on per phase basis, (ie between line and neutral).
A vector diagram of a 33/0.435 kV ZNynl connected earthing transformer is given as Fig. 3. The
zig and zag windings per limb are designed for 11 kV and LV is designed for 0.435/3kV. Here
3 phase voltage ratio is defined as the ratio of the HV line to neutral voltage to LV line to line
voltage (IR-IN/2R-2Y) ie 33/3/0.435 = 43.799
Fig. 3 Vector and voltage relationship or a 33/0.435 kV ZNynl connected earthing transformer For single phase
application, the ratio IR-IN/2R-2Y will be :
11 kV x 2/0435 x2
√3 = 33 /3 x 2 /0.435 / 3 x 2
= 33/√3/ 0.435 kV
= 43.799
i.e., for a zigzag connected earthing transformer to get actual design ratio with single phase ap-
plication, the ratio measurement shall be made by applying line to neutral voltage (per phase) on
inter-star connected main winding and measuring the induced line to line voltage on correspond-
ing star connected secondary windings or vice versa.
Note : For ratio measurement with 3 phase application equal and balanced supply (w.r. to voltage and phase differ-
ence) shall be applied, otherwise ratio error will be high.
SECTION M
Specifications for Furnace Transformers

SECTION M
Specifications for Furnace Transformers
1.0 SCOPE
This section covers specifications for transformers having application to be used along with the
Furnaces. However, this does not purport to include all the necessary provisions of a contract.
For general requirements and tests, reference shall be made to other Sections ‘A’ and ‘BB’ of
the transformer manual.
2.0 GENERAL
Standards IS 2026 and IS 12977 to be followed for furnace transformers. Following are the
major application for the furnace transformers.
2.1 Melting Ferrous and Non Ferrous scraps.
2.2 Refining of steels and many other materials etc.
Furnace Transformers are described as below.
1. Arc Furnace Transformers which includes submergedarc furnace, Electric arc furnace
and Ladle refining arc furnace transformers.
2. Induction furnace Transformers.
Arc Furnace transformers are withlow secondary voltageswith very high secondary currentsand
areused for various process applications.Whereas Induction furnace transformers are having
medium & lowsecondary voltages.
Constructions of both furnace transformers aresimilar to power transformers to some extent

excluding arc furnace transformers which are dealing with very low secondary voltage with
higher currents. Here the secondary voltages are intentionally varied with current to melt and
boil the product mix for attaining defined chemical composition and characteristics. The variance
in voltage and current does depend on the quality of charge which is not predefined with fixed
chemical composition. Hence, to make the same Ferro alloys or produce the same steel you
have to selectively vary the KVA rating of the transformer alongwith the secondary voltage and
current which will ultimately vary from mother ore to mother ore as the ore made available is
various underground mines from various parts of the globe.
3.0 WINDING CONSTRUCTION
Arc furnace transformers based on the process optimization requirements have possibilities to
connect in Star and Delta configuration onprimary winding in order to get additional range of
secondary voltages. Star and Delta change overs is done using either external bushings or with
the help of star delta change over switch.
167
168 Specifications for Furnace Transformers
Secondary windings of Arc furnace transformers are having open delta construction. Closing to
Delta configuration is done within the furnace for such transformers.
In order to provide stability, higher rating Arc Furnace Transformers is often provided with
series reactor. Such reactors may be provided as in built or can be of separate unit.One of the
major purpose of providing the series reactor is also because of fast changing of impedance of
the molten bath in the crucible where the metal is both in solid-liquid state.
Fig. 1 Typical HVwinding connection of Arc Furnace Fig.2 Typical winding connections of Arc Furnace
Transformer having Star Delta Change over Transformer with separate Auto Transformer for tappings.
mechanism
Converter & inverter circuits are connected at the secondaryterminals of Induction furnace
transformers as the furnace panel needs to change the frequency of the molten metal bath
depending upon flux penetration and magnetic coupling required. Induction furnace Transformers
are mainly three winding transformers with secondary windings connected in Star and Delta or
in Star configuration. The number of secondary outputs will also depend on the number of
phases or pulse required in the melting system for more optimal power utilization and reduction
in system harmonics to a large extent.
Phase shifting is also provided for induction furnace transformers for larger furnacesto get
pulses of required numbers.

Tappings in the arc furnace transformers are provided on Primary windings in order to get
optimized process.
Depending upon the process and designrequirement either of the following tapping scheme is
adopted.
4.1 Direct Regulation. Tappings are provided on the main winding.
This is a variable flux voltage variation (VFVV) arrangement. This arrangement which consists
of taps at end of primary winding is used for low rating furnace transformers. The cost of OLTC
is minimum due to lower voltage and current values (the primary winding, may be of the order
Specifications for Furnace Transformers 169
of 33 or 66 kV). In this arrangement the step voltage is variable throughout the range of voltage
regulation.
Fig. 3 Direct Regulation with Tappings provided on the Main winding.
4.2 Regulation with Auto Transformer
This arrangement is used mainly for larger furnace applications. In this arrangement separate
auto transformer is used for voltage regulation.This arrangement gives linear or equal steps
secondary voltage variation with tapping positions. The auto transformer and main transformer
may be housed either in common tank or in separate tanks.
For single phase arc furnace transformers, auto transformers are mounted within the same tank
of main transformer. Practice of providing separate 3 phase auto transformer for a bank of
3 single phase arc furnace transformers is also seen. This configuration is preferred beyond
12MVA requirement mostly to reduce the copper content of the external secondary bus bars of
the furnace system beyond the transformer till the electrodes. These transformers calls for very
high material content and hence it is heavy. Logistics always remains a question and moreover
these transformers are mounted at a height of 14 to 18 meters platform from the ground zero
level. To make the transformers lighter to handle such transformers are manufactured in single
phase units rather than 3 phase unit.
Fig. 4. Typical Schematic for Regulation with Auto Transformer.
4.3 Regulation with Auxiliary Booster Transformer
Such arrangement is used for medium and large rating furnace transformers to avoid constraints
related to OLTC current Rating. In this arrangement it is possible to get voltage variation in
equal steps throughout the full range of regulation. Main and Booster transformers are located in
the same tank, to minimize the length of connections between the secondary windings for both
the transformers in such arrangement. Since the Booster transformer is only for regulation, its
rating is much smaller than the main transformer rating.
Centre to centre distances and window heights of Booster and Main transformer are generally
kept same to facilitate connections between their secondary windings. In this arrangement
Secondary current of Main and Booster transformers are equal; the two winding sets are often
connected by their leads in a figure of eight which is known as the “eight-eight arrangement”,
thus avoiding extra connections between them.
Fig. 5. Typical Schematic for Regulation Fig. 6. Eight – Eight Arrangement for LV
with Auxiliary Booster Transformer. connection of Auxiliary Booster Transformer.
Since frequent tap changing is required for the process applications, Arc Furnace Transformers
are mainly provided with On Load Tap Changer.Since the number of tap changing per day of
continuous operation can go upto 250 operations a day, it is preferred to use Vacuum type OLTC
for this purpose. It is also a practice to use oil online filtration device to maintain oil quality in
the diverter chamber.
Induction Furnace Transformers are mainly provided with Off Circuit Tap Changers in case
the system voltage is stable. In case of unstable system voltage oil type OLTC is required
in the primary where there is no phase shifting done in the HV winding. In case phase
shifting is required to have higher pulse system then either LV phase shifting can be done
with OCTC or OLTC in primary winding. In case phase shifting is done in HV then it is
advised not to use OCTC or OLTC in the HV winding as the phase angle will get distorted
with change in tapping position with respect to nominal tap at which the phase difference
angle has been defined.
Insulation level for the line terminals of shall correspond to as specified in IS 2026 (Part 3).
In case of specific requirement of auto transformer the impedance of the auto transformer needs
to be kept little higher with sufficient hoop resistance to withstand short circuit current flowing
through it. Losses of the auto transformer need to be little higher. On addition of both these
attributes the auto transformer will have higher withstand-ability of high inrush current. This
will save the transformer from failing during switching operationof furnace system. There need
not be too much reduction in losses of the transformer that will unnecessarily give rise to cost
of transformer as the furnace system has higher losses compared to the transformer only in
the secondary bus bar path that carries power from the transformer secondary to the electrode
system. Standardization of losses might not work out feasible as KVA rating, secondary voltage
and current is always varying from rating to rating and application to application.
7.0 RATINGS
The MVA, LV voltage range and current are major factors in case the furnace is operating
in fixed pitch mode or variable pitch mode of the electrodes. The thermal delta (the physical
triangle formed in the molten bath) will decide the power density required to melt the charge.
However, manufacturer of induction furnace based on adopted converter& invertor circuits and
majorly the coil voltage required at the furnace crucible decides secondary voltage rating for
Induction furnace transformers.
For the purpose of standardization of maximum taemperature of oil and winding, the following
ambient temperatures are assumed.
Cooling Medium Air Water
Maximum Ambient Temeprature 50 30
Maximum Daily average ambient temperature 40 25
Maximum yearly weighted average ambient temperature 32 --
With the above ambient temepratures, temeprature rises are as given below.
Part Air Water
Windings (Measured by Hot Resistance) 55 60
Top Oil (Measured by Thermometer) 50 50
9.0 TESTS
IS 2026 is referred to for testing of Furnace Transformers.
9.1 Routine Tests:
9.1.1 Ratio Measurement Test
9.1.2 Check of voltage vector relationship and polarity.

9.1.3 Measurement of winding resistance.
9.1.4 Measurment of Insulation resistance.
9.1.5 Separate Source high voltage withstand test.
9.1.6 Induced over voltage withstand test.
9.1.7 Measurement of No Load Loss.
9.1.8 Measurement of Load Loss.
9.2 Type Tests
9.2.1 Temperature Rise Test
9.2.2 Impulse Test
Dynamic short circuit test is not conducted for furnace transformers. The same is demonstrated using IEC / IEEMA
guidelines and sophisticated software.
Higher time for disconnecting the secondary terminal shorting is expected during hot resistance measurement in
temperature rise test of Arc Furnace transformers, efforts should be made to minimize this duration.
Unless otherwise specified within the contract, following minimum fittings and accessories are
to be provided with transformer.
10.1 Rating and Diagram Plate

10.2 Two Earthing terminals
10.3 Lifting Bollard
10.4 Jacking pads
10.5 Haulage Lugs
10.6 Pocket on tank cover for thermometer
10.7 Air Release device
10.8 Conservator with oil- filling hole, cap and drain valve
10.9 Magnetic type oil gauge with low oil level alarm contacts
10.10 Silicagel breather with oil seal.
10.11 Required number of pressure relief device capable of resealing after release of
pressure.
10.12 Valves
10.12.1 Drain valve.
10.12.2 Two filter valves on diagonally opposite ends - one at top and other at bottom.
10.12.3 Oil Sampling valve at bottom of main tank.
10.13 Valve schedule plate.
10.14 Buchholz relay with alarm and trip contacts

10.15 One number shut-off valve (Size: 80 mm) on conservator side
10.16 Dial type oil temperature indicator.
10.17 Dial type winding temperature indicator for a two winding transformer.
10.18 Cover lifting lugs.
10.19 Weather proof Marshaling box for housing control equipment and terminal
connections.
10.20 Cooling accessories.
10.20.1 ONAN/OFAF cooling
Requisite number of radiators provided with:
Air release device on top
Drain and sampling device at bottom
Lifting lugs
10.20.2 OFWF or ODWF cooling
Oil/water heat exchangers with segregated oil and water headers
Oil pumps with shut-off valves on both sides.
Oil and Water flow indicator with alarm and trip contacts
Dial type thermometer.
Pressure gauge.
Differential pressure gauge with alarm contacts, operating when difference between oil
outlet pressure and water inlet pressure is less than 0.2 kg/cm2
Drain and sampling device on cooler pipe connection.
10.21 It is alwaysrecommended to provide Surge suppressors and RC Elements at the line
terminals of Furnace transformer at users end.
SECTION N
Specifications for Rectifier Transformers

SECTION N
Specifications for Rectifier Transformers
1.0 SCOPE
This section covers specifications for transformers having application to be used along with
the low voltage rectifier circuits. However, this does not purport to include all the necessary
provisions of a contract. For general requirements and tests, reference shall be made to Sections
‘A’ and ‘BB’of the transformer manual.
2.0 GENERAL
2.1 Standards IS 2026, IEC 61378 and IEC 146 to be followed for rectifier transformers.
Following are the major application of the rectifier transformers.
2.1.1 Electrolytic process for Aluminum, Zinc, Copper etc.
2.1.2 Chemical process of Caustic Soda, Zinc, Copper, Chlorine etc.
2.2 Rectifier Transformers are used with either of the following DC circuits.
2.2.1. Rectifier Bridge connection 6 Pulse or 12 pulse for medium to high DC voltages
2.2.2. Rectifier single-way inter-phase connection for low DC voltage levels & high DC
currents
2.2.3. Thyristor or diode rectifiers
Construction of rectifier transformer is decided based on the configuration of the DC circuit

scheme adopted.
The rectifier transformers have typically low voltages in the range of few hundreds only.
The Rectifier Transformers require wide range of voltage regulation on secondary side and
automatic constant current control. For voltage regulation, it is extremely difficult to have taps
on the secondary winding because of few turns in LV and high current value. The taps are
either provided on the primary winding, or a separate regulating transformer (autotransformer)
is used (feeding the primary of the main transformer) which can be accommodated in the same
tank. The required double-wound or auto-connected regulating transformer can, depending on
transport or site limitations, be built into the same tank as the rectifier transformer, or into a
separate tank.
For large rating rectifier transformers, the field due to high currents causes excessive stray
losses in structural parts made from magnetic steel. Hence, these parts are usually made of non-
magnetic steel.
Due to a large variety of applications, there are several influencing factors to consider:
• Voltage range and step voltage.
177
• Double-tier: HV and LV windings in two levels, and Star and Delta connection to
achieve a 12-pulse reaction.
• Pulse numbers higher than 12: requires additional phase shifting windings.
• LV bushing arrangement: adapted to suit rectifier design and to limit structural heating.
Bushings /risersare typically mounted on the tank side wall.
3.0 WINDING CONSTRUCTION
Rectifier transformers are provided with two or multi windings based on DC circuit adopted. In
case of Bridge configuration, two windings connected either in Star or Delta is adopted. In case
of Configuration with inter phase transformer multi windings with secondary connected in Star
configuration is provided.
In both of the cases, Configuration of primary winding can either be star or delta and decided by
the rectifier manufacturer.
Fig. 1 Typical vector diagram of 12 pulse Scheme with Fig.2 Typical vector diagram of 6 pulse
Inter phase Transformer Bridge configuration.
(a) Windings
 HV winding: The HV windings of the rectifier transformer are usually disc type and
are connected in either star or delta or zigzag. These type of connection are used to get
the phase shift between the input and output voltages to increase the no of pulses of the
rectified DC output. More number of pulses of the DC output system reduce the ripples
there by improving the quality of DC output.
 LV winding: The secondary voltage of the rectifier transformer is very less and of the
order of a few volts. Thereby, the turns in the secondary winding are also very less. On
the other hand, current carried by these windings is very high. For this reason a special
winding called half & Sections is used. This resembles the disc winding to the extent
that each coil is wound in two disc accommodating the total number of turns. A number
Specifications for Rectifier Transformers 179
of coils of this type are connected in parallel by bus-bars for sharing total current. The
advantage of this coil is that odd number of turns can be accommodated in two discs of
the coil without any loss of space, which cannot be done with the normal disc-winding
technique. This improves the space factor of the winding and insures compactness.
LV winding arrangements: adapted to minimize the winding hotspots and influence of
harmonics.
 Interleaving of LV windings
The two groups of coils of both the secondary are axially interleaved to ensure that the
impedance between the two secondary is minimum and the impedance of the secondary
with respect to the primary windings is same so that all the coils of both the secondary
share the current equally. The ends of the bus-bars are then connected in star or delta as
the case may be.
The bus bars are placed in go-no go arrangement in such a manner that the fluxes are
getting cancelled as a result there would be minimum reactance between bus-bars and
stray losses..
 Coil disposition
Since the secondary coils carry heavy currents and the coils are connected in parallel by
means of bus-bars, it is essential that the secondary coils are placed outermost for ease
of connection. Consequently, HV coil is placed concentrically over the core, over which
the LV coils are placed. Sometimes an electrostatic shield between coils is provided to
limit transferred surges.
(b) Voltage Regulation
 By OLTC/OCTC
In case of OLTC, the voltage variations are being achieved on line by changing OLTC
taps. The OLTC is generally used with Diode Type Rectifier Unit.
The OCTC tap-changers are generally used for the transformer coupled with Thyristor
rectifier. In this case the voltage variations are being achieved by change of firing angle
of the thyristor, which is not economical alway
 By Auto transformer
The diode rectifiers have a longer range and a higher number of smaller voltage steps
in the transformer. A multi-coarse-fine on-load tap changer (OLTC) or an OLTC/NLTC
combination is preferred, together with LV-side saturable reactors for the voltage fine-
tuning.
Electrolysis processes require wide regulation ranges, fast and tune voltage
regulation.
 The Wide regulation is carried out by a regulating transformer.
 The fast & tune regulation is carried out either by a set of saturable reactors.
Aluminium electrolysis Rectiformer requires wide range of secondary voltage variation
from 0% to 100% to start pot line from beginning. The whole range of regulation is
split up into smaller ranges with a combination of OLTC (On load tap changer) +
Saturable reactor.
(c) Saturable Reactor core (Transductors)
When connected to a diode technology rectifier, Self-Saturable Reactors offer solutions

for fast & tune voltage regulation. These Saturable Reactors are placed in rectifier
transformer tank. Magnetic cores mounted on LV copper busbars carrying the main
current produces a voltage drop. The saturation level is controlled by a DC current
circuit permitting a controlled variation of voltage drop. In normal practice, there
will be two DC windings of Self-Saturable Reactors namely bias winding & control
winding. The control and bias windings are in the form of copper rod passing through
the ring core. This fine regulation is equivalent to 2 or 3 steps of the OLTC and discrete
voltage achieved. Ring type cores are being used.
(d) Interphase Transformers
Two or three rectifier systems may need to be paralleled, when the current rating
increases. The paralleling is done with the help of inter phase transformer which
absorbs at any instant the difference between the direct voltages of individual systems
so that there are no circulating current. Since the flux in the magnetic circuit of the
interphase transformer is alternating with 3 times the supply frequency i.e 150Hz, when
two systems are paralleled, the core losses in IPT are high. Hence, the operating flux
density in the interphase transformer is designed to be around 50 to 67% of the value
used for the conventional transformer. The ‘C’ type cores are used in IPT.
Insulation level for the line terminals of shall correspond to as specified in IS 2026 (Part 3).
Unless otherwise specified, Losses and the Impedance of transformer are specified at the principal
tap. Principal tap is having maximum LV voltage with highest MVA. In case of transformer
having application of self Saturable reactor, values and measurement scheme of losses and
percentage impedance shall be agreed between purchaser and supplier.
Losses in inter phase transformer and Saturable reactors, if not measured shall be demonstrated
by calculations.
There are no standard ratings of Rectifier Transformers. The rating is decided based on the
defineda pplications.
Rectifier Transformers are subjected to non linear loads having significant harmonic contents
during service conditions. Pattern of such harmonics shall be considered during limiting top oil
and winding rises. OFWF cooling is standardized for rectifier transformers. For the purpose of
standardization of maximum temperature of oil and winding, the following ambient temperatures
are assumed.
Cooling Medium Water

Maximum Ambient Temeprature 30
Maximum Daily average ambient temperature 25
Maximum yearly weighted average ambient temperature --
With the above ambient temepratures, temeprature rises are as given below.
Part Water
Windings (Measured by Hot Resistance) 60
Top Oil (Measured by Thermometer) 50
8.0 TESTS
IS 2026 is referred to for testing of Rectifier Transformers.
8.1 Routine Tests

8.1.1 Ratio Measurement Test
8.1.2 Check of voltage vector relationship and polarity.
8.1.3 Measurement of winding resistance
8.1.4 Measurment of Insulation resistance
8.1.5 Separate Source high voltage withstand test
8.1.6 Induced over voltage withstand test
8.1.7 Measurement of No Load Loss
8.1.8 Measurement of Load Loss, Calculation of Load Loss shall be as oer IEC 146.
8.2 Type Tests
8.2.1 Temperature Rise Test considering increased value of losses due to harmonics
8.2.2 Impulse Test
Dynamic short circuit test is not conducted for Rectifier transformers. The same is demonstrated using IEC / IEEMA
guidelines and sophisticated software.
Higher time for disconnecting the secondary terminal shorting is expected during hot resistance measurement in
temperature rise test of Rectifier transformers, efforts should be made to minimize this duration.

9.3 Lifting Bollard
9.4 Jacking pads
9.5 Haulage Lugs
9.6 Pocket on tank cover for thermometer
9.7 Air Release device
9.8 Conservator with oil- filling hole, cap and drain valve
9.9 Magnetic type oil gauge with low oil level alarm contacts
9.10 Silicagel breather with oil seal.
9.11 Required number of pressure relief device capable of resealing after release of
pressure.
9.12 Valves
9.12.1 Drain valve.
9.12.2 Two filter valves on diagonally opposite ends - one at top and other at bottom.
9.12.3 Oil Sampling valve at bottom of main tank.
9.13 Valve schedule plate.
9.15 One number shut-off valve (Size: 80 mm) on conservator side
9.17 Dial type winding temperature indicator for a two winding transformer.
9.18 Cover lifting lugs.
9.19 Weather proof Marshaling box for housing control equipment and terminal
connections.
9.20 Cooling accessories.
OFWF or ODWF cooling
Oil/water heat exchangers with segregated oil and water headers
Oil pumps with shut-off valves on both sides.
Oil and Water flow indicator with alarm and trip contacts
Dial type thermometer.
Pressure gauge.
Differential pressure gauge with alarm contacts, operating when difference between oil
outlet pressure and water inlet pressure is less than 0.2 kg/cm2
Drain and sampling device on cooler pipe connection.
9.21 It is recommended to provide Surge suppressors and RC Elements at the line terminals
of Rectifier Transformer. Location of the same may be decided between purchaser and
manufacturer.
SECTION O
Specifications for Electrostatic Precipitator

Transformers
SECTION O
Specifications for Electrostatic Precipitator Transformers
1.0 Scope
This section covers specifications High voltage rectifier transformers (HVR) having application
for supplying power to Electrostatic Precipitator (ESP) used for cleaning the flue gases.
However, this does not purport to include all the necessary provisions of a contract. For general
requirements and tests, reference shall be made to Sections ‘A’ and ‘BB’ of the transformer
manual.
2.0 General
Since several other components are part of the transformer housed in the same tank, generally
Standard IS 2026, where ever applicable, is followed for HVR transformers.
HVR Transformer is used for thyristor controlled HV DC power supply to the high voltage fields
of Electrostatic Precipitator (ESP). An Electrostatic Precipitator (ESP) used in industries and
especially in power plants, is equipment which utilizes an intense electric field for extraction and
removal of suspended particles / dust from flue gases to clean the flue gases before discharging
the same into the atmosphere to avoid pollution.
3.0 Construction
The HVR Transformer is a single phase step up transformer fitted with various components as
HV Rectifier, HF Choke, HV Resistor column, and a linear reactor inside the same tank. The
single phase AC input supply of 415 V ± 10 % is fed to the transformer through a microprocessor
based electronic controller (EC). EC-HVR combined unit provides controlled HVDC supply to
the ESP electrodes. EC controls the input voltage of the HVR in-order to optimize the ESP
operation based on the HVR output current & voltage feedbacks.
The high voltage side output of the transformer is connected to Diode Bridge Rectifier for full
wave rectification to DC output up to 95 kVp and up to 1600 mA. The positive polarity of the
DC output is earthed during operation. The negative polarity of the transformer is taken out
through a bushing. This negative polarity output is connected to the ESP field coils.
The flue gases passing between the electrodes of ESP are subjected to an Intense Electric
Field. Continuous sparks take place across the electrodes during dust extraction from the Flue
gases, which shorts the HV output of the transformer to the Earth. An HVR transformer has
to withstand these momentary short circuits, in the form of sparks throughout its life. A linear
reactor is connected in the input of the transformer to increase the impedance and limit the short
circuit current in the event of short circuit.The supply to transformer is continuously switched
on and off by electronic controller for controlling spark and maximum dust collection.
The high frequency choke is connected to the output to provide high impedance to high frequency
currents. HV Resistor column is provided as potential divider for providing feedback of output
DC voltage to the electronic controller.
187
The transformer may be manufactured with a breather or may be made in hermetically sealed
construction without a breather.
The transformer tank is filled with Mineral transformer oil (IS-335) or Silicone transformer fluid
(IEC-60836) having high flash point based on the requirement.
4.0 Tappings Changing
The input voltage supplied to the HVR transformer is controlled through the electronic
controller for the required output voltage and current. Tappings are not required for the HVR
transformers.
5.0 Insulation Level
HV winding of the HVR transformer is tested for separate source withstand voltage at 10 kV
since the positive polarity of DC output is earthed at site during operation. However, separate
source withstand voltage for LV winding, induced over voltage withstand and Impulse voltage
withstand levels are as specified in IS 2026 (Part 3).
6.0 Losses and Impedance
Since the transformer experiences frequent short circuits during operation, the impedance
offered to the short circuit is kept high of the order of 25 to 35 % by providing a linear reactor
in the LV side of the transformer.
The voltage rating of the transformer is standardized with DC peak output voltage of 70 kVP
and 95 kVp. The DC output current rating of the transformer varies from 400 mA to 1600 mA
as per the requirement.
Temperature rises of winding and oil above ambient temperature of 50 °C are as given below:
Part Temperature Rise (°C)
Windings (Measured by Hot Resistance) 55

Top Oil (Measured by Thermometer) 50
9.0 Tests
IS 2026 in general is followed for testing of HVR Transformers, where ever applicable.
Specifications for Electrostatic Precipitator Transformers 189
9.1 Routine Tests
9.1.1 Ratio Measurement Test1

9.1.2 Measurement of winding resistance1
9.1.3 Measurment of Insulation resistance
9.1.4 Separate Source high voltage withstand test2
9.1.5 Induced over voltage withstand test
9.1.6 Measurement of No Load Loss and current
9.1.7 Measurement of Load Loss and impedance
9.2 Type Tests:
9.2.1 Temperature Rise Test3

9.2.2 Impulse Test4
9.2.3 Spark Test (Short Circuit Test) 5
9.2.4 Functional Tests – Measurement of parameters pertaining to voltage and current
feedback signals to electronic controller, and check of different functional operational
requirement with the electronic controller.
1
Ratio and resistance of the transformer is measured during assembly of the transformer with other components, since
these tests are not possible after assembly and tanking due to connection of various other components,
2
HV winding of the HVR transformer is tested for separate source withstand voltage at 10 KV since the positive polarity
of DC output is earthed at site during operation
3
The temperature rise will be computed from the hot winding resistance of the LV winding since various components are
connected in series with the HV winding of the transformer.
4
Impulse test is be conducted on the transformer without linear reactor, Rectifiers, HF choke and Resistor column
5
Continuous sparks take place across the electrodes of ESP during dust extraction which shorts the HV output of the
transformer to the Earth. An HVR transformer has to withstand these momentary short circuits, throughout its life.
The short circuit test is conducted on the HVR transformer along with the electronic controller, by simulating this
site condition with a spark gap connected across the output. The gap is adjusted to get the required no. of sparks per
minute at required peak voltage which is the short circuit condition while the electronic controller controls the voltage
to quench the spark.

10.3 Jacking pads
10.4 Air Release plug

10.5 Conservator with oil- filling hole
10.6 Magnetic oil level indicator with low oil level alarm contacts
10.7 Silicagel breather
10.8 Pressure relief valve / vent
10.9 Drain plug
10.10 Valves – Two valves on diagonally opposite ends - one at top and other at bottom.
10.12 One number shut-off valve on conservator side
10.14 Weather proof Marshaling box for housing control equipment and terminal connections
(housing relays, feedback resistor, OTI etc. and the associated wiring).
SECTION P
Specifications for Traction Transformers

SECTION P
Specifications for Traction Transformers
1.0 Scope
This section covers specifications for transformers used on board rolling stock. However, this
does not purport to include all the necessary provisions of a contract. For general requirements,
loss capitalization and tests, reference shall be made to Sections ‘A’, ‘AA’ and ‘BB’ of the
transformer manual.
2.0 General
IEC-60310 is followed for traction transformers. Traction transformers are deployed to power
the main traction circuit as well as various auxiliaries circuits such as train air conditioning, train
pantry car, locomotive/EMU auxiliaries etc. Traction transformers are used in:
2.1 Electric locomotives

2.2 Electric multiple units (EMU)
Traction Transformers can be subdivided as:
l Fixed ratio transformers

l Transformers with HV taps
l Transformers with LV taps
Traction transformers are basically step down transformers – used to step down the overhead
catenary (OHE) voltage levels (typically 25 kV) to traction system levels (around 1000 V).
Traction transformers are generally forced cooled to save the precious equipment space.
Inhibited Mineral oil is generally used for the cooling of the transformers. However other types
of synthetic oils are also gaining popularity owing to high flash points – directly related to fire
safety.
Traction transformers are under slung mounted and should be suitable to withstand the shock/
vibrations experienced during traction service. The transformer base should be rigid enough to
avoid the damages due to the hitting by extraneous objects during service.
3.0 Winding Construction
Traction transformers are single phase transformers. Both shell type and core type configurations
are used. Windings are generally sandwich coils or concentric coils. The complete core-coil
assembly is finally fitted in horizontal position inside the tank. The core coil assembly needs
adequate strengthening and support - to sustain the shocks and vibrations experienced during
traction service.
193
4.0 Tappings
For traction power control, one or more of the windings may be equipped with tappings. Tappings
can be on the HV side or the LV side as per the system configuration.
5.0 Insulation Level
Insulation level for the primary winding and secondary windings shall be as per IEC-60310 or
as specified by the purchaser.
6.0 Losses and Impedance
Losses are normally not specified for traction transformers by the purchaser. For traction
transformer, generally the efficiency is specified at rated load. Losses are generally higher as
compared to the equivalent rating power transformers – in order to pack more power in the
limited space.
Impedance is specified by the system designer based on the traction controls.
7.0 Ratings
Traction transformers usually have several secondary windings e.g. traction, auxiliary, hotel
load etc. The rating of the transformer is specified in kVA which is individually specified for
each winding.
Limits of temperature rises shall be as per IEC-60310 or as specified by the purchaser.
9.0 Tests
IEC 60310 is followed for testing of traction transformers. List of applicable tests is as under:
9.1 Routine Tests
1. Measurement of winding resistance

2. Measurement of voltage Ratio
3. Measurement of No Load Loss & No-load current
4. Measurement of Impedance voltage
5. Measurement of load loss
6. Induced voltage withstand test
7. Separate Source voltage withstand test
Specifications for Traction Transformers 195
9.2 Type Tests
1. Determination of total losses
2. Temperature Rise Test
3. Full wave impulse voltage withstand Test
4. Shock & vibration withstand test
9.3 Investigation tests:
1. Behaviour under short circuit conditions (optional)
Fittings and accessories shall as agreed mutually between the manufacturer and purchaser.
However guidance may be taken from other sections of the manual.
SECTION Q
Specifications for Dry Type Transformers

SECTION Q
Specifications for Dry Type Transformers
1.0 SCOPE
1.1 This section of the specification covers the different types of dry type transformers.
This section does not purport to include all the necessary provisions of a contract. For general
requirements, tests, erection, maintenance and commissioning, reference shall be made to
Sections ‘A’, ‘BB’&‘CC’ of the Manual.
1.2 It is not the intent to specify completely all details of design and construction of the
equipment. However, the equipment shall conform in all respect to high standard of design,
engineering and workmanship and be capable of performing in continuous commercial
operations.
2.0 STANDARDS
2.1 Except where specified otherwise herein, all material, equipment and construction shall
conform to Indian Electricity Act and rules and latest versions of Indian standards specified
below:
2.2 List of Standards
(a) IS-11171 : Dry type transformers

(b) IS - 2026 (Part-I) : Power transformers
- General
(c) IS - 2026(Part-II) : Power transformers
Temperature rise
(d) IS - 2026 (Part-Ill) : Insulation Levels, Dielectric Tests and
External Clearances in Air
(e) IS - 2026 (Part-IV) : Terminal markings,
tappings and connections.
(f) IS - 2026 (Part-V) : Ability to Withstand Short Circuit
(g) IS-12063 : Degree of protection
provided by enclosures
(h) IEC-60076-11 : Power transformers
Dry type transformers
The transformer to be supplied against this specification shall be suitable for satisfactory
continuous operation under the climatic condition prevailing at site and to be specified by the
purchaser as per IS2026/ International Standard as under,
199
(i) Location : ....

(ii) Max ambient air temperature (Deg.C) : ....
(iii) Min. ambient air temperature (Deg.C) : ....
(iv) Max. average daily ambient air temperature (Deg.C): ....
(v) Max. yearly weighed average ambient temperature (Deg.C): ....
(vi) Max. altitude above mean sea level (m) : ....
4.0 TERMINOLOGY
4.1 Dry Type Transformer
A transformer in which mineral oil or any liquid is not employed either as a cooling or insulating
medium. Cooling will be by natural circulation of air or by forced air cooling. (AN or AN/AF
as per IS11171).
4.2 Dry Type Transformers are classified into following categories depending on the
insulation potting process:
(a) Vacuum Pressure Impregnated (VPI) Transformers have coils impregnated with polyester
varnish/resin under vacuum & pressure. These transformers are generally available upto
1800C (Insulation Class ‘H’). Some manufacturers also use silicon resin for impregnation.
(b) Cast Resin Transformers have coils encapsulated in epoxy resin by molding process.
Depending on the temperature class of resin used these transformers are available upto
1550C (Insulation class ‘F’) or 180°C (Insulation Class ‘H’).
5.0 STANDARD RATINGS FOR 3 PHASE TRANSFORMERS
Standard ratings of dry transformers with losses & impedances are recommended in Table 1
Table 1 : Standard ratings and losses of Dry type transformers.

Total Loss Total Loss Total Loss Total Loss
Rating %Z
at 50% load at rated load %Z at 50% load at rated load
kVA kV
kV * kV * kV * kV *
HV upto 22kV class/ LV upto 600V HV 33kv class/LV upto 600V
100 0.94 2.4 4 1.12 2.4 5
160 1.29 3.3 4 1.42 3.3 5
200 1.5 3.8 4 1.75 4 5
250 1.7 4.32 4 1.97 4.6 5
315 2 5.04 4 2.4 5.4 5
400 2.38 6.04 4 2.9 6.8 5
500 2.8 7.25 5 3.3 7.8 5
630 3.34 8.82 5 3.95 9.2 5
800 3.88 10.24 5 4.65 11.4 5
1000 4.5 12 5 5.3 12.8 5
1250 5.19 13.87 6 6.25 14.5 6
1600 6.32 16.8 6 7.5 18 6
2000 7.5 20 6 8.88 21.4 6
2500 9.25 24.75 6 10.75 26.5 6
Specifications for Dry Type Transformers 201
Total Loss values given in above table are applicable for thermal classes,B,E & F and have
component of load loss at reference temperature according to clause 17 of IEC 60076-11.
An increase of 7% in above losses for thermal class H is allowed.
* Reference temperature for load losses = average winding temperature rise as given in column
2 of table 2 plus 30 deg C
Other higher ratings of dry type transformers upto 15 MVA having HV upto 33 kV and LV upto
11 kV are possible depending on the application for which they are required.
6.0 RATED FREQUENCY
The standard frequency shall be 50 Hz with a tolerance of ± 3 percent.
6.1 Operation other than the Rated Voltage and Frequency
6.1.1 Transformer built in accordance with this specification may be operated at its rated kVA
at any voltage within ± 10 percent of the rated voltage at that particular tap.
6.1.2 The transformer shall be capable of delivering rated current at a voltage equal to 105
percent of the rated voltage.
Note : The slight temperature rise increase which would correspond to the 5 percent over voltage
due to high no load loss is disregarded.
6.1.3 A transformer for two or more limits of voltage or frequency or both shall give its rated
kVA under all the rated conditions of voltage or frequency or both; provided an increase in
voltage is not accompanied by decrease in frequency.
7.0 ELECTRICAL CHARACTERISTICS AND PERFORMANCE
(a) Thermal classification of insulation and permissible temperature rises should confirm to
class ‘F or class ‘H’ as per relevant clause of IS 11171.
(b) Impedance voltage and short circuit performance against, thermal and dynamic
requirements arc applicable as per relevant clauses of IS 2026 & IS 11171.
7.1 Core
The core shall be stacked type generally of high grade cold rolled grain oriented silicone steel
lamination having low loss and good grain properties coated with carlite. The stacked lamination
will be bolted or tied with belts firmly to prevent vibration or noise. The complete design of core
must ensure permanency of the core losses with continuous working of transformers. Cruciform
core with Mitred/ step lap joints are used to reduce the core losses and magnetizing current.
7.2 Windings
The low voltage and high voltage windings can be made of Copper, Foil/ insulated rectangular
strips. Aluminium foils/conductors can also be used. However, losses recommended in Table 1
Note: The Low Voltage (<600V) windings of cast resin transformer can be with no casting in mold if insulation , pre
impregnated with heat activated epoxy resin, is used.
7.3 Insulating Material
The insulating material shall conform to the thermal class of Insulation specified.
Table-2: Winding Temperature Rise Limits
Insulation system Average winding temperature

temperature (°C) rise limits at rated current K
105 (A) 50
120 (E) 65
130 (B) 70
155(F) 90
180(H) 115
200 125
220 140
7.4 Protective Housing for Dry Type Transformer

Dry type transformer shall be provided with suitable protective sheet steel housing, if required
by the site conditions with minimum IP 43 degree of protection for the enclosure for outdoor and
IP20 for indoor transformers. The housing shall have ventilation louvers/ opening provided with
wire mesh screens and shall be supplied with suitable lifting lugs. Safety limit switches shall be
provided and wired in such a way that the incoming supply may be disconnected whenever any
one of the sides of the enclosures are opened with the transformer in energized condition.
The provision for suitable padlocking shall be provided on the doors of enclosure for safety.
7.5 Off-Circuit Links
The off-circuit tapping links shall be provided on the HV side with appropriate register plate
to show the link location. The links shall be provided with inspection window for viewing
purpose.
7.6 Insulators & Bushings
HV & LV insulators & Bushings shall be of epoxy mould type.
7.7 Termination
LV & HV termination shall be suitable for cable/ busduct termination as per the purchaser’s
specifications.
7.8 Transformer Fittings
Each transformer shall be fitted with following accessories :
(i) Inspection covers.
(ii) Off circuit links in the primary for voltage variations

(iii) Rating & diagram plates
(iv) Terminal marking plate
(v) Two nos. earthing terminals
(vi) Lifting lugs and haulage lugs / holes
(vii) Winding temperature detectors with solid state type temperature signaliser with digital
read out and requisite sets of remote signaling contacts for alarm and trip operation.
(viii) Under carriage with bi-directional rollers with locking and bolting devices. Suitable
arrangement for core and winding assembly to draw out the same.
(ix) Marshalling box complete with all instruments, accessories and fittings as required for the
transformer.
(x) Danger plate indicating “entry prohibited under energized condition” of the transformer.
Rated lightning
Highest voltage for Rated short duration power impulse withstand
equipment Um frequency withstand voltage voltage kV (peak)
kV (rms) kV (rms)
List 1 List 2
< 1.1 3
3.6 10 20 40
7.2 20 40 60
12.0 28 60 75
17.5 38 75 95
24.0 50 95 125
36.0 70 145 170
Choice between List 1 and List 2 as per relevant clause of IS 11171 & IEC 60076 Part 11
9.0 EXTERNAL CLEARANCES
The following clearances are to be maintained in air between line to earth for the respective
voltage:
Highest voltage for Minimum external

equipment Um clearance between
kV (rms) line to earth mm
< 1.1 25
3.6 60
7.2 90
12.0 110
17.5 170
24.0 210
36.0 280
10.0 TESTS AND TEST CERTIFICATES
The transformer shall be subjected to all the routine, type and special tests as per IS—11171 and
2026 / IEC 60076 as agreed upon between the purchaser and the manufacturer.
10.1 Routine Tests
The following shall constitute the routine tests:

(b) Measurement of voltage ratio and check of voltage vector relationship.
(c) Measurement of Insulation Resistance.
(d) Measurement of impedance voltage (principal tapping), short circuit impedance and load
losses.
(e) Measurement of no-load losses and current.
(f) Separate source voltage withstand lest.
(g) Induced over-voltage withstand test.
10.2 Type Tests
The following shall constitute the typetests:
(a) Lightning impulse test

(b) Temperature rise test
10.3 Special Tests
The following tests may be carried out by mutual agreement between the purchaser and the
supplier:
(a) Short circuit withstand test

(b) Measurement of acoustic sound level
(c) Partial discharge measurement
(d) Mechanical tests: IP test on enclosure
11.0 SURFACE TREATMENT AND PAINTING
Surface treatment and painting shall be done as per Section A of this Manual.
12.0 PACKING, TRANSPORT, STORAGE AND INSTALLATION
12.1 Packing
• Dry type transformers with Enclosure need not be packed and can be dispatched only
wrapped with polythene sheet.
• Dry Type transformers without enclosures should be wrapped with polythene sheet and
packed in wooden crates.
• The Dry Type transformers should be dispatched fully assembled, unless until transport
restrictions do not permit.
12.2 Transport
To lift the transformer, all four lifting lugs must be loaded uniformly with equal length straps
of suitable length in order to avoid distortion to the top core clamping structure and system of
core and coil supports.
12.3 Storage
Dry transformers must be stored in a dry, well-ventilated room and covered with a plastic sheet.
After a long storage period at extreme low temperatures or after a lengthy period of being de-
energised in very humid surrounding, the transformers must be dried before putting back into
service. Drying can be achieved by warm air heaters or by industrial dehumidifiers.
12.4 Installation
• After packing materials and any other blocking means used during transport are removed,
the transformer should be cleaned and dusted-off, taking special care of the air cooling
ducts between the windings and between the low voltage coils and the magnetic core.
Once in final position ensure that the transformer is secured by blocking the rollers. The
installation location should be well ventilated.
• Suitable proper air circulation should be ensured around the transformer during operation
at all times.
• If the Dry Type transformer is required for outdoor installation, then the same shall be
specified by customer in initial specifications.
• Before the putting in service of the transformer, all electrical connections must be checked
(incl. the tapping link connections). A poor electrical connection willcause unnecessary
heating, resulting in possible damage to the transformer insulation.
13.0 TEMPERATURE RISE TEST
Temperature rise of dry type transformers can be conducted as per following methods which is
based on loading type:
(i) Direct Loading Method
This method is generally followed for small transformersdue to loading consideration.

In this method, one winding preferably the inner winding of the transformer is excited at
rated voltage with the other connected to a suitable load such that rated currents flow in
both windings.
(ii) Back-To-Back Method
This method is appropriate when there are two similar transformers. Two transformers,
one of which is the transformer under test, are connected in parallel, and the inner winding
is excited at the rated voltage of the transformer under test. By means of different voltage
ratios or an injected voltage, therated current is made to flow in the transformer under
test until stabilization of the core and winding temperatures (refer Fig-1 below). The hot
resistance of the winding is measured and compared with cold resistance to calculate
average winding temperature rise.
Fig-1 (Back to Back Method)

A Voltage source at rated frequency for no-load losses
B Source for rated current at rated frequency for load losses
C Booster transformer
(iii) Simulated Load Method:
In this method, Temperature rise is established by combining the short-circuited test (load
loss) and the open circuit test (no-load loss) in two stage. In each stage, hot resistance of
the winding is measured and compared with cold resistance to calculate average winding
temperature rise. The final temperature rise is calculated by adding them together as per
IEC 60076-11.
Out of all the above three methods, the widely followed method is simulated loading method
Following procedure may be followed for temperature rise test:
1. Test procedure shall be followed as per IEC 60076-11.

2. Test should be carried out with/without enclosure as per user requirement.
3. Test shall be conducted at Minimum Tap.
4. For measurement of ambient temperature, atleast 4 nos. sensors shall be placed at each
side around the transformer at a level approximate half way up to cooling surface, at a
distance of 2 meters from the cooling surface.
5. For direct measurement of winding temperature through WTI, atleast 4 nos. RTD sensors
(Two in center limb & one in each outer phase) shall be placed as close as possible to the
innermost LV winding conductors at the top of the winding and for measurement of core
temperature, 1 no. RTD sensor shall be placed in the centre of top yoke.
6. Hot resistance of all winding (centre phase) shall be measured and their final winding
temperature rise shall be calculated inline with IEC 60076-11.
7. Accuracy of all the instruments used in testing should be equal to or better than 1 oC.
8. In critical Transformers temperature of core, winding, LV terminals/Busbar/Flange &
enclosure shall also be recorded using Laser Gun/Thermo vision camera immediately
after test.
Vol. II
Application, Standard
Fittings and Accessories
SECTION AA
Capitalization Formula for Transformer Losses

SECTION AA
Capitalization Formula for Transformer Losses
A. Capitalization Formula for Power Transformers
1.0 The rate of capitalisation of transformer losses depends upon the rate of interest, rate of
electrical energy per kWh, life of transformer and average annual loss factor. The annual
loss factor takes into account the loading of the transformer during the year. In computing
the rate of capitalisation of ‘Iron losses’, ‘Load losses’ and ‘Auxiliary losses’, following
methodology is recommended :
(i) Rate of interest (r)
(ii) Rate of electrical energy (EC): It is the cost of energy per kWh at the ‘Bus’ to which the
transformer is to be connected. This has been taken as Rs. per kWh at 11 kV.
(iii) Life of the transformer (n): It is taken as 25 years.
(iv) The transformer may be considered in service (LF) for (365x24) 8760 hours in a year.
With modern techniques in design of Condition-monitoring etc, for calculation of losses
no downtime is considered.
(v) The cooling auxiliaries system has been considered in service for 40 percent of the time,
the transformer is in service.
(vi) Annual losses factor:
LS = 0.2LF+0.8(LF)2
where:
LS is the annual loss factor
LF is the annual load factor. This may be decided by the purchaser depending on the application
of transformer. However assuming annual load factor (LF) as 60 percent, annual loss factor (LS)
works out to 0.408.
(vii) Capitalisation Formula Suggested,
Capitalised Cost of Transformer = Initial Cost (IC) + Capitalised Cost of annual iron losses (Wi) +
Capitalised cost of annual Load losses (Wc) + Capitalised cost of annual auxiliary losses (Wp).
Note:
(i) Actual value can be worked out by the purchaser by considering appropriate values of r, EC, LF and LS.
(ii) For auto transformer, the load losses capitalisation shall consider the losses due to both HV and IV loaded
to their rating with tertiary unloaded unless otherwise required by the purchaser. For other three winding
transformers the loading combinations for capitalisation of losses shall be indicated by purchaser.
213
B. Capitalization Formula for Shunt Reactor
As the losses of the shunt reactor cannot be separated in to Iron Loss and Copper Loss, It is
customary to guarantee the Total Losses of the shunt reactor. In such a case it is recommended
that the capitalization formula as applicable for Iron losses of the power transformers shall be
applied to the total losses of the Shunt Reactor.
C. Capitalization Formula for Distribution Transformers
For distribution transformers, the following illustrates the method for calculating the loading
factors for evaluation of loss capitalization to be specified by the purchaser. The values indicated
are typical values and the utility may adopt values different from those indicated in case the
rates of interest, cost of energy and the number of hours of operation are different from those
indicated in the example below. A life expectancy of less than 25 years is not recommended.
LOADING FACTOR FOR NO LOAD LOSS

A= H x Ec x [{(l+r)n -1} / r(l+r)n ]
Rate of Expected Number Cost of 1+r (1+r) n (l+r) n-l [{(l+r) n–l} A=loading
Interest in life of hours of energy to /r(l+r) n] factor per
n operation in the utility at kW
per unit
a year UkV level
r of iron loss
H Ec
0.08 25 8400 Ec 1.08 6.848475 5.84848 10.67477619 Rs. 89668iEc
LOADING FACTOR FOR COPPER LOSS LLF = 0.2*LF + 0.8 *LF*LF
1 1 1 = 0.3
B = A x LLF
Where
A = Loading factor in Rs. per kW of no load loss.
B = Loading factor in Rs. Per kW for load loss.
H = No. of hours, the transformer will remain charged in a year, i.e., no. of hours of
operation (taken as 8400 hrs.).
Ec = Cost of energy to the utility at 11 kV level.
r = Rate of interest per unit (Taken as 8%)
n = Expected life of the transformer (Taken as 25 years)
LLF = Loss load factor (where LLF=0.2 x Load factor + 0.8 x L.F.2)
LF = Load factor (taken as 0.5)
Ec = Cost of energy (in Rupees per unit at 11 kV feeder level).
Note: In case of non-availability of Ec (Energy cost per unit) at 11 kV feeder level, utility should consider the Bulk Rate
Tariff plus 5% as the cost of energy at 11 kV feeder level. Load factor considered for Bfactor is 0.5, higher load
factor may be considered for urban areas.
SECTION BB
Test Requirements for Transformers

SECTION BB
Test Requirements for Transformers
1.0 General
Test requirements, procedures and criteria for successful testing of transformers are defined in
national and international standards, i.e. IS 2026 and IEC Publication 60076
This Section describes specific requirements for performing tests specified in IEC Publication
60076, IS 2026 and other standards applicable to distribution, power and regulating transformers.
It is intended for use as a guide and reference for testing of transformers. The chapter covers
purpose, interpretation and explanation of specific conditions pertaining to the testing of
transformer and procedure for correction when ideal test conditions can not be achieved.
The main objectives of this manual are following:
• To ensure system needs are met

• To obtain technical uniformity
• To provide inputs for proper interpretation of test results
• To eliminate unsuccessful practices
2.0 Necessity of tests on transformer
When all manufacturing processes have been completed, tests are performed on transformer at
the manufacturer’s works to ensure the following purposes:
(1) To prove that the design meets the specified job requirements and to obtain transformer
characteristics.
(2) To check that the quality requirements have been met and that performance is within the
tolerance guaranteed.
Tests performed for the former purpose are referred to as Type Tests and that for the latter
purpose are referred to as Routine Tests (carried out on every unit manufactured). In addition to
the aforesaid two categories of tests, Special Tests may also be performed to obtain information
useful to the user during operation or maintenance of the transformer.
Transformer is important and vital equipment, it is therefore necessary to ensure its proper
performance throughout its service life. Also during transportation, installation and service
operation, the transformer may be exposed to conditions, which adversely affect its reliability
and useful life. It is therefore necessary to do the field testing to ensure good operating health
of transformers.
3.0 Tests
The general requirements and details of the various categories of tests (Routine Tests, Type Tests
and Special Tests) are in accordance with IEC Publication 60076 (latest edition). The Indian
217
standard IS: 2026 is under revision and is expected to be revised in accordance with IEC. The
customer specific requirements are referred hereto as Additional Special tests and Mechanical
Tests.
The following tests are generally performed on the transformer which may also form part of the
customer acceptance:
(A) Factory Tests
• Routine Tests
1. Measurement of winding resistance

2. Measurement of voltage ratio, polarity and check of voltage vector relationship
3. Measurement of no-load loss and excitation current
4. Measurement of short-circuit impedance and load loss
5. Measurement of Insulation resistance
6. Tests on on-load tap-changers, where appropriate
7. Switching impulse withstand voltage test, transformer winding Um > 170 kV
8. Lightning impulse withstand voltage test, transformer winding Um > 72.5 kV
9. Separate-source withstand voltage test
10. Induced AC over voltage withstand test with partial discharge measurement
(The tests at sl. no.7, 8, 9 and 10 above are referred to as Dielectric Tests)
• Type Tests
11. Lightning impulse voltage withstand test, for Um ≤ 72.5 kV
12. Temperature rise test
• Special Tests
13. Lightning impulse test on neutral terminal

14. Long-duration induced AC voltage test (ACLD) transformer winding Um < 170 kV
15. Short-circuit withstand test
16. Measurement of zero-sequence impedances on three phase transformers
17. Measurement of acoustic sound level
18. Measurement of the harmonics of the no-load current
19. Measurement of the power taken by the fan and oil pump motors
• Additional Special Tests
20. Test with lightning impulse chopped on the tail

21. Magnetic circuit (Isolation) test
22. Determination of capacitances and dissipation factor between winding-to-earth and
Test Requirements for Transformers 219
between windings.
23. Magnetic balance test on three-phase transformers
24. Determination of transient voltage transfer characteristics
25. Dissolved gas analysis (DGA) of oil filled in the transformer before and after temperature
rise test
26. Recurrent surge oscillographic (RSO) test
27. Determination of core hot spot temperature
28. Frequency response analysis (FRA) test
29. Measurement of magnetization current at low voltage
30. Functional tests on auxiliary equipments
31. Tests on oil filled in transformer
32. Dew point measurement before dispatch
Mechanical Tests
33. Oil pressure test on completely assembled transformer

34. Jacking test and Dye-penetration test
35. Pressure relief device test
(B) Recommended Field tests
1. Dew point measurement for large transformer filled with dry air or nitrogen filled
2. Winding resistance measurement
3. Vector group and polarity
4. Voltage ratio test
5. Measurement of magnetizing current
6. Magnetic balance test on three phase transformer
7. Magnetic circuit (Isolation) test
8. Measurement of short circuit impedance at low voltage
9. Insulation resistance measurement
10. Measurement of capacitance and dissipation factor on windings and Bushings of 72.5 kV
class and above.
11. Dissolved gas analysis (DGA) on transformers
12. Tests on oil filled in transformer as per IS 1866 / IEC 60422
13. Frequency response analysis (FRA) test
The dielectric tests (Test Nos. A.7 to A.12) may be routine, type or special tests depending upon
the voltage rating, specific customer requirements and referred standards.
The purpose, interpretation and explanation for specific conditions of the tests are briefly
described as below.
The tests and their sequence shall be mutually agreed between the manufacturer and the user.
3.1 Measurement of Winding Resistance
3.1.1 General
Resistance measurement helps to determine the following:
(a) Calculation of the I2R losses.
(b) Calculation of winding temperature at the end of a temperature rise test.
(c) As a base for assessing possible damage in the field.
3.1.2 Determination of Cold Temperature
The resistance is measured at ambient (cold) temperature and then converted to resistance at 75 0C,
for all practical purpose of comparison with specified design values, previous results and diagnostics.
The cold temperature of the winding shall be determined as accurately as possible when measuring
the cold resistance. The following should be observed.
3.1.2.1 Transformer Windings Immersed in Insulating liquid
The temperature of the winding shall be assumed to be the same as the temperature of the
insulating liquid, provided:
(a) The windings have been under insulating liquid with no excitation and with no current in
the winding from three hours to eight hours (depending upon the size of the transformer)
before the cold resistance is measured.
(b) The temperature of the insulating liquid has stabilized, and the difference between top and
bottom temperature does not exceed 5 0C.
3.1.2.2 Transformer windings without insulating liquid
The temperature of the winding shall be recorded as the average of several thermometers or
thermocouples inserted between the coils, with care taken to see that their measuring points are
as nearly as possible in actual contact with the winding conductors. It should not be assumed
that the windings are at the same temperature as the surrounding air.
3.1.3 Resistance Measurement Methods
The resistance of each winding shall be measured by any one of the following methods. If
winding has tapping, then resistance shall be measured on at least principal, maximum and
minimum taps.
3.1.3.1 Voltmeter-Ammeter method
This method should be employed if the rated current of the transformer winding is one ampere
or more. The following steps are performed to conduct this test.
(a) Measurement is made with direct current, and simultaneous readings of current and
voltage are taken.

(b) To minimize errors of observation:
(1) The measuring instruments shall have such ranges as will give reasonably large
deflection.
(2) The polarity of the core magnetization shall be kept constant during all resistance
readings.
(c) The voltmeter leads shall be independent of the current leads and shall be connected as
closely as possible to the terminals of the winding to be measured. This is to be avoid
including in the reading the resistance of current-carrying leads, their contacts and extra
length of leads.
(d) Readings shall not be taken until after the current and voltage have reached steady-state
values.
(e) Readings shall be taken with not less than four values of current when deflecting
instruments are used.
(f) The current used shall not exceed 15% of the rated current of the winding whose resistance
is to be measured. Larger values may cause inaccuracy by heating the winding and thereby
changing its temperature and resistance.
3.1.3.2 Bridge Method
Bridge methods or high-accuracy digital instrumentation are generally preferred because of their
accuracy and convenience. The current rating of the measuring instrument should not be very
low for large inductive objects. In case of delta connected windings of a large rating transformer,
the resistance meter should have adequate current rating.
For star connected windings with neutral brought out, the resistance shall be measured by two
methods
(1) Between line and neutral

(2) For small transformer with star connected windings, the resistance shall be measured
between phases (line to line), and then resistance of the individual windings shall be
determined by dividing the value by 2. This will rule out the effect of the resistance of
the neutral lead and bus bars which is significant in comparison to phase resistance of
small transformers. However, for the delta connected windings, measurements shall be
made between pairs of line terminals. In this case the resistance per winding will be 1.5
X measured resistance between the pair of line terminals. In case of open delta connected
winding, the resistance can be measured across all the three windings are in series and
also individual winding resistance can be measured.
Few precautions are to be carried out to minimize errors while performing the test as follows:
(a) Charged battery of sufficient capacity or at least 10 A shall be used with the bridge to
avoid errors due to drop in battery voltage during measurements.
(b) To reduce the high inductive effect, it is advisable to use a sufficiently high current to
saturate the core. Therefore the measuring instruments shall have high ranges as well as
large deflection.
(c) The polarity of the core magnetization shall be kept same during all resistance readings. A
reversal in magnetization of the core can change the time constant and result in erroneous
readings.
(d) The voltmeter leads shall be independent of the current leads and shall be connected
as closely as possible to the terminals of the winding to be measured. This is to avoid
including in the reading the resistances of current-carrying leads and their contacts and of
extra lengths of leads.
(e) To protect the voltmeter from injury by off-scale deflections, the voltmeter should be
disconnected from the circuit before switching the current on or off. To protect the
personnel from inductive kick, the current should be switched off by a suitably insulated
switch.
(f) Readings shall not be taken until after the current and voltage have reached steady-state
values.
(g) The current used shall not exceed 15% of the rated current of the winding whose resistance
is to be measured. Larger values may cause inaccuracy due to heating of the winding and
thereby changing its temperature and resistance.
3.2 Measurement of Voltage Ratio, Polarity and Check of Voltage Vector Relationship
3.2.1 Ratio Test
3.2.1.1 General
The turn ratio of a transformer is the ratio of the number of turns in the high-voltage winding to
that in the low-voltage winding.
When the transformer has taps, the turn ratio shall be determined for all taps and for the full
winding.
The ratio tests shall be made at rated or lower voltage and the voltage shall be applied to the
winding with higher voltage rating.
In the case of three-phase transformers, when each phase is independent and accessible, single-
phase supply should be used; although, when convenient, three-phase supply may be used.
3.2.1.2 Tolerances for ratio
The tolerances for ratio shall be as specified in IS 2026 Part 1 and IEC 60076-1.
Ratio test methods
Various types of ratio test methods are possible. Out of those, Ratio Bridge method is most
commonly adopted. In this method, the turn ratio on each tapping between pairs of winding
shall be measured by a direct reading ratio meter. This method gives more accurate results as
compared to other methods described in aforesaid standards.
The modern ratio bridge can also be used to test polarity, phase relation and phase sequence. More
accurate results can be obtained using a ratio bridge that provides phase-angle correction.
3.2.2 Polarity and Vector Group Verification
Polarity and phase-relation tests are of interest primarily because of their bearing on
paralleling or banking two or more transformers. Phase-relation tests are made to determine
angular displacement and relative phase sequence. Phase-relation or vector group
verification test is performed on a three phase transformer or on a bank of three single-
phase transformers.
The details of Additive and Subtractive polarity are given in IS: 2026-Part 1 and IEC 60076-1.
3.2.2.1 Polarity By Alternating-Voltage Test
For a single-phase transformer having a ratio of transformation of 30 to 1 or less, the polarity

test shall be done as follows. The line terminal of high voltage winding (1.1) shall be connected
to the adjacent line terminal low-voltage winding (2.1) as shown in Fig. 1
Fig.1 Polarity by alternating voltage test
Any convenient value of alternating voltage shall be applied to the full high-voltage winding and
readings shall be taken of the applied voltage and the voltage between the right-hand adjacent
high-voltage and low-voltage leads.
When the later reading is greater than the former, the polarity is additive.
When the later reading is less than the former (indicating the approximate difference in voltage
between that of the high-voltage and low-voltage windings), the polarity is subtractive.
3.2.2.2 Verification of Vector Group
The phasor diagram of any three-phase transformer that defines the angular displacement and
phase sequence can be verified by connecting the HV and LV leads together to excite the
unit at a suitably low three-phase voltage, taking voltage measurements between the various
pairs of leads and then either plotting these values or comparing them for their relative order
of magnitude with the help of the corresponding phasor diagrams, e.g. as shown in Fig. 2
and 3. Typical check measurements are to be taken and their relative magnitudes are then
compared.
Example 1
CONNECT 1U TO 2U
MEASURE 1W-2V, 1W-2W, 1U-2W, 1V-2V,
1V-2W
VOLTAGE RELATION
1W-2V= 1W-2W
1W-2V< 1W-1U
1V-2V<1V-2W
1V-2V <1U-1W
Fig 2 : For HV-Delta / LV-Star Transformer
Example 2
Connect 1U to 2U
1V-2W
VOLTAGE RELATION
1W-2W = 1V-2W
1W-2V > 1V-2V
1U-N= (1U-2W)+(2W-N)
Yd11
Fig 3 : For HV-Star / LV-Delta Transformer
3.3 Measurement of No-load Loss and Excitation Current
3.3.1 General
No-load (excitation) losses are those losses that are incident to the excitation of the transformer.
No-load (excitation) losses include core loss, dielectric loss, conductor loss in the winding due
to excitation current, and conductor loss due to circulating current in parallel windings. These
losses change with the excitation voltage.
Excitation current (no-load current) is the current that flows in any winding used to excite the
transformer when all other windings are open-circuited. It is generally expressed in percent of
the rated current of the winding in which it is measured.
3.3.2 No-load Loss Test
The purpose of the no-load loss test is to measure no-load losses at a specified excitation voltage
and a specified frequency. The no-load loss determination shall be based on a sine-wave voltage.
The average-voltage voltmeter method is the most accurate method for correcting the measured
no-load losses to a sine-wave basis and is recommended. This method employs two-parallel-
connected voltmeters; one is an average-responding (possibly rms calibrated) voltmeter; the
other is a true rms-responding voltmeter. The readings of both voltmeters are employed to
correct the no-load losses to a sine-wave basis, using equation given in paragraph for waveform
correction of no-load losses.
Test voltage will be 90%, 100%, 110%, guaranteed at 100% and for reference purpose at 90 and
110%
3.3.2.1 Connection Diagrams
Tests for the no-load loss determination of a single-phase transformer are carried out using
the schemes depicted in Figs. 4 & 5. Fig. 4 shows the necessary equipment and connections
for the case where instrument transformers are not required. When instrument transformers
are required, which is the general case, the equipment and connections shown in Fig. 5 apply.
If necessary, correction for losses in connected measuring instruments may be made by
disconnecting the transformer under test and noting the wattmeter reading at the specified test
circuit voltage. These losses represent the losses of the connected instruments (and voltage
transformer, if used). They may be subtracted from the earlier wattmeter reading to obtain the
no-load loss of the transformer under test.
Tests for the no-load loss determination of a three-phase transformer shall be carried out by
using the three wattmeter method. Figure 6 is schematic representation of the equipment and
connections necessary for conducting no-load loss measurements of a three-phase transformer
when instrument transformers are necessary.
Nowadays, digital power analysers or power meters are available for determination of losses
(both no-load and load). Selection of these power analysers shall be based on the desired
accuracy at low power factors
Fig 4 : Connections for no-load loss test of a single-phase transformer

without instrument transformers
without instrument transformers
Fig : 5 - Connections for no-load loss test of a single-phase transformer

with instrument transformers
Note : Source neutral

should be available
for Y-Y connected
Note : Voltmeters should
transformers when no
be connected Line-to-Neutral
delta winding is
for Y-connected winding
present to provide
or Line-to-Line for
return path from
delta-connected winding
transformer neutral Fig : 6 - Three phase transformer connections for no-load loss and excitation
current tests using three-wattmeter method
3.3.2.2 Voltage and frequency for no-load loss test
The operating and performance characteristics of a transformer are based upon rated voltage
and rated frequency, unless otherwise specified. Therefore, the no-load loss test is conducted
with rated voltage impressed across the transformer terminals, using a voltage source at
a frequency equal to the rated frequency of the transformer under test, unless otherwise
specified.
For the determination of the no-load losses of a single-phase transformer or a three-phase

transformer, the frequency of the test source should be within ± 0.5% of the rated frequency
of the transformer under test. If the excitation frequency is beyond the specified tolerance,
then the test voltage shall be adjusted to maintain the V/f ratio corresponding to the ratio
of rated voltage and rated frequency. The voltage shall be adjusted to the specified value as
indicated by the average-voltage voltmeter. Simultaneous values of rms voltage, rms current,
electrical power and the average voltmeter readings shall be recorded. For a three-phase
transformer the average of the three voltmeter readings shall be the desired nominal value
of the voltage.
The most difficult cases, both with regard to voltage wave shape distortion and power
measurements usually arise when testing large single-phase transformers.
3.3.2.3 Instrument error at low power factor
At low power factors, judicious selection of measurement method and test system components
is essential for accurate and repeatable test results. The phase-angle errors in the instrument
transformers, measuring instruments, bridge networks and accessories affect the loss test
results. Procedures for correcting the losses for meeting phase-angle errors are described in IEC
Publication 60076-8
3.3.2.4 Correction of no-load losses
The eddy current component of the no-load loss varies with the square of the rms value of
excitation voltage and is substantially independent of the voltage waveform. When the test
voltage is held at the specified value as read on the average-voltage voltmeter, the actual rms
value of the test voltage may not be equal to the specified value. The no-load losses of the
transformer corrected to a sine-wave basis shall be determined from the measured value by
means of the following equation:
The above equation is valid only for voltage with moderate waveform distortion. If waveform
distortion in the test voltage causes the magnitude of the correction to be greater than 5%, then
the test voltage waveform must be improved for an adequate determination of the no-load losses
and currents. For large single phase transformers, it is expected that the difference between rms
voltages and average voltage will be greater than 5%, which should be accepted in view of test
voltage source limitation.
The new generation of power analysers are equipped with software for automatic calculation of
corrected losses based on the input data of voltages and power.
3.3.3 Measurement of Excitation (no-load) Current
The excitation (no-load) current of a transformer is the current that maintains the rated magnetic
flux excitation in the core of the transformer. The excitation current is usually expressed in per
unit or in percent of the rated line current of the winding in which it is measured. Measurement
of excitation current is usually carried out in conjunction with the tests for no-load losses. RMS
current is recorded simultaneously during the test for no-load losses using the average-voltage
voltmeter method. This value is used in calculating the per unit or percent excitation current.
For a three-phase transformer, the excitation current is calculated by taking the average of the
magnitude of the three line currents. The tolerance for no-load current should be as per IS 2026
Part -1
3.4 Measurement of Short-circuit Impedance andLoad Loss
3.4.1 General
The load losses of a transformer are those losses incident to a specified load carried by the
transformer. Load losses include I2R loss in the windings due to load current and stray losses
due to eddy currents induced by leakage flux in the windings, core clamps, magnetic shield,
tank walls and other conducting parts. Stray losses may also be caused by circulating currents in
parallel windings or strands. Load losses are measured by applying a short circuit across either
the high voltage winding or the low voltage winding and applying sufficient voltage across the
other winding to cause a specified current to flow in the windings. The power loss within the
transformer under these conditions equals the load losses of the transformer at the temperature
of test for the specified load current.
The impedance voltage of a transformer between a pair of windings is the voltage required to
circulate rated current through one of two specified windings when the other winding is short
circuited, with the windings connected as for rated voltage operation. Impedance voltage is
usually expressed in per unit or percent of the rated voltage of the winding across which the
voltage is applied and measured.
The impedance voltage is measured during the load loss test by measuring the voltage required
to circulate test current in the windings. The measured voltage is the impedance voltage at
the test frequency and the power loss dissipated within the transformer is equal to the load
losses at the temperature of test and at rated load. The impedance voltage is corrected to the
rated frequency and the load losses are corrected to a reference temperature using the formulas
specified in this standard.
3.4.2 Factors Affecting the Values of Load Losses and ImpedanceVoltage
The magnitude of the load losses and the impedance voltage will vary depending on the
positions of tap changers, if any in various windings. These changes are due to the changes in
the magnitudes of load currents and associated leakage-flux linkages as well as being due to
changes in stray flux and accompanying stray losses.
3.4.2.1 Temperature
Load losses are also a function of temperature. The I2R component of the load losses
increases with temperature, while the stray loss component decreases with temperature.
Procedures for correcting the load losses to the standard reference temperature are described
in 3.5.5.
3.4.2.2 Instrument error at low power factor
At low power factors, judicious selection of measurement method and test system components
is essential for accurate and repeatable test results. The phase-angle errors in the instrument
transformers, measuring instruments, bridge networks and accessories affect the load loss test
results. Procedures for correcting the load losses for meeting phase-angle errors are described
in IEC Publication 60076-8
3.4.3 Methods for Measuring Load Losses and Impedance Voltage
Test Conditions
To determine the load losses and impedance voltage with sufficient accuracy, the following
conditions shall be met.
1. The temperature of the insulating liquid has stabilized and the difference between top and
bottom oil temperatures does not exceed 5 0C.
2. The temperature of the windings shall be taken immediately either before or after the
load losses and impedance voltage test in a manner similar to that described in 3.1.1. The
average shall be taken as the winding temperature for computation of losses.
3. The conductors used to short-circuit the low voltage, high current winding of a transformer
shall have a cross-sectional area greater than the corresponding transformer winding leads.
4. The test current shall be at least 50 % of the rated current of the winding across which the
voltage is applied.
5. The measurement of losses shall be done at the earliest after excitation of the transformer
to the test current to avoid heating of the winding resulting in increase in resistance.
3.4.3.1. Wattmeter-voltmeter-ammeter method for load loss and impedance voltage test
The connection and apparatus needed for the determination of the load losses and impedance
voltage of a single-phase transformer are shown in Figures 7 and 8. Figure 8 applies when the
instrument transformers are required, which is the general case.
For three phase transformers, three-phase power measurement utilizing two wattmeter is
possible but can result in very large errors at low power factors encountered in load loss tests of
transformers. It is recommended that the two-wattmeter method should not be used for loss tests
on three-phase transformers of ratings preferably above 20 MVA, 66 kV class.
For three phase transformers, Figure 9 shows the apparatus and connections using the three-
wattmeter method.
Fig 7 : Basic circuit for load loss and impedance measurement

Fig 8 : Single-Phase transformer connection for load loss and

impedance tests with instrument tranformers
Fig 9 : Three phase transformer connection for load loss and

impedance voltage tests using three- wattmeter method
3.4.3.2 Measurement with Power Analyser
Nowadays, digital power analysers or power meters are available for determination of load
losses. Selection of these power analysers shall be based on the desired accuracy at low power
factors.
The new generation of power analysers are equipped with software for automatic calculation of
corrected losses based on the input data of voltage, current, power, frequency and temperature.
3.4.4 Test Procedure
3.4.4.1 Two-winding transformers and auto transformers
Load loss and impedance voltage tests are carried out using the connections and apparatus
shown in figure 8 for single-phase transformers and figure 9 for three-phase transformers.
With one winding short-circuited, a voltage of sufficient magnitude is applied to the other
winding and adjusted to circulate test current in the excited winding. Simultaneous readings
of wattmeter, voltmeter and ammeter are taken. If necessary, the corrections for the losses in
external connections and connected measuring instruments should be made.
The procedure for testing three-phase transformers is very similar, except that all connections
and measurements are three-phase instead of single-phase and a balanced three-phase source
of power is used for the test. If the three line currents cannot be balanced, their average rms
value should correspond to the desired value, at which time simultaneous reading of wattmeters,
voltmeters and ammeters should be recorded.
Single phase and three-phase auto transformers may be tested with internal connections unchanged.
The test is made using the auto transformer connection. The input (or output) terminals are
shorted and voltage is applied to the other terminals. The voltage is adjusted to cause test current
to flow in the test circuit as shown in Figure10. Simultaneous readings of wattmeters, voltmeters
and ammeters are recorded for determination of load losses and impedance voltage.
Fig 10 : Connection for impedance loss and impedance-voltage

tests of an auto-transformer
For the purpose of measuring load losses and impedance voltage, the series and common
windings of auto transformers may be treated as separate windings, one short circuited,
the other excited. In this situation, where the transformer is connected in the two-winding
connection for the test, the current held must be the test current of the excited winding, which
may or may not be the same as rated line current. The load loss watts and applied volt-amperes
will be same, whether series and common windings are treated as separate windings in the
two-winding connection or are connected in the auto-transformer connection, so long as rated
winding current atleast 50 percent is held in the first case and rated line current atleast 50
percent in the second case.
3.4.4.2 Three winding transformers
For a three winding transformer, which may be either single phase or three phase, three sets of
impedance measurements are made between pairs of windings, following the same procedure
as for two winding transformers. Measurement of the impedances Z12, Z23 and Z31 are obtained
between windings 1, 2 & 3.
If the kVA capacities of the different windings are not alike, the current held for the
impedance test should correspond to the capacity of the lower rated winding of the pair
of the windings under test. However, all of these data when converted into percentage
form should be based on the same output kVA, preferably that of the primary winding. An
equivalent three-winding impedance network as shown in Figure 11 can be derived from
the following equations:
Fig 11 : Equivalent three-winding impedance network
Where
Z12, Z23 and Z31 are the measured impedance values between pairs of windings, as indicated all
expressed on the same kVA base.
These equations involve complex numbers, but they may be used for the resistance (in-phase)
component or the reactance (quadrature) component of the impedance voltage or of the
impedance volt-amperes.
The treatment of the individual load losses for temperature corrections, etc., is the same as for
two-winding, single phase transformers.
The total load losses of the three winding transformer is the sum of the losses in the branches of
the equivalent circuit of Figure 11 for any specific terminal load conditions.
3.4.5 Calculation of Load Losses and Impedance Voltage
Load loss measurements vary with temperature and in general must be corrected to a reference
temperature. In addition, load loss measurement values must be corrected for metering phase
angle error. Impedance voltage measurement to vary with frequency and the values must be
corrected for rated frequency.
• Temperature correction of load losses
Both I2R losses and stray losses of transformer vary with temperature. The I2R losses, Pr(Tm),
of a transformer are calculated from the ohmic resistance measurements (connected to the
temperature, Tm, at which the measurement of the load losses and impedance voltage was
done) and the current that were used in the impedance measurement. These I2r losses subtracted
from the measured load loss watts P(Tm), give the stray losses, Ps(Tm), of the transformer at the
temperature at which the load loss test was made.
Ps (Tm) = P(Tm) – Pr(Tm)
Where
Ps(Tm) is the calculated stray losses (watts) at temperature Tm.
P(Tm) is the transformer load losses (watts), corrected in accordance with phase angle errors in
wattmeter at temperature Tm.
Pr (Tm) is the calculated I2R loss (watts) at temperature Tm
The I2R component of load losses increases with temperature. The stray loss component
diminishes with temperature. Therefore, when it is desirable to convert the load losses from the
temperature at which it is measured, Tm, to another temperature, T, the two components of the
load losses are corrected separately.
Thus,
Then
P (T) = Pr (T) + Ps (T)
Where
Pr (T) = I2R loss (watts) at temperature T, 0C
Ps (T) = stray losses (watts) at temperature T, 0C
P (T) = Transformer load losses (watts) corrected to temperature T, 0C
Tk = 234.5 0C (copper) » 235 0C
Tk = 225 0C (aluminium)
• Calculation for impedance
The impedance shall be measured at rated frequency by applying an approximately sinusoidal

supply to one winding, with the terminal of other winding short circuited, and with possible
other winding open circuited. The supplied current should be equal to the relevant rated current.
However, in case of limitation in the rating of supply source the current should not be less than
the 50% of the rated current. Due to fluctuation in load the supply frequency may not be always
be the rated frequency. Then frequency correction should be applied to calculate the actual
impedance at rated frequency as following.
The formula for calculating the percentage impedance with current and frequency correction is
Vtest I rated fr
Z (%)= X X X 100
Vrated I test ft
Where
Vtest = Test voltage

Vrated = Rated voltage
Itest = Test current
Irated = Rated current
ft = Test frequency
f r = Rated frequency
3.5 Measurement of Insulation Resistance
Insulation resistance tests are made to determine the insulation resistance from individual
winding to ground or between individual windings. The insulation resistance in such tests
is commonly measured in mega-ohms, or may be calculated from measurements of applied
voltage and leakage current.
Note
(1) The insulation resistance of electrical apparatus is subjected to wide variation in design, temperature, dryness,
and cleanliness of the parts. When the insulation resistance falls below prescribed values, it can, in most cases
of good design and where no defect exists, be brought up to that required standard by cleaning and drying the
apparatus. The insulation resistance, therefore, may offer a useful indication as to whether the apparatus is in
suitable condition for application of dielectric tests.
(2) Under no conditions, test should be made while the transformer is under vacuum.
• Instrumentation
Insulation resistance may be measured using the following equipment:
(a) A variable-voltage dc power supply with means to measure voltage and current
(generally in micro-amperes or milli-amperes)
(b) A mega-ohmmeter
Mega-ohmmeters are commonly available with nominal voltages of 500 V, 1000 V, 2500 V, and
5000 V; dc or in multiples of 1000 V upto 10,000 V.
• Voltage to be applied
The dc voltage applied for measuring insulation resistance to ground shall not exceed a value
equal to the half of the rated voltage of the winding or 5 kV whichever is lower.
• Procedure
Insulation resistance tests shall be made with all circuits of equal voltage above ground
connected together. Circuits or groups of circuits of different voltages above ground shall be
tested separately. All external insulating parts of the transformer shall be cleaned thoroughly to
remove dust, moisture etc. before the test.
• Examples:
(a) High voltage to low voltage and ground, low voltage to high voltage and ground.
(b) Voltage should be increased in increments of usually one kilovolt and held for one
minute while the current is read.
(c) The test should be disconnected immediately in the event the current begin to
increase without stabilizing.
(d) After the test has been completed, all terminals should be grounded for a period of
time sufficient to allow any trapped charges to decay to a negligible value.
• Polarisation Index (PI)
The purpose of polarisation index test is to determine if equipment is suitable for operation or
even for an overvoltage test. The polarisation index is a ratio of insulation resistance value at the
end of 10 min test to that at the end of 1 min test at a constant voltage.
The total current that is developed when applying a steady state dc voltage is composed of three
components:
(1) Charging current due to the capacitance of the insulation being measured. This
current falls off from maximum to zero very rapidly.
(2) Absorption current due to molecular charge shifting in the insulation. The transient
current decays to zero more slowly.
(3) Leakage current which is the true conduction current of the insulation. It has a
component due to the surface leakage because of the surface contamination.
The advantage of PI is that all of the variables that can affect a single IR reading, such as
temperature and humidity, are essentially the same for both the 1 min and 10 min readings. Since
leakage current increases at a faster rate with moisture present than does absorption current, the
IR readings will not increase as fast with insulation in poor condition as with insulation in good
condition. After 10 min the leakage current becomes constant and effects of charging current
and absorption current die down.
Acceptable PI value for power transformer shall be better than 1.5. For distribution transformer
it should be at least 1.3.
• Interpretation of Results
Insulation resistance may vary with applied voltage and temperature any comparison must be
made with measurements at the same voltage.
The significance of values of insulation resistance tests generally requires some interpretation,
depending on the design and the dryness and cleanliness of the insulation involved. When a user
decides to make insulation resistance test, it is recommended that insulation resistance values be
measured periodically (during maintenance shutdown) and that these periodic values be plotted.
Substantial variations in the plotted values of insulation resistance should be investigated for cause.
3.6 Tests on On-load Tap-Changers

3.6.1 Operation Test
With the tap-changer fully assembled on the transformer the following sequence of operations
shall be performed without failure:
(a) With the transformer un-energised, eight complete cycles of operations (a cycle of
operation goes from one end of the tapping range to the other, and back again).
(b) With the transformer un-energised, and with the auxiliary voltage reduced to 85% of its
rated value, one complete cycle of operation.
(c) With the transformer energized at rated voltage and frequency at no load, one
complete cycle of operation
(d) With one winding short circuited and, as far as practicable, two rated current according
to IEC 60076-1 in the winding, 10 tap-change operations across the range of two steps
on each side from where a coarse or reversing changeover selector operates, or otherwise
from the middle tapping.
3.6.2 Auxiliary Circuits Insulation Test
After the tap changer is assembled on the transformer, a power frequency tests according to IEC
60076-1 shall be applied to the auxiliary circuits as specified in IEC 60076-3.
3.7 Dielectric Tests
The purpose of dielectric tests is to demonstrate that the transformer has been designed and
constructed to withstand the specified insulation levels. The insulation requirements for
the transformers and the corresponding dielectric tests are given in IS 2026 Part-3 and IEC
Publication 60076-3 with reference to specific windings and their terminals. For oil immersed
transformers, the requirements apply to the internal insulation only.
The dielectric tests shall generally be made at the manufacturer premises with the transformers
approximately at ambient temperature.
Transformers, including bushings and terminal compartments when necessary to verify

air clearances, shall be assembled prior to making dielectric tests, but assembly of items,
such as radiators and cabinets, which do not affect dielectric tests is not necessary. Bushing
shall, unless otherwise authorised by the purchaser, be those to be supplied with the
transformer.
If a transformer fails to meet its test requirements and the fault is in a bushing, it is permissible to
replace this bushing temporarily with another bushing and continue the tests on the transformer to
completion without delay. A particular case arises for tests with partial discharge measurements,
where certain types of commonly used high-voltage bushings create difficulty because of their
relatively high level of partial discharge in the dielectric. When such bushings are specified for
the transformer, it is permitted to exchange them for bushings of a partial discharge free type
during the testing of transformer.
Test levels and other test parameters shall be as per IEC Publication 60076-3 and the corresponding
IS 2026 Part-3.
It is recommended to measure voltage at the high voltage terminal of its transformer. The
measuring system shall be in accordance with IEC Publication 60071-2.
In conducting low frequency tests for transformers of 100 kVA and less to be tested at 50 kV
or less, it is permissible to depend on the ratio of testing transformer to indicate the proper test
voltage.
3.7.1 Rules for Some ParticularTransformers
In transformers where uniformly insulated windings having different Um values are connected
together within the transformer, the separate source AC withstand test voltages shall be
determined by the insulation of the common neutral and its assigned Um.
In transformers which have one or more non uniformly insulated windings, the test voltages for
the induced withstand voltage test, and for the switching impulse test, are determined by the
winding with highest Um value, and the windings with lower Um values may not receive their
appropriate test voltages.
During switching impulse tests, the voltages developed across different windings are
approximately proportional to the ratio of turns. Rated switching impulse withstand voltages
shall only be assigned to the winding with the highest Um. Test stresses in other windings are
also proportional to the ratio of numbers of turns and are adjusted by selecting appropriate
tappings to come as close as possible to the assigned value.
3.7.2 Insulation Requirements and DielectricTests
The basic rules for insulation requirements and dielectric tests for different categories of
windings are described in Table 1(Refer IEC Publication 60076-3)
Category of Highest voltage for Tests

winding equipment Um
kV Lightning Switching Long Short Separate
impulse impulse duration duration source AC
(LI) (SI) AC(ACLD) AC(ACSD)
Uniform Um ≤ 72.5 Type Not Not Routine Routine
applicable applicable
Uniform and 72.5 < Um ≤ 170 Routine Not Special Routine Routine
non-uniform applicable
insulation
170 < Um < 300 Routine Routine* Routine Special* Routine
Um ≥ 300 Routine Routine Routine Special Routine
* If ACSD test is specified, the SI test is not required.
The standard dielectric requirements are verified by dielectric tests. They shall, where applicable
and not otherwise agreed upon, be performed in the sequence as given below.
(1) Switching impulse test (SI) for the line terminal
(2) Lightning impulse test (LI) for the line terminals
(3) Lightning impulse test (LI) for neutral terminal
(4) Separate source AC withstand voltage test (applied potential test)
(5) Short-duration induced AC withstand voltage test (ACSD)
(6) Long-duration induced AC voltage test (ACLD)
3.7.3 Switching Impulse withstand Voltage Test, Transformer Winding Um > 300 kV
This test is intended to verify the switching impulse withstand strength of the line terminals and
its connected windings to earth and other windings, the withstand strength between phases and
along the winding under test.
The impulses are applied either directly from the impulse voltage source to a line terminal of
the winding under test, or to a lower voltage winding so that the test voltage is inductively
transferred to the winding under test.
The detailed test procedures and specific test requirements are addressed in IEC Publication
60076-3.
• Switching impulse waves
Polarity
The polarity of test voltage shall be negative because this reduces the risk of erratic external
flashovers in the test circuit.
Wave shape
The voltage impulse shall have a virtual front time of at least 100 μs, a time above 90% of the
specified amplitude of at least 200 μs, and a total duration from the virtual origin to the first zero
passage of at least 500 μs but preferably 1000 μs.
• Test sequence and records

The test sequence shall consists of one impulse of a voltage between 50% and 75 % of the full test
voltage and three subsequent impulses of full voltage. If the oscillographic or digital recording
should fail, that application shall be disregarded and a further application made. Oscillographic
or digital records shall be obtained of at least the impulse wave-shape on the line terminal under
test and preferably the neutral current.
• Test connections
During the test the transformer shall be in a no-load condition. Windings not used for the test
shall be solidly earthed at one point but not short-circuited. For a single phase transformer, the
neutral terminal of the tested winding shall be solidly earthed.
A three-phase winding shall be tested phase by phase with the neutral terminal earthed and
with the transformer so connected that a voltage of opposite polarity and about half amplitude
appears on the two remaining line terminals which may be connected together.
To limit the voltage of opposite polarity to approximately 50% of the applied level, it is
recommended to connect high ohmic damping resistors (10 kΩ to 20 kΩ) to earth at the non
tested phase terminals.
• Failure detection
The test is successful if there is no sudden collapse of voltage or discontinuity of the neutral
current if recorded on the oscillographic or digital records.
Additional observation during the test (abnormal sound effect etc.) may be used to confirm the
oscillographic records, but they do not constitute evidence in themselves.
3.7.4 Lightning Impulse withstand Voltage Test
This test is intended to verify the impulse withstand strength of the transformer under test. This
test shall only be made on windings that have terminals brought out through the transformer
tank or cover.
When non-linear elements or surge diverters are installed for the limitation of transferred over
voltage transients, the evaluation of test records may be different compared to the normal
impulse test. These non-linear protective devices connected across the windings may cause
difference between the reduced full wave and the full-wave impulse oscillograms. To prove that
these differences are indeed caused by operation of these devices, this should be demonstrated
by making two or more reduced full-wave tests at different voltage levels to show the trend in
their operation.
The detailed test procedure and specific test requirements are addressed in IEC 60076-3.
• Impulse wave
The test impulse shall be a full standard lightning impulse: 1.2 µs ± 30% / 50 µs ± 20 %.
But in some cases this standard impulse shape cannot reasonably be obtained, because of low
winding inductance or high capacitance to earth. In such cases wider tolerance may be accepted
by the agreement between purchaser and customer. It is recommended to use IEC Publication
60722 as a guide for non-standard wave shapes.
• Test sequence
The test sequence shall consists of one impulse of a voltage between 50% to 75% of full test
voltage, and three subsequent impulses at full voltage. If, during any of these applications,
an external flashover in the circuit or across a bushing spark gap should occur, or if the
oscillographic recording should fail on any of the specified measuring channels, that application
shall be disregarded and a further application made.
• Test Connections
• During test on line terminals
The impulse test sequence is applied to each of the line terminals of the tested winding in
succession. In the case of a three phase transformer, the other line terminals of the winding
shall be earthed directly or through a low impedance, not exceeding the surge impedance of the
connected line. If the winding has neutral terminal, it shall be earthed directly or through a low
impedance such as a current measuring shunt.
In the case of separate-winding transformer, terminals of windings not under test are earthed
directly or through impedances, so that in all circumstances, the voltage appearing at the
terminals is limited to not more than 75% of their rated lightning impulse withstand voltage for
star connected windings, and 50% for delta- connected windings.
In case of auto transformer, when testing the line terminal of the high voltage winding the non-
tested line terminal shall be earthed through resistors not exceeding 400 Ω to get the impulse
waveform as needed.
• Impulse test on a neutral terminal
Impulse withstand capability of neutral may be verified by :
(a) Indirect application:

Test impulses are applied to any one of line terminals or to all three line terminals
connected together. The neutral is connected to earth through an impedance or is left
open. Then standard lightning impulse is applied to the line terminal which shall not
exceed 75% of the rated LI withstand voltage of the line terminal.
(b) Direct application:
Test impulse corresponding to the rated withstand voltage of the neutral is applied directly
to the neutral with all line terminals earthed. In this case, however a longer duration of
front time is allowed, upto 13µs.
• Records of test
The oscillographic or digital records obtained during calibrations and tests shall clearly show the
applied voltage impulse shape (front time, time to half value and amplitude). The oscillograms
of the current flowing to earth from the tested winding shall also be recorded.
• Test sequence
The test sequence shall consist of one impulse of a voltage between 50% to 75% of full test
voltage, and three subsequent impulses at full voltage. If, during any of these applications,
an external flashover in the circuit or across a bushing spark gap should occur, or if the
oscillographic recording should fail on any of the specified measuring channels, that application
shall be disregarded and a further application made.
Failure detection
• Grounded current oscillograms
In this method of failure detection, the impulse current in the grounded end of the winding tested
is measured by means of an oscilloscope or by a suitable digital transient recorder connected
across a suitable shunt inserted between the normally grounded end of the winding and ground.
Any differences in the wave shape between the reduced full-wave and final full-wave detected
by comparison of the two current oscillograms, may be indication of failure or deviations due to
no injurious causes. They should be fully investigated and explained by a new reduced wave and
full-wave test. Examples of probable causes of different wave shapes are operation of protective
devices, core saturation, conditions in the test circuit external to the transformer.
The ground current method of detection is not suitable for use with chopped-wave tests.
• Other methods of failure detection
Voltage Oscillograms: Any unexplained difference between the reduced full-wave and final
full-wave detected by comparison of the two voltage oscillograms, or any such differences
observed by comparing the chopped-waves to each other and to the full-wave up to the time
of flashover, are indications of failure.
Noise: Unusual noise within the transformer at the instant of applying impulse is an indication
of trouble. Such noise should be investigated.
Measurement: Measurement of voltage and current induced in another winding may also be
used for failure detection.
3.7.5 Separate Source Voltage withstand Test
• Duration, frequency and connections

A normal power frequency, such as 50 Hz, shall be used and the duration of the test shall be one
minute.
The winding being tested shall have all its parts joined together and connected to the terminal
of the testing transformer.
All other terminals and parts (including core and tank) shall be connected to ground and to the
other terminal of the testing transformer.
• Application of voltage for Separate Source Withstand test
The test shall be commenced at a voltage not greater than one-third of the full value and be
brought up gradually to full value in not more than 15 s. After being held for the specified time
of 60 seconds, it should be reduced (in not more than 5s) to one third or less of the maximum
value and the circuit opened.
• Failure detection
Careful attention should be started given for evidence of possible failure that could include items,
such as an indication of smoke and bubbles rising in the oil, an audible sound such as a thump, or
a sudden increase in test circuit current. Any such indication should be carefully investigated by
observation, by repeating the test, or by other test to determine if a failure has occurred.
3.7.6 Induced AC voltage withstand tests with partial discharge measurement
ACSD test is intended to verify the AC withstand strength of each line terminal and its connected
winding(s) to earth and other windings, the withstand strength between phases and along the
winding(s) under test
As per IS 2026 Part 3 and IEC Pub. 60076-3, the test is normally performed with partial
discharge measurement (Method 2) for transformers with highest voltage winding of ≥
300 kV. For transformer with highest voltage winding of < 300 kV, the test is performed
without partial discharge measurement (Method 1). However, with the latest revision of
IEC 60076-3, the methods for induced over-voltage withstand test are reformed as AC
short duration test (ACSD) and AC long duration test (ACLD).
ACSD test is intended to verify the AC withstand strength of each line terminal and its connected
winding(s) to earth and other windings, the withstand strength between phases and along the
winding(s) under test.
For Um >72.5 kV, the test is normally performed with partial discharge measurements to verify
partial discharge free operation of the transformer under operating condition. However, the
requirements for partial discharge measurement during the ACSD test may be omitted. This
shall be clearly stated at the enquiry and order stages.
ACLD test is always performed with the measurement of partial discharge during the whole
application of test. This is test is not a design proving test, but a quality control test and is
intended to cover temporary over voltages and continuous service stress. It verifies PD free
operation of the transformers under operating conditions.
An alternating voltage shall be applied to the terminals of one winding of the transformer. The
voltage shall be as nearly as possible sinusoidal and its frequency is sufficiently above the rated
frequency to avoid excessive magnetizing current during the test.
The test voltage is the peak value of voltage divided by √2 .The test time at full test voltage shall
be 60 sec for test frequency up to and including twice the rated frequency. For frequency above
twice the rated frequency the time duration of test shall be:
Rated frequency ,but not less than 15 sec
120 X
Test frequency
Table below shows the different conditions of induced AC voltage test as defined in IEC
publication 60076-3. The time duration for the application of test voltage with respect to earth
is shown in Figure 12
Table 2 :Induced AC Voltage test
Type of Type of winding Highest Test voltage level Test Remarks
test voltage of Duration
equipment (Refer Fig
Um 12)
Uniformly insulated ≤ 72.5 kV As per Table 2 of IEC 60 sec No PD measurement
60076-3
> 72.5 kV U1= from Table D.1 of C= 120 x PD level should be

IEC 60076-3 Rated Freq. ≤ 300 pC at level U2
U2= 1.3 Um/√3 Test freq.
AC Short D=5 min
duration
(ACSD) Non-uniformly insulated >72.5 kV Phase to U1=from C= 120 x PD level
earth test Table Rated Freq. should be
D.2 of Test freq. ≤ 500 pC at level U2
IEC
60076-3
U2=1.5 D=5 min
Um/√3
Phase to U1=from PD level should be
phase test Table ≤ 300 pC at level U2
D.2 of IEC
60076-3
U2= 1.3
Um/√3
Delta 72.5<Um U1= 1.7 Um/√3 D=30 min PD level should be
connected ≤ 245 kV U2= 1.5 Um/√3 C= 120 x ≤ 500 pC at level U2
HV Rated Freq.
Test freq.
Star 72.5<Um U1= 1.7 Um/√3 D=30 min PD level should be
Uniformly connected <300 kV U2= 1.5 Um/√3 C= 120 x ≤ 500 pC at level U2
AC Long and non- HV Rated Freq.
Duration uniformly Test freq.
(ACLD) insulated
≥ 300 kV U1= 1.7 Um/√3 D=60 min
U2= 1.5 Um/√3 C= 120 x
Rated Freq.
Test freq.
Fig.12: Time sequence for the application of test voltage with respect to earth
Where
Um = Highest voltage for equipment
U1 = Test voltage
U2 = Partial discharge evaluation level
The detailed procedure and specific test requirements are addressed in IEC-60076-3
3.7.7 Switching ImpulseVoltage withstand Test, Transformer Winding Um < 300 kV
Refer to the clause no 3.7.3 of this Section
3.7.8 Lightning Impulse Voltage withstand Test, Transformer Winding Um < 300 kV
Refer to the clause no 3.7.4 of this Section
3.7.9 Long-duration Induced AC Voltage test (ACLD), TransformerWinding Um < 170 kV
The test procedure is same as clause 3.7.6 of this Section
3.8 Temperature Rise Test
Temperature rise test is performed to prove that temperature rise comply to limits specified in
standards and to derive thermal characteristics for the transformer.
The test is carried out supplying full load losses for sufficient time to ensure that the temperature
rise of the winding and oil reach steady state values.
The transformer shall be assembled completely with its cooling equipment. It is desirable
to put the specified conservator with the transformers, if available. Alternatively, temporary
conservator of approximately same capacity can be used for the purpose of the test.
The top oil temperature is measured by a thermometer in a pocket at the top of the transformer
tank, and this is used to verify that steady conditions have been reached. Final winding
temperatures cannot be measured directly.
The transformers shall be tested in the combination of connections and taps that give the highest
winding temperature rises as determined by the manufacturer and reviewed by the purchaser’s
representative when available. This will generally involve those connections and taps resulting
in the highest losses.
All temperature rise test shall be made under normal (or equivalent to normal) conditions of the
means of cooling.
The temperature–rise test shall be made in a room that is free from drafts as practicable and
equipped with its protective device.
• Cooling air temperature
Precautions should be taken to minimise variations of cooling air temperature specially when
the steady state is approached. Rapid variation of reading should be prevented by providing at
least three sensors, and average of their readings shall be used for evaluation. The sensors shall
be distributed around the tank 1m to 2m away from the tank or cooling surface and protected
from direct radiation.
• Cooling water temperature
The temperature is measured at the intake of the cooler. Readings of temperature and rate of
water flow should be taken at regular interval.
Test Method
• Short Circuit Method
During this test the transformer is subjected to the calculated total losses, previously obtained by
two separate determination of losses, namely load loss at reference temperature and no load loss.
The purpose of this test is

- to establish the top oil temperature rise in steady-state condition with dissipation of total losses
- to establish the average winding temperature rise at rated current and with the top oil
temperature rise as determined above.
This is achieved in two steps:
(a) Total loss injection
First the top oil and average oil temperature rises are established when the transformer is
subjected to a test voltage such that the measured power is equal to the total losses of the
transformer. The test current will be above rated current to the extent necessary for producing
an additional amount of loss equal to the no-load losses, and winding temperature rise will be
correspondingly elevated.
The oil temperature and cooling medium temperature are monitored, and the test is continued
until a steady- state oil temperature rise is established.
The test may be terminated when the rate of change of top oil temperature rise has fallen below
1oC per hour and has remained there for a period of 3 hour.
(b) Rated current injection
When the top oil temperature rise has been established, the test shall immediately continued
with the test current reduced to the rated current for the winding combination connected.
This condition is maintained for 1 h, with continuous observation of oil and cooling medium
temperatures.
At the end of one hour, the resistance of windings are measured with suitable method.
During the hour with rated current the oil temperature falls. The measured values of winding
temperature shall therefore be raised by the same amount as the average oil temperature rise has
fallen from the correct value. The corrected winding temperature value minus the cooling medium
temperature at the end of the total losses injection period is the average temperature rise.
By the agreement, the two steps of the test may be combined in one single application of the
power at a level between load loss and the total loss. The temperature- rise figures for the top
oil and for the windings shall then be determined using the correction rules. The power injected
during the test shall however be at least 80% of the total loss figure.
(c) Determination of average winding temperature
The average winding temperature is determined via measurement of winding resistance.

A reference measurement (R1,θ1) of all winding resistances is made with the transformer at
ambient temperature, in a steady condition. When the resistance R2 at different temperature (θ2)
is measured this yields the temperature value
R2
θ2 = R1(235+θ1) - 235
Copper:
R2
Aluminum
: 02= Rl ( 225+ θ1) - 235
The external cooling medium temperature at the time of shutdown is θa
The winding temp. rise is then, finally :
∆θw =θ2-θa
(d) Determination of winding temperature before shutdown
Immediately after disconnection of test power supply and removal of short circuit connection
the resistance of winding is measured with a suitable measuring circuit. The winding has large
electrical time constant therefore accurate reading obtained only after a certain time delay. The
resistance of the winding varies with time as the winding cools down. It shall be measured for a
sufficient time to permit the extrapolation back to instant of shutdown.
The detailed procedure to determine the resistance at the instance of shutdown is accordance
with IEC-60076-2.
(e) Corrections
If the specified values of power or current have not been obtained during the test, the result shall
be corrected according to the following relation. They are valid within a range of +20% from
target value of power and +10% from target value of current.
The oil temperature rise above ambient during the test is multiplied by :
X

 Total losses 
 Test losses
X= 0.8 for distribution transformers
X= 0.9 for larger transformers with ON cooling
X= 1.0 for transformers with OF or OD cooling
The average winding temperature rise above average oil temperature during the test is multiplied by:
Y

 Rated Current 
 Test losses
Y=1.6 for ON and OF cooled transformers
Y= 2.0 for OD cooled transformers
3.9 Short Circuit WithstandTest

This test identifies the requirement for power transformer to sustain without damage the effects
of over current originated by external short-circuit. The test demonstrates the thermal ability and
dynamic effects of power transformer to withstand the rated short-circuit forces. The detailed
procedures describing the magnitude of current, test duration, no. of tests and evaluation criteria
shall be as per IEC 60076-5.
3.10 Measurement of zero–phase–sequence impedances on 3-phase transformers

• Zero–phase–sequence impedance tests of three–phase transformers
The zero–phase–sequence impedance characteristics of three–phase transformers depend upon

the winding connections, and in some cases, upon the core construction. Zero–phase–sequence
impedance tests apply only to transformers having one or more windings with a physical
neutral brought out for external connection. In all tests, one such winding shall be excited at
rated frequency between the neutral and the three line terminals connected together. External
connection of other windings shall be as described in succeeding paragraphs for various
transformer connections. Transformers with connections other than as described in succeeding
paragraphs shall be tested as determined by those responsible for design and application.
The excitation voltage and current shall be established as follows:
If no delta connection is present on the transformer, the applied voltage should not exceed 30%
of the rated line–to–neutral voltage of the winding being energized, nor should the phase current
exceed its rated value. If a delta connection is present, the applied voltage should be such that
the rated phase current of any delta winding is not exceeded. The percent excitation voltage at
which the tests are made shall be shown on the test report. The time duration of the test shall be
such that the thermal limits of any of the transformer parts are not exceeded.
Single–phase measurements of excitation voltage, total current, and power shall be similar to
those described in for load loss measurements. The zero–sequence impedance in percent on kVA
base of excited winding for the test connection is:

E
Z (%)=300 E I
Ir 
 r
Where
E = measured excitation voltage
Er = rated phase–to–neutral voltage of excited winding
I = measured total input current flowing in the three parallel–connected phases
Ir = rated current per phase of the excited winding
A zero-sequence test shall be made on the winding with the available neutral. A single–phase
voltage shall be applied between the three shorted line terminal and neutral. The external
terminals of all other windings may be open–circuited or shorted and grounded.
The zero-sequence impedance is dependent upon the physical disposition of the windings and
the magnetic parts and measurement of different windings may not therefore agree.
3.11 Measurement of Acoustic Sound Level

This test shall be done in accordance with the clauses given in NEMA TR1 and IEC-60076-10.
The guidelines of testing method is given in IEC 60076-10-1
Audible sound from transformer originates principally in the transformer core and is transmitted,
either through the dielectric fluid or the structural support, to other solid surfaces from which it
is radiated as airborne sound. The audible sound also contains the noise emitted by any dielectric
fluid mechanical cooling system.
Measurement should be made in an environment having an ambient sound pressure level at least
five decibels below the combined sound pressure level of the transformer and the ambient sound
pressure level.
The transformer shall be located so that no acoustically reflecting surface is within 3 m of the
measuring microphone, other than the floor or ground.
The transformer shall be connected and energised at rated voltage and rated frequency,
and shall be at no load with the tap changer on principal tap. Pumps and fans shall be
operated as appropriate for the rating being tested. Sound measurements shall begin after the
transformer being tested is energised and steady- state sound level conditions are established.
Measurements may be made immediately on the transformers that have been in continuous
operation.
The rated voltage shall be measured line-line for ∆ connected windings and line-neutral for Y
connected windings. The voltage shall be measured with a voltmeter responsive to the average
value of the voltage but scaled to read the rms value of a sinusoidal wave having the same average
value. The voltmeter should be connected between the terminals of the energized windings.
The reference sound-producing surface is a vertical surface that follows the contour of a taut
string stretched around periphery of the transformer or integral enclosure (Fig 12). The contour
shall include radiators, coolers, tubes, switch compartments, and terminal chambers, but exclude
bushing and minor extensions.
The measurement shall be done with the microphone, which shall be calibrated as recommended
by the sound level meter manufacturer before and after measurement. The first microphone
locations shall coincide with the main drain valve. The number of microphone position is not
less than 4. The microphone shall be located on the measurement surface spaced 0.3 m from
the reference sound- producing surface. When fans are in operation, the microphone shall be
located 2 m from any portion of radiators and coolers. For transformers having an overall tank or
enclosure height of les than 2.4 m, measurements shall be made at half height. For transformers
having an overall tank height of 2.4 m or more, measurements shall be made at one-third and at
two-thirds height.
The sound power rating of the transformer is determined using the following five steps:
(a) Measure ambient sound pressure level
(b) Measure combined ambient and transformer sound pressure levels
(c) Compute ambient corrected sound pressure levels
(d) Compute average sound pressure levels
(e) Calculate sound power levels
The detailed calculation is done in accordance with the ANSI/IEEEC57.12.90.
The average sound level of transformers should not exceed the values given in table 0-2 through
0-4 of NEMA TR1 when measured at the factory in accordance with the conditions outlined in
ANSI/IEEEC57.12.90.
Fig. 13 Microphone location for measuring audible sound from transformers
3.12 Measurement of the Harmonics of the No-load Current
The harmonics of the no–load current in all the phases are measured by means of harmonic analyzer
and the magnitude of the harmonics is expressed as a percentage of the fundamental component.
3.13 Measurement of Power taken by the Fans and Oil Pump Motors
The measurement shall be done by suitable instruments at rated voltage.

3.14 Test with Lightning Impulse Chopped onTail
This test is a special test and should be used for special applications on the line terminals of a
winding. When this test is performed it shall be combined with the full lightning impulse test.
The peak value of the chopped impulse shall be 1.1 times the amplitude of the full impulse.
Usually the same settings of the impulse generator and measuring equipment are used, and only
the chopping gap instrument is added. The standard chopped lightning impulse shall have a time
to chopping between 2 µs and 6 µs.
The triggered type chopping gap should be used with adjustable timing, although a plain rod-rod
gap is allowed. The chopping circuit should be so arranged that the amount of over swing to
opposite polarity of the recorded impulse will be limited to not more than 30% of the amplitude
of the chopped impulse. For this purpose, it is permitted to put a resistance in service with the
chopping gap.
The test is combined with the full impulse test in a single sequence. The order of application is :
one reduced level impulse

one full level impulse
one or more reduced level chopped impulse(s)
two full level chopped impulses
two full level impulses
The same type of measuring channels and oscillographic or digital records are specified as for
the full-wave impulse test.
The detection of faults during chopped impulse test depends essentially on a comparison of the
oscillographic or digital records of full level and reduced level chopped impulses. The neutral
current record presents a superposition of transient phenomena due to the front of the original
impulse and from the chopping. Account should therefore be taken of the possible variations, of
the chopping time delay.
The recordings of successive full impulse tests at full level constitute a supplementary criterion of
a fault, but they do not constitute in themselves a quality criterion for the chopped impulse test.
3.15 Magnetic Circuit (Isolation ) Test

This test is done to detect the presence of inadvertent ground if exists.
This test is done with help of megger or by AC supply. During this test other terminals should
be in open circuit position. This test is done by applying the voltage alternate between the core
clamp to end frame, core clamp to tank and between end frame to tank. The value of test voltage
is varying according the customer requirement and electrical specification. The duration of test
voltage application is 60 seconds.
Alternatively the test is performed with the help of megger. In which the value of insulation
resistance is measured between two terminals. This test shall be conducted in accordance with
IS-2026 Part 1.
The tests will be successful if the terminals withstand the required AC voltage for test duration.
The values of the insulation resistance in mega-ohm (MΩ) should as follows;
Test voltage : 2.5 kV

New equipment : > 10 MΩ
Service aged equipment : > 1 MΩ
Insulation deterioration : < 1 MΩ
Destructive circulating current : < 100 KΩ
3.16 Determination of Capacitance and Dissipation Factor Between Winding to Earth

and between Windings
Capacitance and tan delta are usually determined for winding to earth and between windings by
bridge measuring technique, such as Schering Bridge.
The test specimen shall have the following requirements:
All windings immersed in insulating liquid in case of liquid filled transformer.
All winding short-circuited.
All bushings are in place.
The applied voltage for measuring capacitance and tan delta shall not exceed half of the low
frequency test voltage, for any part of the winding or 10 kV whichever is lower.
This test may be performed with or without guard for the circuit combination as shown below.
Method 1 Method II
Test without guard Test with guard
Two winding Two winding
HV to LV and ground HV to LV and ground
LV to HV and ground LV to HV and ground
HV and LV to ground HV and LV to ground
LV to ground, Guard on HV
Three winding Three winding
HV to IV, LV and ground HV to LV and ground, guard on IV
IV to HV, LV and ground HV to ground, guard on LV & IV
LV to IV, HV and ground LV to IV & ground, guard on HV
HV and IV to LV and ground LV to ground, guard on HV & IV
IIV and LV to IV and ground IV to HV & ground, guard on LV
IV and LV to HV and ground IV to ground, guard on HV & LV
IIV, IV and LV to ground HV &LV to IV & ground
HV & IV to LV & ground
• Temperature correction factors

The temperature correction factors for the insulation power factor depend upon the insulating
material, their structure, moisture, etc. Values of correction factor ‘K’ listed in the below table
are typical and satisfactory for practical purpose for use as given in equation
Test temperature T, 0C Correction Factor ‘K’

10 0.80
15 0.90
20 1.00
25 1.12
30 1.25
35 1.40
40 1.55
45 1.75
50 1.95
55 2.18
60 2.42
65 2.70
70 3.00
FP20 = Fpt /K
Where,
FP20 is the power factor corrected to 20 0C
Fpt is the power factor measured at T
T is the test temperature 0C
K is the correction factor as per table above
Insulation temperature may be considered to be that of the average liquid temperature. When
insulation power factor is measured at a relatively high temperature and the corrected values
are unusually high, the transformer should be allowed to cool and the measurements should be
repeated at or near 20 0C
3.17 Magnetic Balance Test on 3-phase Transformers
This test is conducted only in three phase transformers to check the imbalance in the magnetic
circuit. In this test, no winding terminal should be grounded; otherwise results would be erratic
and confusing.
• Evaluation criteria
The voltage induced in the center phase shall be 50% to 90% of the applied voltage on the outer
phases. However, when the center phase is excited then the voltage induced in the outer phases
shall be 30 to 70% of the applied voltage.
Zero voltage or very negligible voltage induced in the other two windings should be
investigated.
The purpose of this test basically is to ensure that there is no inter turn fault in the winding which
is generally reflected in high excitation current in faulty winding.
3.18 Determination of Transient Voltage Transfer Characteristics
When the low-voltage winding cannot be subjected to lightning over voltage from the low
voltage system, this winding may, by agreement between supplier and purchaser, be impulse
tested with surges transferred from high voltage winding.
This method is also used when the design is such that an impulse directly applied to
the low voltage winding could result in unrealistic stressing of higher voltage windings,
particularly when there is a large tapping winding physically adjacent to the low voltage
winding.
With the transferred surge method, the tests on the low voltage winding are carried out by
applying the impulse to the adjacent high voltage winding. The line terminals of the low
voltage winding is connected to earth through resistance of such value that the amplitude of the
transferred impulse voltage between line terminals and earth, or between different line terminal
or across a phase winding, will be as high as possible but not exceeding the rated impulse
withstand voltage. The magnitude of the applied impulses shall not exceed the impulse level of
the winding to which the impulses are applied.
The details of the procedure shall be same as the lightning impulse test on line terminal of HV
winding.
3.19 Dissolved Gas Analysis (DGA) of Oil Filled in the Transformer
• Introduction
For many years the method of analyzing gasses dissolved in the oil has been used as a tool in
transformer diagnostics in order to detect incipient faults, to supervise suspect transformers, to
test a hypothesis or explanation for the probable reasons of failures or disturbances which have
already occurred and to ensure that new transformers are healthy.
The evaluation criteria with dissolve gas analysis is based on the fact that during its lifetime the
transformer generates decomposition gasses–essential from the organic insulation – under the
influence of various stresses– both normal and abnormal.
The gasses that are of interest for the DGA analysis are the following;
- H2 Hydrogen
- CH4 Methane
- C2 H4 ethylene
- C2H6 Ethane
- C2H2 acetylene
- (C3H6 propene )– not always measure
- (C3H8 propane ) – not always measure
- CO carbon monoxide
- CO2 carbon dioxide
- O2 oxygen
- N2 Nitrogen
- TCG total combustible gas content (= H2 + CH4 + C2H4 + C2H6 + C2H2 + CO)
All these gases except oxygen and nitrogen may be formed during the degradation of the
insulation. The amount and the relative distribution of these depend on the type and severity of
the degradation and stress.
Around the world and during the years several different schemes have been proposed as
evaluation scheme for the DGA. The most commonly known schemes are the one proposed by
Rogers and the scheme laid down in IEC publication 60599
• Procedure
The DGA procedure consists of essential four steps:
- Sampling of oil from the transformer

- Analysis of these gases from oil
- Analysis of the extracted gas mixture in a gas chromatography, GC.
- Interpretation of the analysis according to an evaluation scheme.
Sampling, extraction and analysis procedures are given in IEC publication 60599
• Interpretation
There are several different approaches how to explain and interpret the analyzed gas composition
and to diagnose the condition of the transformer. The well known DGA analysis techniques are
- Identification of the key gas, The key gas identify a particular problem, e.g., H2 indicates
a PD
- Determination of rations between gasses, normally between gas levels.
- Determination of rates of increase (“production rates”), in ppm / day or ml gas/day
The most common known schemes are the one proposed by Rogers forming the basis for the
ANSI method and the scheme laid down in IEC Publication 60599. Both these methods are
using ratios gas concentrations.
This scheme can also be used to understand the evaluation – scheme based on ratios.
For instance, the IEC method uses 3 ratios, C2H2/ C2H4, CH4/ H2, C2H4/ C2H6
CH4/H2 is used to discriminate between a thermal fault and an electric fault. C2H2/C2H4 indicates
the presence of a strong discharge of very severe electric problem and C2H4/ C2H6 is an indication
of the oil temperature.
3.20 Recurrent Surge Oscillographic (RSO) Test
This test is generally performed at pre-stage of transformer manufacturing after completion of

terminal gear.
The insulation of a transformer must be proportioned to the surge voltages, which will appear
at the various points throughout the windings. The surge voltage distribution in the winding is
independent of the magnitude of the applied voltage and that the same results may be obtained
by applying a reduced surge voltage, of the order of a few hundred volts.
This test is conducted with a recurrent surge generator, which consists of a capacitor charged
to a suitable voltage and discharged by means of a thyratron into a circuit which is designed to
generate the required low-voltage surge of the standard wave shape. The charge and discharge
sequence is repeated fifty times per second. The output voltage from the recurrent surge
generator is applied to the terminal of the transformer being tested, in a similar manner to
that in which a high voltage impulse test would be conducted. The surge voltage appearing
at any point of the winding can be measured and displayed on the screen of the cathode-ray
oscilloscope. The time base is arranged so that it is synchronized with the recurrent discharge
of the capacitor. By this means it is possible to obtain a standing picture on the screen of the
applied voltage and of the voltage appearing at the points along the winding, together with a
time calibration wave.
The test provides information on impulse distribution along the winding and transferred surge
voltages on the other windings.
3.21 Determination of Core Hot Spot Temperature
This test is done to check uniform distribution of flux on every point on the core & to determine
the core hot spot temperature.
This test is done by exciting the core with suitable voltage, which is the voltage per turn is
multiplied with the wound turn around the core.
The required voltage is applied to transformer and note down the reading of temperature at the
different point on the core using thermo vision camera or laser temperature scanner. The reading
of the temperature should not vary too much from point to point.
If the temperature is varying from one point to other then the flux is not distributed uniformly
around the core. Scan the point around the core where the highest temperature occurs. This is
the hot spot temperature of the core.
3.22 Frequency Response Analysis (FRA)
Frequency response analysis (FRA) test is conducted on transformers & reactors to determine
the frequency response of windings. The reference frequency responses obtained during
laboratory testing serve as ‘fingerprints’ to monitor the condition of the transformer or reactor
during service.
The frequency response of an electrical winding is obtained by application of sweep frequency
(sinusoidal). The winding will have a characteristic frequency response for the applied signal
at different frequencies. The response is uniquely determined by the winding arrangement
involved and any winding movement or other fault will modify the frequency response due
to changes in inductances and capacitances. The sweep frequency voltage is applied through
network analyzers. The frequency response of the winding is determined between the frequency
ranges of 10 Hz to 2 MHz.
The FRA test is performed on one winding of the electrical equipment at a time. The
transformer / reactor shall be electrically isolated from any other electrical connections or systems,
including earth connections during FRA test. The two end terminals of each winding shall be
made available for measuring the frequency response across the winding.
# For star connected winding, the response shall be measured across the terminal &
neutral.
# For delta connected winding, the response shall be measured across two line terminals &
in case of open-delta, across individual winding.
# For auto connected winding, the response of series & common windings shall be measured
separately.
For a transformer, it is normal practice to earth one end of every winding that is not being tested,
leave the other open end. Alternatively, all other windings may be left unconnected from each
other and from earth. In every case, the termination of each winding for each test should be
recorded.
The frequency response of the winding is determined by plotting the ratio of the output from the
winding to the input at atleast following frequency ranges.
* 10 Hz to 2 kHz
* 100 Hz to 20 kHz
* 1 kHz to 200 kHz
* 10 kHz to 2 MHz
Alternatively frequency ranges specified by the customer can be selected. The test is normally
conducted at maximum, mean and minimum taps, in case of windings having tapping. While
making measurements at mean tap, care should taken to move the tap from higher voltage
taps, for proper comparison of FRA results of different phases of same transformer or different
transformers.
The FRA results is analyzed for
- Changes in response of the winding
- Difference between the FRA records of different phases of the same transformer.
FRA test is primarily a condition assessment test and can be used in conjunction with other
diagnostic tests for detailed analysis and interpretation of the transformer.
3.23 Measurement of Magnetization Current at Low Voltage

This test is performed at 415 V, 3-phase (neutral un-grounded) for three phase transformer and
230 V 1-phase for single phase transformer. This test is performed to locate defect in magnetic
core structure, failures in turn insulation or problem in tap changers.
The acceptance criteria for the results of exciting current measurement should be based on the
comparison with the previous site test results or factory test results. The general pattern is two
similar high readings on the outer phases and one lower reading on the center phase connected in
star, in case of three phase transformers. An agreement to within 25% of the measured exciting
current with the previous test is usually considered satisfactory. If the measured exciting current
value is 50% higher than the value measured during pre-commissioning checks, then the winding
needs further analysis.
3.24 Functional Tests on Auxiliary Equipments

Acceptance test for Oil (OTI) and winding (WTI) temperature indicator
A. Routine test
1. OTI (Range 20º-140º C)
(i) Each completely assembled instrument shall be tested for accuracy over the complete
range i.e. at 40º, 60º, 80º, 100º & 120 º C by keeping the bulb in the hot oil bath
continuously stirred. The accuracy of indication shall be ±1.5 % full scale deflection
(FSD).
2. WTI ( Range 30º - 150º C)
(i) Each completely assembled instrument shall be tested by injecting the current to its
heater coil. Oil bath shall be maintained at 60 0C, Total temperature and temperature
rise shall be recorded for 0, 2, 3 and 4 amperes current. The accuracy of the indication
i.e. oil bath temperature measured by standard. Thermometer plus rise in temperature
due to injection of current in heating coil i.e. total temperature indicated by WTI
shall be within ± 1.5 % FSD. Error allowed shall be 1.5 / 100 x 150 = ± 2.25 0C
Max.
(ii) In case of repeater, both WTI and repeater shall be tested together by injecting the
current as mentioned in 2(I). Accuracy of the repeater readings shall be within ± 1.5
FSD i.e. ± 1.5 0C considering WTI readings as the reference temperature.
• High Voltage Test on Insulation test of auxiliary wiring
Unless otherwise specified the wiring for auxiliary power and control circuitry shall be subjected
to a one minute power frequency withstand test of 2 kV r.m.s. to earth. Motors and other
apparatus for auxiliary equipment shall fulfill insulation requirements according to the relevant
IEC standard (which are generally lower than the value specified for the wiring alone, and which
may sometimes make it necessary to disconnect them in order to test the circuits)
B. Type tests (one instrument of each lot / batch)
Switch setting and operations: Switches shall be able to set between 50–140 0C and their
operation shall be within ± 2.5% of pointer indication unless otherwise specified on purchase
order. Switch setting will be done as below:
OTI: Alarm (S1) – 95 0C

Trip (S2) – 100 0C
WTI: Alarm (S1) – 115 0C
Trip (S2) – 125 0C
Fan start (S3) – 85 0C
Pump start (S4) – 95 0C
Switch differential
Each switch shall have adjustable differential (difference between make and break temperature)
of 6 0C to 90 0C and will be set for 6 ± 1 0C differential.
Switch Rating
5 Ampere, continuous 250 V, AC or DC for make or break.
3.25 Tests on Oil Filled in Transformer
Following test on the oil filled in the transformer shall be necessary performed before conducting
electrical test to ensure proper oil impregnation of the insulation system.
3.25.1 Dielectric Strength
The voltage at which the oil breaks down when subjected to an AC electric field with continuously
increasing voltage contained in the specified apparatus is called dielectric strength. The voltage
is expressed in kV.
The dielectric strength of oil is determined by the two methods. First method utilizes spherical
capped electrode in the test cell, which is recommended primarily for filtered, degassed and
dehydrated oil prior to and during filling of electrical power equipment rated above 230
kV and above. The second method utilizes flat electrodes and recommended for all other
apparatus.
The detailed test procedure is in accordance with IS 6792.
The acceptance value of oil for the different test voltage of transformer in general is recommended
as per the table given below.
3.25.2 Water Content
The recommended value of water content are given in table below
System voltage of transformer BDV kV Water content Tan delta at 90° C

kV ppm, max.
Above Upto and including
- 72.5 60 20 <0.05
72.5 245 65 15 <0.02
245 420 70 10 < 0.01
420 800 75 10 < 0.01
High water content accelerates the chemical deterioration of the insulating paper and is indicative
of the undesirable operating conditions or maintenance requiring correction.
3.25.3 Dielectric Dissipation Factor (Tan delta at 900C)
This test covers the determination of the power factor of new and service aged oil. This test
is used to indicate the dielectric losses in the oil when used in an alternating electric field
and of the energy dissipated as heat. A low power factor indicates low dielectric losses. It
is useful as a means to ensure that sample integrity is maintained, and as an indication of
changes in quality resulting from contamination and deterioration in service or as a result
of handling.
This test is satisfactorily performed in the field, as well as in a laboratory environment.
The detailed test procedure and test equipment shall be in accordance with IS 6262.
Acceptable limit for the dielectric dissipation factor largely upon the type of apparatus and
application. The power factor limits given for oil are based upon the understanding that this is
an indicator test for contamination by excessive water or polar or ionic materials in the oil. High
level of dissipation factor (0.5 % at 25º C) is because of contaminants may collect in the areas
of high electrical stress and concentrate in the winding. Very high dissipation factor ( > 1.0% )
in oil may be caused by the presence of free water which could be hazardous to the operation
of a transformer.
3.25.4 Resistivity
The resistivity (specific resistance) in ohm-centimeters of a liquid is the ratio of the dc potential
gradient in volts per centimeter paralleling the current flow within the specimen, to the current
density in amperes per square centimeter at a given instant of time and under prescribed
conditions. This is numerically equal to the resistance between opposite faces of a centimetre
cube of liquid.
Resistivity measurements are made at many different temperatures. But for acceptance test, it
is generally done at a temperature of 90º C, while for routine testing, it is usually made at room
temperature or 90º C. The average electrical stress to which specimen is subjected to shall not
be less than 200 V/mm nor more than 1200 V/mm. the upper limit is set with the purpose of
avoiding possible ionization if higher stresses are permitted.
The detailed test procedure is as accordance with IS 6103.
Useful information can be obtained by measuring resistivity at both ambient and at higher
temperature such as 90º C. A satisfactory result at 90º C coupled with an unsatisfactory
value at lower temperature is an indication of the presence of water or degradation products
precipitated.
3.26 Measurement of vibration on transformer tank
The vibration measurement on the completely assembled transformer is done to ascertain the
safety of the transformer against any impending mechanical damage due to looseness of the
component leading to high vibrations. The vibration in the transformer caused by the attraction
between the poles at the level of each air gap. Mechanical resonance may appear in the system
formed by the core packets, the yokes and the insulating spacers. Moreover, other components
not located in the magnetic circuit can also enter into resonance, particularly some parts of the
tank, which receive impulses transmitted through oil.
For conducting vibration measurements, the transformer is energized at rated voltage and the
rated frequency. A magnetic accelerometer is fixed at the location where measurement is intended.
The vibration signal from accelerometer is transmitted to a vibration meter which indicates the
vibration level in microns. For thorough checking of vibration pattern, the transformer tank
is marked into several small sections for measurement of the highest amplitude vibrations.
The measurement shall commence after allowing minimum 30 minutes stabilization time after
energizing the transformer at rated voltage.
There is no acceptable criterion for vibrated level on a transformer. However, one should look
for only appreciable increase in the load during the test period and subsequent readings taken at
periodic intervals at site.
3.27 Vacuum Test on Transformer Tank
Vacuum test is carried out to check out any permanent deflection of flat plate after the vacuum
has been released. This test is to be carried out at test figures specified on the tank drawing.
This test is carried out on only one tank of same work order until otherwise specified by
customer.
Tank and its temporary structure are connected as given in the drawing and connect the tank to
the vacuum pumping instrument. The tank shall be capable of withstanding an absolute pressure
as stated on the drawing for at least 60 minute. During and after vacuum test we should examine
all welds for cracks. In the event of repair work, vacuum test should be repeated.
Maximum temporary deflection during test and permanent deflection after test should be
measured. Permanent deflection should not exceed the value specified in the specification.
3.28 Oil Pressure Test on Completely Assembled Transformer
This test is done after completion of all electrical and temperature rise test. Transformer with
cooling bank, bushing and other accessories shall be tested for any oil leakage at high pressure
(normal pressure plus 35 kN per sq.m measured at the base of tank) and at room temperature as
specified by customer.
The procedure for conducting this test is as follows:
1. Conservator along with the protective relay shall be disconnected.

2. Calibrated pressure gauge shall be mounted at the bottom of the tank.
3. Bushings will remain mounted however conservator along with buchholz relay shall be
isolated.
4. In welded cover type construction cooler bank, bushings shall be removed but all turrets
and cover pipe work shall remain.
5. Fill the oil completely and release all trapped air.
6. The specified pressure shall be maintained for the specified test duration as specified in
the test schedule or quality plan.
7. The test duration should be at least one hour unless otherwise specified.
• Criteria for oil pressure test
During the pressure test, there shall not be any leakage. If there is pressure drop during the test
either because of some trapped air inside the transformer or due to ambient
temperature variation, the pressure shall be raised to the specified level. The unit will be
considered to pass the test only if there is no visual oil leakage. Pressure drop shall be considered
as failure of the unit in the test.
3.29 Jacking Test and Dye-penetration Test
This test is done to check out the mechanical capability of jacking pads on bottom tank of
transformer.
The procedure for conducting the above test is as follows:
1. Bring the transformer on to rail track
2. The transformer should be filled with oil.
3. Place jack under jacking pads such that the C.L. of the jack ram coincides with the jack
points on jacking pads at appropriate height.
4. connect the jacks to hydraulic pump unit
5. Raise pressure of oil slowly so that the transformer is lifted gradually.
6. Continue lifting till, the flanges of the rollers are above the R/L and its possible to turn the
wheel.
7. The transformer must be held in the raised condition for 15 minutes.
8. Lower the transformer gradually after the expiry of time period by releasing oil pressure
in stages till the wheel again rest on the rails.
The transformer jacking pads should withstand this test without any deformation or any cracks.
The dye-penetration test is done simultaneously with jacking test to check out any welding
cracks in jacking pads. This is done by applying the dye paint to the welded joints of jacking
pads. If there is no leakage of dye at welding joints, then the welded joint is perfect.
3.30 Pressure Relief Device Test
The pressure relief device shall be subjected to rising pressure (pneumatically). The pressure
at which the device operates shall be noted. The operating pressure should be less than normal
pressure plus 35 kN/m2.
(B) RECOMMEND FIELD TESTS
• INTRODUCTION
Transformer is important and vital equipment between generation station and the utility and
therefore necessary to ensure its proper performance through out its service life. During
transportation, installation and service operation, the transformer may be exposed to conditions,
which adversely affect its reliability and useful life.
Field-testing and condition monitoring are the techniques to ensure good operating health of
power transformers. Interpretations are also included to provide additional information on the
particular test and to provide guidance on acceptable criteria. There is not necessary any direct
relationship between field tests and factory tests.
Interpretation of measured results is usually based on a comparison with data obtained previously
on the same unit under similar condition. It should be noted that some times the results of several
types of tests should be interpreted together to diagnose a problem. Manufactures acceptance
criteria shall also be consulted.
B.1 Dew Point Measurement for Large Transformers Filled with dry air or nitrogen filled
Large rating transformers are transported to site from manufacturing works, without oil and
filled with dry air or nitrogen due to weight limitations. Positive gas pressure is generally
maintained at 0.175 kg/m2 during transportation and storage. As the insulation of transformer is
hygroscopic, it absorbs moisture from atmosphere if positive pressure of gas is not maintained.
After arrival of transformer at site it is necessary to check the gas pressure and if it is not
positive there is every possibility that moisture must have gone inside the transformer during
transportation. To ascertain this factor and to check the dryness of the insulation, dew point
measurement is carried out at site.
Dew point is the temperature at which the water vapours present in the gas filled in the transformer
begin to condense.
It will not be possible to define a limit of dew point of nitrogen gas as dew point depends on the
ambient temperature, pressure of the gas, moisture level of cellulose insulation etc.
The procedure and acceptance limits are given in Section CC of this manual.
• ELECTRICAL TESTS
B.2 Winding Resistance Measurement
Transformer winding resistances are measured at site in order to check for abnormalities due
to loose connections, broken strands of conductor, high contact resistance in tap changers, high
voltage leads and bushings.
The resistance is measured by two methods

(a) Voltmeter Ammeter method
(b) Bridge method

The detailed test procedure of above methods is same as factory testing and is covered in section
A.3.1.2 of this manual. Precautions shall be taken during field testing as given below.
The test shall be conducted at all taps of the transformer winding and the measured value shall
be converted to 75 0C.
The acceptance criterion is usually agreement to within 5% of resistance measurements
made separately on different phases, under field condition. But, for large transformers it is
recommended to compare the resistance values with original data measured in the factory and
in case of large variation, connection tightness to be checked.
The current used for these measurements should not exceed 15% of the rated current in
order to avoid heating the winding thereby changing its resistance. However, the current
should not be too small, which may not be sufficient to avoid inductive effect, due to core
magnetization
The winding resistance shall be preferably done when the difference in the top and bottom
temperature of the winding (temperature of oil in steady-state condition) is equal to or less
than 5oC.
Winding resistance measurement shall be done only after measurement of magnetization current
(excitation current), magnetic balance & SFRA. The polarity of the core magnetization shall be
kept constant during all resistance measurement. A reversal in magnetization of the core can
change the time constant and result in erroneous readings.
B.3 Vector Group and Polarity
To determine the phase relationship and polarity of transformers
The procedure to find out vector group shall be general be same as defined in section
A3.2.2.2.
(a) Connect neutral point and LV phase with earth
(b) Join 1R1 of HV and 3B1 of tertiary
(c) Apply 415V, 3 phase supply to HV terminals
(d) Measure voltage across following terminals
1R1- 1Y1, 1Y1 – 1B1, 1B1 – 1R1, 3Y1 – 1B1, 3Y1 -1Y1, 3R1-N, 3Y1 – N, 1R1- N, 2R1 – N, 2Y1-N, 2B1-N
Example 1
Connect 1U to 2U
1V-2W
VOLTAGE RELATION
1W-2V= 1W-2W
1W-2V< 1U-1W
1V-2V<1V-2W
1V-2V <1U-1W
Fig 1 : For HV-Delta / LV-Star Transformer
Example 2
Connect 1U to 2U
1V-2W
VOLTAGE RELATION
1W-2W = 1V-2W
1W-2U > 1V-2U
1U-N=1U-2W+2W-N
Yd11
Fig 2: For HV-Star / LV-Delta Transformer
The test shall be conducted with three phase supply and voltmeters.
By the measured voltage data it should ensure that the desired conditions of vector group and
polarity are fulfilled.
Ensure the isolation of transformer from high voltage and low voltage side with physical
inspection of open condition of the concerned isolators. In case tertiary is also connected, ensure
the isolation of the same prior to commencement of testing.
B.4 Voltage Ratio Test
To determine the turns ratio of transformers during commissioning and periodic interval decided
by the customer for preventive maintenance
The procedure shall be following
(a) Keep the terminals of IV and LV open.
(b) Apply 3 phase or single phase supply according to the transformer type on HV
terminals.
(c) Measure the voltage ratio of HV and IV.
(d) Repeat the steps for each tap position separately.
The test shall be conducted with three phase supply and voltmeters.
Results of the transformation turns/voltage ratio are absolute, and may be compared with the
specified values measured during factory testing. One should also consider the trend of voltage
ratio values with reference to the ratio values measured during the commissioning tests.
The voltage should be applied only in the high voltage winding in order to avoid unsafe
voltage.
B.5 Measurement of Magnetizing Current
This test is performed to locate defect in the magnetic core structure, shifting of windings,
failure in turn to turn insulation or problems in tap changers. These conditions change the
effective reluctance of the magnetic circuit thus affecting the current required to establish flux
in the core.
The procedure is as follows:
(a) First of all keep the tap position in the lowest position and IV and LV terminals open.
(b) Apply 3 phase 415V supply on the line terminal for 3-phase transformers and 1-phase,
230 V supply on single phase transformer.
(c) Measure the voltage applied on each phase (Phase-Phase) on line terminals and current in
each phase of the line terminal.
(d) After completion of the above steps keep the tap positioning Normal position and repeat
the steps a to c.
(e) After completion of the above steps keep the tap positioning at Highest position and
repeat the steps a to c.
(f) Repeat the test with tap position in normal position.
The test shall be conducted with single phase or three phase supply according to test requirement,
voltmeter and multimeter.
The acceptance criteria for the results of exciting current measurement should be based on the
comparison with the previous site test results or factory test results. The general pattern is two
similar high readings on the outer phases and one lower reading on the center phase, in case of
three phase transformers connected in star. An agreement to within 30% of the measured exciting
current with the previous test is usually considered satisfactory. If the measured exciting current
value is 50 times higher than the value measured during pre-commissioning checks, then there
is likelihood of a fault in the winding which needs further analysis.
Care should be taken during exciting current measurement to avoid the effect of residual
magnetism in the transformer core. The residual magnetism results in the measurement of higher
than normal exciting current.
B.6 Magnetic balance test on 3-phase transformer
This test is conducted only on three phase transformer to check the imbalance in the magnetic
circuit.
The procedure for conducting test is as follows
(a) Keep the tap in nominal tap position
(b) Disconnect the transformer neutral from ground
(c) Apply single phase 230 V across one of the HV winding terminal and neutral then measure
voltage in other two HV terminals across neutral. Repeat the test for each of the three phases.
(d) Repeat the above test for IV winding also
The test shall be conducted with 230 V single phase supply and voltmeter
The voltage induced in the center phase shall be 50 to 90% of the applied voltage. However,
when the center phase is excited then the voltage induced in the outer phases shall be 30 to 70%
of the applied voltage.
Zero voltage or very negligible voltage induced in the other two windings should be
investigated.
Disconnect transformer neutral from ground and no winding terminal should be grounded,
otherwise results would be erratic and confusing.
The purpose of this test basically to ensure that there is no inter turn fault in the winding which
is generally reflected in high excitation current in faulty winding.
B.7 Magnetic circuit (Isolation) test
This test should be performed prior to a unit being placed in-service or following modifications
to the transformer which could affect the integrity of its core insulation.
Refer clause 3.15 part A of this section for test procedures and acceptance criterion.
B.8 Measurement of short circuit impedance at low voltage
To find out the short circuit impedance of transformer the measurement is performed in single
phase mode. This test is performed for the combination of two winding. The one of the winding is
short circuited and voltage is applied to other winding. The voltage and current reading are noted.
The test shall be conducted with variac of 0-280 V, 10 A, precision RMS voltmeter and
ammeter.
The acceptable criteria should be the measured impedance voltage having agreement to within 3
percent of impedance specified in rating and diagram nameplate of the transformer. Variation in
impedance voltage of more than 3% should be considered significant and further investigated.
The conductors used for short-circuiting one of the transformer windings should have low
impedance (less than 1m-ohm) and short length. The contacts should be clean and tight.
B.9 Insulation resistance measurement
Insulation resistance test are made to determine the insulation resistance from individual winding
to ground or between individual windings. The insulation resistance in such tests is commonly
measured in mega-ohms, or may be calculated from measurements of applied voltage and
leakage current.
The test is conducted with the help of Mega-ohmmeter. IR is proportional to the leakage current
through/over the insulation after capacitive charging and absorption currents become negligible
on application of DC voltage. Insulation resistance shall be measured after the intervals of 15

sec, 60 sec and 600 sec. The polarization index (PI) is defined as the ratio of IR values measured
at the intervals of 600 and 60 seconds respectively. Whereas, the dielectric absorption is the ratio
of IR values measured after 60 sec and 15 sec. IR is normally measured at 5 kV DC or lower
test voltage, but the test voltage should not exceed the rated power-frequency test voltage of
transformer windings.
Polarization Index (PI) is useful parameters for logistic interpretation of IR test results. This
ratio is independent of temperature and gives more reliable data for large power transformers. A
PI of more than 1.25 and dielectric absorption factor of more than 1.3 are considered satisfactory
for a transformer when the results of other low voltage tests are found in order. PI of less than
1 calls for immediate corrective action. For bushings, an IR value of above 10000 M-ohms is
considered satisfactory.
The IR value of transformer is dependent on various factors such as configuration of winding

insulation structures, transformer oil, atmosphere condition etc. therefore, present trend is to
monitor oil characteristics for judging the condition of dryness of the transformer and not to rely
solely on absolute values of IR. It may be note that no national/international standards specify
minimum insulation resistance values of transformers. The value of IR could be even zero under
heavy fog or humid conditions.
During IR measurement, we must ensure following conditions.
- Transformer is disconnected from other associated equipment

- Bushings are cleaned and free of moisture
- Transformer tank and core are properly grounded
- Both ends of winding under test are short-circuited.
B.10 Measurement of capacitance and dissipation factor
The insulation dissipation factor (tan delta) is the ratio of the resistive current to the capacitive
current flowing through the insulation on application of sinusoidal voltage under prescribed
condition. The capacitance values are relatively independent of temperature and prevailing
atmospheric conditions. Normally low dissipation factor is indicative of problem in insulation
structure and predictive aging of insulation.
The voltage to be applied shall not exceed half of the power frequency test voltage or 10 kV
whichever is lower. Detailed test procedure is concerned under this manual earlier.
The test is conducted with high voltage supply and Schering bridge
High dissipation factor is indicative of problem in insulation structure and predictive aging of
insulation. But, the comparative values of tests taken at periodic intervals are useful in identifying
potential problems rather than an absolute value of tan delta. The initial reference can be drawn
from the tan delta values measured during factory testing.
The acceptance criterion to assess the probable condition of the insulation of the transformer
is no substantial variation in the measured values of tan delta (dissipation factor) at periodic
interval when compared with previous references. For bushings, the tan delta value shall not
exceed 0.7% during operation.
Environmental factors like variation in temperature, relative humidity, surrounding charged
objects etc. have great influence on measurement of dissipation factor. Care shall be taken to
control the above factors during measurements.
B.11 Dissolved gas analysis (DGA)
Dissolved gas analysis is a well-established condition-monitoring tool for power transformers.

The method is based on analyzing the types of gases dissolved in the transformer oil and their
production rates. The relative concentration of these gases depends upon the type and severity
(energy density) of fault.
The test procedure to conduct DGA test is accordance with the IS 9434.
The main gases formed as result of thermal and electrical faults in a transformer are Hydrogen
(H2), Methane (CH4), Ethane (C2H6), Ethylene (C2H4), Acetylene (C2H2), Carbon Monoxide
(CO) and Carbon dioxide (CO2). Whereas Acetylene is mainly associated with arcing at very
high temperature ranges, Ethylene is related with hot spots and medium temperature ranges.
Hydrogen is mainly result of ‘cold’ gas plasma of corona discharges. Carbon monoxide and
carbon dioxide are the result of thermal decomposition of cellulose material.
For proper interpretation of DGA results, it is essential to collect data at periodic intervals
during the service life of the transformer and the additional information regarding age of the
transformer, past history of failures, loading pattern, history of filtration etc.
B12. Tests on oil filled in transformer as per IS 1866

Refer clause 3.25 part A of this Section
4.0 METHOD OF DECLAIRING EFFICIENCY

4.1 The efficiency to be declared is the ratio of the output in kW to the sum of the output in
kW and the following losses :
(a) No load loss, which is considered to be constant at all loads; and
(b) Load loss, which varies with load.
The total loss, on load is the sum of (a) & (b).
5.0 CALCULATION OF INHERENT VOLTAGE REGULATION
5.1 Two Winding Transformers
5.1.1 The inherent voltage regulation from no-load to a load of any assumed value and power
factor may be computed from the impedance voltage and corresponding load loss measured
with rated current in the winding as follows:
Let
I = rated current in winding excited;
E = rated voltage of winding excited;
ISC = current measured in winding excited;
EZsc = voltage measured across winding excited (impedance voltage);
PSC= watts measured across winding excited;
EXSC = reactance voltage= Ö[ E2zsc-(Psc/Isc)2]
P=PSc corrected to 75 dcg. C, and from current ISC to I;
Ex=EXSC X (I/ISC)
Er = P ;
I
EX%=100EX/E;
Er%=100Er/E;
= Ia/I ; and
Ia = current in winding in excited during the short circuit test corresponding to that obtained when
loading at the assumed load on the output side and with rated voltage on the input side.
5.1.2 For rated load at unity power factor, the percentage regulation is approximately equal to:
Er + (Ex%)
2
200
5.1.3 For rated load at any power factor cosФ, the percentage regulation is approximately
equal to:
Er% cos Ф + Ex% sin Ф + (Ex% cos Ф - Er% sin Ф)2

200
5.1.4 For any assumed load other than rated load and unity power factor, the percentage
regulation is approximately equal to:
n. Er + (n. Ex%)
2
200
5.1.5 For any assumed load other than rated load and at any power factor cos Ф, the percentage
regulation is approximately equal to:
(n .Er% cosφ + n. Ex% sin φ)
+ (n .Ex%cos φ - n .Er% sin φ)2

200
5.1.6 The above formula are sufficiently accurate for transformers covered by this
specification.
5.2 Three Winding Transformers
5.2.1 The formula given in 2.1 for two-winding transformers can be applied to three-winding
transformers and their regulation calculated with an accuracy comparable to that of the data
available by assuming that the currents in the windings remain constant both in magnitude and
phase angle even though the output terminal voltage change, due to the regulation, from their
no-load values.
On a three-winding transformer the no-load voltage of a winding will change with current in the
other windings (even though it remains itself unloaded).
Therefore, the voltages regulation of a winding on a three-winding transformer is expressed

with reference to its no-load open-circuit terminal voltage when only one of the other
windings is supplied and the third winding is on no-load, that is the basic voltage for each
winding and any combination of loading is the line no-load voltage obtained from its turns
ratio.
For the frequent case of two output winding (W2 and W3) and one input winding (W1) the voltage
regulation is usually required for three loading conditions, namely:
Only W2 loaded,
Only W3 loaded, and
Both W2 and W3 loaded.
For each condition two separate figures should be quoted, that is the regulation of each output
winding W2 and W3 (whether carrying current or not) for constant voltage supplied to the
winding W1.
Note: The regulation between W2 and W3 relative to each other for this simple and frequent case is implicit in the values
(W1 to W2) and (W1 to W3) and nothing is gained by expressing it separately.
5.2.2 The data required are the impedance voltage and load losses derived by testing the
three windings in pairs and expressing the results on a basic KVA, which can conveniently
be the rated kVA of the smallest winding. It should be determined from the transformer as
built.
From the data, an equivalent circuit 3 winding transformer is derived as shown below:
5.2.3 The equivalent circuit is derived as follows:

Let
a12 and b12 be respectively the percentage resistance and reactance voltages referred to the base
kVA and obtained on a test, short-circuiting either winding W1 or W2 and supplying the other,
with the third winding W3 on open-circuit:
a23 and b23 similarly apply to a test on the windings pair W2 and W3 (with W1 on open-circuit);
a31 and b31similarly apply to a test on the windings pair W3 and Wj(with W2on open-circuit);
d = the sum (a12 + a23 + a31); and
f = the sum (b12 + b23 + b3I)
Then the mathematical values to be inserted in the equivalent circuit are:
Arm W1a1 = d/2 - a23, and b1 = f/2 - b23
Ami W2a2 = d/2 - a31, and b2 = f/2 - b31
Arm W3a3 = d/2 - a12, and b3 = f/2 - b12
It is to be noted that some of these mathematical values may be negative or may even
be zero (depending on the actual physical relative arrangement of the windings on the
core).
For the desired loading conditions the kVA operative in each arm of the equivalent circuit is
determined and the regulation of each arm is calculated separately. The regulation with respect to
the terminals of any pair of windings is the algebraic sum of the regulations of the corresponding
two arms of the equivalent circuit.
5.2.4 The detailed procedure to be followed in the case of two output windings and one supply
winding is as follows
(a) Determine the kVA in each winding corresponding to the loading being considered.
(b) For the output windings W2 and W3, this is the specified loading under consideration;
deduce n2 and n3, where n is the ratio of the actual loading to the base kVA used in the
equivalent circuit.
(c) For the input winding W1 kVA should be taken as the vectorial sum of the outputs from
W2 and W3 windings, and the corresponding power factor and quadrature factor (sin φ)
deduced from the in-phase and quadrature components.
5.2.5 When greater accuracy is required, an addition should made to the above vectorial sum
of the outputs as follows:
Add to the quadrature component, to obtain the effective input kVA to windings W1,
b2
(output kVA from winding W2) x 100 x n2

+ (output kVA from winding W3) x W x b3 xn

100
n for each arm being the ratio of the magnitude of the actual kVA loading of the winding to the
base kVA employed in determining the network.
A more accurate solution is obtained by adding the corresponding quantities (a x n x output

kVA) to the in-phase component of the vectorial sums of the outputs, but the difference is rarely
appreciable.
5.2.6 Apply the final formula of 2.1.5 separately to each arm of the network, taking separate
values of n for each arm as defined in 2.2.5.
5.2.7 To obtain the regulation between the input winding and either of the loaded windings,
add the separate regulations determined under 2.2.6 for the corresponding two arms, noting that
one of these may be negative. (Note that the summation is algebraic, but not vectorial).
Note: A positive value for the sum determined indicates a voltage drop from no-load to the loading considered while a
negative value for the sum indicates a voltage rise.
5.2.8 Repeat the operation described in 2.2.7 for the other loaded winding.
5.2.8.1 The above procedure is applicable to auto-transformers if the equivalent circuit is based
on the effective impedances measured at the terminal of the auto-transformer.
5.2.8.2 In the case of input to two windings and load from one winding, the above procedure can
be applied if the division of loading between the two supplies is known.
5.2.8.3 Example of Application to a Three-Winding Transformer. Assume that:
W1 is a 66 kV primary winding,
W2 is a 33 kV output winding loaded at 2000 kVA having a power factor cos φ of 0.8
lagging, and
W3 is a 11 kV output winding loaded at 1000 kVA having a power factor cos φ of 0.6
lagging.
The following information is available, having been calculated from test data and is related to
a base kVA of 1000:
a12 = 0.26 b12 = 3.12
a23 = 0.33 b23=1.59
a31=0.32 b31=5.08
It can be deduced that
d = 0.91 and f = 9.79
If follows, therefore, that for
W1, a1 = 0.125 and b1 = +3.305
W2 ,a2= 0.135 and b2 = -0.185
W3 , a3 = 0.195 and b3 =+1.775
The effective full load input kVA to winding W1 is:
(a) with only output = 2000 kVA

winding W2loaded at power factor 0.8 lagging.
(b) With only output = 1000 kVA

winding W3 loaded at power factor 0.6 lagging.
(c) With only output = 2980 kVA

windingW2and W3 loaded at power factor 0.74 lagging.
Applying the formula of 2.1.5 separately to each arm of the network we have for the regulation
of that arms alone:
W1 under condition (a) where n1 = 2.0 is + 4.30 per cent
W1 under condition (b) where n1 = 1.0 is + 2.74 per cent
W1 under condition (c) where n1 = 2.98 is + 7.15 per cent
W2 under condition where n2 = 2.0 is - 0.005 per cent
W3 under condition where n3 = 1.0 is +1.54 per cent
Therefore, the total transformer regulation is:
For condition (a) - with output winding W2 fully loaded and W3 unloaded:
At terminals W2 - 4.30 - 0.005 = 4.295 per cent
At terminals W3 = 4.30 + 0 = 4.30 per cent
For condition (b) - with output winding W2 unloaded and W3 fully loaded:
At terminals W2= 2.74 + 0 = 2.74 per cent
At terminals W3= 2.74 + 1.54 = 4.28 per cent
For condition (c) - with both output windings W2 and W3 loaded:
At terminals W2= 7.15 - 0.005 = 7.145 per cent
At terminals W3= 7.15 + 1.54 = 8.69 per cent

SECTION CC
Guidelines for Erection, Commissioning and

Maintenance
SECTION CC
Guidelines for Erection, Commissioning and Maintenance
As the continuity of supply is of paramount importance in modern power systems, it is necessary
to take all possible precautions during erection and commissioning of the transformers followed
by regular preventive maintenance. This section covers erection, commissioning and maintenance
of Power and Distribution Transformers.
1.0 PACKING AND DISPATCH
1.1 After testing each transformer it shall be dispatched from the works ready for reassembly
of external components which are dismantled for facilitating transportation. According to
the transport facilities available and weight/ height restriction for the route, transformers are
transported either by rail, road or sea depending on the size of transformer. Power transformers
should be dispatched with external fittings dismantled and packed separately. However
distribution transformers can be transported in fully assembled condition.
1.2 Transformer tank is filled with oil or pure dry nitrogen/ air depending upon the transport
weight limitations. Dry air should be preferred due to safety of personnel entering inside the
Transformer. If nitrogen is used, the information shall be stenciled on the tank prominently. In
case the tank is filled with oil, sufficient space is left above the oil to take care of the expansion
of oil. This space is filled with pure dry air/nitrogen gas under atmospheric pressure. In case the
tank is filled with inert gas/nitrogen a positive pressure according to the manufacturer’s standard
practice and dew point of -50 deg C or better shall be maintained. The temperature, pressure
and dew point at the time of gas filling (reading taken after stabilization) shall be painted on the
transformer tank. External gas cylinders should be provided to make up any gas leakage during
transit for transformers having rating 50 MVA and above and voltage rating 132 kV and above.
1.3 Transformer shall be accompanied by escort decided by the manufacturers or the

customers as per the agreement. For large rating transformers of above 100 MVA the digital
impact recorders may be provided during shipment from transformer manufacturer’s works to
site. Provision of SMS alert needs to be provided during transportation and in case of any major
impact, SMS alert shall be sent to representatives of manufacturers and respective utilities. If
required by utility, GPS may also be installed on Transformers to locate the exact position during
transportation. Manufacturer shall specify the limiting values to the purchaser in advance. The
impact recorder is required to be sent back to the manufacturer for their analysis. Joint analysis
of impact recorder may also be carried out at trailer itself after receipt at site to check any
movement outside specified limit during transportation. Manufacturer shall send the analysis
report of impact recorder back to user / utility for their record. Interpretation of impact recorder
may be carried out as per standard DIN EN 13011. In case the impact recorder indicates some
serious shock during shipment, the core and coil will have to be subjected to thorough inspection
before erection. Higher impacts may also be verified with SFRA results comparison of factory
and site.
279
Note:
(i) Impact recorders are attached to the main body of the transformer during transportation to monitor the
shock and impact, which the transformer may be subjected to during transportation. The impact recorder
is a electronic or mechanical recording accelerometer whose main feature is its ability to record shock and
impact from three directions axial, lateral and longitudinal.
(ii) Check at factory that impact recorders have sufficient paper, battery life and memory capacity for the
expected duration of transport.
(iii) Mount the impact recorder as low as possible near the transformer centerline. Always keep the impact
recorder axis aligned with the transformer major axis. This provides the best possible recorder data (Refer
DIN EN 13011).
(iv) For transformers with a N2 gas/ dry air pressure of 0.3 PSI, the acceptable limits of dew point shall be as
under: (Source: Courtesy BHEL, Bhopal)
Temperature of insulation Maximum Temperature of insulation in °C Maximum

in °F permissible dew point permissible
in °F dew point in °C
0 -78 -17.77 -61.11
5 -74 -15.0 -58.88
10 -70 -12.22 -56.66
15 -66 -9.44 -54.44
20 -62 -6.66 -52.22
25 -58 -3.33 -49.99
30 -53 -1.11 -47.22
35 -48 +1.66 -44.44
40 -44 +4.44 -42.22
45 -40 +7.44 -39.39
50 -35 +9.99 -37.22
55 -31 12.77 -34.99
60 -27 15.55 -32.77
65 -22 18.33 -29.99
70 -18 23.11 -27.77
75 -14 23.88 -25.55
80 -10 26.66 -23.33
85 -6 29.44 -21.11
90 -1 32.22 -18.33
95 +3 34.99 -16.11
100 +7 37.75 -13.88
110 +16 43.33 -8.88
120 +25 48.88 -3.88
130 +33 54.44 +0.55
140 +44 59.99 +5.55
Guidelines for Erection, Commissioning and Maintenance 281
1.4 All external fitting such as Conservator, Buchholz relay, Dehydrating Breather, Turrets,
Bushings, Explosion Vent/ Pressure Relief Devices (PRDs), OLTC - Driving Mechanism and
Motor Operated Mechanism (MOM) Boxes, Marshalling Kiosks, Radiators, Rollers, Cooling
Fans, Pumps, Gasket etc., which are liable to damage in transit, shall be removed and packed
separately. All openings created on the tank by the removal of components arc blanked with
identifiable blanking plates & suitable gaskets. All openings on the fittings removed are also
closed with blanking plates & suitable gaskets.
1.5 When any internal parts like tap changers, etc., are removed for transportation, they are
dispatched in tanks filled with oil/inert gas or suitable measures taken so that they do not absorb
moisture.
• All fragile parts such as temperature indicators, oil level gauges, etc., shall be carefully
packed to avoid breakage in transit.
• All blanking plates, tank valve guards, etc., used exclusively for transport is to be
preserved in safe custody by the purchaser for future use.
1.6 Rail Transport
1.6.1 Transformers may be transported by rail / road trailers depending on size of transformer,
destination, delivery time and the route limitations. In case of transformers where the weight and
dimensions of the main body exceed limits, special well wagons are employed. Detached parts
are packed/crated and normally dispatched along with the main body of the unit, so that all the
parts are received at the destination station with the unit.
1.6.2 Loading
1.6.2.1 Most of the transformer manufacturers have their own railway siding and transformers
are loaded at their works using their cranes. In cases where separate siding facilities are not
available, road tractor-trailers are used for the transport from works to loading railway stations.
Mobile cranes and railway cranes are also used for loading the units into the wagons. In the
absence of any crane facility, the transformers are unloaded from the trailers near the railway
track into a platform of adequate height built up of wooden sleepers. Jacks and pull lifts chain
pulley block of adequate capacity are used to slide the transformer over a pair of rails placed on
the sleeper platform bridging the trailer width in full. To prevent the trailer from toppling when
the transformer is moved to the platform the stage end of the trailer is supported by a sleeper
pack. From the platform the transformer is slid onto the wagon taking care to have the rails for
the full width of wagon. The rails are greased for easy movement. The rollers of the transformer
are removed before leaving the works. While providing a sleeper stage it should slightly be at a
higher level to allow for the increase in height of the trailer while the load is released due to the
springs getting relaxed.
1.6.3 Lifting and Jacking
16.3.1 Transformers should be lifted by jacking at the jacking pads provided for the purpose
and simultaneous use should be made of all such lugs or lifting bollards in order to avoid any
unbalance in lifting. Before lifting the complete transformer it should be ensured that all cover
bolts arc tightened. Apart from the main lifting points designed to take the total weight of the
unit, the transformer has subsidiary lifting points suitable for particular components only. Care
must be taken to distinguish between them. It is advisable to use a spreader between slings so
that the lift on the hooks is in the vertical direction. The slinging angle is not to exceed 60°. Safe
loads of wire ropes and the multiplying factors to be used corresponding to the lifting angles are
furnished in Fig. 1. Gunnies are used on the slings to avoid metal contact and consequent damage
to the slings.
Sale load of wire ropes Multiplying factor for different lifting angles
Dia. of wire rope (mm) Safe load (Kg) Lifting angles Multiplying factor
8 600 0 1
12 1,300 20 1.015
16 2,300 40 1.065
20 3,500 60 1.155
24 5,000
28 7,000
32 9,000
36 11,000
40 14,000
44 17,000
56 24,500
64 33,500
70 40,000
1.6.3.2 Where it is necessary to use jacks for lifting, only the Jacking pads provided for the
Lifting angle
Slinging angle
Fig. 1 Correct method of slinging

purpose of jacking should be used. Jacks should never be placed under valves or cooling tubes
or stiffeners. Not more than two jacks should be operated at the same time. When two jacks are
being operated the opposite side of the transformer should be firmly supported by sleepers.
Jacks are also not to be left in position with load for a long time. The transformer should always
be handled in the normal upright position. During the handling operation care must be taken to
prevent overturning or even tilting.
1.6.3.3 Loading on the railway wagons is done as centrally as possible to distribute the weight
equally on all axles and wheels. Manufacturer’s drawing in this regard is to be referred to. It is
desired that the transformer be loaded longitudinally on the wagon. To prevent damage to the
transformer base, the unit is loaded on a row of sleepers or wooden planks placed on the wagon
floor.
1.6.4 Lashing
The transformer is lashed on all four sides by wire ropes or chain of adequate size and lightened
using turn buckles with locking facility. Wooden props are also used. After the movement of
the wagon for a short distance the tightness of the lashing is to be checked. When enroute
transhipment is involved, lashing is to be checked again.
1.7 Road Transport
1.7.1 Transformers may be shipped by road, where well developed roads exist & the route
conditions permit. Multi-axle tractor driven low-platform trailers are used for road transport.
Hydraulic trailers to be used for transportation of heavy Transformers, i.e., weighing more than
50 Tonnes including weight of trailer. The tractors are to have adequate hauling capacity and the
trailers loading capacity.
1.7.2 Route Survey
1.7.2.1 The road system is examined in detail on the following points:
(i) Width of the road Normally not less than 5 m

(ii) Bridges and culverts To have sufficient strength to take the moving load; consultation
with the Highways Department is necessary (Refer Fig. 2 for
assessing the axle load.)
(iii) Encumbrances enroute Like telephone, telegraph, traction and electric utility wires,
avenue trees, cross beams of bridges, subways, aqueducts,
etc., across the roadway.
(iv) Sharp bends Steep gradients up or down with respect to the maneuverability
of the tractor-trailer.
(v) Road worthiness Of the route like sandy stretches, waterlogged areas, crowded
localities like market places, schools and other public places.
(vi) Operational Constraints of the tractor-trailer to be used. To clear up any
doubts as to the feasibility of the route a rehearsal drive of the

tractor-trailer unit is performed.
All turnings clearance from local authorities, PWD, Motor Highways Department should be
obtained before movement. All transport diversions should be thoroughly checked.
WTa = Self weight of tractor
Fig. 2
WTi = Self weight of trailer
WP = Pay load 50 tonnes
Ra = Load in the front axle of tractor
Rb = Load in all the 3 axles of trailer
(Divide by 3 for axle load)
Rc = Load in all the 2 axles of this trailer (Divide by 2 for axle load) Take the
momentum at the points at Ra, Rb and Rc and solve the equations, to get Ra, Rb
and Rc.
In this case if we assume tractor and trailer of equal weight (i.e.) WTa = WTi; = 10 tonnes and
WP = 50 tonnes.
Ra = 5 tonnes axle load in front axle
Rb = 35 tonnes axle load in 2nd axle
Rc = 30 tonnes axle load in 3rd axle
Load per rear axle of the tractor = 35/3 = 11.66 tonnes Load per rear axle of semi-trailer = 30/2
= 15 tonnes
To limit the load per axle to 10 tonnes at the rear axle of trailer, the payload should not exceed
30 tonnes Otherwise the number of axles for the trailer should be increased.
1.7.2.2 Movement of the transformer shall be through the route surveyed for the purpose and no
deviation of the route shall be followed unless it is surveyed again.
1.7.3 Strengthening the Route
1.7.3.1 Such of those bridges and culverts which require strengthening are strengthened by
adopting suitable measures like propping up using timber and steel in consultation with the
Highways Department. For uniform loading, chequer plates, M.S. plates, etc., are used. For
details refer Figs 3, 4 and 5. In some cases an alternative route by-passing such bridges and
culverts may be cheaper than propping up.
1.7.4 Loading, Lifting, Jacking and Lashing
Refer clauses 1.2.2, 1.2.3 and 1.2.4 (Rounded of thicknesses)
Fig. 3 Spreading gravel cushion and placing steel plates above
Fig. 4 Dry stone packed with lose earth in-between

Fig. 5 Wooden sleeper stage platform built on river bed with the plates underneath
1.7.5 Movement
1.7.5.1 A pilot vehicle with all tools and tackles, jacks, sleepers, chequer plates, crowbars, etc.,
and sufficient trained staff should run in front of the vehicle. Red flags and danger lamps should
be exhibited at prominent places to warn traffic on the route.
1.7.5.2 The branches of avenue trees that are likely to foul the equipment should be cleared
while the load is moved. Electric utility power lines likely to foul should be switched off and
lifted temporarily / dismantled while the load is moved.
1.7.5.3 After moving the load for a short distance tightness of the lashing should be checked.
1.7.5.4 In the case of night halt or stoppage of the loaded trailer for a fairly long duration the
trailer should be supported either by sleepers or providing supporting jacks on all sides thus
releasing the load from the tyres. Danger lights should be displayed in the front and rear of the
vehicle.
1.7.5.5 For the normal running, it is desirable not to run the vehicle over 15-20 km per hour with
no load and 10-15 km with loads on good surfaced roads. For bad roads it is desirable to run the
vehicle at much lower speeds.
1.7.5.6 The brake system on the tractor-trailer has to be carefully operated whenever the vehicle
is running with load. While running over any bridge or culvert the vehicle should be run only
at a very slow speed. Long before the approach to the bridge the speed should be brought
down and the vehicle allowed to proceed over the bridge without creating any impact, which
is sometimes caused by applying brakes when running at high speeds. Till all the wheels of the
tractor-trailer are clear of the bridge, the speed should not be increased. Transportation should be
avoided during heavy rains.
1.7.5.7 In case of the vehicle getting locked up in a slipping soil, the safest procedure would be
to detach the tractor after the trailer had been anchored suitably by sleepers. The tractor may be
moved forward and anchored suitably with sufficient sleepers. The trailer can be pulled up by
winches in the rear of the tractor.
1.8 Water Transport
Water transport is the cheapest mode of transport. While ocean going ships are used for the high
seas, barges are used for inland navigation routes. Special care is to be taken for prevention
of rusting of parts and ingress of moisture like use of anti-corrosive paints, silica gel packing,
sealing using polythene covers etc. Packages should not be left on wharves for more than 2
weeks. Storing of heavy packing is to be done only in consultation with port authorities so that
the safety of the wharf is not endangered.
1.8.1 Loading
Usually the wharf cranes may not have sufficient capacity for handling very heavy packages.
Special floating cranes or cranes of ships are used for loading the packages from the wharf to
ships or barges. In the case of barges, special care is required to prevent overturning of the barge
at the time of loading. Packages are to be placed inside the hold. Decks of ships are not to be
used for keeping the packing during transport.
1.9 Unloading at Site
In cases where the substations are having adequate crane facility, the transformer is unloaded by
crane. Alternatively, mobile cranes are used. Where no crane facility is available a trench is dug
to a depth equal to height of the trailer platform and the transformer is slid to position. If this
also is not possible the transformer is unloaded into a sleeper platform and gradually lowered to
plinth level (Fig. 6 for guidance). The sleeper platform level is to be at a slightly higher level to
allow for the increase in height of the trailer while the load is released due to the springs getting
relaxed. Winches are to be used for putting the transformer into position.
Fig. 6
1.10 Inspection and Storage
A thorough external examination shall be made immediately on arrival of the transformer at site.
If any damage is suspected, open delivery is to be taken and a claim made against the carriers
in accordance with the terms of contract. The manufacturers and under-writers are also to be
informed about the details of inspection done jointly in carriers.
1.10.1 Unpacking and Inspection
1.10.1.1 Packages arc to be opened carefully so that the tools used for opening do not cause
damage to the contents.
1.10.1.2 When the transformers are dispatched N2/ dry air filled, pressure shall be checked and it
should be ascertained whether there was any leakage of atmospheric air into the tanks. In case of
any leakage of N2/ dry air, dryness of insulation should be checked by dewpoint measurement
(clause 1.1.2) after fillingwith dry air/nitrogen and after a stabilization period of 12-24 hours.
If insulation is wet, the transformer has to be dried. If the pressure is positive and varies with
temperature of the surrounding air the seal can be taken to be effective.
1.10.1.3 When the transformer is dispatched filled with oil, oil level in main tank at the time of
receipt is to be verified by comparing the oil level before dispatch. Any shortage is to be duly
recorded in the documentation and intimated promptly to the supplier. A sample of oil shall be
taken from the bottom of the tank and tested to IS 1866. If the sample of oil does not meet the
requirements, the matter should be reported to the supplier along with insulation resistance
values of the various windings to earth.
1.10.1.4 Core Insulation Test (at 2.5 kV AC one minute withstand alternatively with 2.5 kV
Megger) shall be carried out to check insulation between Core (CC&CL) and Ground. (Not
applicable for Air Core Reactors). Core insulation value should be comparable with factory
value and generally more than 500 M Ohm.
1.10.1.5 Drums containing transformer oil which have been dispatched separately shall
beexamined carefully for leaks. All drums are dispatched filled up to their capacity and any
shortage should be reported,
1.10.1.6 In case of bushings, oil level shall be checked. The porcelain portion is to be checked
for any crack or chipping. The terminals should be checked for any bends.
1.10.1.7 Fragile instruments like oil level gauge, temperature indicator, etc. are to be inspected
for breakages or other damages.
1.10.1.8 Any damaged or missing components should be reported to the supplier within the
insurance liability period, so that the same can be investigated and shortage made up as per the
terms of contract.
1.10.1.9 Any paint damages are to be touched up after proper cleaning with wire brush, emery
and applying a coat of primer. Generally, manufacturers supply adequate quantity of finish paint
for such purposes.
1.10.2 Storage
1.10.2.1 After arrival at site, it is desirable to erect and commission the transformer with
minimum delay. In case this is not possible the transformer should be erected at its permanent
location with conservator and breather fitted, the transformer should be vacuum dried and
processed oil should be filled in the tank and oil condition to be monitored during long storage.
If this is also not possible, then, it is preferable that the tank containing core and coil be placed
under shed. The tank shall preferably be filled with processed oil up to core & winding level
with dry air/nitrogen filling above the oil. Gas pressure is to be monitored periodically.
1.10.2.2 Transformer/ Reactor should be kept in Dry air/ N2 filled condition for the maximum
period of 6 months including storage at works, transportation and storage at site. If the
transformer/ Reactor is to be stored at site with Dry air/ N2 filled condition, N2 pressure to be
monitored on daily basis so that chances of exposure of active part to atmosphere are avoided.
In case of drop in N2 pressure, dew point of N2 has to be measured to check the dryness of the
Transformer/ Reactor. If there is drop in dew point, fresh nitrogen need to be filled. Leaks are to
be identified and rectified and Nitrogen to be filled to the required pressure.
1.10.2.3 In case the transformer/ reactor is to be stored for more than 6 months, it needs to
be stored in oil filled condition. Processed oil to be filled which complies to the required
specification and ppm ≤ 10 ppm and BDV ≥ 60 kV. In case of storage of transformer in oil-filled
condition, the oil filled in the unit should be tested for BDV and moisture contents once in every
three months. The oil sample should be taken from bottom valve. If BDV is less and moisture
content is more than as given for service condition then oil should be filtered
1.10.2.4 The transformer shall never be stored in polluted areas likely to cause corrosion.
1.10.1.5 Equipment meant for indoor use, such as control panels should be stored indoor. Fragile
components are to be stored carefully.
1.10.2.6 Bushings, if not mounted on the transformer, should be stored in the cases under the
shed.
1.10.2.7 All packing shall be kept above ground by the use of supports so as to allow free
airflow underneath. It is preferable to store all loose parts under cover.
1.10.2.8 Transformer oil when received in drums shall be stored under cover. Drums should not
stand on end but are to be placed on their sides with the bung at 45° downward. (3-9 O’ clock
position)
1.10.2.9 If the accessories are to be stored for a long period they can be repacked. It is advisable
to store the accessories; especially the electrically operated ones’ in a rain protected area and
packing list should be retained so that the contents of cases or crates can be checked at the end
of the storage period. Heaters for marshalling kiosks, etc., shall be kept energized.
1.10.2.10 While in storage, the gas pressure, oil samples, breather condition are to be checked
frequently.
2.0 INSTALLATION
2.1 Erection Schedule
When the erection work is to be carried out by the supplier under the contract agreement, the
supplier and the user shall prepare a schedule of the works to be carried out with specific period
for each item of work involved. All the assembly and erection drawings should be available at
site.
2.2 Precautions
2.2.1 As far as possible no work shall be done during rainy season to avoid moisture
absorption.
2.2.2 Extreme care must be taken to prevent any foreign material from being dropped into the
transformer. Workmen having access to the interior of a transformer should empty their pockets
of all loose materials. Any spanners or other tools used shall be securely tied so that they can be
recovered easily if accidentally dropped.
2.2.3 Fibrous cleaning materials shall not be used. The presence of loose fibres in suspension
in transformer oil can reduce its insulating properties.
2.2.4 All components dispatched separately shall be cleaned inside and outside before being
fitted.
2.2.5 If any internal temporary transportation braces are provided they are to be removed
without disturbing any permanent internal arrangements. Such parts should be clearly marked
on the transportation drawings.
2.2.6 The transformer shall be erected on a level foundation.
2.3 Site Preparation
2.3.1 Since all electrical installation shall comply with the requirements of the Indian Electricity
Act and Rules made thereunder, it is essential that they are complied with. The provisions of the
Factories Act and Rules are also to be complied with to the extent applicable.
2.3.1.1 All tools, tackles and other equipments required for the erection work may be arranged
at the site before the work is started. Generally the following items will be required.
(i) Lifting Equipment: Depending upon the transformer, crane of sufficient capacity will
be required. In the absence of crane facility, a derrick is erected and work carried out
using a chain and pulley block. Wire rope slings, D-shackles, etc. are also required.
(ii) Oil Purifier: A vacuum oil purifier of sufficient capacity provided with thermostatically
controlled heating and filtering facility is required. The following table may be used
as a guide for selecting the oil purifier capacity.
Oil purifier capacity litres/ hr Quantity of oil to be purified litres

2000 Up to 20,000
4000 More than 20,000 but Less than 50,000
6000 More than 50,000 but Less than 80,000
10000 and above More than 80000
Note:
(a) For ODAF cooled Transformers, hot oil flow through the coil to be ensured during the oil circulation.
(b) In 765 kV AC & 500 kV HVDC Transformers and above rating, particle counting to be checked during oil
circulation. The procedure and interpretation shall be in accordance with the recommendation of CIGRE
report WG-12.17 - “Effect of particles on transformer dielectric strength”.
(c) All the hoses, filter machine to be thoroughly flushed before using them for oil circulation.
(d) All the oil tanks should be properly painted inside and sealed with breather provided to prevent entry of moisture.
(e) A higher vacuum filter with a vacuum of 0.1 torr or lower is to be used for a voltage class of 245 kV and above.
(iii) Vacuum Pump: A vacuum pump with a vacuum hose and other fittings capable of
producing a vacuum up to 759 mm mercury.
(iv) Oil Storage Tank: One or more oil tanks of sufficient capacity to store the entire
quantity of the transformer oil will be useful for filling from drums and also when
oil is received at site in tankers for transformers dispatched gas-filled. This will
reduce the time of filling.
(v) Pressure Vacuum Gauge: To read - 0.5 to + 0.5 kg /cm2 for checking inert gas
pressure.
(vi) Oil Testing Apparatus: Conforming to IS: 335
(vii) 5000/ 2500/ 1000 V motorized megger
(viii) Voltmeters, 0 to 500 V, 0 to 100 V range and 0 to 5 V range, milli-ammeter, low
power factor watt meter.
(ix) Set of spanners suitable for metric sizes and B.S. sizes.
(x) Set of drum opener, crowbar, pipes, hammer etc.
(xi) Set of screwdrivers, cutting pliers, screw spanners and pipe wrench.
(xii) Clean cotton cloth and cotton waste.
(xiii) Electric hand lamp.
(xiv) 12 mm vinyl hose of approximate 10 m length for being used as an oil level
indicator during erection.
(xv) Brushes & spray gun with compressor for painting.
(xvi) PVC wires for connecting meters during testing.
(xvii) Set of tarpaulins of suitable size.
(xviii) Earth discharge rods.
The above is only a general list of tools, and measuring instruments etc., used for erection
of transformers. The capacity, sizes, etc., of each tool would depend on the type and size of
transformer.
2.3.2 The installation site shall have easy accessibility for inspection and routine maintenance
etc. Foundation for the transformer should have level floor strong enough to support the weight,
vibrations and prevent accumulation of water. The transformer foundation should be provided
with adequate oil soak pits and drains. Typical designs of such pits are shown in Fig. 7.
Fig. 7
2.3.3 In case of large and costly transformers, fire protection walls may be necessary on either
side of the transformer for isolating each transformer from the rest.
2.3.4 The transformer installation position shall be such that the breather, thermometers, oil
level indicators, diagram plates, etc., can be safely examined with the transformer energized.
It should also be possible to have access to the operating mechanism of on load / off circuit
tap changing equipment, marshalling box, etc. Sampling valve, drain valve, etc., shall be at
accessible and convenient locations, if need be through construction of raised platforms.
2.3.5 For outdoor transformers where rollers are not fitted, level concrete plinth with bearing
plates of sufficient size and strength can be adopted. The plinth shall be above the maximum
flood or storm water level of the site and of the correct size to accommodate the transformer in
such a way that no unauthorized person may step on the plinth.
2.3.6 Where rollers are fitted, suitable rail tracks shall be provided and when the transformer
is in the final position, the wheels shall be locked to prevent accidental movement of the
transformer.
2.4 Unit Erection
2.4.1 Positioning of the Unit
2.4.1.1 The transformer tank containing the core and coil-assembly should be first placed in
the position selected for assembly.
2.4.1.2 In case the rollers are to be fitted, it should be ensured that the wheel shafts are well
greased and the wheels rotate freely. While fixing the rollers, the flanges should come on the
inner side of the rails. The transformer shall then be jacked up and the roller fitted to the
bottom frame. In some of the transformers, skid is provided in place of rollers.
2.4.1.3 All parts, gaskets, bushings, radiators and coolers etc., should be readily available in good
condition. The transformer oil required for filling must also be readily available.
2.4.1.4 In case special foundation bolts are supplied, these are to be used for arresting the
movement of the transformer, including anti-earthquake devices.
2.5 Oil
When oil is dispatched to site separately, it may be done in sealed steel / HDPE drums or
epicoated road tankers. At the time of filling the drums, it is ensured that the oil is filtered, clean
and dry.
2.5.1 Oil Specification
2.5.1.1 The oil as received at site for filling and topping up in the transformer must comply with
IS 335 / IEC 60296/Customer specification for acceptance criteria. Many utilities have different
specifications of oil (stringent than IS/IEC). Some Utilities prefer napthenic oil and others specify
inhibited oil. IEEMA has taken an initiative to standardize a common specification for oil to be
used by all Indian Utilities. Once IEEMA Specification on oil is published, CBIP Manual shall
adopt the same. For the present, extracts from IS 335 Oil Specifications are reproduced below
for reference.
2.5.1.2 The Oil Sample from the Transformer tank, after filling (new/unused) in tank before
commissioning should meet the following specifications as per IS 1866.
Note:
1. These properties are very sensitive to storage and processing, i.e., the temperature and vacuum of filtration, the
cleanliness of the processing system including filter machine, pipes, valves, cleanliness of transformer and its
cooling system, etc., Extreme care should hence he taken in these areas to achieve the values indicated above.
2. When unused oil has been filled in the lank then tests given against SI. nos. 7, 9, 10 & 11 in the above table are
important. Other parameters only form base data for future comparison.
3. Used oil shall meet the BDV and moisture content requirement given in the Table whereas other parametersmay
lie in between the above values and the limiting values given under cl. 2.5.1.3.
2.5.1.3 The recommended limits for mineral insulating oil filled in power transformers in
service (as per IS: 1866) are as follows:
SL. No. Characteristics / property IS 1866

1. Appearance Clear and transparent and without visible sediments
2. Interfacial tension (IFT) min. 0.015 N/m, min
3. Hash point Max. decrease of 15° C from initial value. However the
absolute value should not be less than 125 °C
4. Neutralization value (total acidity) max. 0.3 mg kOH / g Increase frequency of testing if more than
0.2 mg kOH/g
5. Di-electric strength (breakdown voltage)
BDV min Above 170 kV - 50 kV
72.5 KV- 170 kV -40 kV
Below 72.5 kV - 30 kV
6. Dielectric dissipation factor (Tan 5) DDF at 90 Above 170 kV - 0.2 Max. Below 170 kV- 1.0 max.
° C and 40-60Hz, max.
7. Specific resistance (resistivity)
(i) At 90 °C, min. 0.1*1012Q-cm
(ii) At 20 °C, min. 1.0* 1012I2-cm
8. Water content, max Above 170 kV- 20 ppm max
72.5 kV - 170 kV - 40 ppm max.
Below 72.5 kV — No free moisture at room
temperature
9. Sediment and sludge No sediment or precipitable sludge (below 0.02 % by mass)
Note : Recondition/replace the oil if one or more of the above parameters are beyond the specified limits.
2.5.1.4 POWERGRID Specification of oil for 400 / 800 kV Transformers is different and is
given below for reference.
2.5.2 Precautions
2.5.2.1 Oil is easily contaminated. When sampling the oil and filling the oil in the tank, it is very
important to keep the oil free from contamination.
2.5.2.2 All equipment used in handling the oil must be clean and should be washed with
clean transformer oil before use. (The oil used for washing must be discarded). Particular
attention shall be paid to the cleanliness of bungs, valves and other points where the dirt or
moisture tends to collect.
2.5.2.3 Sampling and type of container for DGA, wherever specified, shall be as per IS: 9434 or
IEC: 600567.
2.5.2.4 Flexible steel hose is recommended for handling insulation oil. Some kinds of synthetic
rubber hose are also suitable but only those known to be satisfactory should be used. Ordinary
rubber hose should not be used for this purpose as oil dissolves the sulphur from the rubber and
thereby gets contaminated. Proper flushing of hoses to be carried out before using them for oil
filtration and oil filling in the Transformer. Hose used for handling oil should be clean and free
from loose rust or scale.
2.5.2.5 Transformers must always be disconnected from the electricity supply system before the
oil level in the tank is lowered.
2.5.2.6 Oil must not be emptied near naked lights heater/fire, as vapour released is
inflammable.
2.5.2.7 Minute quantities of moisture (particularly in the presence of fibres or dust) lower the
dielectric strength of the oil. Therefore, to reduce the risk of condensation of the moisture entering
the oil, containers taken into a warm room shall not be opened until the entire body has attained
the same temperature as the room temperature. It is preferable not to mix oils from different
suppliers. However, if the oil-required to be mixed meet the requirements of IS: 335 and if these
are made from the same feed stock, these can be mixed.
2.5.3 Oil Sampling
Oil takes up moisture readily and its condition should always be checked before use. Oil of a muddy
colour is certain to be wet. Water and water-saturated oil are both heavier than dry oil and sink to the
bottom of any container. Samples shall, therefore, be taken from the bottom. Samples should not be
taken unless the oil has been allowed to settle for 24 hours, if from a drum or two / three days if from
a large transformer.
2.5.4 Samples from Tank
Dirt from the draw-off valve or plug should be removed. To ensure that the valve is clean, some
quantity of oil should be allowed to flow into a separate container before collecting samples for
testing. Samples shall be collected either in glass bottle (refer IEC 60567) or in stainless steel
bottle. Detailed sampling procedure for steel bottle is given in Annexure-III to this section. It
is recommended that: Oil sample for any of the major tests (BDV, PPM, Resistivity, Tan Delta,
DGA) must be taken from both top and bottom sampling valves and while drawing the sample
the corresponding top oil temperature must be furnished. The lesser of the values obtained from
the 2 samples shall be considered for decisions regarding BDV and resistivity, while the higher
values shall be reckoned for PPM, Tan Delta.
2.5.5 Sample from Oil Drum
The drum should first be allowed to stand with the bung vertically upwards for at least 24 hours.
The area around the bung should be cleaned. A clean glass or brass tube long enough to reach to
within 10 mm of the lowermost part of the drum should be inserted, keeping the uppermost end
of the tube sealed with the thumb whilst doing so. Remove the thumb, thereby allowing oil to
enter the bottom of the tube. Reseal the tube and withdraw an oil sample. The first two samples
should be discarded. Thereafter, the samples should be released into a suitable receptacle.
2.6 Oil Filling
2.6.1 Before filling oil in the tank, it should be tested to meet the requirements as IEC 60296/
IS 335 (with its latest amendments). In case the oil does not meet the requirement, it should be
processed and shall only be used when it meets the requirements.
2.6.2 For transformers dispatched gas filled, the filling of oil inside the tank is done under
vacuum. Transformers of high voltage rating (132 kV and above) have their tanks designed to
withstand full vacuum. Below 132 kV manufacturer’s instructions should be followed regarding
the creation of full or partial vacuum during filling the oil in the tank.
2.6.3 When filling a transformer with oil it is preferable that the oil be pumped into the bottom
of the tank through a good quality filter machine.
2.6.4 Some radiators may be suitable only for partial vacuum. No higher vacuum than as could
be withstood by radiators should be applied to such radiators type tanks even if the radiator
valves are closed. It should also be ensured that the bushings, tap changer board, relief vent
diaphragm, Buccholz relay, conservator, etc. are not subjected to full vacuum as these may not
designed for the same. (Specific guidelines from manufacturer may be followed)
Note: Now a days pressed steel radiators, bushings - condenser as well as porcelain, buchholz relay, conservator etc.
are designed for full vacuum and are readily available.
2.6.5 In case the transformer is provided with an on load tap changer of in-tank type, while
evacuating the main transformer tank, the diverter switch compartment must also be
evacuated simultaneously so that no undue pressure is allowed on the tap changer chamber.
While releasing vacuum, the tap chamber vacuum should also be released simultaneously.
For this one pressure equalizer pipe should be connected between main tank and tap changer.
2.7 Drying of Transformers
Before the drying out is started all fittings except coolers and associated accessories shall be
fitted. The coolers, etc., can be conveniently fitted after the successful dry-out of windings and
insulation.
The process of drying out a transformer is one requiring care and good judgment. If the drying
out process is carelessly or improperly performed, great damage may result to the transformer
insulation through overheating etc.
In no case shall a transformer be left unattended during any part of the dry-out period.
Transformer should be carefully watched throughout the dry out process and also observations
shall be carefully recorded.
When the transformer is dried out, it is necessary to ensure that the firefighting equipment is
available near the transformer.
The dry out of transformer is necessary in the following cases:
(a) On first commissioning

(b) After prolonged storage at site without nitrogen
(c) After detection of free moisture/ high moisture content in oil
(d) Due to exposure of core and coil assembly for 48 hours or more in case of inspection
at site
Various methods can be adopted for drying out a transformer depending upon the facilities
available at site. Some of them are described below:
2.7.1 Drying out a Transformer using Filter Machine
2.7.1.1 The most practical method of drying out is by circulation of hot oil through a high
vacuum filter machine incorporating oil heater and vacuum chamber (or other oil cleaning and
moisture removing device). The vacuum pump of the filter machine should have the capacity
of creating vacuum as high as possible but not less than 710 mm of mercury. Where possible,
a vacuum pump can be connected to the tank top cover to keep the oil in tank under vacuum
consistent with tank suitability. This may speed up the drying out process. It is preferable to lag
or blanket the transformer tank to prevent loss of heat. Oil is drawn from the bottom and let into
the transformer at the top. This will remove any settled moisture/ impurities. After about 8-12
hours circulation in this manner, the cycle is reversed and oil is drawn from the top and fed at
the bottom.
2.7.1.2 The oil temperature as measured by the oil temperature indicator should be of the order
of 55°C. It should be seen that the oil temperature at the filter machine in no case exceeds 65°C.
The circulation is continued till the insulation resistance and oil samples tests are satisfactory.
2.7.1.3 Plot IR values taken at regular intervals against temperature readings. It will be observed
that in the beginning IR values drop down as the temperature goes up. The IR values will be low
till moisture is coming out of the insulation and start rising before steadying. A typical dry out
curve is shown in Fig. 8.
2.7.1.4 Measuring winding Tan delta also a criteria for knowing the dryness of the Transformer
insulation. During dry-out, winding Tan delta may be measured between different cycles to
check the effectiveness of Dry-out.
2.7.1.5 The heat can also be provided by short circuit heating method as mentioned as clause
2.7.2 Hot Air Circulation
Time in hours
Fig. 8 Typical dry-out curve
2.7.2.1 Hot air from external heaters is blown into the transformer after draining the oil, through
an opening in the bottom of the tank and is allowed to escape through an opening in the tank top
cover (Fig. 9). The speed of the air must not exceed 600 m per minute. The temperature of the
air is raised gradually to 55°C in the first 8 hours, 65°C in the second 8 hours, and 75°C-80°C in
the third 8 hours. In this method also, hourly readings of temperature and insulation resistances
are taken till steady values are obtained.
2.7.3 Short Circuit Heating
Fig. 9
2.7.3.1 The transformer can also be heated up by short-circuiting the low voltage winding
and supplying at the high voltage terminals a reduced voltage. The supply voltage should be
maintained in such a way that the current in the windings does not exceed 70 per cent of normal
full load current and the oil temperature about 75°C. In this case, temperature of oil should
be measured at the bottom of the tank also. Constant watch is to be kept to ensure that the
temperature limits are not exceeded. The temperature of the windings which can be measured
by the following formula should in no case exceed 90°C :
T2 =R2/R1(235+T1])-235
where,
T2 = Final average temperature of copper
T1 = Initial average temperature of the copper
R2 = Final resistance of the windings.
R1 = Initial resistance of the windings. This method should be used in conjunction with streamline
filter as described in clause 2.7.1.
• Caution: Short circuit heating to be carried out with due precaution
2.7.4 Drying by Vacuum Pulling, N2 Filling and Heating
2.7.4.1 This is the most effective method and the quickest too but cannot be applied in case
of transformers not designed for withstanding the vacuum pressure. The vacuum should be
drawn from the top of the tank connecting suitable pump to any valve fitted at the top of the tank.
Vacuum is applied after draining the oil. The transformer core and coil are heated externally by
the use of heater. Temperature at the tank wall to be of the order of 60-70 °C. Another method of
heating active part is to do hot oil circulation for 2-3 volumes and then drain oil immediately.
2.7.4.2 The leakage rate has to be less than 40 m bar-lit/sec- so as to get better vacuum during the
drying out process. After ascertaining that there is no leakage in the transformer from gaskets/
valves etc., pull out vacuum and keep the transformer under near absolute vacuum (1 torr or
less) for about 96 hours running the vacuum pump continuously. The duration of vacuum can
vary between 48 to 96 hrs. depending upon the dew point being achieved. Keep Vacuum machine
ON and collect condensate for measurement.
2.7.4.3 Then the vacuum is broken with dry nitrogen. The dew point of the inlet of nitrogen is
to be measured and will be of the order of - 50 °C or below. When the nitrogen comes to the
positive pressure of 0.15 kg/cm2, it is stopped and kept for 48 hours. Then the nitrogen pressure
is released and the outlet nitrogen dew point is measured. If the dew point is about -30 °C or
below then the dryness of transformer is achieved. If not again the transformer is taken for
vacuum treatment and then nitrogen is admitted as mentioned above and tested. The cycle to be
continued till dew point of -30°C or below is achieved.
2.7.4.4 Duration of vacuum cycle may vary between 48-96 hrs. Initially one or two nitrogen
cycles may be kept for 24 hrs. After that it may be kept for 48 hrs depending upon dew point
being achieved.
2.7.4.5 When condensate collection rate is less than 40 ml/hr for 24 hrs and Dew point of
Nitrogen is about -30 °C at outlet.
2.7.4.6 After completion of the drying of the transformer the following parameters are to be
checked.
(a) PI (Ratio of R600 and R60) may be 1.5 or more
(b) BDV and moisture content of the oil as per IS 1866 or as recommended by transformer
manufacturer
(c) Power factor of winding - Less than 0.5%.at 20 deg C
2.8 Circulation of Oil in Coolers and Tap Changers
2.8.1 Coolers and tap changers are filled with clean dry oil. Oil samples are taken out from
them and tested. Further circulation of oil is carried out till the oil results are satisfactory and meet
the requirements as per IS 1866. It is advisable to carry out the circulation in the main tank and
selector switch/ diverter switch tank simultaneously to remove moisture from the tap changer
terminal board/diverter switch cylinder provided on the tank.
2.9 Important Fittings and Accessories
2.9.1 Gaskets
2.9.1.1 Whenever blanking plates are removed to fix detached parts such as bushing turrets, etc.,
a new gasket shall be used while fixing the same. A set of new unused gaskets of correct size and
thickness is supplied with every transformer for this purpose.
2.9.1.2 Gaskets shall be stored in hermetically sealed containers in a cool place. They must be
protected from damp, oil and grease.
2.9.1.3 To make a gasketed joint, first clean the metal surfaces ensuring that they are free from
oil, rust scale, etc. Then a film of the special gasket adhesive if supplied by the manufacturer
may be applied to one of the surfaces. The gasket may be then stuck to the surface after the lapse
of a few minutes. The other metal surface may also be given a film of adhesive and placed over
the gasket. Both may then be tightened according to the special instructions of the manufacturers.
Some type of gasketed joints is shown in Fig. 10.
(a) Metal Fit Type: In this case the flanges are tightened uniformly till the two metals
touch each other.
(b) Ordinary Type: In this case the gasket should be uniformly compressed such that its
thickness comes down to above 60 per cent of its original thickness.
(c) Distance Piece Type: In this system the flanges are tightened uniformly till the upper
flange touches the metal piece welded to the lower flange.
Joints in gaskets should be scarfed or dove tailed as shown in Fig. 11.
2.9.2 Bushings
2.9.2.1 Normally three types of bushings are used:
(i) Plain porcelain type
(ii) Plain oil filled
(iii) Condenser type
• Plain porcelain type bushings are used up to rated voltage 36 kV.
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 and used up to 110 kV.
Fig. 10
Fig. 11
2.9.2.2 Condenser type bushings are also of three categories, one is the SRBP type, resin
impregnated paper type (RIP) and the other is the oil impregnated paper condenser (OIP) type.
The last one is distinguishable by the presence of porcelain shell below the flange level.
2.9.2.3 The bushings shall be checked for any damage at the oil end as well as the porcelain
before fixing and shall be cleaned thoroughly. The bushings shall be lifted by using the lifting
eyes and soft manila ropes. Steel Wire ropes or slings shall not be used (Fig. 12). The line 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 connection leads should also be provided to avoid mechanical stress
Fig. 12
on the bushing. The shield barriers, if any shall be inspected through the inspection cover for
proper seating. The line connection should be tight and should not strain the terminals. The
arcing horns, if any, shall be in proper position as shown by the supplier in general arrangement
drawing.
2.9.3 Tap Changers
2.9.3.1 Change over switch or link arrangement provided in a multi-ratio transformer has to be
checked for proper ratio.
2.9.3.2 Off-Circuit Tap Changer: The off-circuit tap changer forms 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 manufacturer’s instructions. Care
has to be taken to have correct alignment of the handle. The actual position of tap changer 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.
2.9.3.3 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 lead to earth should be measured and in case of low value, the cause should be
investigated. The leads from the tap changer 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 to be 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.
2.9.4 Cooling Equipments
2.9.4.1 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 gauge,
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.
2.9.4.2 Cooling Fans: Cooling fans are mounted as per manufacturer’s instructions. The fans
are tested for insulation value and normal running before they are mounted.
2.9 4.3 Separate Coolers
(i) Forced Oil Cooled Transformers
In the case of forced oil cooled transformer, 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 pipeline 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 arc 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 center lines of transformer and cooler should be strictly as
per the general arrangement drawings 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 pipeline connecting the transformer tank
to the cooler. Special care should be taken to see that these are 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 supplier’s works to make it absolutely sure that there is no leakage. The
sealing should not be tempered 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.
2.9.5 Conservator
2.9.5.1 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.
2.9.5.2 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.
2.9.5.3 Procedure for mounting air cell and oil filling inside the conservator.
Fig. 13 Oil conservator with air cell

Set up the air cell inside the conservator. Care should be taken to see that the hooks on air cell are
properly engaged in the brackets provided inside the conservator.
Inflate the air cell at a pressure as shown in the instruction plate (DO NOT APPLY EXCESS
PRESSURE AS IT MAY DAMAGE THE AIR CELL) through the breather connection pipe.
Follow the instructions given in the Instruction Plate fixed on the transformer.
Ensure that there is no leakage.
The conservator with Air Cell is pressure tested and dispatched from the factory at a slightly
positive pressure. Confirm that there is no oil leakage.
Fix three numbers air release valves on the conservator.
Keep air release valves open. Fix air filling adapter on breather pipe and inflate the air cell at an
air pressure indicated on the INSTRUCTION PLATE affixed on the transformer and hold air
pressure.
Open the air release valves and start oil filling from the bottom filter valve of the transformer.
• Observe the air release valves and as soon as oil starts overflowing, close the air
release valves one by one. Stop oil filling when all air release valves are closed.
• Remove the air-filling adapter.
• Continue oil filling and observe the Magnetic Oil Level Gauge (MOG)
• Stop the filling when the needle of MOG shows the level corresponding to the ambient
temperature at the time of filling.
• Fix silica gel breather.
Caution:
• Do not open any of the air release valves after completion of oil filling. If air release
valve is opened, air will enter and oil level will drop.
• The plain oil level gauge on the end cover of the conservator should indicate full oil
level always. If air enters the conservator, it can be seen by a fall in the oil level in
plain oil level gauge.
• The plain oil level gauge should be monitored on regular basis.
2.9.6 Buchholz Relay
2.9.6.1 The Buccholz 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 to 7°. The gas release pipe, if provided is to be connected to the top
petcock. In service the top petcock should be open and gas release pipe should be full of oil.
When the gas is to be collected through the gas release pipe, initially the oil will flow out and
then the gas can be collected.
2.9.7 Dehydrating Breather
2.9.7.1 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 over
flown 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. and silica gel to be filled into the breather is dry.
2.9.8 Pressure Relief Device (PRD)/ Explosion Vent
2.9.8.1 PRD: Mount PRD as per manufacturer’s leaflet and also the G.A. drawing of transformer.
Check operation of alarm/ trip contacts.
2.9.8.2 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 airtight 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. The fixing can be done after vacuum
application.
2.9.9 Temperature Indicators
2.9.9.1 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 check is done through hot
oil bath.
2.9.9.2 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.
2.9.9.3 The thermometer pocket should be filled with transformer oil
2.9.9.4 The connection of the winding temperature indicator C.T. is made to the thermometer
pocket as per instructions given on the WTI Terminal Board.
2.9.10 Bushing Current Transformers
2.9.10.1 It is not advisable to remove the bushing CTs unless situation warrants for the same.
In such cases great care shall be taken in handling current transformers. Current transformer
should be kept flat at all time. If it 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.
2.11 Completion of Erection Work
Final topping up is now done up to a level in conservator commensurate with filled oil temperature.
Any other work such as wiring of various alarm/trip contacts, fan motors, pump motors and other
apparatus, earthing of neutral and tank is also to be 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.
3.0 TESTING AND COMMISSIONING
If the foregoing instructions have been carefully followed, the transformer can now be safely put
into service after pre-commissioning tests.
3.1 Tests
The following pre-commissioning tests shall be carried out.
3.1.1 Checking of Ratio, Polarity and Phase Relationship
3.1.1.1 The ratio shall be checked on all taps and between all the windings and the results should
tally with the manufacturer’s factory test results. Preferably Transformer Automatic Turns Ratio
Meter (TTR) should be used. In case of OLTC, continuity during tap change is to be ensured.
This is best done by applying single phase voltage on each HV winding in turn and observing
variations of LV voltage at the instance of diverter operation by using analogue voltmeter. Break
will be indicated by any major deflection of the analogue meter towards zero.
3.1.1.2 Polarity and interphase connections shall also be checked
3.1.2 Resistance Measurement of Windings
3.1.2.1 Kelvin Bridge meter or automatic winding resistance measurement kit (ohm meter,
preferably 25 A kit) should be used for the measurement of resistance. Tapped winding resistance
shall be measured at all tap positions. Pre-commissioning values are to be compared with factory
values after applying temperature correction factors.
3.1.3 Insulation Resistance
3.1.3.1 IR values between windings and between windings to earth are checked; while checking
these values no external lines, lightning arrestors, etc., should be in circuit. Bushings are
thoroughly cleaned before taking IR values. A 5000 / 2500 /1000 volts megger preferably motor
operated should be used for measuring IR values. One minute and 10 minute IR values can be
taken to find out the polarization index also. (PI = R600/R60) Care should be taken that the lead
wires of the megger do not have joints.
Note Now a-days digital meters are also available in the market which can read Polarisation Index (PI) directly and
compensate for magnetic interference.
3.1.4 Magnetizing Current
3.1.4.1 Magnetizing current may be measured using single-phase 230 volts supply for each
phase individually and compare the results with manufacturer’s factory test results. If the test
results at the factory are available with 3 phase supply then magnetizing current at site may also
be measured using 3 phase 415 volts supply. It is recommended to measure magnetizing current
at 10 kV for Transformers having voltage rating in the range of 400 kV and 800 kV
Note: Measurement of magnetizing current is a standard feature available in most of the available Automatic C &Tan
Delta Test kits.
3.1.5 C and Tan Delta I Power Factor Measurement of Transformer Windings and
Bushings
(a) For Transformer windings, measurements shall be done after opening the jumpers and
isolating the transformer from other equipment and the ground.
(b) The test kit should be suitable to work in charged switchyard environment, i.e.,
induction suppression unit should be provided.
(c) Test modes shall be selected as below : Bushings
UST mode between HV and test tap.
Windings
(i) Between two windings - UST mode
(ii) Between winding to Earth- GSTg mode with other winding (s) guarded.
(iii) Between HV to earth in GST mode for comparison of test results taken in (i) & (ii)
above
Notes
While carrying out the test, all 3 phases of the same winding are to be shorted to compensate/nullify the effect
of winding reactance.
The bushing porcelain and test tap are to be properly cleaned before the commencement of test.
Pre-commissioning values are to be compared with factory values after applying temperature correction
factors.
Tan Delta/ Power Factor values should be more frequently monitored if faster deterioration trend is observed.
3.1.5.1 Frequency Response Analysis (FRA)- Measures mechanical movement of windings
and core during transit or in operation.FRA to be carried out at site in same tap position where
it was measured at factory to have better interpretation. Normally, it is preferred to have FRA
signatures in extreme and nominal tap position. These signatures also act as base signatures for
any further measurement to be carried out during operation.
3.1.6 Tap Changer
3.1.6.1 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) Group Operation, if applicable.
3.1.7 Buccholz Relay Test
3.1.7.1 Check whether the Buccholz 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. Buccholz relay operation for alarm and trip are checked by injecting air
through the test petcock (For transformers with ATMOSEAL conservators relay may be tested
either by putting in test position or by draining oil from relay after closing valves from either
sides).
3.1.8 Magnetic Oil Level Gauge
3.1.8.1 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. This can only be checked before installation.
3.1.9.1 The contacts of WTI and OTI for alarm and trip are checked and set at required
temperatures depending upon ambient temperatures and loading conditions.
3.1.10 Fans and Pumps
3.1.10.1 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 that the direction of rotation of fans and pumps is correct.
3.1.11 Marshalling Box
3.1.11.1 The wiring from various accessories to marshalling box shall be checked.
3.1.12 Oil
3.1.12.1 Oil samples from top and bottom of main tank are tested as per IS: 1866 (table given in
clause 2.5.1). DGA tests are to be done to obtain benchmark before charging, one month after
charging, three months after charging, and thereafter every year.
3.1.12.2 Oil of diverter switch should be checked for BDV at the time of commissioning and
subsequently yearly or 5000 operations, whichever is earlier.
3.1.1.12.3 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 and tank etc.
(e) Earthing connections are done.
(f) The colour of silica gel and oil in the breather cup.
(g) Arcing horn gaps on bushings (where provided) are properly adjusted.
(h) Heaters in cubicles, conservator, etc., where provided should be checked.
(i) To check alarm/trip contacts of all accessories, instruments flow meters, differential
pressure gauges etc.
(j) 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 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 venting 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 energisation at no load, the transformer shall
be switched off. The Buccholz relay should be checked for collection of air/ gas. Abnormalities
noticed should be corrected. All protective relays should be reset to normal values. Transformer
can now be re-energized and loaded gradually.
After commissioning, the following details should be furnished to the manufacturer:
(i) Details of transformer including its serial number.

(ii) Date of commissioning, with test results.
(iii) Substation/generating station where commissioned.
(iv) Protection given to the transformer such as lightning arrestor, differential protection,
circuit breaker on H.V/L.V etc.
(v) Loading details with complete temperature log.
4.0 MAINTENANCE
4.1 General
4.1.1 If a transformer is to give long and trouble-free service it should receive a reasonable
amount of attention and maintenance. Following are the causes of breakdown of transformers:
(i) Faulty design and construction.
(ii) Incorrect erection, operation and maintenance.
(iii) Wear and tear, ageing and other deterioration.
(iv) Accidents.
4.1.2 A rigid system of inspection and preventive maintenance ensures long life, trouble
free service and low maintenance cost. Maintenance consists of regular inspection, testing and
reconditioning where necessary.
4.1.3 Records must be kept giving details of any unusual occurrence and also if any test results
taken.
4.1.4 The principal objective of maintenance is to maintain the insulation in good condition.
Moisture, dirt and excessive heat are the main causes of insulation deterioration and avoidance
of these will in general keep the insulation in good condition.
4.1.5 No work should be done on any transformer unless it is disconnected and isolated from
all external / energized circuits, and all windings have been solidly earthed.
4.2 Factors Affecting the Life of a Transformer
4.2.1 Transformer oil readily absorbs moisture from the air. This reduces the dielectric strength
of the oil. It is also reduced by solid impurities present in the oil. Care should be taken that
moisture does not penetrate inside the transformer.
4.2.2 Much of the mechanical strength of paper and-pressboard comes from the long chain
cellulose polymer. Although temperature is a major factor, Oxygen and water clearly have a
significant effect on the degradation of cellulosic material (Kraft paper). It is seen that moisture
is formed in service-aged transformers due to thermal ageing, which results in lower degree of
polymerization (DP) indicating weakening of mechanical strength of paper.
4.3 Maintenance Procedure
CIGRE WG A2.18 – Life Management Techniques for Power Transformers shall be referred.
The maintenance procedure listed in subsequent clauses is to be attended to at the intervals of

time noted against each item in Annexure I.
4.3.1 Oil
4.3.1.1 For maintenance of oil reference may be made to “IS 1866: Code of Practice for
Electrical Maintenance and Supervision of Mineral Insulating Oil in Equipment” which gives
recommendations in detail for the maintenance of insulation oil. A few short notes on the subject
are given below:
The oil level should be checked at frequent intervals and any excessive leakage of oil investigated.
There may be slight loss of oil by evaporation; this need cause no concern if the tank is topped
up at regular intervals.
All leaks should be repaired as quickly as possible so as to avoid possible trouble caused by low
oil level.
Oil for topping up should comply with IS 335 / IEC 60296: New insulating oils and should
preferably be from the same source as the original oil because the oil refined from different
crudes may not be completely miscible and may separate into layers. Furthermore, there may
be a greater tendency to form acidity or sludge in a mixture than in oil from a single source of
supply. Used oil shall not be mixed. New oil may be added as make up only, not exceeding about
10 per cent.
Samples of the oil should be taken at regular intervals preferably half yearly and tested for DGA
and oil parameters.
It may be mentioned that the dielectric strength does not give a true indication of the deteriorated
condition of the oil. Even oil, which is highly deteriorated, may give a high dielectric strength, if
dry. Normal methods of oil purification only maintain the dielectric strength, but do not improve
the deteriorated condition of the oil. It is, therefore, advisable not to rely solely on the dielectric
strength of the oil by periodic tests. In addition to chemical tests other tests as given in Clause
2.5.1 should also be carried out. If the dielectric strength is below, the recommended limit, the
oil should be reconditioned by passing it through either a centrifugal separator or a filter. After
reconditioning, the breakdown voltage should be more than 50 kV r.m.s. across a standard gap
(2.5+0.05 mm apart) and other parameters to be tested as per clause 2.5.1 (IS 1866).
Other Oil parameters play important role for healthy operation of the transformer. In case any of the
parameters like resistivity, IFT reaches the limiting value given in clause 2.5.1 (IS 1866), oil should
be monitored more frequently and in case the values continue to deteriorate, a decision regarding
change of oil is required to be taken.
It may be noted that reconditioning by vacuum filtration only improves BDV, moisture content
and removes dust, dirt suspended material etc. from oil. This process does not improve any other
parameters of oil and will tend to retard the process of deterioration of oil. Other methods may
have to be followed to improve resistivity, acidity etc. In such a case it is better to change the oil
and the old oil may be sent to an oil refinery for reclaiming it.
4.3.2 Rollers
4.3.2.1 Alter a transformer has been in service for a long period, rollers should be examined
carefully. They should be greased and rotated to see that they turn freely. Rollers should also be
inspected for overheating when moved on tracks, during initial erection.
4.3.3 Transformer Body
4.3.3.1 The transformer tank and other parts should be inspected periodically for any rust or and
oil leak. Rusted portions, if any, should be cleaned thoroughly and repainted with proper paints.
Transformer should be completely painted at proper intervals. If any leak is found, it should be
investigated. If it is due to defective welding, the same should be rectified after consulting the
manufacturer. Leaking joints can be rectified by tightening the bolts to the correct pressure or by
replacing the gaskets.
4.3.4 Core and Winding
4.3.4.1 It is recommended that the core and winding be removed from the tank for visual
inspection as per time schedule given in inspection table. The windings should be examined to
ensure that no sludge has been deposited blocking the oil ducts. Any loose nuts and bolts should
be tightened. On transformers with bell type tank, the inspection of core and coil can be done
by lifting the tank. Inspection of core and coil assembly of transformers with conventional type
tank has to be done with extreme care so as not to damage the insulation structure which might
have become brittle due to long service life of transformer
4.3.4.2 Before lifting the core and winding from the tank, it is usually necessary to disconnect
the windings from the bushings or cable boxes inside the tank to disconnect the off-circuit tap
switch handle or leads of the on-load tap changer and to remove any earthing strips between the
core clamps and the tank.
4.3.4.3 The core and winding must be removed with great care. It should be placed under
cover and in a dry place.
4.3.5 Bushings
4.3.5.1 The bushings should be inspected for any cracks or drippings of the porcelain at regular
intervals and kept free from dust and dirt. In location where special and abnormal conditions
prevail, such as sand storm, salt deposits, cement dust, oil fumes etc., bushings should be cleaned
at more frequent intervals.
4.3.5.2 Oil level in oil filled bushings should be checked periodically.
4.3.6 Cable Boxes
4.3.6.1 The sealing arrangements for filling holes should be checked each year. When screwed
plugs are sealed with a bituminous compound, the compound should be examined for cracks. If
the compound has cracked it should be replaced as the cracks may lead to an accumulation of
water around the plug. Gasketed joints should be examined and tightened whenever required.
4.3.7 External Connections
4.3.7.1 All external connections should be tight. If they appear to be blackened or corroded, the
same can be cleaned or should be replaced, if required.
4.3.8 Conservator and Magnetic Oil Gauge
4.3.8.1 Conservators are so arranged that the lower part acts as a sump in which any impurities
entering the conservator will collect. A valve/plug is fitted at the lowest point of the conservator
for draining and sampling. The inside of the conservator should be cleaned every two to three
years. A removable end is generally provided for this purpose.
4.3.8.2 The oil level indicator should be kept clean. Generally the oil level is visible through a
transparent material. In case of breakage immediate replacement is essential. When conservator
is stripped for cleaning, the mechanism of the oil gauge should be cleaned.
4.3.9 Dehydrating Breather
4.3.9.1 Breathers should be examined to ascertain if the silicagel requires changing.

The frequency of inspection depends upon local climatic and operating conditions.
More frequent inspections are needed when the climate is humid and when the transformer
is subjected to fluctuating loads. So long as the silicagel is in active stage its colour
is blue but as it becomes saturated with moisture its colour gradually changes to pale pink.
The gel should then be replaced or reactivated. The saturated gel can be regenerated by
heating up to 110-130 °C for 8 to 10 hours or 150-200 °C for two to three hours and can be
used again.
4.3.9.2 The level in the oil seal must be maintained at the level marked in the cup.
4.3.10 Buccholz Relay
4.3.10.1 Routine operation and mechanical inspection tests should be carried out at one and two
yearly intervals respectively.
4.3.10.2 During operation if gas is found to be collecting and giving alarm, the gas should be
tested and analysed to find out the nature of fault. Sometimes, it may be noticed that the gas
collected is only air. The reasons for this may be that trapped air if any is getting released or due
to leakage of the suction side of the pumps. The trapped air is released in initial stages only when
vacuum is applied during filling of oil. The internal faults can be identified to a great extent by
chemical analysis of collected gas.
4.3.10.3 Buccholz relay may also give alarm/trip signal due to the oil level falling below the
required level.
4.3.11 Explosion Vent
4.3.11.1 The diaphragm, which is fitted at the open end of the vent should be inspected at
frequent intervals and replaced, if damaged. Failure to replace the diaphragm quickly may allow
the ingress of moisture which will contaminate the oil. If the diaphragm has broken because of
a fault in the transformer an inspection must be carried out to determine the nature and cause of
the fault.
4.3.12 Gaskets
4.3.12.1 Gaskets sometimes shrink during service. It is, therefore, necessary to check the
lightness of all bolts fastening gasketed joints. The bolts should be tightened evenly round the
joints to avoid uneven pressure. Leaking gaskets should be replaced at the earliest opportunity.
4.3.13 The pipe work should be inspected at least once a year. Leaks may be due to slack
unions, which should be tightened, or to badly seated joints requiring the pipes to be aligned and
joints remade.
4.3.14.1 At each yearly maintenance inspection, the level of oil in the pockets holding
thermometer bulbs should be checked and the oil replenished, if required. The capillary tubing
should be fastened down again if it has become loose. Dial glasses should be kept clear and if
broken, replaced as soon as possible to prevent damage to the instrument. Temperature indicators
should be calibrated with standard thermometer immersed in hot oil bath if found to be reading
incorrectly.
4.3.15 Coolers and Cooling Fans
4.3.15.1 There are variety of coolers. For radiator type coolers, maintenance primarily consists
of replacing damaged elements, cleaning the outer surface to remove settled dust, repainting
etc.
4.3.15.2 Fan blades are cleaned to remove dust; bearings of the fan motors should be lubricated
occasionally. Greases should not be added while the motor is running. For other coolers,
manufacturer’s instructions should be followed.
4.3.16 On-load Tap Changer
4.3.16.1 Since all on-load tap changers are not of the same design and construction, special
instructions of manufacturer’s should be followed. However, a few points are enumerated.
(a) Diverter Switch: The maintenance primarily consists of servicing of diverter switch
contacts, checking the oil level in the diverter switch chamber, and replacement of
diverter switch oil when the same becomes unsuitable for further service.
(b) Motor Driving Mechanism
(i) Do not allow dirt to accumulate between contact rings of notching controller.
(ii) Do not use oil/grease on contacts rings on notching controller.
(iii) Check the operation of anti-condensation heater.
(iv) If the contacts of contactors are silver faced, no touching up be ever done, if any
is worn out, it should be replaced. Copper contacts may be lightly touched up
with a file when they become rough. The pole faces of electromagnet must be
kept clean.
(v) Do not oil/grease the contact surface of radial multi-contact switches, unless a special
contact lubricant is used. The space between the rings should be cleaned occasionally.
If necessary, a few drops of Benzene be used.
(c) Selector Switch: The contacts do not make/break current. As such, the wear is only due to
mechanical movement of moving contacts. These may be inspected once in 2/3 years.
4.3.17 Spares
4.3.17.1 It is a healthy practice to have essential spares like one number of each type of bushings,
one thermometer, one cooling fan, pump, buchholz etc., for each group of similar transformer.
Suppliers’ recommendations may also be considered in this connection.
4.3.18 Inspection and Maintenance Schedule
4.3.18.1 The frequency of inspections should be determined by the size of the transformer.
Local climatic and atmospheric conditions will also influence the inspection schedule. Use
Annexure I as a guide for determining the inspection schedule.
4.3.19 Transformer Preservation in De-energized Condition for Long Storage
4.3.19.1 Transformers fitted with conservator oil preservation system (COPS)/ diaphragms are
recommended for preservation of Transformers in de-energised condition. Suitable cautions to
be put in placing advising to open the valves before energizing the transformer. Heaters in MB
should be kept ON. Oil level in the conservator should be monitored. (Low oil level could be
indicative of rupture in air cell of COPS (Conservator Oil Preservation System).
4.3.19.2 Following checks to be followed while the transformer is kept for long storage in de-
energised condition :
(A) Quarterly
• Open the valves between tank and radiator, and run the oil pumps for two hours.
• Carry out oil tests for BDV and Moisture content.
(B) Half yearly
• BDV of OLTC oil.
• DGA
(C) Yearly
• Measurement of Tan delta of Bushings.
• Operate Tap changer 2-3 times over full range.
(D) Once in three years
• Measurement of Winding Tan Delta

Annexure I
Table 1 Recommended Maintenance Schedule for Transformers of Capacities
Up to 10 MVa & 33 kV
SL. Inspection Items to be inspected Inspection notes Action required if

No frequency inspection shows
unsatisfactory
conditions
1. Hourly (i) Load (amperes) Check against rated figures
(ii) Temperature (iii) Voltage oil temperature (OTI) and
winding temperature(WTI)
and ambient temperature
2 Daily Position of tap switch air cell Oil level glass to indicate If level drops, check and
conservator full. re-commission air cell.
3 Fortnightly Dehydrating breather Check that air passages If silicagel is pink, change
are clear. Check colour of by spare charge. The old
active agent charge may be reactivated
for use again.
4 Monthly (i) Oil level in transformer. Check transformer oil If low, top up with dry oil.
(ii) Connections level. Check tightness. Examine transformer for
(iii) Explosion vent Check for cracks/ damages. leaks. If loose, tighten,
(iv) Diaphragm Check for any oil spillage. Replace if cracked.
(Pressure relief device)
5 Quarterly Bushings Examine for cracks and Clean or replace. Tighten,
dirt deposits Check for if required
external connections
6 Half yearly (i) Non-conservator transformer. Check for moisture under Improve ventilation,
(ii) Cable boxes, gasket joints, cover. Inspect. maintenance of breathers to
gauges and general paint work be ensured. Take remedial
measures.
7 Yearly (i) Oil in transformer Check for dielectric Take suitable action to
(ii) Earth resistance Strength and water restore quality of oil.
(iii) Relays, alarms, their circuits, etc. content. Check for acidity Take suitable action if
and sludge. < 1 ohm earth resistance is high.
Examine relay and alarm Clean the components and
contacts, their operation, replace contacts and fuses
fuses, etc. Check relay if necessary, Change the
accuracy, etc. setting, if necessary,
8 5 Yearly Non-conservator transformers Internal inspection above Filter oil regardless of
core. condition.
9 10 Yearly Overall inspection Wash by hosing down with
including lifting of core clean dry oil.
and coils.
Note : Inspection of core & coil to be done in consultation with manufacturer,

Table 2 Maintenance Schedule Recommended Maintenance Schedule for

Capacities of 10 MVa and Above
SL. No Inspection Items to be inspected Inspection notes Action required if

frequency inspection shows
unsatisfactory
conditions
1 Hourly (i) Ambient temperature Check that Shut down the transformer
(ii) Winding temperature temperature rise is and investigate if either is
(iii) Oil temperature reasonable.Check persistently higher than
(iv) Load (amperes) against rated normal.
(v) Voltage figures.
(vi) Tap position of tap changed.
2 Daily (i) Oil level in Main and OLTC Check that air If low, top up with dry
conservator passages are free. oil, examine transformer
(ii) Oil colour and level in Check colour of for leaks.
condenser bushings active agent. Contact manufacturer in
(iii) Leakage of water into cooler. Positive pressure to be case of major changes If
(v) Dehydrating breather ensured half of silica gel is pink,
change by spare charge.
(vi) Cooler oil Pumps
The old charge may
(vii) N2 pressure, if applicable
be reactivated for use
again.
3 Quarterly (i) Bushings Examine for cracks Clean or replace. Tighten
(ii) Indoor transformers Checking and dirt deposits. top terminals and
of oil leaks Check for clearance terminal connectors
of arcing horns, if
applicable Check
ventilation.
4 Half Yearly Dissolved gas Analysis of oil sample Test for all fault Action to be taken as
DGA (IS 10593/ IEC 60599/ ANSI/ Gases per DGA test results like
IEEE C57.104) increase in frequency of
sampling to have trend
and any specialized test
if required.
5 Yearly (i) Physical checking of oil level Check with dip stick Top up, if required
Oil in transformer method Check for Take suitable action to
(ii) Oil parameters as per cl no. dielectric strength restore quality of oil.
2.5.1 (IS 1866/IEC 60422) (BDV) and water Filter or replace based
(hi) Cooler fan bearings, motors and content (moisture) on test results
operating mechanism. Check for oil Replace burnt or worn
(iv) OLTC parameters Lubricate contacts or other parts
bearings Check gear
box. Examine contacts.
Check manual control
and interlocks. Check
oil in OLTC driving
mechanisms.
C& tan delta of bushings value should be less Replace based on test
than 0.007, rate of rise result
of C & tan δ to be less
than 0.001/ year
Checking of WTI, OTI pockets Check presence of oil Top up if required
Calibration of WTI.OTI Checking
of operation of buchholz Relay
Yearly (i) OLTC Oil Check for dielectric Filter or replace based
(or earlier if), the strength (BDV) on lest results.
transformer can and water content
conveniently be (moisture)
taken out for
checking). (ii) Disconnecting Chamber Check BDV of oil Replace oil in
disconnecting chamber
if BDV < 50 kV
(iii) Gasket Joints Tighten the bolts Replace gasket, if

evenly to avoid uneven leaking.
pressure
(iv) Cable boxes. Check for scaling Cracked compound
arrangements for around screwed holes to
filling holes. Examine be replaced.
compound for cracks.
(v) Surge diverter and gaps. Examine for cracks Clean or replace.
and dirt deposits.
(vi) Relays, alarms, their circuits Examine relay and Clean the components
etc. alarm contacts, their and replace contacts
operation, fuses, etc. and fuses, if necessary.
Check relay accuracy Change the setting, if
etc. necessary.
(vii) Earth resistance — Take suitable action; if
earth resistance is high.
5. SOS (In case of LV tests like ratio, winding resistance Test results to be If major deviations
any protection at all taps position, c & tan delta, compared with pre- found then specialized
tripping due to magnetizing current and magnetic commissioning test tests like FRA, FDS,
internal fault or balance, results PD tests to be carried
after any major out in consultation with
maintenance manufacturer.
work)
6. 10 Yearly Life assessment test Furan measurement Will help decision
and calculated Degree making for taking up
of Polymerization any major refurbishment
action on transformer.
Notes
SI. No. 1& 2 are in purview of Operation staff whereas the rest to be taken care of by maintenance staff.
With respect to on-load tap changers, the manufacturer’s recommendation should be followed.
The silica gel may be reactivated by heating it to 150 to 200 degree C.
Every time the drying medium of breather is changed, oil seal should also be changed.
No work should be done on any transformer unless it is disconnected from all external circuits and the tank and
all windings have been solidly earthed.
In case of anything abnormal occurring during service, maker’s advice should be obtained, giving him complete
particulars as to the nature and the extent of occurrence, together with the name plate particulars in order to
assist identification.
In case of any through fault seen by the transformer or any major failure, SFRA to be measured and results to
be compared with previous base signatures.
Table 3 : Trouble Shooting Chart for All Transformers
Trouble Cause Remedy

Rise in temperature Over voltage Over current Change the circuit voltage or transformer connections. to
High temperature avoid over-excitation If possible, reduce load. Heating can
often be reduced by improving power factor of load. Check
parallel circuits for circulating currents which may be caused
by improper ratios or impedances. See Electrical Troubles,
below.
High ambient temperature Either improve ventilation or relocate transformer in lower
ambient temperature.
Insufficient cooling If unit is artificially cooled, make sure cooling is adequate.
Lower liquid level Fill to proper level.

Sludged oil Use filter press to wash off core and coils. Filter oil to remove
sludge.
Short circuited core Test for exciting current and no load loss. If high inspect core
and repair. See Electrical Troubles, below.
Electrical troubles
Winding failure Lightning, short circuit, Usually, when a transformer winding fails, the transformer
Overload, Oil of low is automatically disconnected from the power source by the
dielectric strength, Foreign opening of the supply breaker or fuse.
material
Core insulation breakdown Smoke or cooling liquid may be expelled from the case,
(core bolt, clamps, or accompanied by noise. When there is any such evidence or
between laminations) a winding failure, the transformer should not be reenergized
at full rated voltage, because this might result in additional
internal damage. Also it would introduce a fire hazard in
transformers.
After disconnection from both source and load, the following
observations and tests are recommended :
(a) External mechanical or electrical damage to
bushings, leads, potheads,
(b) Level of insulating liquid in all compartments.
(c) Temperature of insulating liquid wherever it can be
measured.
(d) Evidence of leakage of insulating liquid or sealing
compound.
Core failure high Short-circuited core Open Test core loss. If high, it is probably due to a short-circuited
excitation current core joints core. Test core insulation. Repair if damaged. If laminations
are welded together, refer to manufacturer. Core loss test
will show no appreciable increase. Pound joints together and
retighten clamping structure.
Incorrect voltage Improper ratio Supply Change terminal board connection or ratio adjuster position
voltage abnormal to give correct voltage. Change tap connections or readjust
supply voltage.
Audible internal Isolated metallic part The source should be immediately determined. Make certain
arcing and radio that all normally grounded parts are grounded, such as the
interference clamps and core.
Loose connections Same as above. Tighten all connections.
Low liquid level, Maintain proper liquid level.
exposing live parts
Bushing flashover Lightning Provide adequate lightning protection.
Dirty bushings Clean bushing porcelains, frequency depending on dirt
accumulation.
Mechanical troubles
Leakage Foreign material in threads. Make tight screw joints and or gasket joints.
through screw Oval nipples Poor threads
joints Improper filler Improper
assembly
Leakage at gasket Poor scarfed joints Make tight screw joints or gasket joints.
Insufficient or uneven
compression Improper
preparation of gaskets and
gasket surfaces.
Leakage in welds Shipping strains, imperfect Repair leaks in welds.
weld.
Pressure relief Improper assembly. Replace diaphragm. Inspect inside of pipe for evidence of
diaphragm Mechanical damage. rust or moisture. Be sure to dry out transformer if there is
cracked. a chance that drops of water may have settled directly on
windings or other vulnerable locations, as oil test may not
always reveal presence of free water.
Pressure-relief Internal fault In conservator Check to see that valve between conservator and tank is open
diaphragm type transformers-obstructed and that ventilator on conservator is not blocked. Make certain
ruptured oil flow or breathing. In gas- that relief valve functions and that valve discharge lines are
seal transformer-obstructed open. Liquid level should be adjusted to that corresponding
pressure relief valve. In to liquid temperature to allow ample space for expansion of
sealed transformers -liquid liquid.
level too high.
Moisture Improper or insufficient Make sure that all ventilator openings are free.
condensation Ventilators
in open type
transformers and air
filled compartments
Moisture Cracked diaphragm See remedies above for cracked and ruptured diaphragms.
condensation Moisture in oil Filter oil
in scaled
transformers.
Audio noise Leaky gaskets and joints. Make certain all joints are tight. Tighten loose parts. In some
Accessories andexternal cases parts may be stressed into resonant state. Releasing
transformer parts are set pressure and shimming will remedy this condition.
into resonant vibration
giving off loud noise.
Rusting and Abraded surfaces and Bare metal of mechanical parts should be covered with
deterioration of paint weathering grease.
finish
Fractured metal or Unusual strains placed on Cables and bus bars attached to transformer terminals should
porcelain parts of terminal connections be adequately supported. In the case of heavy leads, flexible
bushings connections should be provided to remove strain on the
terminal and bushing porcelain.
Oil Troubles (see also IS: 1866)
Low dielectric Condensation in open type Make certain that ventilating openings are unobstructed.
strength transformers from improper Replace diaphragm. Replace gasket, if necessary. Test
ventilation Broken pressure cooling coil and repair.
relief diaphragm Leaks
around cover accessories
Leaky cooling coil
High moisture content Ingress of moisture in oil/ Filter and monitor ppm for three months. In case moisture
winding content increases again, check points of moisture entry and
take appropriate action.
Badly dis-coloured oil Contaminated by varnishes. Retain oil if dielectric strength, resistivity and tan delta
Carbonized oil due to values of oil are satisfactory as per IS 1866. CI 2.5.1 of this
switching Winding or core section
failure
Oxidation (sludge or Exposure to air ‘Wash down’ core and coils and tank. Filter and reclaim or
acidity) High operating replace oil. Same as above. Either reduce load or improve
temperatures cooling.
*Code of practice for maintenance and supervision of insulating oil in service (first revision). In any event,
filter oil or dry transformer by heating, or both, to restore dielectric strength.
Notes
In addition to the above instructions given in this section reference may also be made to IS: 10028 Part
1,2&3 -Code of Practice for Selection, Installation and Maintenance of Transformers Part 1-Selection,
Part 2-Installation & Part 3-Maintenance
In case of anything abnormal occurring during service, manufacturer’s advice should be obtained, giving
them complete particulars as to the nature and the extent of occurrence, together with the nameplate
particulars in order to assist identification.
Special list of testing equipment required at site are included in Annexure -II.
Annexure II
Equipment’s Required for Pre-Commissioning
and Maintenance Tests
SL. No. Test Equipment Required Ref.
1. IR value of transformer Battery and mains operated 5 kV IS : 2026
winding. motorized Insulation Tester
2. DC resistance of transformer Automatic winding resistance test kit IS : 2026
winding. (25 Amp.)
3. Ratio of transformer windings. Automatic ratio meter IS : 2026
4. Electric strength of transformer Automatic BDV test kit IS : 6792

oil.
5. Moisture content of transformer Karl Fisher Apparatus IS : 2362
oil.
6. Capacitance and Tan delta Automatic Capacitance and Tan delta IEC 60137 IEEE C 57
of transformer bushings and measurement kit
windings.
7. Dissolved Gas Analysis of Portable DGA test set. IS:10569
transformer oil.
8. Vibration measurement. Vibration cum noise level meter. IEEE C 57

9. Moisture content of solid On line Moisture measurement kit CIGRE Brochure 254,
insulation. CIGRE Brochure 414,
Frequency Domain spectroscopy
(FDS)
10. Frequency Response Analysis. Sweep Frequency Response Analyzer IEC 60076-18
Note: HV lead of test kits like Insulation tester and tan delta kits should be with double screen and other leads should
be at least single shielded.
Annexure IiI
Title Oil Sampling Procedures

Scope Sampling of oil from oil filled electrical equipment.
Purpose: This procedure describes the techniques for sampling oil from oil filled equipment
such as power transformer and reactors using stainless steel sampling bottles
fitted with valves on both sides.
Gases may be formed in oil filled electrical equipment due to normal ageing
and also as a result of faults. Operation of the equipment with fault may
seriously damage the equipment. It is valuable to detect the fault at an early
stage of development. During the early stages of fault the gases formed will
normally dissolve in the oil. By extracting dissolved gas from a sample of oil
and determining the quantity of composition of gases the type and severity of
fault can be inferred.
Responsibility : Maintenance engineer. I.E.C. 567
Reference: IS 9434
Apparatus: (i) Stainless steel sampling bottle of volume one litre as per IS 9434.
(ii) Oil proof transparent plastic or transparent PVC tubing.
(iii) A drilled flange in case sampling valve is not suitable for fixing a tube.
Sampling (Refer Fig. 14)
Procedure: (i) Remove the blank flange or cover (2) of the sampling valve and clean the
outlet with a lint free cloth to remove all visible dirt.
(ii) If the sampling valve is not suitable for fitting a tube, it may be necessary
to use a separate flange with a nozzle in the centre suitable to connect the
transparent plastic / PVC tube.
(iii) Connect a short oil proof plastic tube (around one meter long) at both
end of the stainless steel sampling bottle (5) as shown in (Fig. 14)
(iv) Open the valves (4) & (6) on the stainless steel bottle (5), allow 250 ml
(approx.) of oil to flow into the bottle by opening valve (1). Close (4),
(6) and (1). Disconnect tube from the flange and rinse by gently tilting
the bottle upside down such that no air bubble is formed inside during
rinsing. Expel this oil into the waste bucket (7) by opening valves (4) and
(6).
(v) Connect the tube (3) to the flange (2). Hold the bottle in vertical position
as shown in Fig. (14). Slowly open the equipment sampling valve so that
oil flows through the sampling bottle.
(vi) After stainless steel sampling bottle (5) has been completely filled with
oil, allow about one litre to two litres of oil to flow to waste bucket (7),
till no air bubbles are seen from top outlet.
(vii) Stop the oil flow by closing of first the valve (6) and then valve (4) and
finally the sampling valve (1).
(viii) Disconnect the sample bottle (5) and then disconnect the tubing from the
main equipment and the sampling bottle.
(ix) Label the sample. (Refer Annexure III-A)
(x) Send the information as per Annexure-III-B along with the samples
(xi) In case of critical samples furnish information as per Annexure-III-C
also
Precautions: (i) When sampling oil, precaution should be taken to deal with any sudden
release of oil.
(ii) Sample should normally be drawn from the bottom sampling valve.
(iii) Proper closing of both the valves (4) & (6) of the bottle should be ensured
immediately after the collection of sample.
(iv) Due care should be taken to avoid exposure of oil to air while sampling.
(v) Sampling should be done preferably in a dry weather condition.
(vi) Sample should be taken when the equipment is in its normal operating
condition.
(vii) Care should be taken to hold the bottle in place inside the container when
transporting.
(viii) Testing should be carried out as early as possible.
Oil Sampling in Syringes
Now a days, syringes are available of various capacity for oil sampling purpose. These oil
sampling in syringes have advantage than sampling in bottles as bottles are sometimes not
completely tight thus resulting in error in DGA results. Some of the utilities have started oil
sampling in syringes. The specification of syringes and oil sampling procedure for syringes is
given below for reference.
Specification of Syringes
The glass syringe and three way stop cock valve shall meet the following specification
Dimensions Volume 50 ml ± 1.5% Volume

Piston Outside Diameter 27.45 mm ± 0.20 mm
Barrel Diameter (OD) 32.35 mm ± 0.55 mm
Barrel Collar Diameter 44.00 mm ± 0.75 mm
Piston Collar Diameter 34.05 mm ± 0.65 mm
Length (L) 178.00 mm ± 0.50 mm
Increment 2.0 ml
General The Syringe shall be made from heat Resistant borosilicate Glass
The material and construction is resistant to breakage from shock and sudden temperature
changes
Reinforced at luer lock tip at centre and barrel base.
The Cylinder –Plunger fit is leak proof and shall meet the requirement of IEC-60567
Plunger shall be individually ground and fitted to barrel for smooth movement with no back
flow.
Barrel rim is flat on both sides to prevent rolling and is wide enough for convenient finger
tip grip.
The syringe shall be custom fit and uniquely numbered for matching.
The syringe shall be clearly marked with graduations of 2.0 ml and 10.0 ml and shall be
permanently fused for life time legibility.
Three way Valve Shall be made of 100 % Nylon.
Two female ports and one male port.
Two female ports shall be designed to accept luer lock fitting.
Annexure Iii (a)
Labelling of the Oil Sample Bottle/ Syringe
(a) Bottle / SYRINGE Number :
(b) Manufacturer’s Name :
(c) Name of the site :
(d) Equipment Name or Serial No. :
(e) Sampling Date :

Annexure Iii (B)
Details to be furnished along with the Samples
1.0 Sample Sent By
Name / Designation
Organisation Name and
Address
Tel No & Fax
E-mail
2.0 Oil Sample Details
Date & Time of Sampling Bottle Numbers

Sampling Point Weather Condition
Oil Temp DegC Winding Temp, DegC
Load at the time of sample Voltage at the Time of Sampling (kV)
(MW/MV A/AMPS)
Sample Remarks
3.0 Equipment Details
Substation / Plant Trans Name / Feeder

Name Name / Location ID
Make Manufacturer SI. No.
Capacity of Equipment Voltage Rating (In kV)
(MVA)(l Ph/3 Ph)
Type of Cooling ONAN/OFAN / Breather Arrangement Diaphragm / Air

O N A F / / O FA F Cell/Conventional /
OFWF Dry col
Type of Oil Paraffinic / Quantity of oil in the
Nephthenic Equipment, kL
Inhibited /
Uninhibited
Date of Installation Date of Last Filtration
Any Other Information
4.0 Tests to be done: (please tick desired standard and required tests)
Reference Standard: Oil Parameters: IS-1866 (Before Charging) / IS-1866 (In-Service) / IS-335/
IS-12463/
Dissolved Gas Analysis (IS- Water Content (IS-13567) Dielectric Strength (IS-6792)
9434)
Specific Resistance at 90degC Dielectric Dissipation Factor Total Acidity (IEC-62021
(IS-6103) at 90degC Vol-1 / IS-1448 P-l)
(IS-6262)
Inter Facial Tension at 27°C Flash Point (IS-1448-P-21) Sludge Content (IS-1866)
(IS-6104)
Kinematic Viscosity at 27°C Pour Point (IS-1448P-10) Density at 29.5°C (IS-1448
(IS-1448-P-25) P-16)
Carbon Type Composition Oxidation Stability (Annex- SK Value (Annex-D of IS-
(IS-13155) CofIS-335) 335)
Oxidative Aging (IS-12177 Corrosive Sulphur (Annex- Inhibitor Content (IS-13631)
(Method-A)) BofIS-335)
Furan Analysis (IEC-61198)
In case of new transformer following additional information to be furnished :
Date of commissioning :
MVA rating :
kV rating :
Oil type (Parafinic / Naphthanic) :
Cooling (ONAN/ONAF/OFAF/OFWF) :
Type of oil preservation: (Air cell/diaphragm type/Direct breathing)
Make :
Annexure III (C)
ADDITIONAL DATA INPUT FORMAT FOR CRITICAL EQUIPMENTS
1. Voltage profile for last six months indicating maximum and minimum values and % of
time voltage more than rated voltage.
2. Loading Pattern (Monthwise) of the transformer for last six months
Max. load Current (A).... mw mvar

Min. load Current (A).... mw mvar
Normal load Current (A) .... mw mvar
3. Date of last filtration carried out
4. Type of oil preservation system:
5. air cell in conservator/diaphragm in conservator/direct breathing
6. Any Buchholz alarm/trip operation in past: YES/NO
7. Any oil topping up done in the past: YES/NO
8. Whether complete oil was changed any time: YES/NO
9. Present BDV / Moisture content value:
10. Color of silicagel
11. Date of commissioning:
12. Manufacturer’s serial number:

Annexure IV
SPECIFICATIONS FOR TEST EQUIPMENTS
I 5 kV BATTERY OPERATED INSULATION RESISTANCE TESTER
The equipment offered shall be for the measurement of insulation resistance of electrical
equipment.
Technical Requirements
Rated Voltage selection 0.5/1.0/2.5/5 kV (DC volts)
Rated insulation resistance 0-100,000 Mega ohms
Type
Portable, compact and direct reading type of multi voltage and multi rated insulation resistance
ranges. It shall be suitable for DC battery operation. Batteries shall be rechargeable with 230V,
50 Hz AC supply. The necessary accessories for this purpose shall be supplied by the supplier.
The operating temperature shall be up to 50 deg C and humidity 85%.
There should be provision for infinity adjustment. The instrument shall be supplied in a carrying
case with 2 m long mains lead and 25 m long test leads with carrying case.
It shall generally comply with the requirements of IS: 2992 and IS: 11994 or relevant
internationally acceptable standards.
As per requirement of ISO - 9001, calibration certificate for each testing instrument covering
entire range shall be supplied with the test kit at the time of supply.
The testing equipment is generally meant for carrying out testing at site and transportation-
movement from one place to another is unavoidable. Therefore equipments shall be robust in
design so that it gives desired performance even in adverse site conditions. Though the instrument
is capable of operating on battery and are provided with battery condition indicators, it would
be advisable to conduct the tests on mains supply input power to the extent possible. Usage of
battery must be resorted to sparingly.
The supplier should have adequate “After sales service” in India.
II Transformer DC Winding Resistance Measurement Test Kit
The instrument is used for measuring DC winding resistance of the transformer/reactor where
large inductance is present.
The test kit shall be able to withstand inductive kicks from transformer winding.
Variation in test current shall not result in loss of accuracy.
The display of resistance should be through LED/LCD without requiring any balancing of
decades to obtain stable readings.
It should employ four wire method and no lead compensation shall be required for
measurement.
Built-in discharge circuit should be provided to discharge the specimen when test is completed
when current lead accidentally disconnects or when instrument power supply is lost.
Technical Parameters
Test current 25 Amp

Resolution 1 milliohm
Range 0 to 100 ohms
Accuracy ± 0.5% of full scale reading or better
Open circuit voltage min. 30 Volts, DC
General Requirements
The instrument shall contain all standard accessories including test leads of 25 meters with
suitable clamps/connectors and carrying case.
The kit should have been proven for repeatability of test results in charged switchyard conditions
and documentary evidence should be furnished along with the bid. The kit should have been
tested for EMI /EMC as per standards.
Input supply of the kit shall be 230 Volts AC, 50 Hz, Variations + 15% and 5% in voltage and
frequency respectively.
As per requirement of ISO-9001, calibration certificate for each testing instrument covering
The testing equipment is generally meant for carrying out testing at site and movement from one
place to another is unavoidable. Therefore equipment shall be robust in design so that it gives
desired performance even in adverse site conditions.
Battery / mains operated micro ohmmeters employing currents less than 5 amps are not
recommended for transformers.
The supplier should have adequate “after sales service” in India.

III Automatic Turns Ratio Tester
The equipment offered shall be used for measurement of turns ratio of various transformers and
bushing current transformers automatically displaying the ratio without requiring any manual
balancing of decades.
Technical Requirement
Operation Voltage: 240 volts: 50Hz, single phase A.C

Test Voltage: 240 volts AC
Measuring range: 1 to 2000
Accuracy: ± 0.5 % of FSD
Measuring Principle
It should display actual turns ratio of different vector groups in three phase transformers without
conversion
The kit should be supplied with 25 m of test lead. The kit should be tested for successful
operation in charged 765 kV switch yard and be tested for EMI and EMC. The kit shall be
capable of operating at a temperature of 50°C and at a humidity upto 85%.
As per requirement of ISO 9001 calibration certificate for each testing instrument covering
IV 100 kV Automatic Transformer Oil Breakdown Voltage Test Set
The equipment offered shall be suitable for determination of electrical strength (break down
voltage) of insulating oil conforming to IS-335 and IS-1866 upto 100 kV when measured in
accordance with IS:6792.
The test cell shall be as per IS: 6792 and IEC-156 suitable for BDV upto 100 kV without
external flash over.
The unit shall be automatic type having control unit and high voltage transformer in a common
cabinet with necessary partition.
JIV chamber interlocking and zero start interlocking shall be provided.
The unit shall have motorized drive to increase voltage linearly as per the rate specified in IS:
6792. Provision shall also be available for manual increase of voltage.
The unit shall be complete with test cell stirrer, calibrator and necessary gauges for adjusting
the gap.
The equipment shall be suitable for operation at 240 volts, 50Hz, single phase AC supply.
As per requirement of ISO-9001, calibration certificate for each testing instrument covering
V Moisture Content Measurement Set
The test kit shall make use of automatic Karl Fischer titrator capable of measuring water in oil
upto 1 ppm. The measured moisture shall be displayed in microgram or PPM or percentage.
The set should have following features :
• Should be compact and portable.

• Should operate with Karl Fischer reagent which is available.
• Should have error indicator for indicating any defect in vessel charge or generator
solution and electrodes.
• Should have facility for auto-display of ions in parts per million.
• Should be free from effect of humidity, parasitic reactions and inherent drift of
circuitry.
• Should have 3 sets of syringes required for measurement and 6 sets of vessel charge
bottles.
• Should be suitable for 240 V 50 Hz AC supply.
• Should have back up indication for mains on, instrument error, stirrer moving and
titration over.
Resolution range = 1 in ppm
The speed of stirrer should preferably be controllable.
The set should be accompanied with six sets of bottles of reagent.
As per requirement of ISO 9001, calibration certificate for each testing instrument covering
place to another is unavoidable, Therefore equipment shall be robust in design so that it gives
VI Specifications for Automatic Capacitance and Tan Delta Kit
The instrument should be suitable for automatic offline measurement of C& Tan δ of the
switchyard equipments as well as excitation current of transformers/reactors, in live switchyard
upto 800 kV AC and 800 kV DC level. The test results should have repeatability, consistency &
immunity to electromagnetic interference in live switchyard.
Output V: 0-10 kV AC
I: 0-100 mA (Min) continuous, 200 mA(Min) intermittently
Test Frequency 45 Hz to 55 Hz, Independent of line voltage & frequency variations
Accuracy Cp : 0.5 % of reading ± 1pF
Tan δ : 1 % of reading ± 0.02%
Measurement Range Cp : 10 pF to 1 µ F
Tan δ : 0 to 100 %
Power Supply It shall work on single phase 230 Volts ±10 %, 50 Hz ±5 % supply with standard
socket.
Operating temperature & 0 to +50 deg C
humidity
Humidity upto 90 %
Against short circuit, over voltage, improper ground connection over load & transient surges,
the kit should have alarm/cut-off features to protect the instrument. Also the kit should have
facility of stopping automatically on power failure as well as interlock for HV. One complete set
of cables of sufficient length (Min 25Metre) with suitable clamps & connectors, compatible with
the instruments should be provided for successfully carrying out the test.
The supplier should have adequate “after sale service” in India.
VII Technical Specifications frequency Domain Spectroscopy (FDS) Test Kit
Sr.No Description Specifications

1) Function of the kit Instrument shall accurately carry out following,
(a) Analysis of Water content in Oil-Paper, and insulation of Power and
Instrument Transformer.
(b) Diagnosis of all type of bushings and CB insulation.
(c) Diagnosis of Cable and Motor Insulation.
The kit shall be based on Frequency Domain Spectrograph (FDS) as well
as Dielectric Frequency Response (DFR) technique for analysis. The
measurements shall be at lower frequencies and effected through Tan delta
and capacitance measurement of insulation.
(2) Mains Input Power 230V ±10% at 50 Hz

(3) Voltage out put 0-200 V,
Current Out put 0-50mA
Frequency range 0.1m Hz to 5 kHz min
(4) Measurements Capacitance- 10pF to 10μF
Dissipation Factor -0 to 10 @ accuracy of 2% max
(5) Measurement Channels Channel 1, Channel 2.

(6) Measurement Modes UST,GST,GSTg. minimum
(7) PC requirement A reputed laptop with latest specifications such as Core 2 Duo processor, 2GB
DDR RAM 320GB HDD DVD writer,15’’TFT screen or with better specs.
Preloaded with MS Windows XP,/VISTA/latest with antivirus.Original CDs
etc
The cost of PC shall be quoted separately.
(8) Software The test record should download via RS 232 C port to a PC in windows
Excel/equivalent format. Software shall be able to assist in analyzing the
measurements and its reporting in user friendly manner.Softwareupgradation
shall be done as and when applies with no cost to POWERGRID.
(9) Accessories All testing/measurement low noise cables 18 meter long. PC inter phase
cables, Power supply cables,USB cables, Operating manual, Original CD
and software, Application CD etc. Hard carrying case etc.connectors.AC
power adopter.
(10) Repeatability It should offer repeatability of test results in charged switchyard.
(11) Operating conditions Shall operate at Temperature 0 to 50 deg C, Humidity not condensing up
to 95%,
(12) Safety Standards The test set shall meet international safety standard for IEC 61010-1 safety
and IEC 61326-1 EMC
VIII Specification of F.R.A. Test Set
The Instrument shall be able to detect and aid identification of dielectric and mechanical failures
in large power transformers in 400 kV/765 kV charged area, preceded by mechanical changes
in the winding structure due to Transportation damage, Short circuit forces, Natural effects of
aging on the insulating structures etc. The testing method should be based on Sweep Frequency
Response Analysis of complex R-L-C-network. The test instrument shall be designed and supplied
complete with accessories cables connectors, leads etc. alongwith required licensed software for
proper analysis and storage of test data. Detailed specifications of various components of FRA
test set are as below:
SL.No. Particulars Technical Specifications

1 FREQUENCY RANGE 10 Hz to 20 MHz minimum
2 INPUT AND OUTPUT IMPEDANCE 50Ω
3 MEASURING POINTS 1600 minimum
5 DYNAMIC RANGE >80dB
SL.No. Particulars Technical Specifications

6 ACCURACY RANGE ±1dB (down to – 80 dB)
7 PLOT FREQUENCY VS. Magnitude, phase etc.
8 SCALING /SWEEP MODE Log/Linear
Shall be controlled through built in industrial PC
with touch screen/keyboard. Or external laptop PC
of reputed brand with latest specifications such as
Core 2 Duo Intel processor, 4GB DDRRAM 320GB
9 CONTROL AND DISPLAY UNIT HDDDVD writer, 15’’TFT/LCD screen or with
better specs. preloaded with Operating system MS
Windows-7 or latest with antivirus. Original CDs
of PC diagnostics from OEM etc and application
software for the test kit.
One set of 30meters coaxial or equivalent with
10 TEST LEADS clamps and connectors, compatible with the test
instrument.
It shall work on single-phase 230±10% V, 50±5%
11 POWER SUPPLY Hz, supply with variations in voltage and frequency
respectively.
12 OPERATING TEMPERATURE 0 to +50°C
13 STORAGE TEMPERATURE -20 to +70°C
14 RELATIVE HUMIDITY 10 to 90 % non-condensing
15 PROTECTION Against short circuit & overload
It should offer repeatability of test results in 400
16 REPEATABILITY kV/765 kV charged area including for 315/500MVA
Transformers and 50/60/80/125 MVAR reactors.
Software of the kit should be Windows based, Menu
driven and user friendly. It should have all the
17 SOFTWARE templates/features required for complete testing of
transformer, reactors etc. and facility for comparison
of past template of the tested unit.
PC cables, Licensed OS software & antivirus
for PC, Licensed software of the testing kit, ,
combination plugs, power-supply cables, original
hard & soft carrying case (which should be robust/
18 ACCESSORIES
rugged enough for proper safety of the kit during
transportation), manual (both in soft copy & hard
copies) etc, required for carrying out all types of
testing.
The test kit shall be compatible for EMI/EMC
19 ENVIRONMENT environment required for EHV switchyard as per
IEC61000.
CALIBRATION CERTIFICATE Unit shall be duly calibrated before supply and the
20 date of calibration shall not be older than two month
from the date of supply of Kit.
Bidder will have to submit the documentary
evidences of having established mechanism for
21 SERVICES AFTER SALE
prompt services in India as required as per the
specifications.
SECTION DD
Guidelines for Condition Monitoring and Diagnostic

Techniques for Power Transformers and Reactors
SECTION DD
Guidelines for Condition Monitoring and Diagnostic Techniques for
Power Transformers and Reactors
1.0 GENERAL
1.1 Condition monitoring may be defined as a predictive method making use of the fact
that most equipment will have a useful life before maintenance is required. It includes the
life mechanism of individual parts of equipment or the whole equipment, the application and
development of special purpose equipment, the means of acquiring the data and the analysis of
that data to predict the trends.
1.2 Initial stage of a condition monitoring programme consists of establishing the base line
parameters and then recording the actual base line (or finger prints) values. The next stage is
the establishment of routine testing of plants and equipment observing the running condition
and assessing the parameters previously determined for the baseline. These readings are then
compared with the fingerprint and the state of the present plant condition can be determined
from the absolute figures. The rate of degradation and an assessment of the likely to failure can
be estimated from the trend.
1.3 The benefits of condition monitoring can be summarized as below:
• Reduced maintenance costs

• Results provide a quality - control feature
• Limit the probability of destructive failures, leading to improvements in operator safety
and quality of supply
• For assessing possibility & severity of any failure and consequential repair activities.
• Provides information on the plant operating life, enabling business decisions to be made
either on plant refurbishment or replacement.
1.4 Condition Monitoring Techniques
The following condition-monitoring techniques are currently being used by Power Utilities
world over to assess the health of transformer/ reactors in service:
1.4.1 Dissolved Gas Analysis (DGA) provides an early warning of various incipient faults in
transformer winding or core.
1.4.2 Oil Parameters Testing: Low BDV indicates moisture or particulate contaminants in the
oil. High moisture content varying with temperature indicates wet winding. Acidity, resistivity and
interfacial tension (IFT) indicate oil condition. (For other details refer clause 2.5 of section CC)
1.4.3 Capitance & Tan δ measurement of bushing and winding to assess the condition of
insulation, bushing and winding (For details refer clause 6.9 & 8.11 of section BB)
1.4.4 Winding resistance measurement to detect problem of broken sub-conductors, winding
349
contact joints and OLTC connections (For details refer clause 4.1 & 8.3 of section BB)
1.4.5 Impedance measurements with precision instruments to check for dynamic movements
of winding due to system short-circuit faults
1.4.6 Turn ratio test indicates problem in winding and verifies correct tap changer
connections
1.4.7 Excitation/ magnetization current tests to locate faults in the magnetic core structure
such as shorted laminates or core bolt insulation breakdown or shorted turns due to insulation
failures, which have resulted in conducting paths between winding turns.
1.4.8 IR measurement to indicate the presence or absence of harmful contamination (dirt,

moisture etc.) and stress degradation of insulation.
1.4.9 Frequency response analysis (FRA) to check for system resonance condition and
dynamic movements and detection of winding mechanical distortion during transportation and
through fault.
1.4.10 PD measurement through UHF, Acoustic, RFI methods for localization of faults
1.4.11 Furfuraldehyde (FFA) analysis in oil (HPLC chromatography) to detect ageing in

cellulosic material without taking paper samples
1.4.12 On-line dielectric dissipation factor (DDF) monitoring of bushings: Signals from
transducers connected to test taps of bushings are collected and transmitted to User Interface
Module for processing the data by proprietary software and converted to dielectric loss angle/
dielectric dissipation factor (DDF) and leakage current values.
1.4.13 Dielectric Response Methods for Diagnostics for Power Transformers giving general
indication of moisture in insulation and possible paper ageing and oil condition
1.4.14 On-line Gas Monitors
(a) On-Line hydrogen monitors to provide earliest possible detection of gas build up and
alert the user to the need for more detailed analysis
(b) On-line moisture content measurement to continuously monitor water content in oil,
which indicates the status of solid insulation. The data is stored in monitor’s memory
and can be down loaded remotely or locally which can be subsequently analyzed using
window based control software. The software automatically gives trend analyses;
generate graphs and reports for the user to take action based on the same.
Guidelines for Condition Monitoring and Diagnostic Techniques for Power Transformers and Reactors 351
1.4.15 On-line PD detection using probe connected to the test tap
1.4.16 On-line temperature monitoring-direct measurement through fibre optic sensors for
continuous monitoring of hot spot temperature can be the basis for an on-line load management
system which can be accessed by operating staff to control loading pattern and thermal ageing
of the transformer.
1.4.17 Thermo-vision Scanning of Transformer
2.0 DISSOLVED GAS ANALYSIS (DGA)
2.1 The transformer undergoes electrical, chemical and thermal stresses during its service life
which may result in slow evolving incipient faults inside the transformer. The gases generated
under abnormal electrical or thermal stresses are hydrogen(H2), methane(CH4), ethane (C2H6),
ethylene (C2H4), acetylene (C2H2), carbon monoxide(CO), carbon dioxide(CO2), nitrogen(N2)
and oxygen (O) which get dissolved in oil. Collectively these gases are known as Fault Gases,
which are routinely detected and quantified at extremely low level, typically in parts per million
(ppm) in dissolved Gas Analysis (DGA). Most commonly used method to determine the content
of these gases in oil is using a Vacuum Gas Extraction Apparatus and Gas Chromatograph.
2.2 DGA is a powerful diagnostic technique for detection of slow evolving faults inside the
transformer by analyzing the gases generated during the fault which gets dissolved in the oil.
For Dissolved Gas Analysis to be reliable, it is essential that sample taken for DGA should be
representative of lot and no dissolved gas shall be lost during transportation and laboratory analysis.
Suggested sampling procedure based on IEC 60567 is given in Annexure-III of Chapter CC.
Effective fault gas interpretation should basically tell us first of all, whether there is any incipient
fault present in the transformer. If there is any problem, what kind of fault it is. Whether the fault
is serious and the equipment needs to be taken out of service for further investigation. DGA can
identify deteriorating insulation and oil, hot spots, partial discharge, and arcing. The health of oil is
reflective of the health of the transformer itself. DGA analysis helps the user to identify the reason
for gas formation and materials involved and indicate urgency of corrective action to be taken.
2.3 The evolution of individual gas concentrations and total dissolved combustible gas
(TDCG) generation over time and the rate of change (based on IEC 60599 and IEEE C 57-104
standards) are the key indicators of a developing problem. Some of the recognised interpretation
techniques are discussed below:
2.3.1 Individual Fault Gases Acceptable Limits
To ensure that a transformer (with no measured previous dissolved gas history) is behaving
normal, the DGA results are compared with the gassing characteristics exhibited by the majority
of similar transformers or normal population. As the transformer ages and gases are generated,
the normal levels for 90% of a typical transformer population can be determined. From these
values and based on experience, acceptable limits or threshold levels have been determined as
given in Table 1 below:
Table 1 : Ranges of 90% Typical Conc Values (all Types of Transformers) as per IEC 60599 /1999
Transformer FAULT GASES (in µ 1/1) or ppm

Sub Type
H2 CH4 C2H6 C2H4 C2H7 CO CO2
No OLTC 60-150 40-110 50-90 60-280 3-50 540-900 5100-13000
Communicating 75-150 35-130 50-70 110-250 80-270 400-850 5300-12000
OLTC
Note 1 - The values listed in this table were obtained from individual networks. Values on other networks may differ.
Note 2 - “Communicating OLTC” means that some oil and /or gas communication is possible between the OLTC
compartment and the main tank or between the respective conservators. These gases may contaminate the oil
in the main tank and affect the normal values in these types of equipment. “NO OLTC” refers to transformers
not equipped with an OLTC, or equipped with an OLTC not communicating with or leaking to the main tank.
Note 3 - In some countries, typical values as low as 0.5µ l/ l for C2H2 and 10µ l/l for C2H4 have been reported.
However it is improper to apply threshold level concept without considering the rate of change
of the gas concentration. When an abnormal situation is indicated by above table, a testing
schedule is devised with increased sampling frequency.
2.3.2 Total Dissolved Combustible Gas (TDCG) Limits
The severity of an incipient fault can be further evaluated by the total dissolved combustible gas
(TDCG) present. Limits for TDCG are as given in Table 2. An increasing gas generation rate
indicates a problem of increasing severity and therefore we should resort to shorter sampling
frequency.
Table 2 : Action based on TDCG limits (IEEE standard C:57.104-1991)
TDCG Limits, PPM Action
< or = 720 Satisfactory operation, Unless individual gas acceptance values are
exceeded
721-1920 Normal ageing/ slight decomposition, Trend to be established to see
if any evolving incipient fault is present.
1921-4630 Significant decomposition, Immediate action to establish trend to see
if fault is progressively becoming worse.
>4630 Substantial decomposition, Gassing rate and cause of gassing should
be identified and appropriate corrective action such as removal from
service may be taken.
Note : TDCG value includes all hydrocarbons, CO & LH, and does not include C02 which is not a combustible gas.
2.3.3 The relationship of evolved gas with temperature and the type of faults are shown in
Tables 3 and 4 respectively:
Table 3 : Relationship of evolved gases with temperature
Relationship with temperature
Methane (CH4) > 120°

CEthane (C2H6 ) > 120°
CEthylenc (C2H4 ) > 150"
CAcetylene (C2H2 ) > 700° C
Table 4 : Associated faults with different fault gases
Associated faults with different gases Oil Overheating :C2H4, C2H6, CH4
Traces of acetylene with smaller quantity of Hydrogen may be evolved
Overheated Cellulose: CO
Large quantity of Carbon-Di-Oxide (CO2) and Carbon Monoxide (CO) are evolved from overheated cellulose.
Hydrocarbon gases such as Methane and Ethylene will be formed if the fault involves an oil impregnated structure.
Partial discharge in Oil (Corona): H2, CH4
Ionisation of high stressed area where gas / vapour filled voids are present or ‘wet spot’ produces Hydrogen and
methane and small quantity of other hydrocarbons like ethane and ethylene. Comparable amounts of carbon mono-
oxide and di-oxide may result due to discharges in cellulose.
Arcing in Oil :C2H2, H2
Large amount of Hydrogen and acetylene are produced with minor quantities of methane and ethylene in case of
arcing between the leads, lead to coil and high stressed area. Small amounts of carbon mono-oxide and di-oxide may
also be formed, if fault involves cellulose.
It is well known that there is no definite interpretation method in the world, which can indicate
the exact location and type of the fault. The different interpretation methods only provide
guidelines to take an engineering judgment about the equipment. Apart from the DGA results
various other factors are taken into consideration such as past history of the transformer, grid
condition, loading patterns etc.
2.4 Ratio Methods
Several well- known methods/criteria (like Rogers ratio, IEC 60599, Dornenberg, Key gas etc.)
are being used by utilities to interpret the DGA results, based mostly on the relative concentrations
(i.e. ratios) of the constituent gases. These ratios generally give an indication of the existence
and nature of a problem. Some of the interpretation methods used for DGA arediscussed here
in brief:
2.4.1 IEC 60599 Method
This method is applicable only when the fault gas results are ten times the sensitivity limit of
the Gas Chromatograph (GC). As per IEC 60567 the sensitivity limit for the GC should be
maximum 1 ppm for all the hydrocarbons and 5 ppm for hydrogen. In this method three ratios
viz. C2H2/C2H4, CH4/H2& C2H4/C2H6 are used for interpretation. Various combinations of the
ratios are used for diagnosis of type of fault such as PD, Discharge of low energy, Discharge of
high energy, Thermal fault < 300 deg C, Thermal fault 300 - 700 Deg C and Thermal fault > 700
Dcg C. The table (as per IEC 60599) showing different type of faults depending upon the three
key ratios is given in Table 5 :
Case Characteristic Fault C2H4 H2

PD Partial discharges NS <0.1 <0.2
Dl Discharges of low energy >1 0.1 - 0.5 >1
D2 Discharges of high energy 0.6 - 2.5 0.1 -1 >2
Tl Thermal fault T < 300°C NS 1
>1 but NS 1
<1
T2 Thermal fault 300°C < 1 < 700°C <0.1 >I 1-4
T3 Thermal fault <0.2 2
>1 >4
Note 1 — In some countries, the ratio C2H2 / C2H6 is used, rather than the ratio CH4 / HZ Also in some countries,
slightly different ratio limits are used.
Note 2 - The above ratios are significant and should be calculated only if at least one of the gases is at a concentration
and a rate of gas increase above typical values (see clause 9).
Note 3 - CH4 / H2<0.2 for partial discharges in instrument transformers.CH4/H2<0.07 for partial discharges in
bushings.
Note 4 - Gas decomposition patterns similar to partial discharges have been reported as a result of the decomposition
of thin oil film between over-heated core laminates at temperatures of 140 °C
Though this method is quite comprehensive, still there are cases where it does not fit into any
of the cases listed in the diagnosis table. These cases should be dealt through trend analysis and
other interpretation methods. Again interpretation through the above method is meaningless
unless it is correlated with the earlier sample results.
2.4.2 IEEE Method-C57-104/1991
2.4.2.1 Key Gas Method
Characteristic “Key Gases” have been used to identify particular type of fault. Laboratory
simulations and comparison of results of DGA tests combined with observations from the tear
down of failed transformers have permitted the development of a diagnostic scheme of the
characteristic gases generated from thermal and electrical (Corona and arcing) deterioration of
electrical insulation. Table 6 shown the lists of the key gases for the conditions of arcing, corona,
overheating in oil and overheating in paper in the order of decreasing severity.
Table 6 Key gases associated with typical fault
Fault type Key gases

Arcing Acetylene (C,H,), Hydrogen (H,)
Corona Hydrogen (H7)
Overheated Oil Ethylene (C,H4), Methane (CH4)
Overheated Cellulose Carbon Mono-oxide (CO) and Dioxide (CO2)
2.4.2.2 Ratio Method

These methods are used to determine the type of fault condition by comparing ratios of
characteristic gases generated under incipient fault conditions. The advantages to the ratio
methods are that they are quantitative, independent of transformer capacity and can be computer
programmed. The disadvantages are that they may not always yield an analysis or may yield an
incorrect one. Therefore it is always used in conjunction with other diagnostic methods such as
key gas method.
(a) The Doernenberg Ratio method is used when prescribed normal levels of gassing are
exceeded. It provides a simple scheme for distinguishing between pyrolysis (overheating) and PD
(corona and arcing). In this method four ratios viz. CH4/H2,C2 H2C2 H4 C2H6/C2H2 & C2H7/CH4
are used.
Table 7 : Ratios for key gases - Doernenburg
Suggested fault diagnosis Ratio I (Rl) Ratio 2 (R2) C2H2/ Ratio 3 (R3) Ratio 4 (R4)
CH2/H2 C2H4 C2H2/CHd4 C2H6/C2H2
1.Thermal Decomposition >1.0 <0.75 <0.3 >0.4
2.Corona (Low Intensity PD) <0.1 Not Significant <0.3 >0.4
3.Arcing (High Intensity PD) >0.1 >0.75 >0.3 <0.4
In Doemenburg’s method for declaring the unit faulty at least one of the gas concentrations (in
ppm) for H2, CH4, C2H2and C2 H4should exceed twice the values from limit LI (Table 8) and
one of the other three should exceed the values for Limit LI. Having established that the unit is
faulty, for determining the validity of ratio procedure at least one of the gases in each ratio Rl,
R2, R3 or R4 should exceed limit LI. Otherwise the unit should be re-sampled and investigated
by alternative procedures.
Table 8 : Concentrations of dissolved gas
Key gas Concentration LI (in ppm)

Hydrogen(H2) 100
Methane (CH4) 120
Carbon Monoxide (CO) 350
Acetylene (C2H2) 35
Ethylcne(C2H4) 50
Ethane (C2H6) 65
(b) The Rogers Ratio method is a more comprehensive scheme using only three
ratios viz. CH4/H2, C2H2/C H4& C2H4/C2H6, which details temperature ranges for
overheating conditions based on Halstead’s research and some distinction of the
severity of incipient electrical fault conditions (Table 9). A normal condition is
also listed.
Table 9 : Rogers ratio for Key Gases
Case R2 Rl R5 Suggested fault diagnosis

(C2,/H4)
(CH,/H2) (C2H4/C2H6)
0 <0.1 >0.1 <0.1 Unit normal
1 <0.1 <0.1 <0.1 Low-energy density arcing -PD

(See Note)
2 0.1-3.0 0.1-1.0 >3.0 Arcing - High energy discharge
3 <0.1 >0.1<1.0 1.0-3.0 Low temperature thermal
4 <0.1 >1.0 1.0-3.0 Thermal <700°C
5 <0.1 >1.0 >3.0 Thermal >700°C
Note There will be a tendency for the ratios R2 and R4 to increase to a ratio above 3 as the discharge develops in
intensity
lEEIi C57.104 - 1991 standard gives an elaborate way of analysing the type of fault using
Doernenberg, Rogers’s method and TDCG limits.
However it is again emphasized that DGA shall give misleading results unless certain precautions
are taken. These are proper sampling procedure, Type of sampling bottle, cleanliness of bottle,
duration of storage, method of gas extraction, good testing equipment and skilled manpower.
2.5 Trend Analysis
Transformers from the same manufacturer and of same type some time exhibit initially specific
pattern of gas evolution which subsequently slows down (or reach a plateau) is called Fingerprints
or normal characteristics, which are characteristic to the transformer and do not represent an
incipient fault condition.
When a possible incipient fault condition is identified for first time, it is advisable to determine
gassing trend with subsequent analysis giving information such as which gases are currently
being generated and rate of generation of these gases. The level of gases generated in subsequent
analysis provides a baseline from which future judgement can be made. In the examination
of trends, key gases, TDCG, CO2/CO ratio, rate of gas generation and fingerprints (of normal
trends) of particular transformer should also be considered.
The ratio of gas generation is a function of load supplied by the transformers and this informatior-
is vital in determining the severity of fault condition and decision of removal of the equipment
from service for further investigation. Two methods are suggested in literature for assessing the
gassing rate:
• Change of concentration of gas in ppm
• Determination of actual amount of gas generated
General guidelines for rate of gas generation for removal of transformer from service are 100
ppm/day and 0.1 cub feet (0.003 m3) gas per day
A flow chart is given at Fig. 1 for step by step action to be taken based on DGA test results giving
recommendations:
Examination of DGA results Compare with
DGA of previous sample and with typical values
At least one gas above typical values All gases below typical values of
Report as typical
ol gas concentrations and rates gas concentrations and rales
DGA/healthy
of gas increase of gas increase
equipment
Calculate gas ratios
Fault identified by table 4
Gas concentration above alarm values of

ALERT condition
gas concentrations and rates of gas increase,
or change in fault type D2
Take immediate action Institute more frequent sampling

Consider on-line monitoring, Consider on-line monitoring
ALERT condition
inspection or repair
Store data
Fig. 1 Flow chart for DGA from IEC 60599/ 1999
3.0 FURFURALDEHYDE ANALYSIS FOR REMNANT LIFE MEASUREMENT OF

PAPER INSULATION
Degradation of insulating paper can be ascertained by direct or indirect methods. Direct method
employs Degree of Polymerization (DP), which requires a physical paper sample from the
winding. However, this method being destructive to transformer, cannot be employed as a
routine condition monitoring exercise.
3.1 Degree of Polymerization (DP)
One of the most dependable means of determining paper deterioration and remaining
life is the DP test of the cellulose. The cellulose molecule is made up of a long chain
of glucose rings which form the mechanical strength of the molecule and the paper. DP
is the average number of these rings in the molecule. For DP measurement remove a
sample of the paper insulation about 1 centimeter square from a convenient location near
the top of center phase with a pair of tweezers. In general, in a three-phase transformer,
the hottest most thermally aged paper will be at the top of the center phase. If it is not
possible to take a sample from the center phase, take a sample from the top of one of the
other phases.
Table 10 DP values for estimating remaining paper life
New insulation 1,000 DP to 1,400 DP

60% to 66% life remaining 500 DP
30% life remaining 300 DP
0 life remaining 200 DP
3.2 Furan Analysis

It is known that in addition to CO and C02 the ageing process of the paper produces several oil
soluble by products, most notably the furanoid compounds (FFA). When cellulose insulation
decomposes due to overheating, chemicals, in addition to C02 and CO, are released and
dissolved in the oil. These chemical compounds are known as furanic compounds or furans. The
most important one, for our purposes, is 2-furfuraldehyde. When DGAs are required, always
request that furans testing be completed by the laboratory to check for paper deterioration. In
healthy transformers, there are no detectable furans in the oil, or they are less than 100 part per
billion (ppb). In cases where significant damage to paper insulation from heat has occurred,
furan levels have been found to be at least 100 ppb and up to 70,000 ppb. The monitoring
of furanic compounds by annual sampling of the oil and its analysis using High Performance
Liquid Chromatography (HPLC) has beenis under used for condition monitoring on a routine
basis for somein recent years by some utilities.
Source : EPRI’s Guidelines for the Life Extension of Substations, 2002 Update, chapter 3. Table 7: DP Values for Esti
mating Remaining Paper Life
Generally FFAs are extracted from the oil either by solvent extraction or solid phase extraction
and measured by HPLC by UV detector. The major FFA in oil is 2-Furfural and others are
present in very low or undetected levels. 2-Furfural can be measured colorimetrically using
spectrophotometer. This method is rapid and accurate and measures only 2-Furfural in oil. This
technique is useful for quick screening of FFA in transformer oil. The relationship between
the generation of these by-products and condition of in service paper is not well established.
However, it has generally been seen that there is a linear relationship between FFA and DP. FFA
may be used as a complimentary technique to DGA for condition monitoring.
Table 11 : Furans, DP, Percent of Life Used, of Paper Insulation
Non-thermally Thermally Estimated Degree Estimated Interpretation

upgraded paper upgraded of Polymerization Percentage of
55 °C Rise paper 65 °C Rise (DP) Remaining
Transformer 2FAL Transformer Total Life
(ppb) Furans (ppb)
58 51 800 100 Normal
130 100 700 90 Aging
292 195 600 79 Rate
654 381 500 66

Accelerated
1,464 745 400 50
Aging Rate
1,720 852 380 46
2,021 974 360 42
2,374 1,113 340 38 Excessive
2,789 1,273 320 33 Aging
3,277 1,455 300 29 Danger Zone

3,851 1,664 280 24 High Risk of
4,524 1,902 260 19 Failure
5,315 2,175 240 13 End of Expected
6,245 2,487 220 7 Life of Paper

Insulationand of the
7,337 2,843 200 0 Transformer
Testing is done for five different furans which are caused by different problems. The five furans and their most
common causes are listed below:
5H2F (S-IIydroxymethyl-2-Furaldchyde) caused by oxidation (aging and heating) of the paper
2FOL (2-Furfurol) caused by high moisture in the paper
2FAL (2-Furaldchyde) caused by overheating
2ACF (2-Acetylfuran) caused by lightning (rarely found in DGA)
5M2F (5-Methyl-2-Furaldehyde) caused by local severe overheating (hotspot)
(Source: Transformer Diagnostic USBR, June 2003, Page-38)
4.0 CONTINUOUS DGA MONITORING BY ON-LINE GAS SENSORS
4.1 Laboratory DGA is carried out at a predefined interval and the fault developing within that
interval cannot be ascertained till the transformer has actually failed. It is important to appreciate
that some faults may take less than one year to progress from onset to failure; others may remain
in a stable state for a much longer period but have the potential for a rapid increase. In case
of sudden rise in gas levels indicated by on-line sensor, sample should be sent for immediate
laboratory analysis for confirmation and to decide further course of action. One of the most
widely used on line Gas Monitoring system has a membrane, which allows preferentially lighter
molecules to pass through and be detected in a gas reaction cell. Some of the on-line gas monitors
also provide continuous moisture measurement thereby ascertaining the wetness of the winding.
4.2 More recently various companies have developed Fourier transform infra Red (FTIR)
detectors which will detect most of the gases of interest and quantify their amounts. These
systems are not seen currently as an alternative to the very low cost of a laboratory based oil
analysis. Their current role is to investigate particular transformer with gassing problems.
However, an added benefit being gained is the greater understanding of the load temperature,
time relationships for detected gases. This should eventually lead to better understanding and
interpretation of the laboratory analysis.
5.0 CAPACITANCE & TAN δ MEASUREMENT OF BUSHINGS AND WINDINGS
Monitoring of insulation requires knowledge of insulation characteristics and judgement based

on experience. Factors like ambient temperature, humidity, cleanliness of surface of bushings
and electrostatic interference are to be considered before taking any reading so that error in
measurement could be avoided and readings are accurate.
To overcome interference due to charged switchyard, the polarity of the input voltage is
reversed w. r. t. electrostatic interference and second measurement is made; the two averaged
and interference is effectively reduced. The testing kit with its own sinusoidal source and
interference suppression / cancellation unit is used which generates its own signal opposite in
phase and magnitude to cancel out the interference.
While carrying out this test in EHV substation, certain precautions like use of Interference
Suppression Unit along with double-shielded leads, disconnection of jumpers and cleaning of
surface of the bushings are taken. All phases of a particular winding is shorted together and also
with neutral to minimize the effect of inductive currents during measurements.
(a) Bushing Dissipation factor and capacitance values are measured in UST (Ungrounded
Specimen Test) mode.
(b) Measurement for windings is carried out as per the following combinations:
• Winding to winding in UST mode.
• Winding to Ground in GSTg mode with other winding guarded. While carrying out
measurement for HV winding LV winding should be guarded whereas for LV winding
HV winding shall be guarded.
• Winding to Ground in GST mode may be done for verification of test results taken in
UST and GSTg mode.
• Tan delta value for healthy insulation does not change appreciably with change in
temperature. In case of variation of Tan delta with change of temperature, condition

of insulation needs to be investigated. Use of temperature correction factor should not
be applied. In case of any doubt, measurement should be taken as near to 20 °C as
possible.
Rate of change of tan delta and capacitance is very important. Normally Tan delta of bushings
and windings at 20°C should be less than 0.007 during O&M. For new bushings, Tan delta value
generally lower than 0.50.4% and for windings also, Tan delta value should be less than 0.5% at
20 deg C. Capacitance value can be within +10%, -5% of previous capacitance values. Rate of
rise of Tan delta for bushings and windings should not be more than 0.001 per year. The rate of
change of tan delta more than 0.001 per year needs further investigation
6.0 FREQUENCY RESPONSE ANALYSIS
Frequency Response Analysis (FRA) is made to assess the mechanical integrity of the
transformer. Transformers while experiencing severity of short circuit current looses its
mechanical property by way of deformation of the winding or core. These changes cannot be
detected through conventional condition monitoring techniques such as Dissolved Gas Analysis,
Winding Resistance Measurement, Capacitance and Tan delta measurement etc. Sometimes even
transportation without proper precaution may cause some internal mechanical damages. FRA
measurement, which is signature analysis, provides vital information of the internal condition of
the equipment so that early corrective action could be initiated.
Short circuit forces can cause winding movement and changes in winding inductance or
capacitance in Power Transformers. Recording the frequency response with these changes gives
information regarding the internal condition of the equipment. Frequency Response Analysis
(FRA) has proved to be an effective tool to detect such changes.
Fig. 2 FRA test set up

Sinusoidal signal output of approximately 2 V rms from the Frequency Response Analyzer
is applied and one measuring input (R1) is connected to the end of a winding and the other
measuring input (T1) is connected to the other end of the winding. The voltage is applied and
measured with respect to the earthed transformer tank. While the low frequency analysis reveals
the winding movements, the high frequency analysis reveals the condition of joints.
It is ensured that winding which is not under test is terminated in open condition in order to avoid
response difference among the three phases. The same procedure is followed on subsequent tests
on the same or similar transformer, to ensure that measurements are entirely repeatable.
The voltage transfer function T1/R1 is measured for each winding for four standard frequency
scans from 5 Hz to 2 MHZ and amplitude & phase shift results are recorded for subsequent
analysis
• Analysis of Measured Frequency Responses
Interpretation of the test results is based on subjective comparison of FRA responses taken
at different intervals. If changes are observed in the later FRA spectrum with respect to the
reference FRA spectrum, it is left to the experience of the analyst for quantitative condition
assessment of the transformer. However, one should check for any significant shift in the
resonance frequencies and emergence of new resonant frequencies in the later FRA response,
which could be the result of any mechanical deformation in the transformer winding. As FRA
is signature analysis, data of signature of the equipment when in healthy condition is required
for proper analysis. Signatures could also be compared with unit of same internal design or
with other phases of the same unit. Normally measured responses are analysed for any of the
following:
• Changes in the response of the winding with earlier signature.

• Variation in the responses of the three phases of the same transformer.
• Variation in the responses of transformers of the same design.
In all the above cases the appearance of new features or major frequency shifts are causes for
concern. The phase responses are also being recorded but normally it is sufficient to consider
only amplitude responses.
Fig.3
As per EuroDoble Client Committee, the traces in general will change shape and be distorted in
the low frequency range (below 5 KHz) if there is a core problem. The traces will be distorted
and change shape in higher frequencies (above 10 KHz), if there is winding problem. Changes
of less than 3 decibels (dB) compared to baseline traces are normal and within tolerances. In
general, changes of +/- 3 dB (or more) in following frequency range may indicate following
faults:
Table 12
• Following international standards are available for FRA and its interpretation:
(a) IEC 60076-18 Edition 1.0
(b) CIGRE Technical Brochure 342; Mechanical condition assessment of Transformer

winding using FRA
7.0 PARTIAL DISCHARGE MEASUREMENT
PD techniques for detection and location are important for diagnostics, as they not only
help to identify the inception of damage caused, but also assist to monitor the evolving
and deteriorating situation affected by the various stress factors existing in the service
condition. There can be various reasons for PD inception. It can be the result of electrical
stress caused by mechanical deformation, overheating of insulated conductor or even can
be the result of inherent defect. The PD detection at site can be done by various techniques
such as:
• Dissolved Gas Analysis
• Conventional IEC 60270
• Acoustic measurement
• RFI measurement
• UHF measurement
All these techniques have their strength and weakness in terms of sensitivity and accuracy. The
sensitivity and effectiveness of these techniques depends upon the type of defect and location
of the fault.
• Analysis of Dissolved Gases for PD detection
Normally Oil samples are taken once or twice a year from the main tank for laboratory
analysis. From dissolved gas analyses it is possible to detect damage caused by both
overheating and PD. However a direct measurement of PD will be much helpful to
ascertain a rapidly increasing rate of PD than relying upon the trending of dissolved
gases.
• Conventional IEC 60270
PD measurement for factory acceptance testis based upon IEC 60270 standard. The measurement
with this method is usually made using the bushing tap as a capacitance divider and measuring
PD transients in the 30-500 kHz range.
The PD measurement at the bushing taps is affected by the attenuation, the winding resonance,
external corona, various electromagnetic discharges present at the site and the weather
condition.
Fig. 4
• Acoustic PD Measurement
Acoustic discharge detection is based on detection of the mechanical signals emitted from the
discharge. The discharge appears as a small “explosion,” which excites a mechanical wave that
propagates throughout the insulation. These waves propagate through different media before
reaching the container of the equipment under test. AE sensors mounted on the container
of the equipment pickup these AE signals and convert into electrical signals, which could
be analysed using a data acquisition and processing system. Acoustic PD detection system
usually consists of AE sensor, preamplifier and a data acquisition, storing and analyzing
instrument.
• RFI Scanning
The important advantage of this method is that it can be included in the routine monitoring
schedule and will survey all substation equipment. It will indicate bushing problems and
this is one area where dissolved gas analysis is limited by the difficulties in extracting a
gas sample. Sensors such as telescopic, duck antenna or high frequency split core current
transformers can be used. The main advantage is that this method can detect the PD without
the need for outages or any special connections. For effective analysis, the RFI signals
are monitored in frequency domain from 50 MHz to 1000 MHz as well as in time domain
mode.
A typical baseline reading is taken prior to measurement on any HV equipment. A baseline

reading will show all the RF frequency signature for the area where a substation is located.
The frequency spectrum from 50 MHz to 1000 MHz consists of several different continuous
signals like FM radio, mobile signals, TV stations, Essential wireless services and other
telecommunication sources. Example of a typical frequency scan is shown in Figure given
below, where these telecommunication signals are present.
Fig. 5
The broadcasted signals are narrowband in nature whereas the RF signals produced by PD
are broadband in nature. It is therefore necessary to discriminate between these two signals to
recognize the presence of PD source.
The facility of both peak and average detectors in the instrument facilitates discrimination
between the narrowband characteristics of broadcast RF emissions and the broadband impulsive
RF emissions from PD. The amplitudes of the peak and average measurements for broadcasted
RF emissions are nearly same whereas in case of broadband RF emissions resulting from PD
the average value has much lower amplitude. Figure given below shows the variation in average
and peak amplitude measurements.
Average and peak amplitude Suspected PD detected

Fig. 6
• PD Detection- with UHF Probe
In this method, UHF probe inserted in an oil valve or access port allowing the transformer tank
to screen interference acting like a Faraday cage. This probe detects the electromagnetic radiation
from the PD and is not affected by winding resonances. The UHF method technique can be used on
site even when the transformer is energized, in a high electromagnetic interference environment.
UHF method cannot be calibrated ay injecting a known charge across the winding as is done in
case of conventional method as per IEC 60270. Performance/Sensitivity Check is performed by
Injecting high-frequency test impun the additionally integrated electrode.
Fig. 7
The PD output of the UHF probe is connected via coaxial cable to a pre-amplifier and the
measuring instrument. Optimum measuring frequencies for better signal and S/N are selected
for measurements and measurements are performed
Figures given below shows a typical probe inserted through an oil valve and typical curve
obtained during measurement.
UHF probe inserted in drain valve Typical UHF measurement

Fig. 8
8.0 Dielectric Response Methods for Diagnostics for Power Transformers

The dryness and ageing state of the oil-paper insulation is a key factor for deciding reliability of
a power transformer since moisture has deleterious effects on dielectric integrity and insulation
ageing rates. Today the water content of the cellulose of a transformer in service is determined
indirectly via moisture measured from oil. As moisture distributes unequally between the oil and
the pressboard, the greater part resides within the solid insulation. Because the water concentration
in the oil is highly temperature dependent, the measurement of moisture in oil is not a particularly
reliable indicator of dryness in the cellulose, particularly not for lightly loaded transformers.
Recently, methods are developed of determining moisture content and ageing of the pressboard
and paper more directly by measuring the effects of moisture on electrical properties. The two
foremost techniques are:
(a) Dielectric spectroscopy in time domain, i.e. measurements of polarization and
Depolarization currents (PDC)
(b) Dielectric frequency domain spectroscopy (FDS), i.e. measurements of electric
capacitance C and loss factor tan δ in dependency of frequency.
• Polarization and Depolarization Currents Measurement (PDC)
In the polarization and depolarization current (PDC) method, a DC voltage is applied to the
insulation system under test for a specific time and the polarization current is measured. After
then, the insulation system is shortened and the depolarization current is measured. From the
polarization and depolarization currents the dielectric response is evaluated and the dissipation
factor frequency characteristic is calculated. The PDC method is much faster than the FDS
at very low frequencies. Measurement results are usually presented in a log/log scale with
charging and discharging current over time. According to the common interpretation guideline
the first 1-100 seconds are influenced by oil conductivity. The end value of polarization current
is determined by the pressboard resistance and therefore by moisture
Fig. 9 Measurement of the relaxation currents using PDCAnalyser& Principle waveform of relaxation currents
Interpretation of PDC Measurement data
Fig. 10
• Dielectric Frequency Domain Spectroscopy (FDS)

In frequency domain spectroscopy (FDS), the dissipation factor of the insulation system under
test is measured by frequency sweep. Frequency versus Tangent Delta measurements method
is called Frequency Domain Spectroscopy (FDS). In this method, frequency range is much en-
hanced especially to low frequencies. The dissipation factor plotted via frequency shows a typi-
cal s-shaped curve. With increasing moisture content, temperature or aging the curve shifts to-
wards higher frequencies. Moisture influences the low and the high frequency parts. The middle
part of the curve with the steep gradient reflects oil conductivity. Insulation geometry conditions
determine the “hump” left of the steep gradient. In order to determine the moisture content of the
insulation, the measurement should also provide data left of the “hump”, where the properties
of the solid insulation dominate.
Fig. 11
Following table may be considered for determining the level of wetness and taking necessary
action for Dryout.
Table 13 : Moisture content in paper
Source : IEEE Std. 62-1995
Insulation condition % Moisture by dry % Saturation of Waterin oil

weight in paper (Wp)
Dry (at commissioning) 0.5-1.0 % <5%
Moderate to Wet (Lower no. indicate fairly dry whereas <2% 6-20 %
large no. indicate moderately wet insulation)
Wet 2-4 % 21-30 %
Extremely wet > 4.5 % > 30 %
(Source : CIGRE DOC. No. 227. Life Management Technique for Power Transformer)
9.0 ON LINE WINDING TEMPERATURE MEASUREMENT

9.1 The life of a transformer is shortened considerably if it is operated consistently at el-
evated temperatures. A winding temperature indicator (WTI) is used to monitor the temperature
of winding by indirect methods and give alarm / trip commands to protection circuits when tem-
perature rises beyond the set limits to protect the transformer. This method uses a thermal image
of the transformer and is based on the transformer load current. Calibration consists of assigning
an assumed hot temperature to full load current. However it is not a direct measurement of the
winding temperature and cannot reliably represent the transient conditions.
9.2 The direct measurement of winding temperature of transformer by hot probes with fibre-
optic links is based on fluoroptic thermometry technology where a temperature sensitive phos-
phor is connected to the detector. Blue violet light pulses are sent down the fibre causing the
phosphor to glow. Decay of fluorescence after each pulse varies accurately with temperature.
The same optical fibre transmits the excitation pulses and returns the fluorescent signal. It has a
very wide temperature range of measurement (-200°C to + 450°C) and has a high accuracy of
+ 0.1 °C. The optical signals do not get distorted in presence of even very high electromagnetic
fields. The cables/links are non-corrosive in transformer oil and they do not influence the electric
field inside transformer.
9.3 The change in decay time of fluorescent light is detected by a detector, which is directly
calibrated in terms of temperature. The response time of the change is very high and of the order
of 0.2 sec. So, fibre-oplic point sensors for direct hot-spot measurement can measure the actual
hot-spot and have a much faster response. Accurate knowledge of thermal behaviourand hot-
spot temperature enables the manufacturer to refine designs and calculating procedures and the
customer to fully utilize the overload capabilities of plant without reducing life expectancy and
degrading the dielectric integrity.
10.0 THERMO VISION SCANNING OF TRANSFORMER
A thermo vision camera determines the temperature distribution on the surface of the tank as
well as in the vicinity of the Jumper connection to the bushing. The information obtained is use-
ful in predicting the temperature profile within the inner surface of tank and is likely to provide
approximate details of heating mechanism
The following temperature rises above ambient have been found to be practical during infrared
inspections:
Table 14 : Action based on temperature rise above ambient
Temperature rise Recommendation

above ambient (°C) (based on IEEE Std 62-1995)
0-10 Repair in regular maintenance schedule : Little probability of physical damage

11-39 Repair in near future; Inspect for physical damages
40-75 Repair in the immediate future. Disassemble and check for probable damage
>76 Critical problems; Repair immediately
Note : Any decision to remove any equipment from service has to he taken based on test results, special tests if any (in
totality) and manufacturers’ recommendation.
11.0 CONCLUSION
Condition monitoring uses sensors to provide raw data and warning signals from the equipment
under surveillance. The diagnostic and condition monitoring together is a powerful tool for
optimizing assets life. It also helps to reduce maintenance, failure and consequential losses and
to assist in predicting residual life. Based on the results, refurbishment strategy, upgrading and
replacement decisions can be taken.
SECTION EE
Guidelines for Fire Protection of Power

Transformers
SECTION EE
Guidelines for Fire Protection of Power Transformers
1.0 GENERAL
1.1 Introduction
The hazard of fire originating in or spreading to power transformers has always been recognised in
the Power Industry. With the increasing size of generating units and associated transmission and
distribution networks the number of transformers or large capacities has increased phenomenally
thus necessitating more stringent protection measures to prevent fire risk to transformers and
damage to equipment. This section of the transformer specification discusses the various aspects
of transformer fire protection.
1.2 Strategy
The strategy for safeguarding against fire is to emphasize fire prevention rather than fire fighting.
Nevertheless, it is equally important to provide adequate fire fighting arrangements. This applies
also to associated equipment like bushings, circuit breakers, instrument transformer, cables,
etc., since a fire originating in these can easily spread to the power transformer. In effect, all
the transformer installation should be provided with the prevention as well as fire detection and
fighting systems.
1.3 Other Factors
Factors like proximity of the transformer to buildings and other equipment such as switchgear
play an important role in design of the fire prevention scheme. It is desirable that these equipments
be segregated from the transformer installation or be provided with fire prevention measures to
avoid spread of fire to the transformer installations.
2.0 DESIGN CONSIDERATIONS
A majority of fires originating in transformers are due to inadequate design and installation,
apart from faulty operation and maintenance practices, Proper installation, house keeping and
maintenance can reduce fire hazards to a great extent. Hence, fire hazards must be given utmost
attention while designing, selecting and installing power transformers and correct operation and
maintenance procedures must be adhered to strictly.
2.1 Bushings
Bushings are often the source of transformer failures and consequent fires. This is due to the
fact that dielectric stresses in bushings are very high and sometimes oil tightness may not be
ensured. Only bushings of proven design, which have been fully type tested and have passed all
acceptance tests shall be used, Bushings shall be provided with test taps and regular (annual)
checks of bushing tan delta shall be carried out. Also, the oil level, in oil filled bushings, shall
be checked daily.
373
2.2 Tapchanger
Tap changer, particularly on-load type are a potential fire risk. The selection of tap changer
design, and proper maintenance of its mechanism are important. In no case should an off-load
tap changer be operated when the transformer is energised from any of its windings.
2.3 Cable Sealing Ends
The level of compound in the sealing ends should be checked periodically.
3.0 INSTALLATION REQUIREMENTS
The general recommendations for safeguarding power transformers are given below and specific
recommendations arc given in clause 4. The requirement relevant to transformers, in increasing
order of importance of installation are:
(a) Soak pits

(b) Drain pits
(c) Barrier walls
(d) Fire detection system
(c) Fire hydrant
(f) Deluge, spray or mulsifire system
(g) Nitrogen injection system
In case of remote controlled or unattended substations, automatic fire detection and fighting
system (e.g. nitrogen injection system) along with conventional system can also be provided.
3.1 Outdoor Transformers
(a) Soak Pit and Drain Pit
The transformers foundation shall be surrounded by a suitable soak pit enclosed by a 150 mm
high non-combustible curb. This soak pit shall be filled with coarse crushed stones about 25 mm
in diameter to a minimum depth of 300 mm. The volume of the soak pit minus the volume of the
stones should be sufficient to contain the entire oil content of the transformer if the oil content is
less than or equal to 5 kl. In case the oil content is more than 5 kl, the volume of soak pit minus
the volume of stones should be sufficient to contain at least one third of the total oil content. The
excess should be led through two or more hume/concrete pipes (min. 150 mm dia.) from bottom
of pit to a central remote burnt oil tank.
Control cables emanating from transformers shall be led through the soak pit through hume
RCC pipes. The marshalling kiosk of the transformer shall be installed outside the pit and away
from the potential fire hazard zone.
Guidelines for Fire Protection of Power Transformers 375
(b) Barriers between Transformers
Barrier wall of brick or reinforced cement concrete shall be provided for separation of
transformers wherever adequate space is not available (Refer clause 4). The barriers shall extend
at least 300 mm above the highest transformer bushing and pressure relief vent and lengthwise
600 mm beyond the transformer including any radiators and tap changer enclosures.
(c) Fire Detection, Hydrant and Deluge Systems
Selection of these systems should be based on the importance of an installation. The fire detection
system only detects a fire and sends an alarm, whereas the other systems are active fire fighting
systems. Selection guidelines are given in clause 4.
(d) Nitrogen Injection Transformer Explosion and Fire Protection Systems
Selection of this system is based on the importance of installation, criticality of availability of

power supply and permitted restoration time of transformer after failure of transformer. The
fire detection system only detects an incidence of fire and sends an alarm to other water based
systems, which operates only after fire, whereas nitrogen injection systems are designed for
automatic tank explosion prevention apart from fire extinguishing. Selection guidelines are
given in clause 4 and details in clause 7.4 .
3.2 Indoor Transformers
(a) For indoor installation with oil filled transformers rated at more than 75 kVA, each of
the transformer should be located in a vault. Transformer vaults should preferably have
a minimum fire resistance rating of 3 hours but where transformers are protected by
water spray and Carbon dioxide systems, construction with one hour rating is adequate.
Facilities for remote monitoring of vault temperature shall be provided.
(b) It is recommended that a trapped floor drain be provided which discharges burning oil
to a safe location. A fire door and a noncombustible curb at least 100 mm high should
be provided at each doorway. Switchboards etc. should be physically separated from the
vaults and the latter should never be used as offices, filing cabinets, work rooms etc.
(c) Adequate ventilation should be provided in the transformer vault. Self cooled transformer
should be separated by 600 to 750 mm to permit free air circulation. It is recommended
that air filters be provided on all vents wherever the installation is located in dusty, high
pollution areas. The vent should automatically close in the event of a fire in the vault.
3.3 General
The requirements laid down in Section 5 of Tariff Advisory Committee’s “Regulations for the
Electrical Equipment of Buildings” and Section 7.9 of IS : 10028 (part II) shall be followed for
all transformer installations. In addition, the following measures are recommended for cables:
(a) The power cables entering the transformer shall be coated with fire resistant
material in the immediate vicinity of the transformer cable box entry so as to prevent
spreading of fire from or to the transformer cable.
(b) Cable trenches shall be filled with sand to prevent spread of fire.
It is recommended that trenches of more than 1000 cm2 cross-sectional area be provided with
incombustible barriers at intervals not exceeding 45 meters. The barriers shall be at least 50
mm in thickness and of the same height as the cable trench. The cables shall be carried through
holes in the barriers which shall be made good thereafter to prevent passage of fire beyond the
barriers.
4.0 INSTALLATION REQUIREMENTS: SPECIFIC
A summary of various recommendations for fire protection and fighting systems for indoor and
outdoor transformers is given below:
4.1 Fire Protection for Outdoor Power Transformers
Size (each) Number Transformer Protection

(a) Under 10 MVA One or more Hydrant protection
(b) 10 to 100MVA One only Hydrant (protection with water spray)Equipment
as per IS -3034: OR Nitrogen Injection System
(See Note 2)
1. Provide a 7.5 m clearance between units and 60
More than one mm hose with two portable spray nozzles: or
2. Masonry barriers between units with 60 mm hose
and two portable spray nozzles: or
3. Fixed automatic water spray with separate piping
for each unit or
4. Nitrogen Injection System for each unit.
(c) Above 100 MVA One only Hydrant (protection with water spray) Equipment
as per IS -3034 or Nitrogen Injection
(See Note 2) Injection System
More than one 1. Fixed automatic water spray(mulsifire)
separate riser and piping for each unit; or
(Sec Note 3) Nitrogen Injection System for each unit and
2. Provide a 7.5 m clearance or masonry barriers
between units.
(d) Above 200 MVA One only Hydrant (protection with water spray) Equipment
however, fixed water spray protection may be
(See Note 2) desirable in addition. as per IS -3034 or, Nitrogen
Injection System
1. Fixed automatic water spray with separate piping
for each unit as per IS 3034 or Nitrogen Injection
System for each unit
More than one
2. Provide a 15 m clearance or masonry barriers
(Sec Note 3) between units.
Notes 1.
The enclosure should consist of a masonry barrier with wing walls of the same height extending 0.6 to 1 m beyond
the transformer, including any radiators and tapchanger enclosures. The enclosure should also be provided with a
roof of equal fire resistance to the walls.
Where there are important or high value bus structures exposed to a transformer oil fire and/or electric service
or production could be interrupted for an extended period resulting in a large loss, a fixed automatic water spray
system should be provided to minimize the physical damage from fire and reduce the downtime for repairs.
Multiple transformer of 100 MVA and above may be protected as single units if separated by a minimum of 35 m.
For those separated by a distance between the minimum clearance shown and 35 m transformer protection may be
either a barrier or fixed water spray.
Cables, isolated bus duct, or cable tray penetrating an exposed wall should be sealed with a fire barrier or stop.
Ventilation louvers should be relocated to an unexposed area.
“Wherever water spray nozzles are provided, the nozzle should be separated from the transformer by over 4 in for
voltages below 250 kV. For voltages beyond this and for solid hose streams, this distance varies with factors such
as water pressure, wind velocity and direction, size of nozzle etc.
4.2 Fire Protection for Indoor Power Transformers
Typical size of Type of Building/ Protection (Sec Note 2)

Transformer Transformer encl. (See
Note 1)
(a) Upto 100 kVA Combustible Automatic sprinklers. Alternatively, use dry
type transformers.
Non-combustible Usual first aid protection.
(b) Upto 30 MVA Non-combustible 1. Fire resistive vault

2. 40 mm fire hose with two water spray
nozzles; and
3. Usual portable extinguishers. Or,
Nitrogen Injection system.
Combustible 1. Fire resistive vault, and
2. Automatic sprinklers, water spray, CO2
system
Or, Nitrogen Injection System
(c) Above 30 MVA Any 1. Fire resistive vault, and

& upto 100 MVA 2. Automatic sprinklers, water spray, CO2
system.
(d) Above 100 MVA Any 1. Fire resistive vault

2. Automatic sprinklers water spray,
CO2 system
Notes
1. Combustible and non-combustible buildings are generally classified based on type of construction materials used
and type of occupancy.
2. This protection applies for all new installations and at existing locations when a large loss possibility exists
without improvement.
3. If transformers are of unusual importance or large (above 10 MVA) located within fire resistive transformer houses
or vaults, install fire resistive walls between units to reduce the exposure to adjacent transformers unless automatic
fixed extinguishing systems of 7.5 m clearances are provided.
5.0 RECOMMENDED MAINTENANCE AND TESTING PRACTICES
It is essential to monitor certain parameters to check the healthiness of the transformer and to
minimise fire risks. The parameters to be checked and their frequencies shall be as brought out
elsewhere (Section CC) in the transformer manual. Some of the parameters more relevant to
transformer fires are discussed below.
5.1 Oil Leakage
Oil leakage from transformer tank, bushings or radiators may become sources of major fires.
It is recommended that all transformer installations be inspected daily for leakage of oil. Any
leakage detected should be immediately attended to. In case of excessive leakage the transformer
should be de-energised and repair work carried out.
5.2 Hot-oil Circulation
During hot-oil circulation in the transformer, it must be ascertained that all combustible materials
are kept at a safe distance from the transformer. The transformer shall be covered with non-
combustible materials. Under such condition, it is essential that the transformer is kept under
close watch.
5.3 Terminal Equipment
Sparks from improper terminal connectors and neighbouring fuses etc., falling on the transformer
can cause great fires. To prevent such occurrences it is recommended that the terminal connectors
be regularly inspected for over-heating/sparking. Infra-red temperature scanners can be used for
this purpose. It is also recommended that fuses be installed at a distance from the transformer
such that sparks generated during their operation will not reach the transformer.
5.4 Transformer Oil
The condition monitoring of transformer oil can give valuable insights into the healthiness
of transformers. It is recommended that dielectric strength, acidity and oil tan delta (90°C)
be monitored continuously and detailed investigation be carried out whenever any of these
characteristics indicate signs of deterioration of oil quality.
5.5 Housekeeping
The importance of good housekeeping and cleanliness in reducing fire hazard cannot be over-
emphasised. Many fires have been caused by oil drips and collection of rags in dirty cluttered
surroundings. It is very important to remove possibilities of such fires, by ensuring that the
installations arc spacious and the vacant spaces are periodically cleaned to remove obstructions
to ventilation and movement of personnel.
6.0 FIRE FIGHTING EQUIPMENT
In addition to the fire protection systems described above, it is essential to provide primary fire
fighting equipment for every transformer installation. The equipment required for indoor and
outdoor installations should be as per following guidelines :
Typical size For the first two units For every additional two Units or part
of transformer thereof
45 ltrs. 2 llrs. Sand & 45 ltrs. 2 ltrs. Sand &
foam type from type water foam type from type water
extinguishers extinguishers buckets extinguishers extinguishers buckets
Upto 20 MVA 2 4 2 each 1 2 2 each
(Indoor) (Indoor)
4 each 4 each
(Outdoor) (Outdoor)
Upto 50 MVA 3 6 2 each 2 2 2 each
(Indoor) (Indoor)
4 each 4 each
(Outdoor) (Outdoor)
50 MVA 4 8 6 each 2 2 6 each
Notes
1. The sand and water buckets shall be of 9 litre capacity each and shall have round bottoms.
2. Sandpits of adequate sizes shall be provided in central location for catering to any sand requirements. These pits
should always be kept filled with dry sand.
7.0 FIRE FIGHTING SYSTEMS
Some of the major types of fire fighting systems are discussed below:
7.1 Automatic Mulsifire System
This system is widely used for fire fighting of outdoor transformers. Fire detectors located at
various strategic points are used to sense high temperature near the transformer. If the temperature
exceeds the set value the automatic mulsifire system sprays water at a high pressure on the
surface of the transformer to control fire on any burning oil spilled over. Various subsystems are
used to make a complete mulsifire system.
(a) Main Hydrant: This is used to carry the water to various parts of the switchyard or
transformer substation and forms the backbone of the system. Sturdy corrosion free pipes
and valves should be used for this purpose. The materials should be able to withstand fire
for a reasonable duration.
(b) Fire Detectors: Fire detectors can either be thermocouples or specially designed bulbs
which burst when a high temperature is applied and release any valves or checking device
to start the water spray.
(c) Ring Mains and Nozzles: Ring mains which surround the transformer are provided to
feed the water to the nozzles at various levels. Since the water pressure is high, the ring
mains should be designed to withstand this pressure. Nozzles should be located such that
the water spray, in the event of a fire, envelopes the entire surface of the transformer. The
whole system should be periodically checked to detect any leakages.
(d) Pumps: Pumps are provided to fill the hydrants initially and to maintain its pressure.
Pumps driven by electrical motors are a standard provision; however, the standby pumps
should preferably be diesel engine driven. It is recommended that the main and standby
pumps in a pump house be segregated.
7.2 Sprinkler and Hydrant System
This system is similar to the mulsifire system but water in this case is sprayed on the transformer
body at lower pressure, Hence the name sprinkler. This system is normally not capable of
extinguishing large fire. For this reason, it is desirable to connect an alarm to the sprinkler
system. Whenever the sprinkler operates an alarm is given to signal requirement of additional fire
fighting arrangement. The auto-starting pump valves and alarm must be periodically checked.
7.3 Foam System
This system is used to cut off the oxygen supply to the burning parts and thereby extinguish
the fire. For this it is essential that the entire surface of the burning part or oil be covered with
foam.
The system includes a foam compound chamber, which contains the compound. In the event of a
fire, this compound comes in contact with water and air to form foam. This foam is then sprayed
onto the burning parts. The compound chamber should be corrosion proof and the valves should
be periodically tested to ensure their healthiness.
7.4 Nitrogen Injection System for Transformers /Reactors 10 Mva and above
Nitrogen injection system shall be used to prevent the transformer explosion and possible fire,
in the case of internal fault and as such acts as fire preventer. In certain cases, tank explosion
cannot be prevented and transformer oil catches fire. In such cases and also in the event of fire by
external causes, it shall act as firefighting system. In either way it shall protect the transformer
and eliminate or minimize the post fire damages. Thus, System shall be suitable for protecting
the transformer tank from explosion and also transformer, OLTC and cable box from fire. The
system operation shall be automatic and also be made to operate with remote control from
control box and manually from extinguishing cubicle in the event of power loss.
7.4.1.1 Operation
On receipt of signals, e.g Differential protection parallel with Fire detector, Buchholz (surge)
parallel with PRV and transformer/reactor isolation signals, a predetermined quantity of oil drain
shall commence and simultaneously Nitrogen shall be injected at a pre-determined flow rate to
create stirring action and to bring down temperature of top oil surface below ignition point and
shall extinguish fire within shortest possible time, say, 30 seconds. Transformer Conservator
Isolation Valve (TCIV) shall block oil passage and isolate conservator tank oil and shall prevent
escalation of fire.
System shall have following characteristics:
• System shall operate in automatic, remote and manual mode in the event of power
failure.
• System shall have provision of testing on live transformers to ensure healthiness at all
times.
• System shall have interlock to ensure operation of system only after transformer electrical
isolation to avoid nitrogen injection in energized transformer.
• System shall have mechanical locking arrangement for nitrogen release system as well
as oil drain to avoid unnecessary operation during maintenance and /or testing of the
transformer and /or system.
• System shall have provision to monitor nitrogen injection pressure as well as cylinder
pressure.
• Pressure monitoring switch for back-up protection for nitrogen release as redundancy
to first signal of oil draining commencement for Nitrogen release shall preferably be
provided.
• System shall have individual mechanical release devices and provision for oil drain and
nitrogen release to operate manually in case of operation DC supply failure.
• Nitrogen release scheme shall be designed in such a way that the nitrogen gas shall not
enter the energised transformer/reactor tank even in case of passing/leakage of valve.
• Individual system component/equipment should preferably not have working voltage
other than Station DC Voltage.AC-DC/DC-DC converter shall not be used for reliable
operation.
• All outdoor panels / equipment shall be of IP55 protection class.
Schematic diagram of typical Nitrogen Injection system, is shown in Fig.1
Fig.1
Pipe layout of Nitrogen Injection system as suggested by Supplier of Nitrogen injection system
shall be provided by transformer manufacturer typically shown in Fig.2
Fig. 2
• Major System components
Nitrogen injection system shall broadly consist of the following components. However, all other
components which are necessary for fast reliable and effective working of the fire protective
system are also provided.
(a) Fire Extinguishing Cubicle (FEC) : shall be mounted 5-7 m away from transformer /
reactor or placed next to the fire wall if fire wall exists. Cubicle shall be suitable for
outdoor as well as indoor installation. It shall have hugged split doors fitted with high
quality tamper proof lock. Cubicle shall contain nitrogen gas cylinder, mechanism for
oil drain and nitrogen release with essential back up of pressure switch for operation
alongwith control unit
(b) Control box : shall be placed in the control room for monitoring system of operation,
automatic control and remote operation. All individual components,instruments shall
work on station DC supply. Following alarms, indications, switches, push buttons, audio
signals etc. shall be provided : System on, Oil drain valve closed, Gas inlet valve closed,
TCIV(see below) closed, OLTC oil surge relay trip, Oil drain valve open, Extinction in
progress, Cylinder pressure low, Differential/fire detector, Buchholz relay /PRV / RPRR
trip, Master relay of transformer / reactor trip, System out of service, Auto/ Manual /
Off, Extinction release on / off, Lamp test, Visual/ Audio alarm, Visual/ Audio alarm for
DC supply fail, Fault in cable connecting fault : fire detector, differential relay, Buchholz
relay, PRV / RPRR, transformer /reactor trip, TCIV alarm etc.
(c) Transformer Conservator Isolation Valve : (TCIV) shall be fitted in the conservator pipe
line, between conservator and Buchholz relay shall operate for isolating the conservator
during abnormal flow of oil due to rupture / explosion of tank or bursting of bushing
including tank depressurization during system operation. The valve will not isolate
conservator during normal flow of oil during filtration or filling or refilling, locking
plates shall be provided with handle for pad locking to ensure no movement of valve
position during service and filter position. It shall have proximity switch for remote alarm
and indication glass window for visual inspection similar to Buchholz glass inspection
window for physical checking of the status of valve. The TCIV shall be of the best quality
as malfunctioning of TCIV could lead to serious consequence. The closing of TCIV means
stoppage of breathing of transformer/reactor. Fire survival cable connecting TCIV shall
be terminated in transformer marshalling box.
(d) Fire detectors : shall be specially designed to generate signals after sensing higher
temperature.
(e) Piping : Heavy duty pipe connecting the transformer/reactor tank for oil drain, and for
nitrogen injection shall be provided. Pipes connecting oil tank laid underground, shall be
preferably be galvanized, medium duty.
(f) Cables:Fire survival, copper cables (capable to withstand 750° C.),Fire Retardant Low
Smoke (FRLS), copper cable of 12 core x 1.5 sq. mm and 4 core x 1.5 sq.mm size shall
preferably be used for interconnection.
7.4.1.1 Transformer/reactor manufacturer shall provide following provisions :
(a) Oil drain opening with gate valves on transformer / reactor tank at upper portion at ~120
mm from top cover.
(b) Nitrogen injection openings with gate valves on transformer / reactor tank at bottom side
of tank.
(c) Flanges with dummy piece in conservator pipe between Buchholz relay and conservator
tank for fixing TCIV.
(d) Fire detector brackets on transformer / reactor tank top cover.

(e) Mounting support/ frame on tank side wall for signal box.
7.4.1.2 Technical particulars
Typical technical parameters of a Nitrogen injection system are as follows
Fire extinction period from commencement of 30 s (Max.)

nitrogen injection
Total time duration to bring oil temperature 30 minutes (Max.)
below flash point
Fire detector’s (quartz bulb) heat sensing 141 deg.C
temperature
Transformer Conservator Isolation valve 40 l / min
setting for normal operation (valve should not
close) to ensure no obstacle for transformer
breathing
Transformer Conservator Isolation valve 60 l / min (Minimum)
setting for operation during abnormal flow
of oil due to rupture / explosion of tank or
bursting of bushing / oil drain during system
operation
Capacity of nitrogen cylinder 10 m3 gas at pressure of 150 kg/cm2 upto
60000 litres oil capacity of transformer
/ reactor tank and 20 m3 gas at pressure
of 150 kg/cm2 above 60000 litres oil
capacity of transformer / reactor tank .
Power supply As per substation DC voltage.
For Control Box
For Fire extinguishing cubicle for lighting 230V AC
7.4.2. Information shall be provided to system equipment manufacturer in the following

typical format
Customer: End User :
Work Order Nr/Tender Nr/Project details :
Quantity :
Manufacturer : Sr. No. :
MVA Rating : Voltage ratio :
Oil Qty in tank : Litres
Oil Qty in Conservator : Litres
Power Supply (Pl tick √ ):
Substation/ Control room D.C. Supply : 220V 110V 48V 24V Other
A.C. Supply available : Control room Marshaling box Single phase, 240V, 50 Hz
Conservator pipe diameter : mm Conservator pipe angle : degree
Spare contacts in relay panel :

Differential RPRR Trip 1 Nr Buchholz Trip Restricted
relay trip 1 Nr NO potential 1 Nr 1 Nr NO potential Free Earthfault relay
1 Nr NO potential
NO potential free Free Free Free
OLTC oil surge Master relay PRV Trip HV & LV
relay trip 1 Nr. Trip 1 Nr NO 1 Nr NO potential circuit breaker trip,
No potential free potential fre Free 1 Nr each NC
potential free
NO : Normally Open, NC : Normally Close, RPRR : Rapid Pressure Rise Relay
Main Dimensions of tank :
L= mm
B= mm
H= mm
A= mm
Bevelled cover Yes No
Built-in On load Tapchanger : Yes No

Oil Filled Cable Box : Yes No
If Yes : Provide general arrangement drawings
Cooling details :
If OF type NR OF PUMPS : HEAD : Flow :
KW/HP : BACK FLOW WHEN PUMP SWITCH OFF : LPM
Installation : New Post
Distance from Trs to control room through cable trench : mtrs
Distance from Control room to Relay Panel through cable trench mtrs
Additional information :
7.5 Other Systems and Selection
Various other systems are also available for fire fighting of transformers notable among them
being:
Carbon dioxide and clean gas agent system for indoor or enclosed installations.
However ,limited experience of these systems exists.
8.0 STANDARDS AND GUIDELINES RELEVANT TO TRANSFORMER FIRE

PROTECTION :
(a) IS: 10028 (Part II) : Code of practice for selection, installation
and maintenance of transformer.
(b) Tariff Advisory Committee : Regulations for the electrical equipment of
buildings.
(c) BS 5306 Part 4 : Carbon dioxide fire fighting systems.
(d) NFPA-15 : Water spray fixed systems.
(e) NFPA 70 : Fire protection of transformers and
transformer vaults.
(f) Central Electricity Authority, The : Technical standards for constructions of sub
Gazette of India, Extraordinary 2010 stations and switchyards.
: Technical standards for construction of
Thermal Generating Stations.
: Safety provisions for electrical installations
and apparatus of voltage exceeding 650 volts
SECTION FF
Guidelines for Repair of Power Transformers

at Site
SECTION FF
Guidelines for Repair of Power Transformers at Site
1.0 INTRODUCTION
Transformers are amongst the most efficient equipment made by mankind and as with all
manmade equipment the power transformer also fails. The reasons for the failures can be
attributed to design, manufacturing, operational and maintenance issues.
Design, manufacturing and process validation is ensured during the routine and type testing of
the transformers at the manufacturer’s works. Over the years the manufacturers have had better
understanding and reduction in the knowledge gap regarding transformer technology and this
led to improved and compact designs. The inclusion of newer tests in the test schedule verify
the enhanced knowledge base.
With rapid growth of the network, increased fault levels and faster ageing, the equipment are
subjected to increased operational stress.
Increased consumer awareness, privatization, competition and profitability has forced utilities
and generation companies to focus on longer life cycles and increased revenue generation from
every investment made.
With the increased cost of acquisition the options of refurbishment and repairs at site have
gained prominence and are commercially lucrative also due to the faster turn around for product
to be back into action.
In this chapter effort has been made to focus on various aspects that need to be kept in mind
when planning for repair at site. The focus areas are diagnosis of the fault and localization of
the fault zone to determine nature and extent of repairs. Based on this assessment the logistic
requirements for the repairs the quantum of work involved and various technicalities involved
in the process are to be carried out.
2.0 ON-SITE REPAIRS
Performing on-site repairs on a transformer has multiple advantages and the major ones are
described in this section.
2.1 Advantages of Site Repairs
2.1.1 The damaged equipment can be brought into service much faster than repairs at the
factory by way of saving in to & fro transportation time as well as completion of repair-to-
commissioning carried out in single set-up.
2.1.2 On-site repair costs considerably less than repair at the factory particularly, for large
power transformers in remote areas.
389
3.0 REASONS FOR RELUCTANCE TOWARDS SITE REPAIR OF POWER

TRANSFORMERS
3.1 The reluctance of the utilities/customers for encouraging repairs at site are listed
below:
(a) Validation techniques of the repair work carried out at site (customers generally have a
mind-set that high voltage test is the only validation procedure and this testing will not be
available in case of repair at site).
(b) Concern about drying out of the transformer at site, after the repairs have been carried out
and the validation of the end point of drying out.
(c) Non-availability of the logistics arrangement which the owner has to necessarily make
for effecting the repair at site and lack of expert manpower to assist in carrying out the
work.
(d) Other reasons could be :
(i) Exorbitant hourly rates of technical manpower deputed by the reputed
manufacturers generally with no ceiling, for carrying out repairs at site.
(ii) Unavailability of suitable storage facility for oil, equipment for drying out of power
transformer at site and other logistics at site.
(iii) Guarantee and warrantee requirement to match that of new transformer or in case
the repairs are carried out under controlled conditions at the factory.
(iv) Unavailability of suitable tooling for carrying out transformer repairs.
(v) Lack of understanding of changes in maintenance methods as transformer insulation
ageing would have occurred.
(vi) Lack of covered high roof space for repairs, since repairs at site need dry and clean
conditions.
(vii) Lack of indepth knowledge about transformer manufacturing, practices and various
stage checks.
(viii) Play safe attitude and not to take any chance on performance after repairs.
(ix) Demonstrated high voltage withstand capacity (as guarantee) of repairs carried
out.
3.2 From the manufacturer end the reluctance is because of the following reasons:
(a) Diversion of manpower and tooling from the regular manufacturing activity.
(b) Lack of confidence on alternative drying out methods and the availability of suitable
instrumentation for quantification.
(c) Other reasons are
(i) Their engineers would have difficult time in delivering results and perform in
conditions not under their control.
(ii) Though no guarantees may have been agreed but reputation of the company remain
at stake.
Guidelines for Repair of Power Transformers at Site 391
(iii) Accuracy and quality of available history & available performance data.
(iv) Disruption in production activity if manpower is sent to site.
(v) Repair activity is not treated as a regular business activity.
(vi) The quantum of work is double i.e., once for dismantling and the second for
assembly which is generally not well appreciated by the end user.
(vii) Difficulty of duplication of drying out process at site and reliability of instruments/
the data collected.
3.3 Repairs of power transformers at site is controversial and is still a subject of discussion
amongst engineers. While examples of successful repairs of power transformers up to 400 kV
class exist, still most of the utilities and the manufacturers are shy of taking up this activity at
site. One of the most common reasons for the utilities not promoting this activities is the non-
availability of high-voltage test equipment at site for HV testing after repairs. The fact is, that
this is a type test and a manufacturer during the manufacture of the power transformer even at
his works is not using any high voltage tests in the production process or as part of in-process
quality checks.
However, the trend world over is for site repairs. Mobile High Voltage test facilities and mobile
Low frequency heating facilities are being created to address two main issues of Insulation
drying and high voltage testing at site.
4.0 SITE REPAIR CATEGORIES AND REQUIREMENTS
4.1 Repairs can be categorized in to :
(a) Minor repairs.
(b) Major repairs
4.1.1 Minor Repairs
Generally repairs involving low volume of oil draining and attending to minor defects in the
transformer like replacing a defective bushing, bushing CT, gasket, bolt or burnt-out connection
at a bushing or small repairs of diverter switches.
4.1.2 Major Repairs
These repairs generally involve draining of main tank oil for accessibility to the problem area
and arc mostly in the core-coil assembly i.e., Winding, Core, OLTC selector switch. It involves,
total oil draining, storage, oil filling under vacuum and during out activities for restoration of
the transformer to service.
4.2 Site Repair Requirements
4.2.1 Power transformer repair at site is in no way any different from the repair process
followed at the factory. The repair will be successful if all the quality check parameters adopted
at factory are religiously duplicated at site and so also the tooling and the environment.
4.2.2 The information required for decision on carrying out repair at site is given below :
(i) Nature of the fault.

(ii) Location of the fault.
(iii) Extent of damage due to the fault.
(iv) Scope of work based on information collected.
(v) Material required for carrying out the repairs.
(vi) Sequencing of activities during the repairs.
(vii) Time required for various repair activities.
(viii) Facility and tooling needed at site for repairs.
(ix) Suitable equipment for drying out transformer at site.
(x) Validation method of the repair to be carried out.
4.2.3 The scope of work determination is the most important activity for site repair as this will
govern the material, tooling and facilities required for the successful completion of the work.
The whole scope of work can be divided into following main activities :
• Pre repair work assessment.

• In process stage checks and review of repairs work assessment.
• Post repair activities including the final in-process checks.
• Drying out and commissioning activities.
4.2.4 After the fault detection techno-economic assessment is done in respect of down time
and cost of repairs at site, to the overall time (including transportation time) and cost of repairs
at the factory and it is generally found that the down time is an important aspect than the rather
pure economics.
As soon as the service interruption has taken place restoration of the supply becomes the prime
activity. To determine the health of the transformer and its suitability for the immediate restoration
requires that the condition of the equipment be determined to the maximum possible accuracy.
The manufacturer can also contribute in this assessment. It has been generally observed that after
the disruption has occurred the condition determination is not done systematically as required
for correct assessment. Most of the time it is attributed to lack of equipment, test instruments and
at times required expertise of the available technical persons.
5.0 DIAGNOSTIC TESTING OF THE TRANSFORMER
5.1 Record of the system condition at the time of outage as well as immediately before is
one of the most important activity. The load conditions at the time of disruption i.e., the load
current, voltage, the status of the various equipments and protection in service, any fault history
etc. and also weather condition needs to be recorded. Many failures in transformers have been
found to be due to the abnormal system operation and/or protective device malfunction therefore
the status of all the protections is extremely important and need to be correctly recorded.
5.2 Immediately after the interruption, temperature of the top oil may be recorded, and the
oil samples must be collected for measuring moisture content in oil, Dissolved Gas Analysis
(DGA) and for furfural content specifically for old transformers (in service for more than 10
years). As these tests are trending tests, the earlier test readings will act as reference and help in
reaching some conclusion.
5.3 The fault detection comprises of the combination of the following electrical tests after the
transformer has been shutdown to determine the cause of the failure and the location therefore.
• Magnetising Current.
• Magnetic Balance.
• SFRA signature test
• Voltage Ratio.
• Single Phase Short Circuit Current.
• Winding Resistance.
• Vector Group.
• OLTC Contact Resistance.
• Insulation Resistance and tangent delta of windings and condenser bushings
For diagnostic testing it is mandatory to repeat all the tests in all the possible tap positions
as fault can exist in isolated condition even with normal operating condition. These electrical
tests are indicative of the location of the fault and to further accurately establish the fault some
invasive tests may need to be done. These invasive tests are generally done at the winding level
after isolating the OL TC to further localize the fault and if OLTC is the culprit then also these
invasive tests help in locating the fault.
Condition assessment helps in determining the scope of work and the tests to be followed for
determining the healthiness of the various aspects of the transformer are to be so selected that at
least two diagnostic tests should indicate the same parameters/findings.
5.4 Most of the manufacturers recommend that the testing to determine the condition of the
equipment after operational disruption be done in single phase and/or at reduced or elevated
voltage values to exactly determine the extent of the problem.
Example 1. A fault at 240 volts may be showing no abnormality but when carried out at 2 kV level
can give a totally different value. Magnetising current test and magnetic balance test results have
been known to show variations in values in the case of interturn and interdiscinsulation failures.
Example 2. A high winding resistance value in a winding having the OLTC connected can
mean improper contact for bushing termination or defective joint or improper OLTC contact in
the selector switch or the diverter switch. The improper diverter switch contact will reflect in
multiple test results either in the odd position or the even position for in-tank OLTC construction
based on the Dr. Jansen principle. For different OLTC construction the result may reflect in only
one position and may be confusing and require invasive testing.
Example 3. A 160 MVA power transformer in prefect working condition for 15 years is taken
in for overhauling due to low IR values of the insulation. After drying out it is found that the
winding resistance results of the transformer are erratic and indicated some problem. A vigorous
motion given to the tap connections restores winding resistance values to near normal values.
On investigation, stripping the taping of the tap lead joint revealed a burnt out joint and the best
part was that the DGA history of the transformer indicated no problem of this type. The other
finding here was that the transformer was being routinely tested for winding resistance only in
three positions first, nominal and the last position.
5.5 For transformers in the network with history of tripping under fault conditions the
FRA is an invaluable tool for the determination of the condition of the transformer. The FRA
record of the transformer is to be maintained meticulously and after the transformer faces
a tripping, the FRA test is to be conducted to determine any change in the geometry of the
assembly or loss of clamping pressure of the winding. This helps in detecting small changes
so that the repair/refurbishment/overhauling/replacement plan can be done properly to avoid
unpleasant surprises.
6.0 REPAIRING OF TRANSFORMERS
6.1 Even some 400 kV class transformers have been successfully overhauled at site involving
changing of old gaskets, changing of oil, drying out of the job for IR value improvement and are
in successful operation. Though not in the repair category it clearly demonstrates the adequacy
of the drying out method, if properly done at site.
6.2 The repair process needs either the involvement of the manufacturer’s engineers or
skilled manpower experienced with similar activity at some manufacturing location. Different
repair activities require different materials, tooling and facilities. The facility requirement is also
governed by the manufacturing methodology adopted for the transformer manufacturing. Large
power transformers are generally manufactured in three different configurations
(a) Cover mounted construction

(b) Cover free construction.
(c) Cover free and bell cover construction.
These constructions have their own advantages and disadvantages and the choice of the
method of construction is either specified by customer or is decided by the manufacturer. The
manufacturer is conversant with all the construction configurations and has facilities and tooling
to enable manufacturing of all the configurations.
6.3 Procedure of Major Repairs
Major repairs in the core coil assembly are categorized in to three main types :
(a) Core components.

(b) Winding and its connections.
(c) OLTC selector switch and its components.
For various components/mountings fitted on the transformer, the major repairs are in :
(a) High voltage bushings.

(b) OLTC diverter switch and its components.
These repairs require draining of oil, internal inspection for determining the extent of the problem
and remedial action thereof including the components required to be procured. Generally the
problem solving does not take much time compared to the time required for the pre repairing
and post repairing activities leading to successful commissioning. Winding repairs are the most
complicated of all the repair works carried out and generally require replacement of the defective
coils or the whole composite coil of the winding. For winding replacement the maximum tooling
and logistics arrangement is required including the new winding from the manufacturer or third
party supplier. Winding replacement activities are preferably to be carried out under the guidance
of manufacturer though such guidance is now a days available from third party sources also.
During the repair activity some improvements or refurbishment can be also done to increase the
reliability of the equipment and ensure trouble free operation.
6.4 Facility Planning for Site Repairs
6.4.1 Most power stations are adequately equipped for handling large and heavy weight equipment/
transformer and generally have a Service-bay equipped with crane and working area. In case of
non-availability of overhead crane facility, adequate crane capacity needed for the repairs should be
determined and hired out. At this point of time the need is to assess the following :
(i) Location where the refurbishment is to be carried out, preferably covered space.
(ii) Adequate space availability for dismantling the transformer and storage of the dismantled
transformer parts.
(iii) Crane of adequate capacity with enough working space by height clearance.
(iv) The selected area should be dry, away from any open source of water, dust free and shall
allow additional covering if necessary.
(v) Power supply point of adequate capacity for lighting and supply for various equipment
operations like hydraulic crimping tools, brazing machines, pneumatic spanners heating,
filter machines etc.
(vi) The power supply should not be very near either as it is a fire hazard in case of any
problems with the supply wire or electrical equipment failure. Generally the supply should
have ELCB protection facility.
6.4.2 Lifting Facilities for Tank Cover
Transformer manufacturers use various types of tank covers and each one has its own typicality
of handling. Some of the points to be taken care of when planning for the crane and lifting
facilities are given below :
• For Top Cover Type Transformers
(i) Weight of the top cover.

(ii) Dimension of the cover.
(iii) Dimension of the active part.
(iv) Weight of the active part.
(v) Height to be lifted for minimum clearance.
(vi) Generally it is preferable to have vertical overhead cranes, in case other cranes are used
then adequate boom height should be available and the clearance of the boom from the
active part during lifting (i.e., if 40 ft high working height is required then with the mobile
cranes the same distance is to be available from the top of the active part lifted such that
the active part is clear of the tank top and not from the boom top).
(vii) The top cover should be inspected for unbalance load distribution and all mountings on
the top cover should be removed.
(viii) The mobile crane should be rated at least 75% more than the maximum load to be
lifted.
(ix) Four nos. slings having total load lifting capacity atleast twice the maximum load to be
lifted.
(x) The OLTC mounting to be checked and dismantling procedure selected.
• For Bell Cover Type Transformer
(i) Weight of the bell cover.

(ii) Dimension of the bell cover.
(iii) Height to be lifted for clearance of at least 30 cms from the top most part of the active part
assembly.
(iv) Lifting height is to be calculated from the top of the bottom part of the bell cover and not
from the ground level.
(v) Generally it is preferable to have vertical overhead cranes, in case other cranes are used
then adequate boom height should be available and the clearance of the boom from the
active part during lifting (i.e., if 40 ft high working height is required then with the mobile
cranes the same distance is to be available from the top of the active part lifted such that
the active part is clear of the tank top and not from the boom top).
(vi) Top cover should be inspected for unbalance load distribution and all mountings on the
top cover should be removed.
(vii) The mobile crane should be rated at least 50 % more than the maximum load to be
lifted.
(viii) Four nos. slings having total load lifting capacity atleast twice the maximum load to be
lifted.
(ix) The OLTC will be mounted on the top cover but resting fork will be fitted on to the end
frame.
• For Top Covers with the Active Part Fitted to it
These are nearly similar to the transformers with the top cover type and the main consideration
is that the weight to be lifted is now the weight of the active part plus the weight of the top cover.
Also in these type of transformers OLTC etc. are all mounted on to the top cover and weight
eccentricity can be experienced. The transformer is to be first inspected from inside and then
the slings of different lengths may have to be used for balancing the same during the lifting of
the job.
6.4.3 OtherFacilities and Related Requirements
The place selected to carry out the repair and/or refurbishment activity should preferably be
covered, but in case of unavailability of such space then a temporary cover around the transformer
may have to be built such that the top of the same is removable and the crane hook can be
brought in after removing the cover and the required activity is carried out. Also at some places
it will be preferable to build a temporary cover such that the same can be rolled out to expose
the transformer for work requiring crane access and then rolled back to cover the transformer
again.
The area/location for repair/refurbishment activity of the transformer should have adequate
space so as to store the removed fitments from the transformer at the same place. Generally
when the transformer is disassembled for repair/refurbishment lot of fittings and mountings on
the transformer cover will have to be dismantled. Internally the active part may be earthed to the
tank and in some of the older designs of temperature sensors the WTI CT are mounted as part
of the active part and the CT connections for the heater are terminated at the end of the pocket
as the heater is part of the pocket and not part of the meter. Also the place should not be near to
any source of open water and also no water dripping should occur near by. The other facilities
for site repair of the transformers and related requirements are tabulated below:
SI. No. Facility Requirements

1. Lighting (i) Should be provided with cool lighting as the internal environment is going to be warm
and oil saturated.
(ii) All light fittings should be provided with glass cover, Hand lamps are to be explosion
proof type.
(iii) The routing of the supply wires to the various light fittings and facilities should
be preferably new wires and without joints, and all termination's to be properly
secured.
2 Fans & (i) Ventilation is of paramount importance. As the transformer exposed parts are to
ventilation be protected from moisture. Ingress it is desirable that the internal environment be
maintained hot and dry. Humidity control will ensure faster final drying out.
(ii) The enclosure environment can be kept dry by injecting dry air through a dry air
generator.
(iii) The routing of the supply wires to the various light and fittings should be preferably
new and without joints, and all termination’s to be properly terminated.
3 Access (i) Access to the enclosure is to be highly regulated, preferably as far as possible dirt
method carrying objects like shoes etc. are to be kept out of the enclosure,
(ii) The access opening should not be directly open type, it should be at such a place that
at least two covers should overlap each other.
4 Cleanliness (i) Shoes should be left out side.
(ii) The area within the shed is to be covered with tarpaulin in case it is not hard surface
and should be cleaned with vacuum cleaners only.
(iii) The transformer areas where people are moving while working are to be cleaned at
least 2-3 times daily with vacuum cleaning and any oil wet smears are to be cleaned
with oil washing.
5 Enclosure (i) The enclosure size should be such that it should accommodate all the materials being
removed from the active part assembly at the same place.
(ii) The structure should be rigid and the moving part should be light and arrangements
should be such that after placing it should be easily tied to the main structure tightly.
(iii) Height of the enclosure should be 1½ man height above the topmost part of the
transformer tank.
6 Power (i) The power supply should be made available at two places near the supply work area
but not within the enclosure.
(ii) Half of all the fittings are to be supplied from one of the source and the other half from
the other source.
(iii) The light and power fittings from one source are to be fitted all around the enclosure
and the second set in the same fashion.
(iv) In case any one source failure the work enclosure will not get dark and adequate light
and air circulation will be maintained.
(v) No live wire insulated or otherwise is to be routed over the transformer active part
during the repair process and are to be only routed along the enclosure body.
7 Storage (i) All insulation materials are to be wrapped in polyethylene, bound and tagged and
stored in the sequence of their removal from the active part (e.g. : The part removed
first from the winding is to be kept nearest to the winding and in front while the
last opened object is to be located at the farthest so that it is also the last object
assembled).
(ii) The windings not to be handled are to be wrapped preferably with polythene during
the working hours and removed(when subjected to any hot oil bath or treatment.
(iii) All common blocks, winding clamping ring, winding pressuring /packing blocks,
washers are to be tied and stacked to-gather and preferably kept soaked in oil drum.
8 Safety (i) As the transformer active part insulation is a combination of paper soaked in oil it
is a potential fire hazard and should never be left unattended.
(ii) All lighting fixtures are to be of cool daylight type.
(iii) No electrical connections arc to be made by twisting wires, they are to be made by
male female connectors.
(iv) Joints of wires taped with insulation tapes should be of bright colours so that any
heating could be detected easily by discolouration.
(v) The whole enclosure is a no smoking zone.
(vi) Fire extinguishers both, of Dry chemical powder and CO2 gas type arc to be located
such that there are no obstacles in the path.
(vii) Asbestos sheets should be available handy to cover any ignited surface.
(viii) No inflammable material should be stored near the work area.
(ix) There should be no fire source near the work area.
9 Safety aspects Working within the transformer require special skills, some of the common and important
related to safety measures are:
working (i) All tools being taken inside the transformer tank must be tied at one end with some
inside the object outside the transformer tank or to the wrist of the person going to work inside
transformer the transformer.
(ii) For climbing in and out of the transformer it is mandatory that rope ladders be used
for climbing in and out of the transformer. At no point of time metallic ladders
should be used as slipping can cause damage to manpower or the active part.
(iii) Person working on or within the transformer should not carry anything metallic in
the pockets like loose change, pens etc. All watches etc. are to be removed before
entering the transformer tank.
(iv) The clothes worn during the visit inside the transformer should not contain any
metallic buttons etc. Also the belts are to be left outside as generally they contain
metallic buckles.
(v) Movement within the transformer should be very carefully done, so that body
weight is not put on any cleates or various supports used within the transformer.
(vi) The active part should not be disturbed without marking the present position at two
or three reference points so that the various clearance are maintained as per the.
manufacturer recommendations.
(vii) No body weight should be put on the various connection leads of the winding to the
bushing, tap coil to the OLTC etc.
(viii) Any new material being fitted within the transformer particularly insulation
materials made of pressboard or permawood should be first dried in a oven at 90°
C for minimum of 12 hours preferably in a vacuum oven and then soaked in filtered
oil for an equal duration. Thicker items require longer soaking time.
7.0 QUALITY ASPECTS DURING THE REPAIR OF THE TRANSFORMER AT SITE
7.1 The Joints Quality
The connection phase consists of joining of the winding to various cables and their further
termination on to the OLTC/OCTC or to the various bushings. For the termination of the winding
to cables and the subsequent connection two process have been followed:
• Jointing by brazing.
• Jointing by crimping.
As the repair unit is generally oil soaked the repair by crimping is a better method. For jointing by
brazing, resistance brazing for smaller dimension cables and copper conductors can be followed
but for large dimension cables and multiple parallel conductors flame brazing is followed. The
flame brazing process is well established and highly skilled workers arc required with adequate
provision for safety to avoid any incident of fire hazard. The process also entails surrounding the
nearby oil soaked insulation with asbestos sheets. After the brazing has been carried out the joint
is to be cleaned of all bum marks and the brazing material spatters the joint is filed to bring about
smooth finish so as to avoid any sharp points and subsequent damage to the taping.
The crimping method is a cleaner and a safer process because no heating is involved but it
requires custom designed ferrules and sockets to be crimped on and the crimping machine and
joint qualification be carried out before the start of the jointing process.
7.2 Shrinkage Arresting after Drying Out
This is a grey area in repairs but a mandatory process is to be followed for any repair jobs for the
successful completion of the repair process. Various manufacturers have their recommendations
regarding the methods to be followed for this process. A standard recommendation could be
that after completion of drying out process the transformer is to be oil filled and the insulation
soaked in for duration of 24 hours. After that the oil be drained and the job extracted and the
coils clamped to required height. The job is then retanked and the drying out process repeated
for 2 more cycles before final oil filling and circulation and preparation of the job for testing and
final commissioning. The above mentioned recommendations are based on site experiences.
8.0 TOOLS REQUIRED FOR SITE REPAIRS
A tentative list of tools required for the activities related to transformer repairing at site is given
below:
8.1 Tools
SI. No. Tools
1. Special tools for dismounting of the OL TC.
2. D shackles -1 ton
3. D shackles -5 ton
4. D shackles - Max. load /3, multiple quantities
5. Slings - 1 ton (wire rope/nylon)
6. Slings - 5 tons (wire rope/nylon)
7. Slings - Max load/3, (wire rope) 4 nos.
8. Pump- 1/2 hp
9. Pump - 3 hp + starter
10. Hose 25 m long minimum (multiple quantities)
11. Extension board - 3 ph & 1 ph
12. Spanners DE type (size : 8-9 to 32-36)
13. Spanners ring type (size : 8-9 to 32-36)
14 Ring &Dli spanner 55 size
15 Box spanner (size : 8-9 to 32-36)
16 Torque spanner handles
17 Sledge hammer - 5 kg
18 Hammer - 1 kg
19 Mallet
20 Screwdrivers - various sizes
21 Hacksaw frame standard size
22 Hacksaw blades HSS type
23 Tommy bars -20 mm dia 3 ft long
24 Chisels: 1 in wide, 2’ wide
25 No. punch (8×8) various sizes
26 Flat files (small & regular
27 Half round files (small & regular)
28 Round files (small & regular)
29 Welding machine
30 Drilling machine
31 Grinding machine
32 Gas cutting set with cylinders
33 Pipe 3” dia 5 ft. long
34 Knives for paper cutting etc.

8.2 Special Tools
1 Winding lifting arrangement
2 Lead cutting tools
3 Brazing machine
4 Brazing rods
5 Brazing torch nozzles and oxy-acclylene cylinders
6 Hydraulic Crimping Tools (cutting tools & crimping dies)
7 Stools for yoke unlacing of adequate height and wt. capacity
8 Nylon slings for tying the winding to lifting frame
9 Wooden / ms pallets for lamination storage
10 Fans
11 Torches
12 Vacuum cleaners
13 Lamination stack tying arrangement
14 Lamination stack tying arrangement
15 Heat insulation during brazing.
16 Dry air generator and compressor setup.
17 Scaffolding arrangement for access to the active part during
8.3 Test Instruments

1 2.5 kV test set
2 Megger 1 kV
3 Megger 5 kV motorised
4 Ratio meter
5 Winding resistance kit
6 Multimeters
7 Dew point meter

8 Tan delta kit
9 Clampmeters
10 Variac 1 ph and 3 ph
11 Continuity tester.
9.0 CONSUMABLES REQUIRED FOR REPAIR / REFURBISHMENT JOBS
SI. No. Materials
1. Crepe Paper Rolls -25 mm wide
2. Crepe Paper Rolls -15 mm wide
3. 20 mill Paper Rolls
4. PCB Sheets -1.5 mm thk. (impregnated)
5. PCB Sheets -3.0 mm thk. (impregnated)
6. Cotton Tape Rolls-1/2"
7. Cotton Tape Rolls-I"
8. Newar Tape Rolls-
9. Permali studs & nuts -10 mm
13. 25 thk' PCB/PW off cuts (impregnated)
14. PVA glue
15. Fibre glass tube-core bolts
16. Fibre glass washer-core bolts
17. Oil drums with 209 litres each as per IS : 335
18. Common Blocks (various sizes)
19. Terelene Tapes
20. Cotton waste

21. Cotton cloth (markin type)
22. Sand paper
23. Blanking plates-various sizes
24. Plastic sheets/polythene
25. Carbon Tetra Chloride (cleaning agent)
26. Wooden coil bobbins
27 Empty oil drums
28 Wooden boxes with locks
29 Plastic bags (small)
30 Plastic bags (medium)
31 Undelible markers
32 Tags (fibre)
33 String roll
34 Plastic buckets and mugs
35 Tarpaulins (large)
36 Themocoal foam - 8 mm thk. Profile
10.0 DRYING OUT OF TRANSFORMERS AT SITE AFTER REPAIRS
Various methods are prevalent for carrying out the final drying out activity at site after the
repairs have been completed. Some of them are briefly discussed below:
10.1 Drying Out by Hot Air Blowing and Vacuum Pulling
In this method the active part is heated up by blowing in hot air into the tank and the temperature
of the active part is raised to a higher temperature of around 70° to 75° celcius and then vacuum
pulling is done for extraction of moisture from the insulating materials. Multiple cycles of
heating and vacuum pulling, are carried out till the termination criteria is reached. Oxygen
present in the hot air has a tendency to oxidize the thinner insulation faster than the thicker
insulation. This method is not recommended for CCA above 66 kV class.
10.2 Drying Out by Hot Air Blowing
Inthis method hot air is blown into the main tank and the active part is heated up, the temperature
of the hot air is themlostatically controlled at the blower end at around 70° to 75° Celsius and
the drying process is continued in this manner. This method is adapted for transformers whose
tank cannot withstand high vacuum. The hot air removes moisture from the insulation of the
active part and the vapour pressure difference ensures removal of moisture from the insulating
material to the hot air. The presence of hot oxygen in hot air tends to oxidize the thin insulation
faster than the thick insulation. The process is continued till the termination criteria is achieved.
This method is recommended only for 33 kV class CCA and below.
10.3 Heating in Inert Environment and Vacuum Pulling
In this the transformer tank is first evacuated and then filled with dry N2 gas and the active part
heated up by applying external heat to the tank body. The heating can be by means of Halogen or
infrared lamps or by winding some turns of cable on the tank body and passing low voltage and
high current through the cable. The temperature of the active part is raised between 80° to 90°
Celsius and then vacuum pulled on the tank for faster extraction of moisture from the active part
insulation. Due to the inert atmosphere this is the most widely adopted method and this ensures
that the oxidation of the insulation paper is minimized. Multiple heating and vacuum cycles are
repeated till the proper drying out criteria is achieved.
10.4 Heating by Hot Oil Circulation and Vacuum Application
In this method the heating of the active part is carried out by circulation of hot oil. The maximum
temperature of the oil can be 60° Celsius. On reaching the desired temperature the oil is drained
very fast from the tank and vacuum applied on the tank. The fast draining is necessary to
minimize the heat loss during the oil draining operation. The heating of the oil is carried out by
high vacuum oil filter machine and during the process the moisture carried by the oil is removed
during the passage through the filter machine. Multiple heating and vacuum cycles are repeated
till suitable drying out criteria is achieved.
10.5 Heating by Oil Spray and Vacuum Pulling
In this method hot oil is sprayed on to the active part through pipes mounted inside the tank with
multiple nozzles in them. During this process vacuum is also applied into the tank to remove the
moisture from the insulating material. The heating through oil spray is limited to again up to 60
degrees for the oil but this method is least prevalent as the installation of spray pipe is required
inside the tank, but widely followed in the eastern European countries. The main advantage of
this process is the simultaneous flushing of the moisture from the insulation by the oil and also
the cleaning of the insulation due to the oil flow on the insulation.
10.6 Drying Out by Hot Oil Circulation
Generally used for small transformers upto 10 MVA and 33 kV class of transformers where the
insulation mass is not much and the tank is not designed to withstand full vacuum. Generally
special transformers like furnace and rectifier transformers are also in this category of transformers
and the oil does the heating and also the moisture removal from the insulation.
10.7 Termination Criteria for the Drying Out Process
The termination criteria for the drying out process is expressed differently by different manufacturers
but they are all aimed towards achieving good dry insulation which ensures trouble free operation
of the equipment. The moisture content in the insulation is kept at around 0.5% of the insulation
weight for new transformers at the time of manufacturing. But for older transformers the moisture
content is kept between 1 to 2 % of the weight of the insulation, as beyond this value there is a
chance of the thin paper insulation getting brittle during the heating and vacuum pulling process.
Some of the common methods of measurement of the termination criteria are:
(i) Measurement of Insulation Resistance Values
Measurement of the insulation resistance values through the drying out process and this
is generally followed for small transformers and those being dried out by hot air or hot oil
circulation. The IR curve has a tendency to follow the bath tub curve and the subsequent
calculation of the Polarization Index values form the Insulation resistance values.
(ii) Dew Point Measurement
The dew point of the dry gas generally N2 is taken before the same is injected into the tank and
the value should be around -60° Celsius. It is then held inside the tank for 24 hours to achieve
vapour phase balance and then again measure the dew point value. Dew point values at around
-25° celsius at a temperature 40° celsius are considered satisfactory but lower the value better is
the drying out. The process needs to be repeated with fresh dry gas everytime till the termination
criteria is achieved.
(iii) Tan Delta Value of the Insulation
Generally followed for transformers being dried out with oil circulation and oil being used for
heating of the insulation. Voltage should not be applied to the active part under vacuum. The
tandelta measurement should be done after oil filling, circulation and standing time. Tan delta
values of 0.5 are considered to be good values for termination of the process.
(iv) Rate of Moisture Extraction
Another method is the measurement of the water extraction rate during the vacuum pulling
process applied after the heating phase. The rate of water extraction after certain duration is
measured and the acceptable value of around 30 to 50 ml/hour/ton of insulation would be
considered sufficient for termination of the process. One school of thought advocates the
measurement of the water extraction rate of 100 ml/hr, reading repeated for 3 consecutive hourly
readings irrespective of the quantum of the insulation.
(v) Recommendation of the Manufacturer
Termination criteria as recommended by the manufacturer can be considered as the final say
in the matter and multiple measurements can be carried out to confirm the achievement of the
termination criteria. The factory based drying out process using HAV or vapour phase method
has the termination criteria of 30 gms /hour/ton of water extraction rate
11.0 REFURBISHMENT OF POWER TRANSFORMERS
Refurbishment can be defined as an activity undertaken to improve the existing condition of the
transformer or transformer insulation.
The options available for the transformer refurbishment are as under:
(i) Over loading the existing transformers with additional coolers and increased condition
monitoring with insulation refurbishment.
(ii) Refurbishment of the transformer.
11.1 Requirement for Option (i) above
(a) For the new loading, recalculation of the temperature rises of the top oil and the windings
temperature for the 145, 245 & 420 kV class transformers.
(b) Check the extent of the excess over the permitted / standardized values.
(c) If additional cooling keeps the temperature within the permitted value then the existing
winding can be used with minimum risk.
(d) Parallely the diagnostic testing to determine the residual life of the transformer insulation,
the present condition of the insulation and the mechanical condition of the active part
should also be done.
11.2 Requirement for Option (ii) above
When the calculated temperature rise of the windings exceed permissible limits and extra
cooling is not effective but the condition of the insulation indicate high residual life, the best
effective situation could be:
(a) Use the same core with necessary insulation change.

(b) Use of the same tank but with changing of the gaskets.
(c) Use of latest methods to reduce the stray losses.
(d) Replacement of the old winding by new winding & new insulating material.
(c) Suitable up-gradation of off circuit tap switch or OLTC.
(g) Suitable modification to use new bushings.
(h) Suitable testing process could be identified to check and prove the various parameters
after refurbishment and refurbishment could be carried out even at site to minimize the
time and cost implications.
While planning for overhauling/refurbishment of transformers it is necessary to determine at the
onset the scope of work to be carried out. The refurbishment activity can be categorized roughly
into following:
(a) Improving the insulation condition of the transformer with no replacement of oil and the
condition assessment and RLA indicates significantly good condition.
(b) Improving the insulation condition of the transformer with replacement of oil as the oil
condition is beyond improvement by filtration and RLA indicates good life condition.
(c) Improving the insulation condition of the transformer and also minor changes to accessories
for up-rated operation.
(d) Improving the insulation condition of transformer with major overhauling and repairs of
the transformer for up-rated operation.
11.3 The Main Activities/Benefits of Refurbishment one listed below:
11.3.1 Activities
• Inspection, testing and repair / replacement / up-gradation of protective devices fitted on

the transformer (Temp, indicators, Buccholz relay etc.)
• Changing of old gaskets and stoppage of leaks from the main tank and accessories.
• Inspection and up-gradation / repair / replacement of bushings, bushing leads.
• Inspection and up-gradation / repair / replacement of off -load or on -load tap changer
diverter switch, selector switch and motor drive unit.
• Fitting of new / latest condition monitoring systems.
• De-sludging and tightening of the various joints with an eye not to introduce any other
problem in the transformer during the over hauling.
• Generally most of the HV windings have wraps and removal of the same during inspection
for assessing the condition of winding could be beneficial in terms of de-sludging and
suspected deterioration due to heating or PD.
• Re-fitting of the wraps (removed for inspection) as per the original is of utmost importance
particularly for transformers with DOF cooling.
• If the oil parameters are within limits then vacuum re-conditioning of the oil.
• Reconditioning or modification of the conservator or sealing system.
• Drying out of the transformer with heating and vacuum cycles in its own tank.
11.3.2 Benefits
• Slowing the ageing rate of the paper insulation and oil.

• Humidity in the paper insulation to be kept in the range of 1 % -2%.
• Improving or sustaining the short circuit withstand capacity of the winding (ageing
reduces the withstand capacity) generally by coil re-tightening
SECTION GG
Guidelines for Voltage Control of Power

Transformers
SECTION GG
Guidelines for Voltage Control of Power Transformers
This section covers voltage control of OFF-circuit as well as ON-load type.
1.0 VOLTAGE CONTROL (OFF-CIRCUIT TYPE)
1.1 When specified, each transformer shall be provided with off-circuit tap changing switch
or off-circuit links for varying its effective ratio of transformation whilst the transformer is de-
energised and without producing phase displacement.
1.2 The off-circuit switch handle will be provided with a locking arrangement along with tap
position indicator, thus, enabling the switch to be locked in position. A warning plate indicating
that switch shall be operated only when the transformer is de-energised shall be fitted.
2.0 VOLTAGE CONTROL (ONLOAD TYPE)
2.1 When specified, each transformer shall be provided with voltage control equipment of
the tap changing type for varying its effective transformation ratio whilst the transformers are
on-load and without producing phase displacement.
2.2 Equipment for local and remote electrical and local manual operation shall be provided
and shall comply with the following conditions. Local remote switch may be housed in remote
control panel or in tap changer driving unit.
2.2.1 It shall not be possible to operate the electric drive when the manual operating gear is in
use.
2.2.2 It shall not be possible for any two electric controls to be in operation at the same time.
2.2.3 The equipment shall be suitable if specified for supervisory control and indication on
multi-way switch, make-before-break, having one fixed contact for each tap position, shall
be provided and when specified, wired to the tapchanger drive gear. This switch shall be
provided in addition to any which may be required for remote tap position indication purposes.
Supervisory indication shall also be provided when specified in the form of contacts to close
on “Tapchange incomplete”. All other components of the supervisory gear if required will be
specified separately.
2.2.4 Operation from the local of remote control switch or push button shall cause one tap
movement only until the control switch or push button is returned to the off position between
successive operations.
2.2.5 All electrical control switches and the local operating gear shall be clearly labelled in a
suitable manner to indicate the direction of tapchanging.
2.2.6 The local control switches shall be mounted in the marshalling box, or driving gear
housing.
411
412 Guidelines for Voltage Control of Power Transformers
2.3 The equipment shall be so arranged as to ensure that when a tapchange has been
commenced it shall be completed independently of the operation of the control relays or
switches. If a failure of the auxiliary supply during a tapchange or any other contingency such
as tapchanger getting stuck would result in that movement not being completed, adequate means
shall be provided to safeguard the transformer and its auxiliary equipment.
2.4 Suitable apparatus shall be provided for each transformer to give indications as
follows:
2.4.1 To give indication, mechanically at the transformer and electrically at the remote control
point if specified, of the number of the tapping in use on the transformer.
2.4.2 To give an indication at the remote control point that a tapchange is in progress, by
means of an illuminated lamp.
2.5 For remote control, the switches, push button tap position indicator, etc., shall all be
supplied as loose apparatus unless a remote control panel is specified.
2.6 All relays and operating devices shall operate correctly, at any voltage between the limits
specified in the relevant Indian Standard.
2.7 The tapchanging switches and mechanism shall be mounted in oil tanks or compartments
mounted in an accessible position on the transformer tank.
2.8 Any enclosed compartment not oil filled shall be adequately ventilated. Metal clad
thermostatically controlled heaters shall be provided in the driving mechanism chamber and in
the marshalling box. All contactors, relay coils or other parts shall be suitably protected against
corrosion or deterioration due to condensation, fungi, etc.
2.9 The tap changer contacts which are not used for making or breaking current like
separate selector switch contacts can be located inside main transformer tank where tapchanger
construction permits such an arrangement. On load tapchangers having separate compartment
for selector contacts, the oil in such compartment shall be maintained under conservator head
by means of pipe connection from the highest point of the chamber to the conservator. Such
connection shall be controlled by suitable valve and shall be arranged so that any gas leaving the
chamber will pass into the gas and oil actuated relay. A separate buchholz relay may be provided
for this compartment.
2.10 It shall not be possible for the oil in these compartments of the tapchange equipment,
which contain contacts used for making or breaking current, to mix with the oil in the
compartments containing contacts not used for making or breaking current.
2.11 Any ‘DROP DOWN’ tanks associated with the tapchanging apparatus shall be fitted
with guide rods to control the movement during lifting or lowering operations. The guide rods
shall be so designed as to take support of the associated tank when in the fully lowered position
Guidelines for Voltage Control of Power Transformers 413
with oil. Lifting gear fitted to ‘DROP DOWN’ tanks shall include suitable device to prevent run-
away during lifting and lowering operations. They shall be provided with adequate breathing
arrangement. If specified the tapchanger shall be mounted in such a way that the cover of the
transformer can be lifted without removing connections between windings and tapchanger.
2.12 Each compartment in which the oil is not maintained under conservator head shall be
provided with a suitable direct reading oil gauge.
2.13 The alternating supply for electrical operation of the control and indicating gear shall be
standard 415 volts, three-phase, 3 wire, 50 Hz, along with 240 volts single phase, 2 wire 50 Hz,
subject to a variation of + 10 per cent so that the equipment offered can withstand variation in
A.C.
2.14 Limit switches shall be provided to prevent over running of the mechanism and except
where modified in clause 2.15 shall be directly connected in the circuit of the operating motor.
In addition a mechanical stop or other approved device shall be provided to prevent over-running
of the mechanism under any condition.
2.15 Limit switches may be connected in the control circuit of the operating motor provided
that a mechanical declutching mechanism incorporated.
2.16 Thermal devices or other means like motor circuit breakers with shunt tripcoil shall
be provided to protect the motor and control circuits. All relays, switches, fuses, etc., shall be
mounted in the marshalling box or driving gear housing and shall be clearly marked for purposes
of identification. They shall withstand the vibration associated with tapchanger gear operation.
2.17 The control circuits shall operate at 110 V single phase to be supplied from a transformer
having a ratio of 415 or 240/55-0-55 V with the centre point earthed through a removable link
mounted in the marshalling box or tapchanger drive.
2.18 The whole of the apparatus shall be of robust design and capable of giving satisfactory
service without undue maintenance under the conditions to be met in service, including frequent
operation.
2.19 A five-digit counter shall be fitted to the tapchanging mechanism to indicate the number
of operations completed by the equipment.
2.20 A permanently legible lubrication chart shall be fitted within the driving mechanism
chamber, where applicable.
2.21 Loose equipments shall be supplied for mounting on the purchaser’s control panel and
the control panel will be additionally supplied as and when required by the purchaser.
3.0 PARALLEL OPERATION OF TRANSFORMERS WITH ONLOAD

TAPCHANGER
3.1 Besides the local and remote electrical control specified in clause 2 on-load tapchangers,
when specified, should be suitable for remote electrical parallel control as in clause 3.2.
3.2 Remote Electrical Parallel Control
3.2.1 In addition to the methods of control as in clause 2, the following additional provision
shall be made.
3.2.2 Suitable selector switch be provided, so that anyone transformer of the group can at a
time be selected as ‘Master’, ‘Follower’ or ‘Independent’.
3.2.3 Necessary interlock blocking independent control when the units are in parallel, shall be
provided.
3.2.4 The scheme will be such that only one transformer of a group can be selected as
‘Master’.
3.2.5 An out-of-step device shall be provided for each transformer which shall be arranged to
prevent further tapchanging when transformers in a group operating in ‘Parallel control’ are
one tap out-of-step.
4.0 ONLOAD TAP CHANGER CONTROL SCHEME
4.1 The control scheme for tap changer can be as under :
(i) Non-automatic independent-as per Scheme 1. The scheme used for independent control
from local or remote panel.
(ii) Non-auto/automatic independent-as per Scheme 2. The scheme used for independent
control with automatic voltage control relay and line drop compensation as optional. If
required non-auto condition can be availed.
(iii) Non-automatic simultaneous parallel operation-as per Scheme 3. The scheme used for
non-automatic simultaneous parallel operation.
(iv) Non-auto/automatic simultaneous parallel opcration-as per Scheme 4, Sheet 1 and 2.
The scheme used for automatic simultaneous parallel operation with facility for use with non-
auto condition also. Sheet I of the Scheme represents main control scheme and with sheet 2 line
drop compensation control scheme can be achieved as optional.
4.2 General
Local control items shall be mounted inside the on-load tapchanger driving mechanism or
marshalling box. Remote control items are to be mounted on remote control cubicle installed in
the control room. All the control items are to be mounted in easily accessible position and clearly
labelled. AH the control item shall be of best quality and or class most suitable for working
under the conditions specified and shall withstand the variation of temperatures and atmospheric
condition arising under working conditions so also withstand vibrations. All the control items
shall be wired and connected as per ‘Schematic Diagram of tapchanger control equipment given
in Scheme 1.
4.3 Motor
On-load tap changer driving gear Motor shall be of squirrel cage totally enclosed type and shall
comply with Indian Standard IS: 325. It shall be suitable for direct starting and continuous
running from 415 volts 3-phasc or 240 volts single phase 50 Hz supply. Motor shall be capable
of continuous operation at any frequency between 48 and 51.5 Hz together with any voltage
within 10 per cent of nominal value. Motor shall have ball or roller bearing and vertical spindle
motor shall have bearing capable of withstanding thrust due to the weight of the moving parts.
The stator windings shall be adequately braced and suitably impregnated to render them non-
hygroscopic.
4.4 Overload Protection Relay
The overload protection relay shall be of robust, adjustable triple-pole construction. It should
provide accurate and reliable protection against overload, single phasing, over heating and
short circuit. The relay should be provided with temperature compensating device to off-set the
effect of ambient temperature variation. For single phase motor, over-load protection device
with feature similar to those of the three-phase motor as far as these are applicable shall be
provided.
4.5 Contactors/Relays
Contactors/Relays shall be of robust and compact construction and shall comply with Indian
Standard IS : 2959. The electromagnetically operated air break type contactor with sufficient
number of contacts shall be suitable for mounting on a vertical supporting structure.
The contactors shall be suitable for operation at 110 Volts A.C.-15 per cent to + 10 per cent 50
Hz. Main and auxiliary contacts of contactor shall be suitably rated. For sufficient long life these
contacts shall be break type and shall make contacts practically bounce-free.
4.6 Control Supply Transformer
The control supply transformer shall be single phase having ratio 240/55-0-55 or415/55-0-55.
Its insulation shall be suitably impregnated to render it non-hygroscopic.
4.7 Control Selector Switches
All the control selector switches shall be of robust and compact construction and shall comply
with Indian Standard IS : 4064 and 4047. The control switches shall be suitable for on-load
switching of resistive and inductive loads. The switches shall incorporate multi air brcak type
wiping contacts housed in an assembly of packets moulded from anti tracking material. The
knob of the handle of the switch shall be suitably designed so that while operating a firm grip
is obtained.
4.8 Remote Tap Position Indicator
Remote tap position indicator mounted on remote control panel shall show accurately same
tap position as indicated by local tap position indicator on on-load tap changer. The remote
indication can be by means of an analogue indicator, or digital indicator or by means of lamp
indications. Transmitter switch in the driving gear shall be make before break type. This
switch in the driving gear shall be mounted in accessible position so that it can be cleaned and
maintained regularly. The remote indicator mounted on control panel shall not be affected by
normal auxiliary voltages supply variation.
4.9 Indicating Lamp
Necessary indicating lamps provided shall be of low watt consumption and of filament type
or Neon or LED type. Lamps shall be of such construction so that these can be replaced very
easily.
4.10 Space Heater
Space heater of adequate capacity and robust construction shall be provided inside each control
cabinet to prevent moisture condensation. Space heaters shall be rated for 240 volts 1 phase, 50
Hz supply. Heater shall be complete with miniature circuit breaker or “ON-OFF” switch. HRC
fuse on phase and link on the neutral. Mounting of the heater and its location shall not cause
localized intensive heating of control equipment and wiring.
4.11 Wiring
All the wiring shall be carried out for motor circuit with 1100 volts grade PVC insulated stranded
copper conductors of size 2.5 sq mm and for control circuit with 650 volts grade PVC insulated
copper conductor of size 1.5 sq mm suitable for tropical atmosphere. All wiring shall be in
accordance with relevant IS. Engraved / printed core identification ferrules, marked to correspond
with the wiring diagram shall be fitted at both ends of each wire. Ferrules shall fit tightly on the
wires and shall not fall off when the wire is removed. All wiring shall be terminated on terminal
blocks through suitable lugs. Insulated sleeves shall be provided at all the wire terminations.
All wiring shall be neatly bunched and cleated without affecting access to equipment mounted
within the cabinet.
One piece moulded 1100 V grade terminal blocks complete with insulation barriers, terminal
studs, washers, nuts and lock nuts shall be used. Terminal blocks shall be numbered for
identification and grouped according to function. 10 per cent spare terminal blocks for control
wire termination shall be provided on each panel.
Terminal board rows should be spaced adequately apart to permit convenient access to wires
and terminations.
Terminal boards shall be so placed with respect to the cable gland plate (at a minimum distance
of 70 mm) as to permit satisfactory arrangement of multicore cable tails without undue stress or
bends. Opening of door should not disturb or stress the wire termination.
4.12 Voltage Regulating Relay
(i) Introduction: Voltage Regulating Relay is used for regulating the secondary voltage of
power transformers with on-load tapchangers. The required dead band settings are set
by setting the nominal value, and lower and upper levels independently. The time delay
setting on the front panel eliminates the relay operations for momentary fluctuations of the
regulated voltage thus reducing the number of operations of the tap changer. “
When the regulated voltage falls below the specified under voltage limit, the control\
relays are automatically blocked, i.e., there is no voltage correction, and a pair of contacts
is made available for alarm.
(ii) General Description: Voltage regulating relay should be designed for maximum
operational simplicity for regulating the secondary voltage of power transformer with
onload tapchangers. The deadband (band width) can be set by setting the nominal value
adjustment (NVA) to the required value “110V+10 per cent”.
The desired time delay can be set on the front panel and the control action will take place only
if the voltage continues to remain outside the deadband after the time delay has elapsed. For
voltage corrections requiring more than one tap change, time delay is initiated again before
further tapchange. The relay is reset automatically after the voltage is brought within the selected
deadband. For repeated short duration voltage fluctuations on the same side of the deadband, the
time delay is effectively reduced to provide a voltage time integral response of the regulator.
Operation of the Raise Control relay is automatically inhibited when the voltage falls below the
specified under-voltage limit. One pair of normally open relay contacts are provided to effect
the tapchanger, Raise and Lower operation and to trigger an alarm in case of undervoltage
conditions.
(iii) Specifications
Auxiliary Supply : -15% 50 Hz

+ 10%
PT Supply (regulated : 110 V ± 10 per cent 50 Hz
Voltage)
Sensitivity (Dead Band) : Nominal value adjustable (NVA) and Nominal Value
Range between + 0.75 to + 2.5 per cent
Time Delay Setting : Fixed, i.e., (Voltage independent) time delay continuously
adjustable from 10 to 110 secs.
Time Delay Resetting : Instantaneous resetting with voltage deviation occurring
in opposite direction.
Under Voltage Blocking : Internal blocking at 80 per cent of regulated value.
Restoration at 85 per cent of regulated value.
Control Relays : One pair of normally open potential free contacts of
suitable rating.
Control Operation : Single pulsed operation of sufficient duration to initiate
tapchanger.
Operating Temperature : - 5° to + 50°C
Option : Line drop compensator with resistive and reactive

compensation of either polarity upto 20 per cent adjustable
in steps or continuously and suitable for operation with 1
Amp. current transformer. If required suitable interposing
current transformer to be used to get 1 Amp. secondary
current. 1 pair of NC (UV) contacts provided.
4.13 Line Drop Compensator (LDC): Description
I The Line Drop Compensator is an optional unit designed to match with the Automatic
Voltage Regulator Relay. The unit is housed in the same enclosure or separately mounted.
The voltage at the generating end and at thereceiving end are not the same due to the drop across
the line. The LDC is used to compensate for this line drop, and the amount of compensation
required is calculated as a per cent of the nominal voltage knowing the length of the line, its
resistance/unit length, its reactance/unit length and the rated current, and set on the front panel.
The line current is stepped down to 1 Amp. and fed to the LDC. The resistive and reactive
drops are simulated by having 90° phase shifted voltage and their polarity selected by polarity
switches. The net compensation is then fed to the stepped down PT voltage.
II Specifications
Resistive Compensation : 0-20 per cent of the regulating value continuously adjustable.
Reactive Compensation : 0-20 per cent of the regulating value continuously adjustable.
Input Rated Current : 1 Amp. 50 Hz.
Power Consumption : As required (CT burden will depend on power consumption).
Accuracy : 10 per cent.
Max. Overcurrent : 50 per cent of rated current (1.5 Amp.)
Polarity Selection : Both positive and negative compensation.
III Operating and Connection Requirements
Connection to the LDC unit are made through the rear panel terminals. The line current is
stepped down to 1 Amp. 50 Hz and fed to the LDC. The net compensation is fed to the AVR
circuit, internally or external connections.
The required amount of percent R and per cent X compensation can. be set on the front panel of
the LDC. The polarity selector switches provide both positive and negative compensation. The
per cent R and per cent X settings can be calculated from the following formulae:
√3ILRL
Per cent R = ________ x 100 per cent
VL
√3I1XL
Per cent X = ––––––––– X 100 per cent
V,
where IL = the primary rated current of the line.

VL - the voltage between lines of the power transformer.
XL = the line reactance in ohms/phase.
RL = the line resistance in ohms/phase.
Note : When LDC unit is not to be used, keep per cent R and per cent X settings to Zero, i.e., on min. position.
5.0 NOTES ON TAP CHANGER SCHEME
5.1 Note on Schematic Diagram of Tap Changer for Parallel Control
The parallel scheme is prepared keeping in mind that any one of the on-load tapchanger is
selected to the master position and the other to the follower position. This is being done by
selector switch SSS provided on control cubicles for each transformer. With selector switches
SSS in their respective position as above bus wires N 504 and N 505 become source of supply
to the OLTC control circuits of all the transformers. Selecting Local/Remote switches CSS in
remote position one can press Master unit push button RPB or LPB, for desired raise or lower
operation, a direct impulse for Raise or Lower goes to Master unit OLTC. Also through Master
unit selector switch SSS the bus wires N 506 or N 507 energize and transmit Raise or Lower
impulse to follower OLTC unit through their own selector switch SSS.
5.2 Out-of-Step Circuit
Out-of-step circuit is designed on the principle of odd/even position of on-load tap changers.
Through the link provided on first unit between bus wire N 504 and N 513 bus wire N 518
becomes source of supply to out-of-step relays of all the units. Under normal working condition
the out-of-step relays of all the units are energised.
The out-of-step relays of all the follower units get supply from bus wire N 511 or N 512 through
their own odd/even switch OSS. The bus wire N 511 or N 512 gets supply from bus wire N 515
through Master units selector switch SSS and odd/even switch OSS. The out-of-step relay of
Master unit gets supply from bus wire N 518 through selector switches SSS and contacts of out-
of-step relays of follower units.
When any of the on-load tapchanger from group lags behind by one step or moves ahead by one
step, for what so ever the reason may be, creates condition of out-of-step of transformers running
in parallel. Under the out-of-step condition the supply to the out-of-step relay is cutoff and hence
it gets de-energised and one of its contactenergises a time delay relay TDR which initiate visual
and audible alarm.
5.3 Automatic Control
Automatic control feature is used to keep voltage constant at desired level, 110 volts 2 wire
PT supply should be arranged as input to AVC relay. OSS switch is to be set on auto mode by
which AVC relay circuit comes into operation. The setting are to be done as required prior to
commissioning the relay.
5.4 Line Drop Compensation
The feature to be used along with AVC relay to compensate for the voltage drop across the line
and to maintain desired voltage at receiving end. Input to LDC device through secondary current
1 Amp. from line CT and output from LDC is connected with AVC. Suitable adjustments for line
resistive and reactive compensation to be made on LDC to suit.
SECTION HH
Guidelines for Protective Schemes for Power and

Distribution Transformers
SECTION HH
Guidelines for Protective Schemes for Power and Distribution
Transformers
1.0 GENERAL
This section of the Transformer Manual covers recommended protection schemes for distribution
and power transformers. This part specification does not purport to include all necessary
provisions of a contract. For general requirements, ratings and tests reference shall be made to
other sections of the Transformer Manual.
2.0 PROTECTION OF DISTRIBUTION TRANSFORMERS
2.1 Pole mounted distribution transformers of capacities ranging from 16 kVA to 200 kVA
with voltage ratio of 11000/433-250 volts shall have the protection as given in Table 1.
Table 1
Voltage Capacity Protection

ratio (kVA)
Primary Secondary
side side
11000/433- 16,25,63,100 Dropout/Horn Moulded case circuit
250 Volts and 200 fuse breaker (MCCB)
2.2 Ground mounted distribution transformers of capacities ranging from 200 kVA to 1600
kVA with voltage ratio of 11000/433, 33000/433 and 33000/11000 volts shall have the protection
as given in Table 2. However, wherever circuit breakers are provided following protections are
recommended:
2.2.1 DMT type over current and earth fault relay and if required, delayed neutral earth fault
protection to take care of high resistance faults in the outgoing feeders/transformer LT cable can
be provided.
2.2.2 Oil temperature indicator with one electrical contact for alarm or trip shall be provided
for distribution transformers of capacities 1000 kVA onwards. Winding temperature indicator
with two electrical contacts for alarm and trip can be specified by purchaser as an optional item
for distribution transformers of capacities 1000 kVA onwards.
2.2.3 Buchholz relay with alarm and trip contacts shall be provided for transformer of capacity
1000 kVA onwards.
Table 2
Voltage ratio Capacity (kVA) Protection

Primary Secondary
side side
11000/433-250 315,630, 1000 HRC/Expulsion MCCB/ACB
and 1600 fuse
33000/433 630, 1000, 1600 HRC/Expulsion MCCB/ACB
fuse
33000/11000 1600 HRC/Expulsion CB
fuse
429
2.3 The 33 kV and 11 kV windings of the distribution transformers located outdoors and
connected to overhead lines shall be protected by lightning arrestors.
3.0 PROTECTION OF 12 KV CLASS POWER TRANSFORMERS
3.1 12 kV Class Power transformers with capacities ranging above 1600 kVA as covered in
Section D of Transformer Manual shall have the following protection :
• Circuit breakers both on primary and secondary side.
• IDMT over current and earth fault relay shall be provided on the 11kV side.
• IDMT over current and earth fault relay shall be provided on the secondary side and if
required, delayed neutral earth fault protection to take care of high resistance faults in
the outgoing feeders/Transformer LT cable can be provided
• Buchholz relay with alarm and trip contact.
• Winding temperature indicator with alarm and trip contacts, pressure relief device with
trip contact shall be provided. However, oil temperature indicator with alarm and trip
contacts, oil level indicator with alarm contact can be specified by the purchaser as
optional items.
• Lightning arrestors on both primary and secondary sides when the transformer is located
outdoors and connected to overhead lines.
4.0 PROTECTION OF 36 KV CLASS POWER TRANSFORMERS
4.1 36 kV class power transformers of capacities ranging from 3.15 MVA and above as
included in Section ‘E’ of the Transformer Manual shall have the following protection :
• Circuit breakers both on the primary and secondary sides.

• High speed percentage biased differential relay with second harmonic restraint.
• IDMT type overcurrent relay with high set elements on the primary side.
• IDMT type over current and earth fault relay on the secondary side.
• Oil temperature indicator with one electrical contact for alarm or trip contact.
• Winding temperature indicator with three electrical contacts for (a) alarm (b) trip (c)
control of fan for transformers above 10 MVA can be specified by the purchaser.
• Lightning arrestors on both primary and secondary sides when the transformer is out
doors and connected to overhead lines.
• Oil surge protection for OLTC (if provided) diverter tank with trip contact.
• Pressure relief device with trip contact.
• Oil level indicator with alarm contact shall be provided
Guidelines for Protective Schemes for Power and Distribution Transformers 431
5.0 PROTECTION OF 72.5 KV CLASS POWER TRANSFORMERS
5.1 72.5 kV class Power Transformers with capacities as covered in Section ‘E’ of
Transformer Manual shall have the following protection :
• Circuit breakers on both primary and secondary sides.

• Back up IDMT over current and earth fault relay on primary side.
• Back up IDMT over current and earth fault relay on the secondary side.
• Oil temperature indicator with alarm and trip contact.
• Winding temperature indicator with three electrical contacts for (a) alarm (b) trip (c)
control of fan for transformers above 10 MVA can be specified by the purchaser.
• Magnetic oil gauge with low oil level alarm contact.
• Lightning arrestors on both primary and secondary sides when the transformer is outdoors
and connected to overhead lines.
• Oil surge protection for OLTC diverter tank with trip contact.
• Restricted earth fault protection
• In case of non-clearance of fault on operation of transformer protection, utilities may
consider tripping of all other circuit breakers feeding the fault by devising appropriate
scheme logic.
6.0 PROTECTION OF 145 AND 245 KV CLASS POWER TRANSFORMERS
6.1 145 kV class power transformers with capacities as covered in Section ‘F’ of Transformer
Manual and 245 kV class power transformers with capacities as covered in Section ‘G’ of

• High speed percentage biased differential relay with second harmonic restraint
• Restricted earth fault relay on star connected primary and secondary sides.
• Back up IDMT over current and earth fault relay on the primary and secondary sides
• Over flux relay.
• Magnetic oil gauge with low level alarm contact.
• Oil surge protection for OL TC diverter tank with trip contact.
outdoors and is connected to the overhead lines.
• Winding temperature indicator with four electrical contacts for (a) alarm (b) trip (c)
control of fan and pumps for transformers above 10 MVA can be specified by the
purchaser
• Transformer fire protection trip and isolation of power supply to cooling fans and
pumps
• Local breaker backup relays on all sides of Transformer
7.0 PROTECTION OF 145 KV AND 245 KV CLASS INTERCONNECTING AUTO

TRANSFORMERS
7.1 145 kV and 245 kV class interconnecting auto transformers with capacities as covered
in Section ‘F’ & Section G of Transformer Manual shall have the following protection:
• High speed percentage biased differential relay with second harmonic restraint
• Restricted earth fault relay.
• Back up directional over current and earth fault relay on the primary and secondary
sides
• Over fluxing relay.
• Winding temperature indicator with three sets of contacts for alarm, trip and control of
fans (ONAN/ONAF) and four sets of contacts for (ONAN/OFAF).
outdoors and is connected to overhead lines.
pumps.
• Definite time over current relay for alarm.
• Local breaker backup relays on all sides of auto transformer.
7.2 In addition to the protection mentioned in this clause, for large inter connecting auto
transformer (inter connecting two different systems/utilities) with OLTC and tertiary delta
winding along with neutral grounding transformer for tertiary winding, the following
additional protection may be provided. The typical protection diagrams showing Relaying
connection and trip logics are enclosed as Annexures I and II.
(i) Restricted earth fault relay for neutral grounding transformer.

(ii) Definite time over current relays on secondary and tertiary side of auto transformer for
alarm.
(iii) Overcurrent relay on primary neutral.
(iv) Overcurrent and earth fault protection on tertiary side.
(v) Overcurrent relays on neutral of NGT.
(vi) Buchholz relay for NGT with alarm and trip contact
(vii) Overload trimming relays on secondary and tertiary sides for load trimming.
Teed protection is used wherever the transformer is charged on primary side and secondary
side breaker/isolator are open. In that case backup directional overcurrent/earth fault relays on
secondary side arc non-operative. Hence, the instantaneous overcurrent protection provided on
bushing CTs of the transformer to be wired for trip through secondary side breaker/isolator ‘b’
contact, will be provided as backup protection to transformer differential protection.
8.0 PROTECTION OF 420 KV CLASS AUTO TRANSFORMERS
8.1 420 kV class Auto Transformers with capacities as covered in Section ‘H’ of
Transformer Manual shall have the following protection.
• High speed percentage biased differential relay with harmonic restraint.
• Restricted earth-fault relay.
• Neutral displacement relay or restricted earth fault relay for protection against ground
faults in the tertiary winding/associated connections depending upon the tertiary
earthing arrangements.
• Backup directional overcurrent and earth fault or impedance relays.
• Over flux relay.
• Buchholz relay with alarm and trip contact
• Lightning arrestors on both sides of the transformer.
pumps
• Definite time over current relay for alarm.
• Oil surge protection for OLTC diverter tank with trip contact
• Local breaker backup relays on all sides of auto transformer
9.0 PROTECTION OF GENERATOR TRANSFORMERS
9.1 Generator transformers with capacities as covered in Sections ‘F’, ‘G’ and ‘H’ of the
• Circuit breakers on HV side.

• Overall differential current relay covering the generator zone also, in addition to
transformer differential protection.
• Restricted earth fault relay on the HV side.
• Neutral overcurrent relay against sustained external system earth faults.
• Lightning arrestors on the HV side when the transformer is located outdoors and is
connected to the overhead lines.
• Oil flow indicator with one contact for alarm, wherever applicable.
• Water flow indicator with one contact for alarm wherever applicable.
pumps
• Oil surge protection for OLTC diverter tank with trip contact
• Local breaker backup relays
10.0 PROTECTION OF 800 KV AUTO TRANSFORMERS
10.1 800 kV Auto Transformers with capacities as covered in Section ‘I’ shall have the
following protection:
• Restricted earth-fault relay.
• Neutral displacement relay or restricted earth fault relay for protection against ground
faults in the tertiary winding/associated connections depending upon the tertiary earthing
arrangements.
• Backup directional over current and earth fault relay with non-directional high-set
feature or impedance relays.
• Back-up neutral E/F protection with IDMT characteristics.
• Over flux relay for both HV & MV/LV side.
• Lightning arrestors on both sides of the transformer.
• Pressure relief device with trip contact

pumps.
• Definite time over current relay for alarm in HV side.
• Local breaker back up relays on all sides of Auto Transformer.
• Neutral over Current relay (for alarm)
11.0 PROTECTION OF 800 KV GENERATOR TRANSFORMERS
• Generator transformers with capacities as covered in Section ‘I’ shall have the following
protection:
• Circuit breakers on HV and LV side.

• Overall differential current relay covering the generator zone also, in addition to
transformer differential protection.
• Generator transformer differential protection
• Restricted earth fault relay on the HV side.
• Overhead line connection differential protection including generator transformer HV
winding
• Neutral over current relay against sustained external system earth faults.
• Magnetic oil gauge with low level alarm contact
• Lightning arrestors on the H.V side when the transformer is located outdoors and is
connected to the overhead lines.
• Oil flow indicator with one contact for alarm wherever applicable.
• Water flow indicator with one contact for alarm wherever applicable.
pumps.
• Buchholz relay with alarm & trip contact for OLTC
• Local breaker back up relays.
SECTION II
Specifications for Transformer Bushings upto

1200 kV Voltage Class
SECTION II
Specifications for Transformer Bushings upto 1200 kV Voltage Class
1.0 GENERAL
This specification covers outdoor capacitance graded Oil Impregnated Paper (OIP) bushings
with values of highest voltage for equipment (Urn) from 52 kV upto 1200 kV voltage class
and with values of rated current (Ir) upto 5000A and solid porcelain and oil communicating
type bushings for voltage class < 36 kV for use in oil filled transformers and reactors. The
Synthetic Resin Bonded (SRBP) type and Resin Impregnated Paper (RIP) type bushings are
not covered in this section. These bushings, if required by the purchaser shall be supplied as
per purchaser’s specification. In case of Bushings other than those specified, dimensions will
be subject to agreement between manufacturer and purchaser.
The specification establishes essential details and dimension to ensure interchangeability and
adequate mounting of the bushings.
1.1 The porcelain components shall be sound, free from defects, thoroughly vitrified and
smoothly glazed.
1.2 Unless otherwise specified, the glaze shall be brown in colour. The glaze shall cover
all exposed porcelain parts of the bushings except those areas which are required to be left
unglazed.
1.3 The design of the bushing shall be such that stresses due to expansion and contraction
in any part of the bushing shall not lead to deterioration.
1.4 Cement if used in the construction of the bushing shall not cause fracture by expansion
or loosening by contraction. Cement thickness shall be as small and even as practicable.
1.5 All exposed ferrous metal parts shall be hot dip galvanized wherever possible.
1.6 No arcing horns shall be provided on the bushings unless otherwise specified or agreed
between purchaser and supplier.
1.7 Any stress shield shall be considered as an integral part of the bushing assembly.
1.8 52 kV to 1200 kV voltage class bushings shall be Oil Impregnated Paper (OIP) type
condenser bushings. The bushings below 52 kV voltage class shall be of porcelain and oil
communicating type unless otherwise specified.
1.9 Each bushing shall have marked upon it the manufacturer’s identification mark.
441
1.10 The duration and rated short time current of the bushing for various voltage ratings shall
be as specified.
1.11 Limits of temperature rise shall be in accordance with IEC 60137
1.12 Permissible variation in the value of capacitance, and maximum value of dielectric
dissipation factor (tan delta) of bushing and the test tap on transformer bushing shall be as per
IEC 60137
1.13 Bushings made of solid porcelain and oil communicating type and those having insulation
which docs not flow under service conditions shall be suitable for mounting at any angle of
inclination. Unless otherwise specified, those having a liquid insulation shall be suitable for
mounting at any angle of inclination to the vertical, not exceeding 30°.
1.14 The cantilever strength of the bushing shall be in accordance with Level – I of IEC-
60137, unless otherwise specified.
1.15 The profile of the porcelain and spacing of the petticoats shall suit the duty specified.
The petticoats shall preferably be of aerodynamic type conforming to IEC 60815 to enable hot
line washing during service.
1.16 OIP Bushings shall preferably be of hermetically sealed.
2.0 STA NDARDS
2.1 The electrical characteristics of the bushings shall be in accordance with IEC 60137
3.0 SOLID PORCELAIN, OIL COMMUNICATING AND OTHER TYPE BUSHINGS

UPTO 36 KV VOLTAGE CLASS
3.1 The dimensional parameters of the bushings upto and including 36 kV voltage class
have already been standardised in IS : 3347 and shall be referred to.
3.2 Rated Voltage, Current and Basic Insulation Level
3.2.1 The rated voltage, current and basic insulation levels of the bushings shall be in
accordance with IS: 2099 or IEC 60137.
4.0 OIP CONDENSER TYPE BUSHINGS FROM 52 KV TO 1200 KV VOLTAGE

CLASS
4.1 Interchangeability
4.1.1 All the bushings from 52 kV to 800 kV voltage rating shall have dimensions as mentioned
in clause 4.3 to enable interchangeability with different makes of bushings manufactured in
conformity with this specification.
Dimensions of 1200kV Bushing are for information only.

4.1.2 The standardized dimensions shall be kept in view by the transformer manufacturers as
well, while designing the transformers, so that the transformer can accept any bushing of the
parameters and dimensions specified herein.
4.1.3 Other ratings of bushings, not covered in the specification, shall be supplied, if
required.
4.2 Basic Insulation Level, Voltage, Current Ratings and Creepage Distances
The basic insulation level, rated voltage and current and creepage distances for various voltage
class bushings shall be as under:
Highest System Rated Rated Power Current Rating Creepage

Voltage rating Lightning Switching frequency (Amps) distance (mm)
(kV) Impulse Impulse withstand
withstand withstand voltage (kV)
Voltage(kVp) voltage (kVp)
1200 2400 1950 1200 2500 30000
800 2100 1550 970 2500 20000
1250
420 1425 1050 695 2000 10500
2500
1250
245 1050 850 505 6125
2000
800
145 650 NA 305 1250 3625
2000
800
72.5 350 NA 155 1250 1815
3150
1250
52 250 NA 105 3150 1300
5000
Note:
The above insulation level refers to operation at any altitude not exceeding 1000m. For installations at an altitude
higher than 1000m, the arcing distance shall be increased according to IEC 60137.
4.2.1 The minimum value of creepage distance specified is 25 mm/kV of the rated voltage of
bushings.
4.2.2 For areas with very heavy or extremely heavy pollution the minimum creepage distance
shall be as specified by the user.
4.3 Standardized Parameters of Bushings
4.3.1 To render the bushings interchangeable, certain parameters of the bushings have been
identified and their maximum and minimum dimensions have been standardized. The identified
parameters shall be as indicated in Table 1.
Table 1
SL. No. Parameter Identification of Parameter
1. LI Length between top of air end terminal and bottom seat of flange.
Length between bottom seat of flange and bottom of the oil end shield/ stress relieving
2. L2
electrode/ oil end terminal whichever is the longest.
3. L4 Flash over length.
4. L5 Length of the air end terminal.
5. L6 Length for bushing current transformer (BCT) accommodation.
6. Dl Outside diameter of live metallic tank.
7. D2 Maximum diameter of oil immersed end.
8. D3 Outside diameter of fixing flange.
9. D4 Fixing flange holes pitch circle diameter.
10. D5 Diameter of fixing hole.
11. N Number of fixing holes.
12. D6 Maximum diameter of oil end shield/stress relieving electrode.
13. D7 Minimum inside diameter of central tube.
14. D8 Diameter of air end terminal.
4.3.1.1 The standardised dimensions for various voltage and current rating bushings shall be as
indicated in Figs. 1 to 4.
4.4 Lead Arrangement
The lead arrangement, inside diameter of the central tube, rod and jointing rod for different
current ratings and voltage class bushings shall be as under.
4.4.1 Definitions
4.4.1.1 Draw-Lead Conductor
Conductor consisting of one or more flexible leads in parallel drawn into the central tube of the
major insulation body of the bushing, (preferred up to 1000 A).
4.4.1.2 Draw Rod Or Solid Stem
Conductor consisting of a round rod either removable and drawn into the central tube of the
major insulation body of the bushing or fixed rod or tube and not removable, (preferred from
1250 A up to 5000 A).
Voltage rating Current rating Type of lead Dia. of the Minimum Internal
Dia. of the central
(kV) (Amps) Jointing rod/rod
(mm) tube (mm)
1200 2500 SS -- ---
800 2500 SS --
420
1250 DL 45 60
2000 DR/SS 50/NA 60
2500 DR/SS 50/NA 60
245 1250 DR 45 48
2000 ss -- --
145 800 DL 35 38
1250 DR 35 38
2000 SS --- ---
72.5 800 SS -- --
1250 SS -- --
3150 SS -- --
52 1250 ss - -
3150 ss - -
where, DL- Draw Lead

DR- Draw Rod
SS- solid Stem
Note :
Diameter of Jointing rod may be different from the standard , in case lesser diameter is chosen, it should be proved
by temperature rise test at rated current. However the clamping dimensions shall be as per Fig.2
4.5 Bushing Current Transformer (BCT)
4.5.1 To accommodate the bushing current transformers, space provided on various voltage
class bushings shall be as under:
800 kV : 600 mm
420 kV : 400 mm
600mm
245 kV : 300 mm
600 mm
145 kV : 100 mm
300 mm
600 mm
72.5kV : 100 mm
300 mm
600mmm
52 kV : 100 mm
300 mm
600mm
4.5.2 Bushings with space as necessary for the accommodation of bushing current transformers
specified shall be also offered.
4.6 Lead Joint
4.6.1 Draw lead and draw rod type leads shall have joint as shown in Fig. 2a & 2b respectively.
The dimensional details, material composition, finish, bolts spacing etc., have also been shown
in the figure. The joint shall be provided at the bushing fixing flange level. The bottom portion of
the joint shall be in flush with the bottom of the flange. The complete joint with the top portion
of the lead upto the joint with nuts and bolts shall be supplied along with the bushing. The free
portion of the joint shall be brazed / crimped by the purchaser with the lead to be supplied along
with transformer to make the complete lead.
4.6.2 In case of draw rod type lead arrangement, the complete rod upto the joint with free end
of the rod forming one portion of the joint with necessary nuts and bolts shall be supplied along
with bushing. The remaining portion of the rod with one end to match the joint shall be arranged
by the purchaser through the transformer supplier.
4.7 Oil End Terminal and Shield Fixing Arrangement for 245 kV Solid Stem Type
Bushing
The oil end terminal and shield fixing arrangement for 245 kV Solid stem type bushing shall be
as shown in Fig. 3. The entire oil end terminal arrangement along with corona shields shall be
supplied along with bushing.
4.8 Oil End Terminal for 72.5 kV/ 52 kV/ Solid Stem Type Bushing
For 72.5 kV & 52 kV bushings the palm type terminal at the oil end of the solid stem type
bushings shall be supplied in accordance with Fig. 4(a) & 4(b) as applicable.
4.9 Air End Terminal
The lengths and diameters of the air end terminals for the various bushings shall be as under:
Bushings upto 800 amps - 30 mm x 125 mm (D x L)
Bushings of 1250 Amps - 60 mm x 125 mm (D x L)
(Upto 3150 Amps)
Bushings of 5000 Amps - 90 mm x 125 mm (D x L)
4.10 Test Tap
OIP bushings shall be provided with test taps of proven design unless otherwise specified.
Tan delta of bushing at Um/√3 should not be more than 0.005 at ambient temperature, when
measured at factory.
4.11 Oil Level Indicator
4.11.1 The bushings shall be provided with oil level indicators as under:
420 kV & 800 kV Bushings: Magnetic oil level gauge / Oil sight window 245 kV and
below - Oil sight window
The oil level indicator shall be so designed and dimensioned that oil level shall be clearly visible
from ground level.
5.0 PRECAUTIONS TO BE TAKEN ON RECEIPT OF BUSHINGS AT SITE

5.1 PACKING AND STORAGE
To prevent physical damage to the bushings, generally only one bushing is packed in a wooden
packing case. At times, more than one bushing are also packed in the case of bushings of lower
voltage rating.
The bushings may be stored either in the same case or removed and placed vertically. When
the packed bushings are stored outdoors, they should be kept horizontal and covered with a
tarpaulin for protection from rain and other atmospheric contaminants.
5.2 CHECKS BEFORE INSTALLATION / RECIEPT OF BUSHINGS AT SITE
(i) Inspect the bushing physically for any leakage or damage on the porcelains. The oil end
and inner portion of the central tube should be cleaned thoroughly. Care should be taken
to prevent scratching of the painted surface of the bottom stress shield / base plate.
(ii) Check oil level of the bushing in vertical position. The oil level should be such that the
oil level is clearly visible through the oil sight glass provided on the bushing. Topping
of oil inside the bushing at site is not prohibited.
(iii) Ensure the top terminal is tightened firmly with its gasket provided to avoid water/
moisture entry into the transformer.
(v) Capacitance (C1) and Tan delta values of the bushing should be measured between
the top terminal and test tap at 2 kV to 10 kV(Maximum). The measurement should
be preferably carried out in indoors with RH not exceeding 60% and at ambient
temperature.
(vi) Place the bushing vertically on a suitable stand. Remove the threaded test tap cover.
Insert a plug/clip into the central stud of the test tap and connect to the Schering Bridge
through a screened cable. The flange body should be grounded. Connect the high
voltage supply to the top terminal. Measure the capacitance and tan delta value of the
bushing upto a maximum of 10kV in UST mode.
CAUTION:
• The voltage applied on the bushing should be limited to 10 kV, when the bottom end is
not immersed in oil. Utmost care should be taken to avoid any contact with the bushing
during testing as this will result in fatal injury to the personnel.
• The test tap should be dry, free from any moisture condensation and dirt deposition.
Ensure not to damage the soldered pin of the test tap while inserting the clip or plug
during measurements. The threaded test tap cover should be fixed back to the test tap,
immediately after the test.
• Do not carry out measurements with bushing either placed in wooden box or in horizontal
position.
Factory test values of tan delta and capacitance are indicated on the name plate or in the test
report of individual bushing at working voltages. However site values may vary as they do not
resemble factory test condition. The site values recorded at the time of commissioning should
be taken as the reference value for comparison with future measurements.
5.3 PERIODICAL CHECKS AND MAINTENANCE
The bushing is a self contained unit and as such there is no specific maintenance to be carried
out. However a periodical check of the oil level and cleaning of the porcelains will normally
suffice.
In order to determine the healthiness of the bushing, measurement of capacitance and tan delta
may be carried out during annual maintenance. These values are to be compared with pre-
commissioning test results. Tan delta value of 0.007 or more and increase in capacitance by 5%
or more, if observed, should be referred to bushing manufacturer.
Due to the limited quantity of oil in bushings, sampling of oil from bushings is not recommended.
In case of a special requirement like DGA Analysis, sampling should be done only under the
supervision of manufacturer.
SECTION JJ
Specifications for Valves for Transformers

SECTION JJ
Specifications for Valves for Transformers
1.0 SCOPE
1.1 This section covers specification for valves for transformers. This part specification does
not purport to include all necessary provision of a contract. For general requirements reference
shall be made to other sections of the Transformer Manual.
2.0 GENERAL
2.1 All valves in oil line shall be suitable for continuous operation with transformer oil (IS:
335) at 100°C.
2.2 Gland packing/ gasket material shall be of teflon rope/nitrile rubber. In case of GM/CI
(gun metal/cast iron) gate and globe valves, gland packing preferably of teflon rope shall be
used to prevent oil seepage through gland. Asbestos or graphite (gun metal/cast IMM) packing
material shall not be used as they are not compatible with hot transformer oil and asbestos is a
banned item..
2.3 Inside surface of valves shall be clean and valve ends shall be suitably blanked at the
time of dispatch. Machined and flange surfaces shall be suitably protected against rusting and
transit damage. Butterfly and radiator valves shall be covered in polythene bags before packing
for dispatch.
2.4 After testing, inside surface of all C.I. valves coming in contact with transformer oil
shall be applied with one coat of oil resisting paint/ varnish.
Inside surface of all valves in water lines shall be applied with two coats of paint conforming to
IS: 9862, two coats of black Japan conforming to Type B of IS: 341 or any other suitable water
resistant compound.
Unless specified otherwise by the purchaser, outside surface of all valves with ferrous body
shall be painted with two coats of red oxide zinc chromate primer followed by two coats of full
gloss finishing paint conforming to IS: 2932 and of shade matching with the transformer body
or shade no. 631 of IS: 5.
Outside surface of all valves with non ferrous body shall be painted with one coat of etch primer
followed by two coats of red oxide zinc chromate primer followed by two coats of full gloss
finishing paint conforming to IS: 2932 and of shade matching with the transformer body or
shade no. 631 of IS: 5.
After testing, inside surface of all C.I. valves coming in contact with transformer oil shall be
applied with one coat of oil resisting paint/varnish. Inside surface of all valves in water lines
shall be applied with two coasts of pant conforming to IS : 9862 or two coats of black Japan
conforming to Type B of IS : 341. Outside surface of the valves shall be painted with two
457
coats of red oxide zinc chromate primer followed by two coats of full gloss finishing paint
conforming to IS : 2932 and of distinct different shade (631 of IS - 5) to that of main tank
surface.
2.5 All hardwares used shall be electro-galvanized.
3.0 SIZE OF THE VALVE AND VALVE FLANGES

3.1 The size of the valve and valve flanges shall be as per Table 1. All flanges shall be drilled
at off-centres.
3.2 Recommended size of the valves for drain, filter, sampling and air release applications
shall be per Table 2.
Table 1
Nominal size of Diameter of Diameter of No. of Bolt Diameter of

valve (nominal flange bolt circle bolts size bolt hole
pipe bore) mm mm mm mm
15 95 65 4 M12 14
25 115 85 4 M12 14
50 150 115 4 M16 18
80 185 145 4 M16 18
100 215 180 4 M16 18
150 285 240 8 M20 23
200 340 295 8 M20 23
250 395 350 12 M20 23
Table 2
Transformer rating kVA

Over Up to and Size of drain Size of filter Size of sampling Size of vacuum
including valve mm valve mm valve mm valve mm
— 1600 50 25 15 --
1600 10000 50 25 15 -
10000 50000 80 50 15 --
50000 100000 100 50 15 100
100000 — 100 50 15 100
4.0 TYPE OF VALVES

4.1 Gunmetal Globe Valves
4.1.1 15 mm valves used for oil sampling or air release shall be made of gunmetal gate /globe
valve (screw down stop) type generally conforming to class 1 of IS: 778 with inside screw stem.
The oil sampling valve shall have provision to fix 15 mm PVC pipe.
4.1.2 The flanges shall be either drilled as per Table 1 (of this specification) or screwed as
explained in Table 2 of IS: 778.
4.1.3 Preferred dimensions shall be as per Table 3.
Specifications for Valves for Transformers 459
Table 3
Size of valve Face to face dimension Thickness of flange

mm mm mm
15 (Screwed) 57
15 (Flanged) 72 6.6
4.1.4 Tests
(a) Pressure tests :
(b) Body ..15 kg/cm2
Seat ..10 kg/cm2
Duration .. 2 minutes
(c) Seepage test in open condition:
Test pressure.. 2 kg/cm2
Duration .. 12 hrs.
Note: Transformer oil (IS : 335) or water at ambient temperature shall be used for pressure and oil seepage tests.
4.2 Gunmetal Gate Valves
4.2.1 25 mm valves used for oil filtering, oil drainage or in Buchholz pipe shall be gunmetal
gate (screw down step) type generally conforming to class 1 of IS : 778) with inside screw
stem.
4.2.2 The flanges shall be drilled as per Table 1.

Table 4

mm mm mm
25 (Flanged) 90 8.0
4.2.4 Tests as per clause 3.1.4
4.3 Cast Iron Taper Plug Valves
4.3.1 50 mm, 80 mm and 100 mm C.I. taper plug or gate valves may be used for oil filtering,
oil draining.
4.3.2 Valves shall be self-lubricating, short pattern type, provided with valve operating
wrenches. The lubricant used shall be compatible with transformer oil (IS: 335) at 100°C.

Table 5

mm mm mm
50 178 (7”) 19
80 203 (8”) 19
100 229 (9”) 22
4.3.4 Tests
(a) Pressure tests

Body ..15 kg/cm2
Seat ..10 kg/cm2
Duration ..2 minutes
(b) Seepage test in open condition
Test pressure..2 kg/cm2
Duration ..12hrs.
Note: Transformer oil (IS : 335) at ambient temperature shall be used for pressure and seepage tests.
4.4 C.I. Gate Valves
4.4.1 50 mm, 80 mm, 100 mm, 150 mm, 200 mm and 250 mm, C.I. gate valves may be used
in cooling water pipe lines.
4.4.2 C.I. gate valve shall generally conform to class PNI of IS : 780 double flanged, inside
screw, non-rising spindle, Solid wedge gate and with screwed (inside screw type or bolted
bonnet, Gunmetal trim material, teflon rope gland packings and nitrile rubber gaskets. The
valves shall be provided with open and shut indicator.

Table 6
Size of valve Preferred face to face dimension Thickness of flange
mm mm mm
50 215 16
80 230 18
100 255 20
150 280 22
200 318 25
250 355 26
4.4.4 Hydrostatic Pressure Tests

Body ..15 kg/cm2 for 5 minutes
Seat ..10 kg/cm2 for 2 minutes

Specifications for Valves for Transformers 461
4.5 C.I. Check Valves

4.5.1 100 mm, 150 mm, 200 mm, and 250 mm C.I. check valves may be used in oil pipe lines
of forced oil cooled transformers to avoid reverse flow and/or cross flow of oil where required.
4.5.2 C.I. Check valves shall be of horizontal swing check type generally conforming to
IS: 5312 (Part I), without bypass arrangement. The weight of the swing (flap) shall be such
that full opening is available at a minimum oil velocity of 1.0 m/s at a pressure of 1.5 kg/cm2.
The pressure drop through the valve shall be less than 0.3 m of oil column (0.026 kg/cm2) with
normal flow rates. The above requirement should be proved by calculations if test facilities not
available.
Table 7

mm mm mm
100 300 20
150 400 22
200 500 25
250 600 26
4.5.4 Testing as per CI. 7.1, 7.2 and 7.3 of IS: 5312 (Part 1).
4.6 Butterfly Valves
4.6.1 Cast iron butterfly valves shall be of the nominal sizes; 50, 80, 100, 150, 200 and 250
mm. These valves are used in oil pipe lines such as Buchholz relay pipe lines and as shut off
valves between transformer main tank and cooler tank.
4.6.2 The body and cap of butterfly valves shall be made from any of the seven grades of grey
iron casting conforming to IS: 210 except grade FG 150 and the disc shaft and stop pin shall be
made from mild steel conforming to Fe 410-WA of IS : 2062 disc and body of the valve shall
be in direct contact without any sealing ring. Valve is operated by a spanner and provision shall
be given for locking in open/closed position. ‘OPEN’, ‘CLOSE’ markings on the body and an
arrow mark on the tap for position indication shall be provided. To indicate the disc position in
the cap removed condition, some suitable marking on the spindle head shall also be provided.
Table 8
mm mm mm
50 40 16
80 40 16
100 40 16
150 40 16
200 40 16
250 45 22
4.6.4 Tests
The valves shall be tested with transformer oil at 1.5 kg/cm2 with the assembled valve in closed/
open position, the leakage shall not be more than as specified below:
(i) Leakage through body when pressure is applied for thirty minutes Nil
(ii) Leakage around top spindle with cap fitted on Nil
(iii) Leakage around top spindle when cap is removed:
for 50, 80 and 100 mm valves-2 drops per minute (max.)
(iv) Leakage past diaphragm in closed position:
for 150, 200 and 250 mm valves-6 cc per minute (max.)

4.7 Radiator Valves
4.7.1 Radiator valves shall be of 80 or 100 mm size
4.7.2 Construction same as per clause 4.6.2

Table 9
Size of Size of Diameter of No. of Bolt hole Face to Thickness of

valve flange bolt bolt size face flange
square A/F circle dimension
mm mm mm mm mm mm
80 150 160 4 18 40 16
100 180 180 4 18 40 16
4.7.4 Tests: Same as per clause 4.6.4

SECTION KK
Specifications for Cable Boxes for SF6 Gas

Insulated Transformer Terminations for Rated
Voltages of 72.5 kV and above
SECTION KK
Specifications for Cable Boxes for SF6 Gas
Insulated Transformer Terminations for Rated
1.0 SCOPE
The purpose of this specification is to establish electrical and mechanical interchangeability

between cable terminations and the gas-insulated enclosure and to determine the limits of
supply.
This technical specification covers the connection assembly of cables to SF6 gas insulated
terminations (cable boxes) in single phase or three-phase arrangements, where the cable
terminations are gas filled and there is a separating insulating barrier between the cable insulation
and the gas insulation of the transformer/ switchgear.
This also covers the connection assembly of extruded insulation cables to gas insulated enclosure,
where the cable terminations are of dry type. In this arrangement, the cable termination design
comprises an elastomeric electrical stress control component in contact with a separating
insulating barrier between the cable insulation and the gas insulation of the transformer/
switchgear. The cable termination does not include any insulating fluid.
2.0 STANDARDS
IS 2026 (Part 1) : Power Transformers - General.

IS 2026 (Part 3) : Power Transformers - Insulation level and dielectric tests.
IS 2026 (Part 4) : Power Transformer - Terminal marking, tapping and connections
IS 2099 : Bushings for alternating voltages above 1000 V.
1EC 60137 : Bushings for alternating voltages above 1000 V.
IEC 60141-1 : Tests on oil filled and gas pressure cables and their accessories - Part-1: Oil
filled, paper or polypropylene paper laminate insulated, metal-sheathed
cables and accessories for alternating voltages up to and including 500
kV.
IEC 60141-2 : Tests on oil filled and gas pressure cables and their accessories - Part-2:
Internal gas pressure cables and accessories for alternating voltages up to
275 kV.
IEC 60517 : Gas insulated metal enclosed switchgear for rated voltages of 72.5 kV
and above.
IEC 60694 : Common specifications for high voltage switchgear and control gear
standards.
465
I EC 60840 : Power cables with extruded insulation and their accessories for rated
voltages above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) - Test
methods and requirements.
IEC 60859 : Cable connections for gas insulated switchgear for rated voltages of 72.5
kV and above.
IEC 61639 : Direct connection between power transformers and gas insulated
switchgear for rated voltages of 72.5 kV and above.
3.0 LIMITS OF SUPPLY
The limits of supply for fluid filled cable terminations shall be according to Fig. 1 and for dry
type cable terminations shall be according to Fig. 3.
To limit the voltage under transient conditions, between parts 6 or 11 and part 13 of Fig. 1 for
fluid-filled cable terminations and non-linear resistors (part 15) of Fig. 3 for dry type cable
terminations may be connected across the insulated junction.
The number and characteristics of the non-linear resistors shall be determined and supplied by
the cable termination manufacturer, taking into consideration the requirements of the user and
the switchgear manufacturer.
4.0 RATING
When dimensioning the cable connection assembly, the following rated values shall apply:
(a) Rated voltage (72.5 kV - 100 kV - 123 kV - 145 kV - 170 kV - 245 kV -300 kV - 362
kV - 420 kV - 550 kV)
(b) Number of phases in one enclosure (One or three phases for Ur <170 kV and single
phase for Ur>l 70 kV)
(c) Rated insulation level (ref. IEC 50694)
(d) Rated normal current and temperature rise (2000 A at a temperature 90° C is standardised
for interchangeability)
(c) Rated short time and peak withstand currents (ref. IEC 60517; cl. 4.5, 4.6 and 4.7)
(f) Rated duration of short circuit

Specifications for Cable Boxes for SF6 Gas Insulated Transformer Terminations for Rated 467
5.0 DESIGN CONSTRUCTION REQUIREMENTS

5.1 Pressure Withstand Requirements
The maximum recommended design pressure (absolute) for the outside of the cable termination
is 0.85 MPa.
In addition, the bushing and cable termination shall be capable of withstanding the vacuum
conditions when the transformer connection enclosure is evacuated as part of the gas filling
procedure.
The transformer connection enclosure shall satisfy the requirements as per IEC 60517 for the
design pressure.
The maximum operating gas pressure (absolute) of a direct connection assembly shall not
exceed:
• The design pressure of the transformer connection enclosure plus 0.1 MPa when the
design pressure is lower than 0.75 MPa (gauge);
• 0.85 MPa (absolute) when the design pressure equals or exceeds 0.75 MPa (gauge).
5.2 Mechanical Forces on Cable Terminations
The manufacturer of the cable termination shall take into account, in the three-phase connection,
the total dynamic forces generated during short circuit conditions. These forces consist of those
generated within the cable termination and those coming from the main circuit of switchgear.
The maximum additional force to be applied from the switchgear to the connection interface
transversely and being transferred from the main circuit end terminal shall not exceed 5 kN.
For single-phase connections, even taking into account lack of symmetry, it is considered that
the additional force is small. However, a total mechanical force of 2 kN applied to the connection
interface transversely should be assumed.
It is the responsibility of the manufacturer of the switchgear to ensure that the specified forces
arc not exceeded.
5.3 Mechanical Forces Applied on the Bushing Flange
In addition to the maximum operating gas pressure specified 5.1, the flange of the bushing
attached to the transformer connection enclosure is subjected, in service, to the following
loads:
• part of the weight of the switchgear not supported by the switchgear’s own supporting
structures;
• part of the wind load, if applicable, not supported by the switchgear’s own supporting
structure’s;
• expansion/ contraction stresses due to the temperature variations of the switchgear
enclosures. For the evaluation of these stresses, it shall be considered that, on the
transformer side the variation height of the bushing flange due to temperature variation
docs not exceed ±0.0008 times the transformer tank height in the case of a steel tank.
These loads result in the simultaneous application, at the centre of the bushing flange, of:
• a bending moment M0;
• a shearing force Ft;
• a tensile or compressive force Fa.
The bushing and the transformer shall be capable of withstanding, in service, the values of Mo,
Ft and Fa specified in Table 1, and it shall be the responsibility of the switchgear manufacturer to
ensure that these values are not exceeded.
Table 1 : Moment and forces applied on the bushing flange and transformer
Rated Bending Shearing Tensile or compressive force Fa

voltage moment M0 force Ft kN
kV kNm kN
72.5 - 100 5 7 4
123 - 170 10 10 5
245 - 300 20 14 7
362 - 550 40 20 10
Except where specified otherwise by the customer, the relative positions and levels of the
transformer and switchgear foundations respectively shall be considered as not varying.
5.4 Vibrations
The vibrations generated inside the energised transformer are transmitted by the oil and the
tank wall of the transformer to the bushing rigidly fixed on this wall and to the switchgear. The
switchgear manufacturer and the transformer manufacturer shall agree to take into account these
vibrations.
6.0 STANDARD DIMENSIONS AND SPECIAL REQUIREMENTS
6.1 Fluid Filled Cable Terminations
Standard dimensions for fluid filled cable connection enclosures, main circuit end terminals and
cable terminations applied to single phase enclosures are shown in Fig. 2. With the given four
standard sizes, the voltage range (Ut) from 72.5 to 550 kV is covered.
6.2 Dry Type Cable Terminations
Standard dimensions for dry type cable connection enclosures, main circuit end terminals,
and cable terminations applied to single phase enclosures are shown in Fig. 4. With the given
four standard sizes, the voltage range (Ut) from 72.5 to 550 kV is covered. Figure 3 shows the
two types of dry type cable termination. Type A incorporates an elastomeric electrical stress
control component inside the insulating barrier. For type B, the elastomeric electrical stress
control component is located is located externally.
7.0 TESTS
7.1 General
The testing of the cable termination and the gas insulated metal enclosed switchgear is to be
performed for cable terminations in accordance with [EC 60141-1 for oil filled cables, IEC
60141-2 for gas filled cables, IEC 60840 for cables with extruded insulation and IEC 60517 for
switchgear. In addition, this specification gives recommended arrangements for dielectric tests
and for the tests after cable installation.

7.2 Dielectric Type Tests
7.2.1 Dielectric Type Tests of Cable Terminations
The dielectric type test of the cable termination fitted with a representative cable shall be
performed in an enclosure filled with insulating gas at a pressure according to the values
specified in Table 2.
If a shield is an integral part of the cable termination design, it shall be mounted in its service
position during the test.
An additional test shield may be used to screen the exposed connection interface, if required
by the cable termination manufacturer, provided it does not overlap the connection interface by
more than the distance l2 in Fig. 2 for fluid filled cable termination.
Table 2 : Gas-pressure limits for dielectric type test of cable-terminations
Range of rated voltages Minimum SF6 functional

Ut kV pressure °C (absolute) at 20°C
MPa
72.5 - 100 0.10
123 - 170 0.30
245 -300 0.35
362 -550 0.40
Notes : The gas pressures are intended as a guideline for the manufacture of the cable-termination.
Higher values are permissible. If a gas other than SF6 is used the minimum functional
pressure should be chosen to give the same dielectric strength.
7.2.1.1 Dielectric Type Test of Single-Phase Cable-Terminations
The cable-termination is surrounded by a metal cylinder connected to earth, the internal diameters
of which are 300 mm, 300 mm, 480 mm and 540 mm respectively for the four standard sizes
of cable connection enclosure (d5 in Fig. 2 for fluid-filled cable-terminations and Fig. 4 for dry
type cable-terminations).
7.2.1.2 Dielectric Type Test of Three-Phase Cable-Terminations
The non-symmetrical arrangement for Ut <170 kV with a cylinder of 650 mm internal diameter
(Fig. 5) is intended to simulate the conditions for a three-phase cable connection. Cable-
terminations, which are intended for a single-phase cable connection, may be tested in the
same cylinder of 650 mm internal diameter to cover all expected sizes of cable connection
enclosures.
7.2.2 Dielectric Type Test of Cable Connection Enclosures
The cable connection enclosure and main-circuit end terminal may be subjected to the dielectric
type test according to IEC 60517 without the cable-termination.
Fig. 5 Non-symmetrical arrangement for dielectric tests of cable terminations
The gas pressure for the dielectric type test may be specified by the manufacturer of the
switchgear in accordance with Table 1.
7.3 Tests after Cable Installation
If parts of the switchgear directly connected to the cable connection assembly cannot withstand,
at rated filling density for insulation gas, the test voltage specified for the cable test (IEC 60141
and IEC 60840), or, if in the judgement of the switchgear manufacturer, it is not acceptable
to apply the test voltage to the switchgear, the switchgear manufacturer should make special
provisions for the testing of the cable, for example disconnecting facilities and/or increasing gas
pressure in the cable connection enclosure.
If required by the user, the switchgear manufacturer shall provide the location for a suitable test
bushing and provide the user with all necessary information for mounting such a bushing to the
cable connection enclosure.
For cases where electrical clearances are inadequate, the term bushing shall include a suitable
insulated connection and test terminal.
The requirement for the test bushing shall be specified by the user in the enquiry.
8.0 INFORMATION TO BE GIVEN WITH ENQUIRIES, TENDERS AND ORDERS
Refer to IEC 60840, IEC 60141 and clause 9 of IEC 60517. In addition, the user and the
manufacturers shall consider the installation requirements of the equipment. Manufacturers
shall state the specific requirements for civil, electrical and installation clearances applicable to
the switchgear, cable-termination and cable.
9.0 RULES FOR TRANSPORT, STORAGE, ERECTION, OPERATION AND

MAINTENANCE
Refer to IEC 60694, clause 10.
The cable-termination manufacturer should ensure that during manufacture, handling, storage and
installation of the cable-termination, provisions should be made to ensure that the requirements
given in 5.2 of IEC 60694 can be satisfied after final assembly of the connection. The cable-
termination manufacturer should supply the necessary information to enable these requirements
to be satisfied, if the cable-termination is to be installed by others.
Note : It should be noted that increasing the gas pressure is not a reliable method of improving the electrical strength at
the surface of an insulator when tested with d. c. voltage.
APPENDICES
Appendix I
New Technologies, UHV AC/DC Transformers,

Phase Shifting Transformers,
Controlled Shunt Reactors
Appendix I
NEW TECHNOLOGIES, UHV AC/DC TRANSFORMERS,

PHASE SHIFTING TRANSFORMERS,
CONTROLLED SHUNT REACTORS
1. TRANSFORMERS FOR SMART GRID
Smart grid is the future of electrical systems, designed to meet the four major electricity
requirements of the global society viz. capacity, reliability, efficiency and sustainability.
Transformers in future will have to meet the demands of smart grid. Trends and changes required
in transformer technology to meet this new development in transmission and distribution of
electric power are reviewed below.
Transformers will be called upon to meet more and more emergency over loadings to maintain
the supply even with equipment breakdowns with minimal spare capacity. Maintenance free
accessories will be demanded for transformers especially tap-changers, silica gel breather. Hot
dip galvanized radiators and Distribution transformers with stainless steel tanks or superior
surface treatment systems will be demanded to eliminate maintenance.
Fail-safe transformers, without causing fires on failure will be demanded. More and more dry
type (Resin impregnated Paper – RIP) condenser bushings will be used in critical transformers.
Failure of such bushings will not cause oil spill and consequent fires. High flash point insulating
fluids (e.g., Synthetic Esters) will be preferred for transformers required in thickly populated
urban areas. Advanced on line monitoring, control and diagnostics will be incorporated in
critical transformers. Utilities will demand early detection devices more and more. Multiple
intelligent electronic devices (IED) will monitor the behaviour of the core, windings, oil, tap
changer and bushings of transformer.
Green Transformers are being offered by a number of manufacturers. These are transformers
with high efficiency and with bio-degradable insulating fluid instead of mineral oil( natural esters
made from sunflower oil). High efficiency is achieved at no-load by using amorphous cores or
superior grade silicone steels, working at low magnetic flux density. Low current density with
unique measures for stray loss reduction, results in low load losses. Utilities will insist for star
rated distribution transformers with low levels of losses.
Environment friendly manufacturing processes will be used in the production of transformers:
Mercury contacts from instruments are changed to magnetic contacts. Silica gel with cobalt
chloride (standard blue indication - cobalt salts are suspected to be carcinogenic) are replaced
with gel with organic indicators. Asbestos paper is totally prohibited as insulation. Water based
paints are replacing solvent paints to reduce carbon emission.
Silent transformers will be demanded in future. Transformer noise, major pollutant, is no more
tolerated in cities. Even at 100 MVA units, 45- 50 dB noise levels are possible.
Increased adoption of renewable power generation will feed power directly to distribution lines,
causing voltage up swings at distribution voltage. To check this, distribution transformers will
have to be fitted with on-load tap changers.
481
Smart grid technology is not a single silver bullet but rather a collection of existing and
emerging technologies working together. When properly implemented, these technologies will
increase efficiency in production, transport and consumption, improve reliability and economic
operation, integrate renewable power into the grid, and increase economic efficiency through
electricity markets and consumer participation.
2 UHV AC & DC TRANSFORMERS
2.1 UHV AC Transformers
Currently the maximum AC transmission voltage in the country is 800 kV and the next transmission
voltage being planned is at 1200 kV. Such UHV lines will be required for transferring large
power for short distances (say 6000 MW for 200-500 kms) for interconnecting high load centres
with minimum right of way (ROW) and low transmission losses.
PGCIL has put up a national 1200 kV test station at Bina, Madhya Pradesh where it will carry
out field tests and evaluation of transmission and distribution equipment developed for 1200
kV power transmission. Two banks of 1000 MVA 1150/400 kV auto-transformer banks are
used at Test station to step up power and then to step down to the grid. Transformers actually
used for UHV transmission will be of 3000 MVA bank capacity, consisting of 1000 MVA
single phase units. These will be made of 5 limbed core with three parallel wound limbs of 333
MVA capacity. Tertiary voltage will be 33-66 kV with possible use for reactive compensation.
Proposed specifications of such transformer will be as below:
Table 1 : Proposed specifications of 1000 MVA 1200 kV single phase Transformer
Rated Power(MVA) HV/IV/LV 1000/1000/333 MVA

Rated no load voltage(kV) HV/IV/LV 1150/√3/400/√3/33
Rated frequency and No of phase 50Hz , 1 Phase
Percentage impedance
HV-IV 18% (+/- 10% tolerance)
HV-LV 40% (Min)
IV-LV 20% (Min)
Insulation Levels(HV/IV/LV)
Lightning Impulse withstand level (kVp) 2250/1300/250
Switching Impulse withstand level(kVp) 1800/1050/-
One Minute Power Frequency withstand voltage(kVrms) 1040/-
Cooling OFAF/ODAF
Temperature rise
Top oil 400C
Mean winding 450C
Maximum Partial discharge level 300pC at 1.5 Um/√3
Sound pressure level at rated voltage 90dBA

New Technologies, UHV AC/DC Transformers, Phase Shifting Transformers,Controlled Shunt Reactors 483
The major challenge for such units will be limiting transport weight to 325 Tonnes, probable
limit of transportation.1200 kV OIP Condenser bushing, 14 m long, weighs nearly 6 tonnes.
When the commercial units are to be made, on-load tap-changing will be achieved by providing
tappings at the neutral end for HV or MV variation. MV variation tap changer will result in
less variation in flux density in the core. Due to transport weight restrictions, tap winding and
excitation winding will be accommodated in a separate tank with core for connection to neutral
end of main winding.
2.2 UHV DC Transformers
EHV and UHV DC transmission is used to for transferring large power for long distances with
minimum right of way and line losses. It is the most environmentally friendly and economical
way of transmitting large amounts of electric power. Compared to AC, DC transmission needs
much narrower right-of-ways ,while higher voltage reduces both electricity losses and the cost of
building large scale power lines. As generation takes place further and further away,higher and
higher transmission voltgaes are required. Currently we have DC transmission lines at 500 kV
and new lines at 800 kV are being executed in the country. These will be capable of transmitting
up to 8000 MW for 2000-3000 km. UHV DC transmission is being developed for 1100 kV DC
where two conductors will carry 10,000 MW for 5000 km.
The AC to DC converters are built as ± 800 kV double circuits with eight series connected, six
pulse converters. The transformers are single phase two winding units. In total 24 converter
transformers are needed at each end of the line. Depending on the position of transformers within
the converter ,four different designs are needed with different DC voltage ratings (800, 600, 400
and 200 kV) where the transformers connected to the uppermost and lowermost bridges had to
be built for the highest DC potential. (see sketch below)
The basic function of HV DC converter transformer is to adjust the line voltage of the AC side
to the HV DC transmission voltage. It should also meet the following requirements:

• A galvanic separation between the DC and AC systems

• Specified short circuit impedance

• High content of current harmonics

• Large range of voltage regulation by on-load tap-changer.
In conventional AC/DC converters, the transformer acts as a barrier to prevent DC voltage from
entering the AC network. One of the transformer windings is connected to the AC side, which is
also called the line-side winding. The other winding is connected to the converter valves, called
the valve-side winding.
HVDC Transformer is used for stepping down the AC voltage to suit the converter or inverter
valve voltages. The valve windings of transformer should be capable of withstanding DC
voltages that will impinge on them during the pole reversals, necessary for reversing the power
flow in lines. During DC voltage applications, resistivity of insulation structure will predominate
instead of permittivity during AC application. DC voltage results in additional demands on the
insulation structure in comparison to AC voltages.
The design of the valve is such that the rate of current increase must be controlled when the
valve starts carrying current. The rate of increase largely depends on the transformer reactance,
which also has to be fulfilled within narrow limits for two individual transformer units.
The high content of current harmonics requires special attention be paid to controlling additional
and stray losses in the transformer, when it comes to total losses and the risks of local overheating
in the windings and metallic components exposed to stray flux from windings and internal
current carrying leads. In order to optimize the reactive power needed for the operation of the
converter, depending on load variations the system designer generally specifies a large range of
voltage ratio variation between the line and valve sides.
The transformer concept normally used is a single-phase design, with two wound limbs and two
outer limbs for the return flux. The windings are arranged concentrically with the valve winding
on the outside. The line winding is divided into two coils – the one for the tapped part is located
closest to the core, followed by the non tapped section. This arrangement is beneficial for the
topology of the valve-side, which require AC as well as DC insulation.
Compared with a conventional power transformer in the AC network, an HVDC converter

transformer must be tested for the ability of valve-side windings to withstand.
DC voltages. In operation, the valve windings are exposed to an AC voltage and a superimposed
DC voltage. A DC transmission must be able to handle the fast transition of power from one
direction to the other. Such transitions also mean a switch in converter polarity, from positive to
negative, and vice versa . Operation with continuous DC voltage, superimposed.
AC voltage and DC polarity reversal will be reflected in additional dielectric tests of the valve-
side windings; tests with DC voltage, tests with AC voltage and tests with switching surge voltage
are in accordance with IEC standards. All four types of test are considered to be non transient,
with a uniform voltage along the valve winding. For that reason, the two external terminals of the
winding are connected together and the voltage is applied to the two terminals simultaneously.
During the test with applied DC voltage, the level of partial discharge is measured. During the
transient period after the application of voltage, there may be Occasional charge movements
within the insulation system. These movements give rise to a noticeable partial discharge signal
on the valve-side terminals. The phenomenon is well known and recognized in current standards.
The industry has therefore accepted an upper limit on the number of occasions such bursts of
partial discharge can take place during the tests. Furthermore, the frequency of bursts must
diminish during the course of the test.
3. PHASE SHIFTING TRANSFORMER
Phase shifting transformers help to control the real power flow in transmission lines. Existing
transmission systems are often operated and stressed to the limit of their performance capability
of their original design. In order to increase the power transfer through existing lines, phase
shifting transformers is a solution to maximize asset utilization. To ensure that under these
conditions the economical, reliable and secure operation of the grid is maintained, the need
for various aspects of power flow management within the power systems is becoming evident.
Phase shifting transformers help control the real power flow in a complex power distribution
network in a very efficient way. They allow for better utilization of existing networks allowing
load growths.
Function of phase shifting transformer can be described through the current distribution over
parallel lines. The natural distribution of current depends on impedance of lines. If X/R of two
lines are extremely different then distribution is inefficient. There will be difference in phase
angle and magnitude of load voltage UL1 and UL2.
The two load sides are connected together, thus equivalent reactance reduces and system stability
improves. For the load voltages to be equal load currents I1 and I2 are different in magnitude
and phase angle. Based on the currents I1 and I2 this difference can be expressed by a circulating
current IC flowing in the loop. Tie line 1 is overloaded by circulating current IC and tie line 2
is under loaded by same amount. By adding phase shifting transformer in one of the tie line
the circulating current can be controlled by changing the phase angle between the two tie line
voltages. The load currents can thus be equalized.
The Electric Power Flow
Line reactance form major portion in line impedance, inserting a voltage in phase with or
opposite to the line voltage i.e. changing magnitude of voltage will have impact on reactive
power. The boost voltage with phase angle perpendicular to the line voltage /i.e., creating a
phase shift influences active power. Following example shows calculation of active, reactive
power and load angle.
System specification:
Base MVA: 400 MVA
Phase shifting transformer: 400 MVA, 220 kV ± 10 x 1.5% & 10x1.20
%X = 12%, %R = 0.17% (based on load losses)
Overhead line: Length 50 km, r =0.063Ω /km, x = 0.36Ω/km
Solution:
Base impedance =
R=0.063 x 50 = 3.15Ω
X= 0.36 x 50 = 18Ω
ZTotal p.u = Ztransformer p.u + Zline p.u
= (0.0017 + j0.12) + (0.026+j0.149)

= 0.028 + j 0.27
≅ j 0.27 (mainly reactive in nature) = XTotal p.u

Current lags 900 to due to purely inductive nature.

Reactive power, Q=√S2–P2
Phase Regulation using Phase shifting Transformer:

Vsource=1pu∠00
Vload=1pu∠-15.660
PST rating 220 kV±10x1.20
Δφ = ± 120
Vload=1pu∠-15.660 - Δφ)0
1. Phase shifting transformer phase angle set at -12° i.e. - 10 x 1.2° (Δφ= - 120)
2. Phase shifting transformer phase angle set at +12° i.e. + 10 x 1.2° (Δφ =+120)
Operating condition Active Power (P) Reactive Power (Q) Change in Active Change in
power (∆P) Reactive power
(∆Q)
Initial Condition (∆φ=O°) 1 pu 0.14 pu
∆φ= –12° 0.2364 pu 0.01 pu 0.7636 pu 0.13 pu
∆φ=-12° 1.72 pu 0.42 pu -0.72 pu -0.28 pu
Significant variation in active power is achieved by changing phase angle. Minor change is
observed in reactive power.
Types of Phase Shifting Transformer
1. A nonsymmetric, quadrature type and single core PST
The phase shift between source and load terminals is achieved by connecting the regulating
winding of phase B to the delta connection point of phase A and C, and analogous for the
remaining phases.
A quadrature voltage that can be regulated by means of the variable tap is added to the input
voltage in order to obtain a phase shift ‘α’. The direction of phase shift can be change by using
the switches. In this manner, the power flow in the line can be increased or decreased. The
relation between the tap position and angle ‘α’ is non-linear and can be derived from phasor
diagram:
...(1)
The relation between the output voltage and the injected quadrature voltage is given by:
...(2)
Substitute angle ‘α’ value from equ1 to equ 2.
...(3)
The power flow through the line is increased by adding an angle ‘α’ to the existing angle’δ’.
...(4)
After simplification,
...(5)
Relation between P, α and the quadrature voltage for a direct asymmetrical PST with δ = π
6
The curve of angle ‘α’ is relatively linear up to 0.6 rad i.e. 34°.
2. A symmetric, quadrature type and single core PST
A symmetric design is made with an additional regulating winding and an additional tap changer.
The maximum possible phase angle can be increased significantly. The relation between
the quadrature voltage and the angle ‘α’ is still non-linear and can be derived from phasor
diagram,
...(6)
Substitute value of angle ‘α’ in active power equation.
...(7)
The curve of angle ‘α’ is relatively linear up to 1.5rad i.e. 85°. Range of linearity has
increased.
3. A symmetric, single core PST with hexagonal winding connection.
An alternative implementation of a direct and symmetrical PST is shown in above fig. The
resulting phasor diagram has hexagonal shape. Additional impedance, connected to the load
side terminals is necessary, to protect the tap changer from short circuit currents, because no
transformer impedance is present at phase angle zero.
4. A symmetric, quadrature type and dual core PST with series and exciting unit.
Symmetric, quadrature type, dual core PST with

series and exciting unit
The series winding between source and load terminals is split into two halves, and the exciting
winding of the exciting unit is connected to the connection point of these two windings.
Thus, total symmetry between source and load is achieved. The regulating circuit, consisting
of the tap winding in the exciting unit and an exciting winding in the series unit, can be design
independently from main circuit, with regard to the voltage level. This provides more freedom
for the selection of the tap changer, which sometimes is quite difficult and can even determine
the limits for a specific design.
5. Asymmetric, quadrature type and dual core PST with series and exciting unit
Series winding is not split into two halves, thus voltage does not get added symmetrically.
Therefore this arrangement becomes asymmetrical. Exciting winding is connected at load
terminals. This arrangement gives freedom in selection of Tap changer. Independent design of
exciting winding is possible from main circuit.
The selection of OLTC for PST
To achieve variable phase angle shift, OLTCs are used in PSTs. Phase shifting transformer
can be built to provide discrete phase angle shift, continuous variable phase angle shift, or
a combination of both. Discrete phase angle shifters normally provide settings for a plus-or-
minus fixed degree value and zero. If a variable phase shift is desired, an On Load Tap-Changer
(OLTC) is required. OLTCs are used to provide several tap positions for any desired angle
range. A Phase-Shifting Transformer can be constructed as a shell or as a core form transformer.
In addition to the MVA rating, the amount of phase shift also directly affects the physical size
of the transformer.
Two typical types of regulation are used with OLTCs. One involves direct regulation at the line
end and the other involves a series and an exciting unit.
1. Direct regulation at line end
The tapped windings are wound on the same core leg as the main delta winding and the OLTCs
are designed as reversing types. The tapped windings of phase 1(energized by Ue) are connected
between phases 2 and 3 produces the voltages UAA’ and UA’A’’. The voltages of the source (US1)
and load side (UL1) are out of phase by an angle α . The input and output voltage magnitudes
are equal.
While selecting an OLTC the maximum through-current and the maximum step voltage Ust must
be taken into consideration. Because the phasor of the exciting winding is located electrically
between the phasors of US and UL, account must be taken of the fact that exciting voltage
changes with the phase angle.
Delta hexagonal phase shifter
These transformers have OLTCs with linear regulation, i.e. without changeover selector. The
tapped winding is wound on the same core leg as the main delta winding. The tapped winding of
phase 1 is located between phases 2 and 3 and produces the voltage UAA’. The input and output
voltage magnitudes are equal.
• Potential connection of the tap winding
In case of phase-shifting transformers with regulation at the line end and reversing type
OLTC, high recovery voltages can occur due to the winding arrangement. There are methods
available to reduce recovery voltage viz. use of tie in resistors, use of electrostatic screens
to shield the tap windings and use of Advance Retard Switch (ARS) as the change-over
selector. This additional unit allows the change-over operation to be carried out in two steps
without interruption. With this, the regulating winding is connected to a fixed potential for
the whole operation. The limiting factors for the ARS are the processes of commutation
which have to be controlled by the ARS.
Minimum number of OLTCs required for regulation at the line end
Regulation Number of OLTCs Number of ARSs

OLTC with reverser 3 two-phase-units
None
Or 6 single phase units
OLTC plus ARS acting as change-
6 single phase units 3/6 units
over selector
OLTC without change-over selector 6 single phase units None
2. Regulation with Series and Exciting Unit
These types of transformers basically consist of a series unit and an exciting unit, located on two
separate cores. These units can be enclosed in one tank, but for large capacity transformers, they
are constructed in two separate tanks.
Minimum number of OLTCs required in case of regulation using exciting unit
Regulation Number of OLTCs Number of ARSs
With reverser 3 phase-units(star point)

None
With one coarse winding 3 phase-units(star point)

1/3 units
With several coarse windings 3 phase-units(star point)

1/3 units
With two OLTCs in series with coarse 3 phase-units(star point)

change over selector
Or 3 single phase units and 3 single 1/3 units
phase units
Phase Shifting Transformer Ratings & Specifications
- Shunt Unit
Three phase Voltage ratio Tapping range Percent impedance Voltage Cooling Phase Shift
rating MVA per cent Angle
As per line 400/V1/V2/33 Tapping range Between main windings ONAN/ For PST system,
MW rating may vary from it shall be as per system ONAF/ shall be as per
±10% to requirement. OFAF system require-
full tapping ment. Generally
winding ie Between other pair of between 5ºto 15º
±100% windings it shall be as per
system requirement.
Note : V1/V2 and other voltages shall depend on the usage of PST ie the lines in which PST is required.
- Series Unit
Three phase Voltage ratio Tapping range Percent impedance Voltage Cooling Phase Shift
rating MVA per cent Angle
Shall depend V3/V4 NA for series Shall be as per system ONAN/ For PST system,
on the unit requirement. ONAF/ shall be as per
amount of OFAF system require-
phase shift ment. Generally
required. between 5º to
15º
Note : V3/V4 shall depend on the usage of PST ie the lines in which PST is required.
In practice many solutions are possible to the design of PST. The user’s electric power system
requirements and the manufacturer’s preference generally determine the design. The major
factors determining the type of PSTs are given below:
Performance factors
- The power rating and phase-shift angle requirements

- The voltages
- The connected system’s short-circuit capability.
Design factors:
- Type of construction (core form or shell form)

- Shipping limitations
- OLTC performance specifications
These factors decide whether a single-core, two-core type or a single tank with two cores has
to be chosen. The most popular of all the above is two core design. Every design has its own
advantages and disadvantages.
Other Parameters (Shunt Unit)
(i) Connections HV Star neutral effectively earthed,

IV & LV Star neutral effectively earthed,
SV delta
(ii) Connections symbol YNyn0yn0d11, YNyn0yn0d1 etc
(iii) Tappings As in table above
three-phase unit rating. Wherever transport restrictions impose, single phase ratings
equal to one-third of the three phase bank rating may be specified.
under ONAF condition shall be about 80 per cent.
(vi) Air core reactance of HV winding shall not be less than 20 per cent and knee point
voltage shall not be less than 1.1 pu.
(vii) Short circuit level - Transformer shall be suitable for connection to for 420 kV system
the system having the following short circuit and duration levels and duration: 40,50
and 63 kA for one second.
(a) HL/IV/LV/SV Terminals: Oil filled condenser bushing. No arcing horns shall be
provided.
(b) Neutral End: 36kV porcelain bushing. No arcing horns shall be provided.
Other Parameters (Series Unit)
(i) Connections HV Open delta,

LV Delta
(ii) Connections symbol Dd9, Dd3 (for quadrature boosters)
(iii) Tappings As in table above
(vii) Short circuit level of transformer shall be suitable for connection to for 420 kV system
(a) HV & LV Terminals: Oil filled condenser bushing. No arcing horns shall be
provided.
(b) Tolerance on percentage impedance voltage shall be as under:
Pairs of windings Tolerance

HV-IV (for shunt unit) ±10 per cent
HV-LV (for series unit) ±10 per cent
Phase Shifting Transformer Testing
Most of the rules and standards which exist for power transformers can be applied to PST’s
as well. However, there are a few topics which are specific to PST’s and some of the more
important are related to testing practice.
One of these is heat run test, which can differ from the normal practice because of the complexity
of the unit. This becomes obvious for a dual core design. Normally total losses are applied during
the initial phase of the heat run, in order to determine the oil temperature rise. As this is done
with a short circuit condition, no losses are actually generated in the core, and the actual core
losses need to be generated by increasing the load current and thus the load losses accordingly.
This works fine for any normal transformer, but it needs some additional consideration for a dual
core phase shifter. Due to specific properties of dual core PST’s it is not possible to achieve the
correct total losses for both active parts at the same time. The two active parts would always
have the same losses in the maximum tap position. Thus either separate heat runs are necessary
or a correction must be applied.
For a dual core design of a quadrature type phase shifter; With the PST in service, normally both
ends of the series winding are exposed to disturbances in the system. The standard lightning
impulse test at all terminals of the PST helps to ensure that the series winding is able to withstand
these stresses. A PST can face even more severe stresses during a lightning storm: In case of
a closed by-pass breaker, a lightning impulse will appear simultaneously at the source and the
load side terminal. This very likely produces oscillations with high magnitude at the center
of the series winding, where the exciting winding of the exciting unit is connected. If such a
condition is likely to appear during normal operation, it might be useful to specify a lightning
impulse test with source and load terminals connected, to ensure that the PST can withstand the
stresses of a lightning stroke in this situation.
Switching impulse testing can cause different kinds of problems. As usual, the secondary
side needs to be left open, in order to achieve an appropriate wave shape. It can then happen,
influence by the mutual interconnection of windings in different phases, that the magnitude of
the voltage oscillation at the secondary terminal exceeds the applied voltage. Therefore it is
sometimes appropriate to make the switching impulse test “indirectly”, which means that the
tested terminal is not the terminal, where the impulse is applied.
Phase shift angle measurement shall be done by interconnecting both the units of PST.
Typical Connection diagram of PST
REFERENCES
1 Walter Seitlinger Phase Shifting Transformers, Va Tech T&D (Va Tech Elin
Transformatoren Gmbh
2. A.Kramer and J.Ruff Transformers for Phase Angle Regulation Considering the
Selection of On-Load Tap Changer. IEEE Transactions on Power Delivery, Vol. 13,
No. 2, April 1998.
3. Jody Verboomen, Member IEEE, Dirk Van Hertem, Member IEEE, Pieter H.
Schavemaker, Wil L. Kling, Member IEEE, Ronnie Belmans, Fellow IEEE Phase
Shifting Transformers: Principles and Applications.
4. Josef Rusnak Power Flow Control By Use Of Phase Shifting Transformer
5. Paola Bresesti, Member, IEEE, Marino Sforna, Vittorio Allegranza, Deniele Canever,
and Riccardo Vailati Application of Phase Shifting Transformers for a secure and
efficient operation of the interconnection corridors.
6. ANSI C57.135: IEEE guide for the application, specification and testing of phase
shifting transformers
• Controlled Shunt Reactors
Application & Principle
The basic principle of CSR is to control the reactive power by using a thyristor valve, which
can provide the necessary speed of switching and control by means of firing angle control.
The CSR generally consists of controlled shunt reactor transformer (CSRT) with apprx. 100%
impedance, thyristor valves, controller, neutral grounding reactor, necessary circuit breakers and
other auxiliaries.
The CSRT is a power transformer with nearly 100% impedance between primary and control
winding (secondary winding). In other words when the control winding is short circuited with
rated voltage applied on the primary winding, the reactive power flow will be similar to the
power flow in a shunt reactor of similar rating connected to the same rated voltage. The CSR
is not merely a substitute of Shunt Reactor, but the advantages of CSR are much more than a
shunt reactor. The CSR offers various added advantages like fully controllable reactive power,
reduction in dynamic over voltages, increased power carrying capacity of lines, fast response,
full compatibility to single phase auto reclosure, economy of size, minimum harmonics etc.
The rating of CSR depends on the line parameters i.e. the line length and the compensation
required. Further the control winding design is dependent upon the control winding current
which is governed by the max. current allowed for the thyristor valves.
Typical Ratings & Specification
Three Voltage ratio Tapping range Percent impedance Voltage Cooling

phaserating per cent
MVA
Generally 50, 63 400/V1/V2 NA Between Primary (HV)-Secondary ONAN/
and 80 MVAr ONAF/
for 400 kV (Control) it shall be 100%. OFAF
line or as per Between other pair of windings it
compensation shall be as per system requirement.
required for line.
Note : V1/V2 shall depend on the current carrying capacity of thyristor valves.
In practice many solutions are possible to the design of CSR.
The basic variants of CSR are :
- CSR with continuous control.
- CSR with On/Off thyristor control.
- CSR with VCB control.
Other Parameters
(i) Connections HV Star neutral effectively earthed,
Control Star neutral effectively earthed,
SV delta
(ii) Connections symbol YNynd11, YNynd1 etc.
(iii) Tappings NA
(vii) Short circuit level - Transformer shall be suitable for connection to for 420 kV system
(a) HL/IV/LV/SV Terminals: Oil filled condenser bushing. No arcing horns shall be
provided.
(b) Neutral End: 36 kV porcelain bushing. No arcing horns shall be provided.
Typical Connection diagram of CSR
Principle of Controlled Shunreactor
Testing of CSR
Testing of CSR shall be in line with IEC 60076 as is followed for 400 kV class power
transformers.
Appendix II
Reference Standards and Books

Appendix - II
REFERENCE STANDARDS AND BOOKS

As on April 2013
1. SPECIFICATIONS
IEC ANSI / IEEE IS

Specifications
-Oil filled 60076-1 C57.12.00 2026-1
-Dry 60076-11 C57.12.01 11333
Reactors 60076-6 C57.21 (Shunt)
-Specifications
-Testing C57.16 5553 Part 1-8
-Dry type series
-Smoothing reactors 1277
for HVDC
- Self protected liquid filled 60076-13
transformer
Design and application of 60076-14
liquid-immersed power
transformers using high-
temperature insulation
materials
-SF-6 filled 60076-15
Transformers for Wind 60076-16
Turbine applications
-Converter transformer 61378-1 C57.18.10
-HVDC transformer 61378-2 C57.129
-Traction transformer 60310
-Phase shifting transformer 62032 C57.135
Transformers < 230 kV, C57.12.10

1~10 MVA single phase,
0.8~100 MVA 3 Phase
Overhead distribution C57.12.20
transformers
< 500 kVA 34.5/13.8 kV
Pad Mounted Compartmental C57.12.21
type Single Phase distribution
transformers HV 34.5 kV LV
240-120 V =<167 kVA
Pad mounted 3 Phase DT C57.12.22

< 2.5MVA 34.5/0.48kV
505
IEC ANSI / IEEE IS

Pad mounted single Phase DT C57.12.25
< 167 kVA 34.5/0.48kV
With separable HV Connector
Pad mounted 3 Phase DT-with C57.12.26

insulated HV connectors
< 2.5MVA 34.5 kV with
separable HV connector
Pad mounted 3 Phase DT C57.12.34

< 5 MVA 34.5/0.48kV
Enclosure Integrity-Pad C57.12.28

mounted
Enclosure Integrity- C57.12.29

Pad mounted for coastal
environments
Enclosure Integrity-Pole C57.12.31
mounted
Enclosure Integrity- C57.12.32
Submersible equipment
Electronics Power 295
Transformers
Liquid immersed distribution C57.12.36
substation transformers
Secondary network C57.12.40

transformers – subway and
vault type
Secondary network protectors C57.12.44
Ventilated, Dry type power C57.12.51

transformers
1~500 kVA single phase
15~500 kVA 3 phase
Sealed, dry power C57.12.52
transformers
> 0.5 MVA 3 phase 34.5 kV
Dry type transformers used in C57-12.55
unit substations
Transformers underground C57.12.23

-Type self-cooled, single phase
distribution transformers with
separable, insulated High
voltage connecters high-
voltage connectors: High
voltage (24940 Grd Y/14400
V and below) and low voltage
240/120 V, 167 kVA and
smaller
Reference Standards and Books 507
IEC ANSI / IEEE IS
Transformers underground C57.12.24

type three-phase distribution
transformers 2500 kVA and
smaller: High voltage 34500
Grd Y/19920 volts and below,
Low voltage, 480 volts and
below
Distribution transformers 1 to C57.12.50
500 kVA, single-phase and 15
to 500 kVA, three-phase with
high-voltage 601-34500 volts,
low voltage 120-600 volts.
Ventilated Dry-Type
Ventilated dry type network C57.12.57
transformers 2500 kVA and
below. Three phase, High
voltage 34500 volts and below
low-voltage 216 Y/125 and
480 Y/277 volts, requirement
External Clearances in Air 2026-3
Outdoor distribution 1180-1
transformers up to and
including 100 kVA, 11 kV:
Part 1 Non-sealed type
Outdoor distribution 1180-2
transformers up to and
including 100 kVA, 11 kV:
Part 2 Sealed type
Earthing Transformer 3151
2. TESTING
IEC ANSI / IEEE IS

Testing 60076-1 C57.12.91 2026-1
-General, Dry transformer C57.12.90
-General, oil filled C57.129
-HVDC transformer
Dielectric tests 60076-3 C57.12.90 2026-3
Temperature rise test 60076-2 C57.12.90,1538 2026-2

-Oil filled
-Dry transformer C57.134
Impulse/ switching surge test 60076-4 C57.98

C57.138 2070 / 11349 / 15638
(Distribution transformer)
Short circuit withstand 60076-5 C57.12.90 2026-5

requirements & testing
Determination of Sound 60076-10 2026-10
Levels
Measurement of frequency 60076-18
response
Loss measurement C57.123
Temperature rise test for C57.119
Overload
PD testing 60270 C57.113 2026-3
-Oil filled 60076-3 C57.127
-Acoustic C57.124
-Dry transformer
Test for thermal evaluation of C57.12.60
dry type transformers (Cast
resin & Resin encapsulated)
Test for thermal evaluation C57.12.56
of dry type transformers
(Ventilated dry type)
Test for thermal evaluation 259
of dry type transformers (Dry
type specialty and general
purpose)
Guide for determination 1538
of maximum winding
temperature rise in liquid filled
transformers
Test procedure for thermal C57.100
evaluation of insulation
systems for liquid immersed
transformers
3. TRANSFORMER OIL
IEC ANSI / IEEE IS

Transformer oil
-Mineral Oil Specifications 60296 ASTM D3487-08 335
-Silicone Oil Specifications 60836 ASTM D4652-1987
-Organic ester oil 61099
Specifications
-Synthetic Aromatic oil 60867
specifications
-Mineral oil Maintenance 60422 C57.106 1866
-Natural Ester oil maintenance C57.147
-Silicon oil maintenance 60944 C57.111
-Synthetic Organic Ester 61203
Maintenance
-Hydrocarbon fluid C57.121
maintenance
-Sampling 60475 ASTM D923-97 9434
60567 ASTM D3613-98 6855
-BDV 60156 ASTM D1816-97 6792
ASTM D 877-00
-Oxidation stability 61125 ASTM D2440 12422 / 12958
ASTM D2112-01
-Water content 60814 ASTM D1533-05
-DGA-Interpretation of results 60599 C57.104 10593
-DGA- Bushings TS 61464
DGA – OLTC PC57.139 D12
-DGA -During factory test 61181 PC57.130/D17
-DGA – Sampling 60567
-DGA – Test method ASTM D 3612-01
-DGA–Silicone oil filled C57.146
transformers
-Reclamation of Oil 637
Gassing of insulating liquids 60628
under electrical stress and
ionization
4. ACCESSORIES
IEC ANSI / IEEE IS

Fittings and accessories for 3639
power transformers
Tap changers 60214-1 C57.131 8468
Bushing 60137 C57.19.00 2099 / 7421
-General 60518 C57.19.03 3347 / 8603 / 13312 /
-HVDC Bushings C57.19.01 12676
-Dimensions C57.19.100 15137 / 4257
-Terminals TS 61463
Bushing Application Guide
Bushings Seismic Qualification
Induction voltage regulator C57.15
Control Cabinet C 57.148
Surge Arresters 15086-1
- Part 1 : Non-Linear Resistor 15086-3
Type Gapped Surge 15086-5
Arresters for AC System
- Part 3 : Artificial Pollution
Testing of Surge Arresters
- Part 5 Selection
and Application
Recommendations
Voltage Transformers 186 C57.13.0, 13.1, 13.2 3156-1

Part 1 General requirements 3156-2
Part 2 Measuring voltage 3156-3
transformers 3156-4
Part 3 Protective voltage
transformers
Part 4 Capacitor voltage
transformers
Insulating oil conditioning 6034

plants
Insulation resistance tester,

- hand operated (magnets
generator type) 2992
- electric type 10656
- Portable mains operated 11994
Portable earth resistance meter 9223
Pressure and vacuum gauge 3624
Danger notice plates 2551
Warning symbol for dangerous 8923

voltage
Galvanized strand for earthing 12776
Ready mixed paint, bushing, 104

zinc chrome priming
Ready mixed paint, air drying, 2074

red-oxide-zinc chrome,
priming
Enamel synthetic, exterior 2932

- (a) undercoating
- (b) finishing
Polyurethane full gloss enamel 13213
Epoxy based zinc phosphate 13238

primer
Epoxy enamel, two component, 14209

glossy
Paper insulated lead-sheathed 692

cables for electricity supply
PVC insulated cables for 694

working voltages up to and
including 1100 V
PVC insulated (heavy duty)

electric cables 1554-1
- for working voltages up to
and including 1100 V 1554-2
- for working voltage from 3.3
kV up to and including 11 kV
Cross linked polyethylene

insulated PVC sheathed cables
- for working voltage up to and 7098-1
including 1100 V
- for working voltages from 3.3 7098-2
- for working voltages from 66 7098-3
Compression type tubular in- 8308

line connectors for Aluminum
conductors of insulated cables
Compression type tubular 8309

terminal ends for Aluminum
conductor of insulated cables
of insulated cables
Cable sealing bores for oil 9147

immersed transformers suitable
for paper
insulated lead sheathed cables
for highest system voltages
from 12 kV up to and including
36 kV
Conduits for electrical 9537-1
installations
- General requirements 9537-2
- Rigid steel conduits
- Rigid plain conduits of 9537-3
insulating materials
- Pliable self-recovering
conduits of insulating materials 9537-4
Brass glands for PVC cables 12943
Current transformers 60044-1 C57.13.0, 13.1, 13.2 2705-1

- General 2705-2
- Measuring Current 60044-6 2705-3
transformers 2705-4
- Protective Current
transformers
- Protective Current
transformers for
special purpose application
Cork composition sheets: Part 4253-2

2 Cork and rubber
Dimensions for ‘O’ rings and 6838
grooves for vacuum flanges
‘O’ rings 9975-1
- Dimensions 9975-2
- Material selection and quality 9975-3
acceptance criteria 9975-4
- Seal housing dimensions and
tolerances
- Terminology and definition
of terms
Rubber gaskets 11149
Hexagon head bolts, screws 1363-1
and nuts of product grade C 1363-2
- Hexagon head bolt 1363-3
- Hexagon head screws
- Hexagon nuts
Hexagon head bolts, screws 1364-1

and nuts of product grades A 1364-2
&B 1364-3
- Hexagon head bolts 1364-4
- Hexagon head screws 1364-5
- Hexagon nuts
- Hexagon thin nuts
-(chamfered)
- Hexagon thin nuts (un
chamfered).
Slotted counter sunk head 1365
screws
Plain washers 2016
Slotted grub screws 2388
Fastners - single coil 3063
rectangular section spring
washers
Activated alumina 9700
Nitrogen 1747
Copper alloy gate, globe and 778
check valves for water works
purposes
Sluice Valve for Water Works 14846
Purposes (50 to 1200 mm
Size)-Specification
Swing check type reflux (non- 5312-1
return) valves Part 1 single
door pattern
Steel plug valves for petroleum 11699
Petrochemical and allied
industries
Steel ball valves for the 11792
Petroleum and allied industries
Gas operated relays 3637
Propeller type ac ventilating 2312
fans
Electric axial flow fans 3588
Shell and tube type heat 4503
exchangers
Oil to water heat exchangers 6088
for transformers
Silica gel 3401
Electric power connectors 5561
Porcelain post -insulator for 2544

systems with nominal voltage
greater than 1000 V
Hollow insulators for use in 5621
electrical equipment
Silicone compound for 7648
application on high voltage
porcelain insulators
Guide for the selection 13134
of insulators in respect of
pollution conditions
Permissible limits of visual 13305
defects for insulating porcelain
for electrical circuits
Pressed Steel Radiators IEEMA 9
Tests on indoor and outdoor IEC 60168
post insulators of ceramic
material or glass for nominal
voltages greater than 1000 V
5. INSTALLATION, OPERATION & MAINTENANCE
IEC ANSI / IEEE IS

Installation & maintenance - C57.93, C57.12.11, 10028 Part 1-3
-Oil filled - C57.12.12
-Dry type transformer C57.94
Loading guide 60076-7 C57.91,C57.92, C57.115 2026-7, 6600

-Oil filled 60076-12, 60905 C57.96
-Dry type transformer
Failure investigation C57.125

Reporting failure data C57.117
Evaluation and Reconditioning C57.140
of oil filled transformers
Diagnostic field testing 62
PC 57.152 D2
Monitoring Of transformers PC57.143 D21
&accessories
Guide for safety procedures 5216–1
and practices in electrical work
Guide for safety procedures 5216-2
and practices in electrical work
(lifesaving technique)
Code of practice for earthing. 142 3043
Steel wire ropes for general 2266

engineering purposes
Dee-shackles and bow 6132
shackles
Hand operated chain pulley 3832
blocks
Eye bolts with collars 4190
Automotive vehicles -portable
jacks for automobiles -Part I 4552-1
mechanical jacks
Automotive vehicles-portable 4552-2
jacks for automobiles - Part 2
Hydraulic jacks
Wire rope slings - safety 12735
criteria and inspection
procedure for use
Colors for ready mixed paints 5
and enamels
Code of practice for painting 1477-1
of ferrous metals in
buildings -Part I Pre-treatment
Code of practice for painting 1477-2

of ferrous metals in Building -
Part 2 painting
Code of practice for 1255
installation and maintenance
of power
Cables up to and including 33
kV rating
Code of practice for electrical 732
wiring installations
Class - 2 and Class - 3 1585
Transformers
Methods of measurement of 60990
touch current and protective
conductor current.
Grounding of instrument C57.13.3
transformers secondary
circuits
Application of transformers C57.105
connection’s in three phase
distribution systems
Guide for liquid-immersed C57.109
transformer through fault
current duration
Seismic guide for power C57.114
transformers and reactors
Fire protection, guide for 979
substation
Recommended practice for 242
protection and co-ordination
of industrial and commercial
power system
Recommended current ratings 3961-1
for cables. Part 1 paper
insulated lead sheathed cables
Recommended current ratings 3961-2
for cable Part 2 PVC insulated
and PVC sheathed heavy duty
cables
Recommended current 3961-5
ratings for cables Part 5 PVC
insulated light duty cables
Recommended short circuit 5819
ratings of high voltage PVC
cables
Recommendation for heat 10864
exchanger gasket
Guide for loading power C57.19.101
apparatus bushings
6. APPLICATION GUIDES
IEC ANSI / IEEE IS

Transformers 60076-8 2026-8
High temp. Insulation 60076-14 1276
materials
Converter transformers 61378-3
Tap changers 60214-2 8478
Transformers connected to - C57.116
generators
Transformers for non- - C57.110

sinusoidal currents (loads with
Harmonics)
Loss Evaluation Guide - C57.120
Phase shifting transformer 62032 C57.135
Terminal marking & TR 60616 C57.105 (Connections)
connections C57.12.70 2026-4
(Terminal markings)
Apparatus bushings C57.19.100
Standard terminology 60050-421 C57.12.80
Through fault current C57.12.59
duration- (Equipment damage C57.12.109
curves) Dry Oil filled
Insulation co-ordination 60071-1,2,3 1313.1

60664-1 (Low voltage) (Definition & principles) 3716 / 15382 Part 1-4,
1313.2
(Application guide)
Preferred voltage ratings 60038 1312
Transformers for Nuclear 638
generating station
Bar coding of Distribution C57.12.35

transformers
Selection of insulators for TS 60815
polluted environments
Permissible temperature rise 60943
for terminal
Bushings-Seismic TS 61463
Qualification
Direct connection details 61639
between transformers & GIS
Determination of sound level 60076-10-1 C57.136 2026-9

Guide for sound abatement C57.12.58
Cleaning of Insulators 957
Occurrence and Mitigation of C57.142

Switching transients induced
by transformers
Metric conversion of C57.144
transformer standards
Transient Voltage Analysis of C57.12.58
Dry type transformer Coil
Determination of max 1538
winding temperature rise in
liquid filled transformers
Electrical Power System 61850-7-4 C37.2
Device Function Numbers,
Acronyms, Contact
designations
Recommended electrical 1427
clearances in air insulated
electrical power substations
Guide for protecting C37.91
Transformers C37.108
Guide for protection of C37.109
network Transformers C37.110
Guide for Protection of Shunt
Reactors
Application of CTs used for
Protective Relays
current transformers 4201
voltage transformers 4146

capacitor voltage transformers 5547
Application guide for gas 3638

operated relays
Application guide for 3842-1
electrical relays for ac
systems. Part 1 over current
relays for feeders and
transformers
7. Books on Transformer Engineering
1. First Books on Transformers
1889 - Friedrich Uppenborn History of the Transformer, Pages 60 E&F.N, Spon,

London (Translated from German)
1889 - John Ambrose Fleming The Alternate Current Transformer in Theory and
Practice Vol 1 Induction of Electric Currents, Pages 487 Vol 2 The
Utilization of Induced Currents, Pages 507 The Electrician Printing &
Publishing Co. Ltd, London
2. Evergreen Classics (Theory)
1938,1951 - F Blume , G Camilli , A.Boyajian , VM Montsinger Transformer Engineering –

A Treatise on the theory ,operation and application of transformers , Pages 496,
John Wiley & Sons Inc , New York
1943-1965 – ed 13.0 Electrical Engineering Department, MIT, US Magnetic Circuits and

Transformers- A first course for Power & Communication Engineers , Pages 742
John Wiley & Sons, New York
1942-1997 – ed 5.0 ABB Electric system Technology , Raleigh USA Electrical

Transmission and Distribution Reference Book. (Earlier Westinghouse
T & D Book)
3. First Transformer Books Published from India
1962 - S B Vasutinsky Principles, Operation and Design of Power Transformers PSG

College of Technology , Coimbatore Incidentally the same Russian author’s title
in Chinese came out in 1983- Theory and Calculation of Transformers, Pages
554
1982, 2003 - ed 2.0 BHEL Transformers
4. Current Books
Accessories
2011 – Keith Ellis Bushings for Power Transformers , Pages 116 Author House ,
Bloomington , IN
2011 – Faiz J Siah Kolah B Electronic Tap Changers for Distribution Transformers ,
Pages 183 Springer-Verlong , London
2000 – Axel Kramer On- Load Tap -Changers for Power Transformers , Pages 232 MR
Germany
1979,1987 – HP Moser & V Dahinden Transformer Board Vol 1( 1979) & 2(1987) Weidman,
Rapperswill , Switzerland
Application
1925-2007 - ed 13.0 Martin Heathcote The J & P Transformer Book , Pages 973 Newness
Publications , Amsterdam 14th edition expected in 2013 √2003,2007- ed2.0
James H Harlow Electric Power Transformer Engineering, Pages , CRC Press ,
New York
2003-2007 – ed 3.0 ABB Power Transformer Business unit Transformer Hand Book , Pages 23
Maintenance
2006-2010 – ed3.0 ABB Transformer Services Business unit Service Hand Book for
Transformers √1981-2004 – ed 3.0 M Horning , J Kelly, S Meyers , R Stebbins
Transformer Maintenance Guide SD Meyers Inc , Ohio
Theory
2004-13 – ed2.0 SV Kulkarni , SA Kharparde Transformer Engineering Design & Practice

Marcel and Dekker Inc , New York
2008 – A.V. Chiplonkar Design, Operation and Maintenance of Core type oil filled
Transformers, Pages 720
2001,2010 – ed 2.0 Robert M Del Veechio, Rajendra Ahuja , Bertland Poulin , Pierre T
Feghalli, DM Shah Transformer Design Principles with Applications , Pages 720
CRC Press
1987,1995 – ed 2.0 K.Karsai, D Kerenyi , L Kiss Large Power Transformers Akademiai Kiado , Budapest
Theory – Specifics
1966 – ed 2.0 M Waters The Short Circuit Strength of Power Transformers Macdonald
& Co. , London
1996-2008 – ed 3.0 G.Bertagnolli Short Circuit Duty of Power Transformers , Pages 225 ABB
Management Services , Transformers, Zurich
1974 – Richard Stoll Eddy currents Clarendon Press , Oxford
2005 – ed 5.0 William H. Hayt , J A Buck Engineering Electromagnetics Tata Mcgraw

Hill , India
2006 – ed 2.0 Joseph A Edminister Electromagnetics Tata Mcgraw Hill , India
1964 – F H Kreugar Discharge Detection in High Voltage Equipment Heywood Book ,

London
1993 – D.Konig , Y N Rao Partial Discharges in Electric Power Apparatus VDE Verlag
Gmbh , Berlin
1980 – M V K Chari and PP Silvester Finite Elements in Electrical and Magnetic Field
Problems John Wiley & Sons
2008 – ed 9.0 J P Holman, Heat Transfer, Pages 676 Tata Mcgraw Hill, New Delhi
2011 – Suhas V Patankar Numerical Heat Transfer and Fluid Flow Taylor & Francis
Testing
2003,2011 – ed 2.0 Ake Carlson, Jitka Fuhr Testing of Power Transformers, Pages ABB Power
Transformer Business Area
Transformer Oil
2012 – A K Pandey A Glance on Power Transformer Oil – 100 Questions , Pages 73

Shroff Publishers , Mumbai
2011 – ed 3.0 Nynas Naphthenics AB, Sweden Transformer Oil Hand Book, Pages 223
2000 – Marcelo M Hirschler ASTM Publication No. 1376 Electrical Insulating Materials,
pages 211
1988 – H.G. Erdmann (ed) Electrical Insulating Oils , Pages 146 ASTM Publication STP
998
5. More Details
www.eng-tips.com FAQ238-1287: What are good references for a Power Engineer?

http://www.transformerscommittee.org/ - Bibliography on transformer books
flipkart.com – On line book store abebooks.com bookfinder.com - For used books and out of print books
6. List of CIGRE Brochures for Transformers
S. No. Technical Title Year

Brochure No.
1 TB -96 Thermal aspects 1995
2 TB-170 Static electrification 2000
3 TB-157 Effect of particles 2000
4 TB-156 Customer specifications 2000
5 TB-209 Short circuit performance 2002
6 TB-204 Design reviews 2002
7 TB-227 Life management of transformers 2003
8 TB-248 Economics of Transformer Management 2004
9 TB-298 Guide on Transformer Lifetime Data Management 2006
10 TB-349 Moisture Equilibrium and Moisture Migration within Transformer 2008
Insulation Systems
11 TB-343 Recommendations for Condition Monitoring and Condition 2008
Assessment Facilities
12 TB-342 Mechanical Condition Assessment of Transformer Windings 2008
13 TB-378 Cooper Sulphide in Transformer Insulation 2009
14 TB-436 Experience in service with new insulating liquids 2010
15 TB-407 HVDC converter transformers - guidelines for design review 2010
16 TB-406 HVDC converter transformers - test procedures, ageing, evaluation 2010
and reliability in service
17 TB-393 Thermal Performance 2010
18 TB-445 Guide for transformer maintenance 2011
Appendix III
Typical Quality Assurance Plan

(Format for Illustration only)
Appendix Iii
TYPICAL QUALITY ASSURANCE PLAN (FORMAT FOR ILLUSTRATION ONLY)
SL. No. Component / Classification Type of Insp. Quantum REF.Doc. & Form INSP/TEST
operation and / test of insp. ACPT. Norm of
description of test record
V/SV MQ
1.7 TANK AND

FABRICATION
1.7.1 Verification of welders Major Verification of Each WPS/ASME V/SV P VE
Qualification / Specification Records Welder Sec. DC IR/TC
1.7.2 Thickness verification of Major Measurement Sampling DRG/Material V/SV P P

Steel under use TRQS 82403 Spec. No. ~ IR/
TC
1.7.3 MECH&CHEM. properties Major Testing -do~ ~do~ -do- -do- VE

of steel
1.7.4 Verification of dimensions Major Measurement 100% for ~do~ ~do~ ~do~ -do-
of components and assly. Major assly
1.7.5 Inspection of fit up and Major Visual & ~do~ ~do~ ~do~ ~do~ -do-
major weld, preparation Measurement
Weld finish & size.
1.7.6 Check for flatness of Major Measurement -do- —do- —do— —do— H
gasketing surface
1.7.7 Leak proof ness of oil filled Major Testing Each unit Process spec. NO.-/ -do- -do- VE
Compartments CBIP
1.7.8 Pressure test Major -do- One unit of -do- -do- H

new design
1.7.9 Vacuum test Major Testing One unit of V/SV P H

new design IR/
TC
1.7.10 D.P. Testing of major weld Major Testing Jacking / Process Spec. No. -do- -do- VE
Lifting pad
1.7.11 Verification as per OGA Major 100% DRG. No. -do- H
1.7.12 Blast cleaning Major 100% Process Spec. -do- H

No. —
1.7.13 Paint type and shade Major Sampling DRG. No. - -do~ H
1.7.14 Paint thickness Major -do- DRG. No. - -do~ H
1.7.15 Uniformity of finish Major -do- Process Spec. -do- -do-

No. -
1.7.16 Paint adhesion test Major -do- Process Spec. No.~ -do~ -do~
525
Legends:
V Vendor
SV Sub Vendor
MQ Manufacturer’s Quality
Assurance
WPS Welding Process
Specification
P Perform
IR Inspection Record
TC Test Certificate
Appendix IV
Guaranteed Technical and Additional Technical

Particulars
Appendix IV
GUARANTEED TECHNICAL AND ADDITIONAL

TECHNICAL PARTICULARS
I. Guaranteed Technical Particulars:

1. Name of the manufacturer and county of origin:
2. Installation indoor/outdoor:
3. Reference standard:
4. Continuous ratings under service conditions specified in IS: 2026:
(a) Type of cooling
(b) Rating (MVA)
(i) With ONAN cooling HV IV LV
(ii) With ONAF cooling
(iii) With OFAN cooling
(iv) With OFAF cooling
(v) With OFWF cooling
(vi) With ODAN cooling
(vii) With ODAF cooling
(viii) With ODWF cooling:
(c) Rated Voltage :
(i) HV kV :
(ii) IV kV :
(iii) LV kV :
(d) Rated frequency Hz :
(e) Number of Phases :
Current at rated no load voltage and on principal tap:
(i) HVAmps : (ii) IV Amps : (iii) LV Amps:
5. Connections :
(i) HV:
(ii) IV:
(iii) LV:
6. Connection symbol:
7. Temperature rise:
(a) Temperature rise of oil above reference peak ambient temperature
(By thermometer) (°C):
(i) At full ONAN rating (°C):
(ii) At full OFAF/ODAF/OFWF/ODWF rating (°C):
(b) Temperature rise of winding above reference peak ambient temperature
(By resistance method) (°C):
(i) At full ONAN rating:
(ii) At full OFAF/ODAF/OFWF/ODWF rating:
529
(c) Limit of hot spot temperature for which the transformer is designed (°C) Over the maximum yearly
weighted average ambient temperature:
8. Type of tap changing switch:
(i) Off circuit switch/links:
(ii) On load:
9. Tappings on windings HV/IV/LV for:
(i) Constant flux/variable flux/combined regulation:
(ii) Location (Line/Central/Neutral) end of winding:
(iii) Number of steps:
(iv) Variation of (HV/IV/LV):
10. (i) No load loss at rated voltage and frequency at principal tap (kW):
(ii) No load loss at the voltage corresponding to the highest tap (kW):
(iii) Tolerance, if any, on the above values:
11. (a) Load loss at rated output, rated frequency and corrected for 75°C winding temperature at:
(i) Principal tap (kW):
(ii) Highest tap (kW):
(iii) Lowest tap (kW):
(b) Tolerance, if any, on the above values:
12. (a) Auxiliary losses at rated output, normal ratio, rated voltage, rated frequency and ambient
tmperature (kW):
(b) Tolerance, if any, on the above values:
13. Total losses at normal ratio inclusive of auxiliary equipment losses (kW):
14. Positive sequence impedance on rated MVA base at rated current and frequency at 75°C winding temperature
between: HV-IV HV-LV IV-LV
(i) Principal tap, per cent:
(ii) Highest tap, per cent:
(iii) Lowest tap, per cent:
15. Zero sequence impedance at reference temperature of 75° C at principal tap, per cent:
16. Reactance at rated MVA base at rated current and frequency, per cent:
17. Regulation at full load and 75°C winding temperature expressed as a percentage of normal voltage:
(i) At Unity Power Factor per cent:
(ii) At 0.8 Power Factor (Lagging) per cent:
18. Efficiency at 75°C winding:
temperature as derived from guaranteed loss figures and at Unity power factor
(a) At full load, per cent:
(b) At 3/4 load, per cent:
(c) At 112 load, per cent:
19. (i) Maximum efficiency, per cent:
(ii) Load at which maximum efficiency occur s (per cent of full load):
20. Time in minutes for which the transformer can be run at full load without exceeding the maximum
permissible temperature at reference ambient temperature when:
(a) Power supply to fans is cutoff but the oil pumps are working:
(b) Power supply to oil pumps is cut-off but fans are working:
(c) When power supply to both fans and pumps is cut off:
21. Short time rating for 2 seconds of:
(a) HV winding:
Guaranteed Technical And Additional Technical Particulars 531
(b) IV winding:
(c) LV winding:
22. Permissible over loading:
(a) HV winding:
(b) IV winding:
(c) LV winding:
23. Terminal arrangement:
(i) High voltage (HV):
(ii) Intermediate voltage (IV):
(iii) Low voltage (LV):
(iv) Neutral-HV/IV/LV:
(v) Tertiary:
24. Insulating and cooling medium:
25. Test Voltage: HV / IV / LV
(i) Lightning impulse withstand test voltage (kV peak):
(ii) Power frequency with-stand test voltage dry as well as wet for I minute (kV rms):
(iii) Switching impulse withstand test voltage (kV peak):
26. Partial discharge level at 1.5Um/ √ 3 kV rms (pC):
27. Noise level when energised at normal voltage and frequency without load (db):
28. External short circuit withstand capacity (MVA) and duration (seconds):
29. Over flux withstand capability of the transformer:
II. ADDITIONAL TECHNICAL PARTICULARS
(These figures are indicative only. These shall not form the basis for upward or downward revision of
prices).
1. Details of Core:
(a) Type of core construction:
(b) Type of core joints:
(c) Flux density at rated voltage and frequency and at principal tap Tesla:
(d) Magnetizing current at normal ratio and frequency: (i) 90 per cent of rated voltage:
(ii) 100 per cent of rated voltage:
(iii) 110 per cent of rated voltage:
(In case kVA ratings of windings are different, this may be specified in terms of magnetizing kVA):
(c) Power factor of magnetizing current at normal voltage ratio and frequency:
(f) (i) Material of core laminations:
(ii) Thickness of core laminations (mm):
(g) (i) Whether core construction is without core bolts:
(ii) Insulation of core bolt:
(iii) Insulation of core bolt washers:
(iv) Insulation between core laminations:
(v) Core bolt insulation withstand voltage for 1 minute (kV rms):
(vi) Are the core bolts grounded. If so how:
(h) (i) Material of core clamping plate:
(ii) Thickness of core clamping plate:
(iii) Insulation of core clamping plate:
(i) Describe location/Method of core grounding:
(j) Details of oil ducts in core:

Details of windings: HV IV LV
(a) Type of winding:
(b) Material of the winding conductor:
(c) Maximum current density of windings (at rated current) A / Sq. mm
(i) HV:
(ii) IV:
(iii) LV:
(iv) Regulating:
(d) Whether HV windings are interleaved / intershielded:
(e) Whether winding are preshrunk:
(f) Whether adjustable coil clamps are provided for HV and LV windings:
(g) Whether steel rings used for the windings if so, whether they are split:
(h) Whether electro-static shields are provided to obtain uniform voltage distribution in the HV
windings:
(i) Insulating material used for:
(i) HV winding:
(ii) IV winding:
(iii) LV winding:
(iv) Regulating winding:
(i) Insulating material used between:
(i) HV and IV, winding:
(ii) IV and LV winding:
(iii) LV winding and core:
(iv) Regulating winding and earth:
(k) Type of axial coil supports:
(i) HV winding:
(ii) IV winding:
(iii) LV winding:
(l) Type of radial coil supports:
(i) HV winding:
(ii) IV winding:
(iii) LV winding:
(m) Maximum allowable torque on coil clamping bolts:
(n) DP value conductor paper:
Bushings: HVIV LV Neutral
(a) Make and type:
(b) (i) Rated voltage class kV:
(ii) Rated current (Amps):
(c) Lightning impulse withstand test voltage
(1.2x50microsecond) (kV peak):
(d) Switching surge with-stand test voltage (kV peak):
(e) Power frequency with-stand test voltage:
(i) Wet for 1 minute (kV rms):
(ii) Dry for 1 minute (kV rms):
(f) Partial discharge level:
(g) Creepage distance in (mm):

(h) Creepage distance (protected):
(i) Whether test lap is provided:
(j) Quantity of oil in bushing and specification of oil used (kg):
(k) Weight of assembled bushing (kg):
(1) Minimum clearance height for removal of bushing (mm):
Minimum clearance (mm): In Air-
(i) HV: Between Phase to
(ii) IV: phases ground
(iii) LV:
Approximate weight
(a) Core with clamping:
(b) Coil with insulation:
(c) Core and winding:
(d) Oil required for first filling:
(e) Tank and fittings with accessories:
(f) Untanking weight:
(g) Total weight with oil and fittings:
(h) Weight of total insulation:
Detail of Tank
(a) Type of tank: (mm)
(b) Approximate thickness of sheet (mm)
(i) Sides (mm)
(ii) Bottom (ton-)
(iii) Cover (torr)
(iv) Cooling Tubes/Radiators (torr)
(c) Vacuum recommended for hot oil circulation
(d) Vacuum to be maintained during oil filling in transformer tank:
(e) Vacuum to which the tank can be subjected without distortion:
(f) No. of bi-directional wheels provided:
(g) Track gauge required for the wheels.Longitudinal Axis Transverse Axis
(h) Type of pressure relief device/explosion vent
and pressure at which it operates: Conservator
(a) Total volume (Litres):
(b) Volume between the highest and lowest visible oil levels (Litres):
(c) Power required by heaters (if provided) (kW):
(i) Quality
(i) Governing standard:
Specific resistance at (ohm-cms)

27°C:
90°C:
(iii) Tan delta:
(iv) Water content (ppm):
(v) Dielectric strength (Breakdown voltage) (kV):
(vi) Characteristic of oil after ageing test:
(a) Specific resistance at (ohm-cms)
27°C:
90°C:
(b) Tan delta:
(c) Sludge content:
(d) Neutralization Number:
(vii) Details of oil preserving equipment offered:
Radiator
(i) Overall dimensions 1 x b x h (mm):
(ii) Total weight with oil (kg):
(iii) Total weight without oil (kg):
(iv) Thickness of Radiator tube /fins (mm):
(v) Types of mounting:
(vi) Vacuum withstand capability:
10. Cooling System
(a) Make and type: :Fan Motor Pump Motor
(b) No. of connected units:
(c) No. of standby units:
(d) Rated power input:
(e) Capacity (cu m/min.) or (Litres/min.):
(f) Rated voltage (Volts):
(g) Locked rotor current (Amp):
(h) Efficiency of motor at full load (Per cent):
(i) Temp, rise of motor at full load (ºC):
(j) B HP of driven equipment:
(k) Temperature range over which control is adjustable (°C):
(1) Whether the fan and/or pumps suitable for continuous operation
at 85 per cent of their rated voltage:
(m) Estimated time constant in hours for
(i) Natural cooling:
(ii) Forced air cooling:
11. Gas and Oil operated relay make and type:
12. Temperature Indicators Oil temperature
Indicator
Winding
(i) Make and type: temperature
(ii) Permissible setting ranges for alarm and trip: Indicator
(iii) Number of contacts:
(iv) Current rating of each contact:

(v) Whether remote indicators provided. If so, whether equipment required at purchasers control room is
included:
13. Approximate overall dimension :
(a) Length : mm
(b) Breadth : mm
(c) Height : mm
14. (i) Minimum clearance height for lifting core and winding from tank:
(ii) Minimum clearance height for lifting tank cover:
15. Shipping details
(a) Approximate weight of heaviest package:
(b) Approximate dimension of largest package:
16. Transformer will be transported with oil/gas:
17. Size of rail recommended for the track:
18. Details of bushing current transformers (HV IV LV Neutral)
19. (i) Quantity:
(ii) No. of cores:
(iii) Ratio:
(iv) V.A. burden:
(v) Accuracy class:
(vi) Knee point voltage:
(vii) Magnetizing current at knee point voltage:
(viii) Secondary resistance:
19. Lifting jacks
(i) Governing standard:
(ii) No. of jacks in one set:
(iii) Type and make:
(iv) Capacity (tonnes):
(v) Pitch (mm):
(vi) Lift (mm):
(vii) Height in closed position (mm):
(viii) Mean diameter of thread (mm):
20. Marshalling kiosk
(i) Make and type:
(ii) Details of apparatus proposed to be housed in the kiosk:
21. Details of anti-earth-quake device provided, if any:
22. Separate conservator and Buchholz relay provided:
23. Tap Changing Equipment (These details refer to the basic rating
of O.L.T.C. as guaranteed by O.L.T.C manufacturers):

(a) Make:
(b) Type:
(c) Power flow-unidirectional/bi-directional/restricted bi-directional:
(d) Rated voltage to earth (kV):
(e) Rated current (Amps):
(f) Step voltage (Volts):
(g) Number of steps:
(h) Control-Manual/Local Electrical/Remote Electrical:
(i) Voltage control-Automatic/Non-Automatic:
(j) Line drop compensation provided/Not provided:
(k) Parallel operation:
(1) Protective devices:
(m) Auxiliary supply details:
(n) Time for complete tap change (one step) sec.:
(o) Diverter selector switch transient time (cycles):
(p) Value of maximum short circuit current (Amps):
(q) Maximum impulse withstand test voltage with 1.2/50 micro-seconds full wave between switch
assembly and ground (kV peak):
(r) Maximum power frequency test voltage
between switch assembly and earth (kV rms):
(s) Maximum impulse withstand test voltage
with 1.2/50 microseconds across the tapping range (kV peak):
(t) Approximate overall dimensions of tap changer
(In case of separate tank type) (mm):
(u) Approximate overall weight (In case of separate tank type) (kg):
(v) Approximate mass of oil (In case of separate tank type) (kg):
(w) Particulars of the O.L.T.C. control panel for installation in the control room:
24. Driving mechanism box
(i) Make and type:
(ii) Details of apparatus proposed to be housed in the box:
Appendix V
List of Transformer Accessories and Test

Certificates Required
Appendix V
LIST OF TRANSFORMER ACCESSORIES AND TEST CERTIFICATES REQUIRED
SI. Accessory Ref. Std. Test-certificates required

No
1. Appearance, construction and dimensional check
2. Test for leakage of internal filling at a pressure of 1.0 kg/cm2 for
12 h
3. Insulation resistance measurement with 2000 V megger
1. Condenser Bushing IS 2099 4. Dry power frequency voltage withstand test
5. Dry power frequency voltage withstand test for test tap insulation.
6. Partial discharge measurement up to 1.5 Um / √3 kV
7. Measurement of tangent delta and capacitance
1. Appearance, construction and dimensional check.
2. IS Bushings IS 2099 2. Insulation resistance measurement with 2000 V megger.
3. Dry power frequency voltage withstand test.
1. Oil tightness test for the diverter switch oil chamber at an oil
pressure of 0.5 kg/ cm2 at 100°C for 1 h.
2. Mechanical operation test.
3. Operation sequence measurement.
4. Insulation resistance measurement using 2000 V megger.
3. OLTC IS 8468 5. Power frequency voltage withstand test on diverter switch to earth
and between even and odd contacts.
6. Power frequency voltage withstand test on tap selector- between
stationary contacts, between max. and min. taps, between phases
and supporting frames, between phases.
7. Operation test of complete tap changer.
8. Operation and dielectric test of driving mechanism.
1. Calibration test.
2. Dielectric test at 2 kV for one minute.
Winding
3. Accuracy test for indication and switch setting scales.
4. Temperature 4. Test for adjustability of switch setting.
Indicator 5. Test for switch rating.
6. Measurement of temperature rise with respect to the heater coil
current.
1. Calibration test.
2. Dielectric test at 2 kV for one minute.
Oil Temperature
5. 3. Accuracy test for indication and switch setting scales.
Indicator
4. Test for adjustability of switch setting.
5. Test for switch rating.
1. Functional test with compressed air to check bursting
Pressure Relief pressure, indication flag operation and switch operation.
6. 2.
Valve Dielectric test at 2 kV for one minute.
3. Switch contact testing at 5A 240 V AC.
1. Insulation resistance measurement.
2. Dielectric test at 2 kV between winding and body for 1 minute.
7. Cooling Fan IS 2312
3. Operation check.
539
1. Insulation resistance measurement.

2. Cold resistance measurement at ambient temperature.
3. Motor efficiency at full load.
4. No load voltage, current, power input, frequency and speed.
IS 325 5. Locked-rotor readings of voltage, current and power input.
Transformer Oil 6. Water pressure test for pump casing at 5 kg/cm2 for
8. &
Pump
10 minutes at ambient temperature.
IS 9137
7. Transformer oil pressure test for the pump set assembly at 2 kg/cm2
for 30 minutes at 800 C.
8. Measurement of head, discharge, current, power input to motor and
overall efficiency of the pump set at rated voltage.
1. Observation of flow with respect to requirement.
Oil Flow Indicator/ 2. Switch contact test at 5A 240 V AC.
9. Water Flow
Indicator 3. Dielectric test at 2 kV for one minute.
1. Leak test with transformer oil at a pressure of 3 kg/cm2
for 30 minutes at ambient temperature for relay casing.
2. Insulation resistance measurement with 500 V megger.
3. Dielectric test at 2 kV for 1 minute.
4. Elements test at 1.75 kg/cm2 for 15 minutes using
10. Buchholz Relay IS 3637 transformer oil at ambient temperature.
5. Loss of oil and surge test.
6. Gas volume test.
7. Mechanical strength test.
8. Velocity calibration test.
9. Appearance construction and dimensional check.
1. Test for oil levels.
2. Switch operation for low level alarm.
11. Oil Level Indicator 3. Switch contact test at 5A 240 V AC.
4. Dielectric test at 2 kV for 1 minute.
Pressed Steel 1. Air pressure test at 2 kg/cm2 under water for 15 minutes.
12. IEEMA 9
Radiators 2. Appearance, construction and dimension check.
OLTC Control 2. Electrical operation.
13. Cubicle/Cooler 3. Insulation resistance measurement using 500 V megger at ambient
Control Cubicle temperature.
4. Dielectric test at 2 kV for 1 minute
2. Polarity check.
3. Measurement of insulation resistance.
4. High voltage power frequency test.
5. Determination of ratio error and phase angle of measuring
Bushing Current and protection BCTs.
14. IS 2705
Transformers 6. Determination of Tunis ratio error for PS class BCT.
7. Determination of composite error for protective class BCT.
8. Inter turn insulation withstand test.
9. Exciting current characteristic test.
10. Secondary winding resistance measurement.
11. Knee-Point Voltage, measurement for PS class BCT.
List of Transformer Accessories and Test Certificates Required 541
1. Construction and dimensional check.

2. Mechanical operation check.
3. Insulation resistance measurement using 2000 V megger.
Off Circuit
15. 4. Millivolt drop test of contacts.
Tap Changer
5. High voltage power frequency withstand test by applying appropriate
voltages to live parts to earth, between maxi¬mum and minimum
taps, between change over contact and intermediate bearing, between
adjacent taps, between tap changer contact and intermediate bearing
and between tap changer contact and current take off terminal.
1. Test certificates for the materials of construction.
2. Manufacturers in process inspection records for all parts, sub-
assemblies, accessories and complete assembly.
Oil to Water Heat
16. 3. Shell side pressure test at 10 kg/cm2 with transformer oil at a
Exchanger
temperature of 70°C + 10°C for 6 h.
4. Water side pressure test at 5 kg/cm2 with water at ambient temperature
for 6 h.
Pressure Gauges/
17. Differential 2. Calibration test.
Pressure Gauges
3. Alarm contact setting test.
Appendix VI
Design Review Parameters

Appendix VI
Design Review Parameters
Project:
Transformer Name and Rating:
1. DESIGN DETAILS
Sl. No. Aspect Design Parameter Value

Type of Magnetic Circuit (Nos. of Limbs etc.)
Core Dia (mm) / Weight (kg)/ Flux density (T)
Whether Split Core used
Core Joint Details (Mitred etc.)
Magnetic Whether core bolts are used
1 Circuit Core Grade
Thickness of core material / Building Factor
Core hot spot actual / permissible
No. of cooling ducts in core
No Load Loss (kW) Designed/ Guaranteed
Winding Type
Winding Arrangement
No of turns :
HV
IV
LV
RW
Winding Dimensions (in mm) (e.g. ID/OD/Height) :
HV
IV
LV
RW
Asymmetry in Windings
Winding Conductor details (e.g. PICC/netted CTC/paper
2 Winding CTC) :
HV
IV
LV
RW
Winding Conductor Dimension (in mm) :
HV
IV
LV
RW
Current density HV/IV/LV/RW (A / Sq. mm)
Shunt details (Wall & Yoke)
Load loss at Normal tap :
I2R Loss (kW)
Stray Loss (kW)
545
Total Load Loss (KW) Designed / Guaranteed

Load loss at Maximum tap :
I2R Loss (kW)
Stray Loss (kW)
Total Load Loss (KW)
Load loss at Minimum tap :
2 Winding I2R Loss (kW)
Stray Loss (kW)
Total Load Loss (KW)
% Impedance at 75 Deg C:
Normal Tap, Designed / Guaranteed
Maximum Tap, Designed / Guaranteed
Minimum Tap, Designed / Guaranteed
Stresses During Dynamic Short Circuit :
Radial (Actual/Permissible) N/mm2
HV
IV
LV
RW
Axial Bending (Actual/Permissible) N/mm2
HV
IV
3 LV
SC Withstand
Capability RW
Unbalance axial forces acting on clamping structure (kN)
Compressive forces in Winding (Actual/Permissible) kN
HV
IV
LV
RW
Spiraling (Tangential) Force in LV winding (Actual/
Permissible) kN
SC Current density HV/IV/LV/RW (A / Sq. mm)
Ring Detail (Top & Bottom)
Dielectric Stresses:
Lightning Impulse Distribution
Transferred Surge On LV (LI)
Radial Duct Arrangement
Oil stress in HV (kV/mm)
Oil stress in IV (kV/mm)
Dielectric
4 Oil stress in LV (kV/mm)
Design
Oil stress in RW (kV/mm)
Creep stress HV (kV/mm)
Creep stress IV kV/mm
Creep stress LV kV/mm
Creep stress RW kV/mm
Paper stress in HV (kV/mm)
Design Review Parameters 547
Cooling Type
Maximum Oil Velocity
Directed Oil flow washer details
Temperature rise (above Ambient of 50 Deg C):
Top Oil (Designed / Guaranteed)
HV Winding (Designed / Guaranteed)
Cooling
5 IV Winding (Designed / Guaranteed)
Design
LV Winding (Designed / Guaranteed)
Cooler Details:
Nos. of Coolers
Fans & Pumps per cooler
Cooler Loss Designed / Guaranteed
Cooler Inlet & Outlet Temp Difference Deg C
Tap Changer Type, Range (& Steps)
Tap Changer Type (Reversing / Coarse Fine / Linear)
Tap Changer Rated Current
Voltage Of Tap Changer To Earth
6 Tap Changer Voltage Across Taps
Step Voltage
Maximum Switching Capacity
Recovery Voltage Detail (if OLTC)
Whether Tie In Resistor Required (if OLTC)
2. ENCLOSURES
Sr. Enclosure
No.
1 Core hot spot calculation.
2 Calculation of inrush current & air core reactance
3 Dynamic ability to withstand short circuit (including forces details in tabular format as per IEC 60076-5.)
4 Thermal ability to withstand short circuit.
5 Cooling calculations design details.
6 Calculation to show that during total failure of power supply to cooling fans and pumps, the transformer shall
be able to operate at full load for at least ten minutes without the calculated winding hot spot temperature
exceeding 140 Deg c.
7 Impulse voltage distribution graph/details.
8 Transfer surge calculation graph/details.
9 Sectional view of Winding Assembly showing Top and Bottom Rings
10 Winding arrangement sketch.
11 Calculation of Ohmic resistance at different taps. (applicable for ICT)
12 Recovery voltage calculation (for OLTC).
Appendix vii
Salient Technical Specifications and

Particulars of Power Transformers
for Power Plant Application
Annexure VII
SALIENT TECHNICAL SPECIFICATIONS AND PARTICULARS OF POWER

TRANSFORMERS FOR POWER PLANT APPLICATION
Sl. No. Technical Specifications/ Generator Transformer in Coal Generator Transformer in Station Transformer Station Transformer Unit Transformer Unit Transformer in LV Transformer (Dry
Particulars based power plants Gas based CCPP in Coal based power in Gas based CCPP in Coal based Gas based CCPP Type/ Oil immersed) in
plants power plants Coal/ Gas based power
plants
A. GENERAL
1. Application Generator Transformer Generator Transformer Station Transformer Station Transformer Unit Transformer Unit Transformer Unit Aux/Station Aux
Transformer
2. Quantity 1 X 100% 1 X 100% 2 X 100% or 1 X 1 X 100% 1 X 100% or 2 X 1 X 100% 2 X 100% per system
100% 50% or 2 X 100% (normally)
3. Applicable Standards IS 2026 / IEC 60076 IS 2026 / IEC 60076 IS 2026 / IEC 60076 IS 2026 / IEC 60076 IS 2026 / IEC 60076 IS 2026 / IEC 60076 IS 11171, IS 2026 or
IEC60076
4. Service & Duty Outdoor & Continuous Outdoor & Continuous Outdoor & Outdoor & Continuous Outdoor & Outdoor & Continuous Outdoor/ Indoor &
551
Continuous Continuous Continuous
5. Number of phases 3-phase or 3 nos. 1 phase 3-phase 3-phase 3-phase 3-phase 3-phase 3-phase
6. Number of windings (per Two winding Two winding Two/ Three winding Two/ Three winding Two winding /Three Two winding Two winding
phase to be mentioned for winding
single phase)
7. Frequency (Hz) 50 Hz (Frequency variation to be 50 Hz (Frequency variation 50 Hz (Frequency 50 Hz (Frequency 50 Hz (Frequency 50 Hz (Frequency 50 Hz(Frequency
considered as per Grid frequency to be considered as per Grid variation to be variation to be variation to be variation to be considered variation to be considered
variation) frequency variation) considered as per considered as per Grid considered as per as per Grid frequency as per Grid frequency
Grid frequency frequency variation) Grid frequency variation) variation)
variation) variation)
8. Winding connection
(a ) HV Side Star Star Star Star Delta Delta Delta
(b ) LV Side Delta Delta Star Star Star Star Star
9. Vector Group YNd11 or YNd1 YNd11 or YNd1 YNyn0 or YNyn0 or Dyn11 (if Gen. Dyn11 (if Gen. Trafo. Dyn11 or Dyn1
Salient Technical Specifications and Particulars of Power Transformers for Power Plant Application
YNyn0yn0(3-wdg) YNyn0yn0(3-wdg) Trafo. -YNd1) or -YNd1) or Dyn1 (if Gen.

Dyn1 (if Gen. Trafo Trafo - YNd11)
- YNd11)
Sl. No. Technical Specifications/ Generator Transformer in Coal Generator Transformer in Station Transformer Station Transformer Unit Transformer Unit Transformer in LV Transformer (Dry 552
plants
B. RATINGS
10. Type of cooling ONAN/ONAF cooling ONAN/ONAF cooling ONAN/ONAF ONAN/ONAF cooling ONAN/ONAF ONAN/ONAF cooling AN or AN/AF or ONAN
(80%/100%) OR ONAN/ONAF/ (80%/100%) OR ONAN/ cooling (80%/100%) (80%/100%) cooling (80%/100%) (80%/100%)
OFAF cooling (60%/80%/100%) ONAF/OFAF cooling (60%/ OR ONAN/ONAF/ OR ONAN/ONAF/
OR ONAN/ONAF/ODAF 80%/ 100%) OR ONAN/ OFAF cooling (60%/ OFAF cooling
cooling (60%/80%/100%) OR ONAF/ODAF cooling 80%/ 100% or 50%/ (60%/ 80%/ 100%)
ODAF cooling, in case of unit (60%/80%/100%) 75%/ 100%)
coolers (100%)
11. Transformer Rating Generator transformer shall be Generator transformer For power plant Station Transformer Unit Transformer Unit Transformer (UT) In line with IS 2026-I,
(MVA) sized to deliver the continuous shall be sized to deliver having two or more (ST) will be sized (UT) will be sized to will be sized to deliver MVA rating shall be
gross output of the Generator at the continuous output number of units to deliver following deliver unit loads. In unit loads + Balance sufficient to cater to
Steam Turbine TMCR and /or power of the Gas Turbine and two Station power output (under case of plant having of Plant (BoP) loads. the maximum running
VWO conditions, minus total of at ISO condition. (i.e. at Transformers (ST), most stringent Generator Circuit (If there is no Station load on the respective
excitation power (if applicable) 15° C) MVA rating of this each ST will be sized condition) (i) tart-up Breaker (GCB), Transformer and GCB Switchgear/Load Centre.
and one (1) 50% capacity Unit transformer shall be sized to deliver following loads of one Unit (ii) Unit Transformer is provided) 5% design 5% design margin
Transformer loading. Generator based on the gas turbine power output with shutdown loads of shall be sized to take margin (minimum) may (minimum) may be taken
Transformer shall be sized to generator maximum output other ST out of other Units (iii) 00% care the loads of be taken on above on above
evacuate MVA arrived as above minus total of generator service. (under most station common loads units as well as the
at a generator terminal voltage excitation power and unit stringent condition) (iv) % design margin common auxiliaries/
of 0.95 PU. auxiliary loads, depending (i) tart-up loads of (minimum) may be systems. 5% design
Manual on Transformers
on the plant configurations. Unit-1 (ii) hut-down taken on above [For margin (minimum)
Generator Transformer loads of Unit- 2, on large size coal based may be taken on
shall be sized to evacuate bypass operation (iii) power plant (say > above
MVA arrived as above at a 00% station common 500 MW), considering
generator terminal voltage of loads (iv) % design the availability
0.95 PU. margin (minimum) of secondary side
may be taken on equipment of ST,
above [For large size simultaneous starting
coal based power of Unit-1 & shut-down
plant (say > 500 of Unit-2 under
MW), considering one ST out, may be
the availability decided as per project
of secondary side requirements]
equipment of
ST, simultaneous
starting of
plants
Unit-1 & shut-down
of Unit-2 under
one ST out, may be
decided as per project
requirements]
12. Rated Voltage – HV (kV) 245 kV for 3-phase bank & 245 kV for 3-phase bank 220 kV for 220 kV 220 kV for 220 kV grid As per Generator As per Generator terminal As per Plant distribution
245/√3 for single phase bank For for 220 kV grid system. 420 grid system. 400 system. 400 kV for 400 terminal voltage voltage System
220 kV Grid System. 420 kV for kV for 3-phase bank for 400 kV for 400 kV grid kV grid system. 765 kV
3-phase bank & 420/√3 for single kV grid system. 765 kV for system. 765 kV for for 3-phase bank for
phase bank For 400 kV Grid 3-phase bank for 765 kV grid 3-phase bank for 765 765 kV grid system
System. 765 kV for 3-phase bank system. kV grid system
&765/√3 for single phase bank
For 765 kV Grid System.
13. Rated Voltage-LV (kV) As per Generator terminal As per Generator terminal As per Plant As per Plant As per Plant As per Plant distribution As per Plant distribution
voltage voltage distribution System distribution System distribution System System System
14. Rated Current-HV As per MVA rating & voltage As per MVA rating & voltage As per MVA rating & As per MVA rating & As per MVA rating As per MVA rating & As per kVA rating &
windings (A) rating rating voltage rating voltage rating & voltage rating voltage rating voltage rating
15. Rated Current- LV As per MVA rating & voltage As per MVA rating & voltage As per MVA rating & As per MVA rating & As per MVA rating As per MVA rating & As per kVA rating &
windings (A) rating rating voltage rating voltage rating & voltage rating voltage rating voltage rating
16. Over voltage Withstand
Time Sec
110% of rated voltage Continuous Continuous Continuous Continuous Continuous Continuous Continuous
125% of rated voltage 60 sec 60 sec 60 sec 60 sec 60 sec 60 sec NA
140% of rated voltage 5 sec 5 sec 5 sec 5 sec 5 sec 5 sec NA
17. Over-fluxing
Capability
(a) For over fluxing Continuous Continuous Continuous Continuous Continuous Continuous Continuous
factor 1.10
(b) For over fluxing 60 Sec 60 Sec 60 Sec 60 Sec 60 Sec 60 Sec 60 Sec (for Oil filled)
factor 1.25
(c) For over fluxing 5 sec 5 sec 5 sec 5 sec 5 sec 5 sec Not required
factor 1.40
553
plants
18. Over loading capacity As per IS - 6600 As per IS - 6600 As per IS - 6600 As per IS - 6600 As per IS - 6600 As per IS - 6600 As per IS – 6600, 2026&
11171
19. Maximum current density
of windings
HV 3- 3.50 A/ Sq. mm 3- 3.50 A/ Sq. mm 3- 3.50 A/ Sq. mm 3- 3.50 A/ Sq. mm 3- 3.50 A/ Sq. mm 3- 3.50 A/ Sq. mm 3- 3.50 A/ Sq. mm
LV 3- 3.50 A/ Sq. mm 3- 3.50 A/ Sq. mm 3- 3.50 A/ Sq. mm 3- 3.50 A/ Sq. mm 3- 3.50 A/ Sq. mm 3- 3.50 A/ Sq. mm 3- 3.50 A/ Sq. mm
C TEMPERATURE RISE
20. Design Ambient 50°C (say)/ lower ambient 50°C (say) / lower ambient 50°C (say) / lower 50°C (say) / lower 50°C (say) / lower 50°C (say) / lower 50°C (say) / lower
Temperature temperature as per plant temperature as per plant ambient temperature ambient temperature ambient temperature ambient temperature as ambient temperature as
requirement requirement as per plant as per plant requirement as per plant per plant requirement per plant requirement
requirement requirement
21. Temperature rise over 50°C 50°C 50°C 50°C 50°C 50°C 50°C (for Oil filled)
maximum ambient of Top
oil by thermometer
22. Temperature rise over 55°C (for OFAF) 60°C (for 55°C (for OFAF) 60°C (for 55°C 55°C 55°C 55°C 55°C(for Oil filled) 90°C
maximum ambient of ODAF) ODAF) (for Dry type. Class-F)
winding by resistance
D TAPPINGS
23. Type Off circuit tap changer/ On load Off circuit tap changer/ On On load tap changer On load tap changer On load tap changer On load tap changer Off circuit tap changer
tap changer(preferably for 3-ph load tap changer
bank transformer)
24. Range - Steps x % Indicative range: +/-5% in steps Indicative range: +/-10% in Indicative range: ± 10% in steps of Indicative range: ± 10% or ±12.5% in steps ± 5% in steps of 2.5%
Variation of 2.5% for OCTC and +10% steps of 2.5% for OCTC and ± 10% in steps of 1.25% ± 10% in steps of of 1.25%
to -15% for OLTC in steps of +7.5% to -15% for OLTC 1.25% 1.25%
1.25%, however exact range to in steps of 1.25%, however
be decided to meet the system exact range to be decided to
requirement of evacuating the meet the system requirement
total generated power within of evacuating the total
the operating range of generator generated power within the
power factor. operating range of generator
power factor.
25. Taps provided on HV/LV HV Neutral end HV Neutral end HV Side HV Side HV Side HV Side HV Side
Winding
plants
26. Category of voltage Constant Flux Voltage Variation CFVV CFVV CFVV CFVV CFVV CFVV
variation (CFVV)
E IMPEDANCES
a) Base MVA Rating a) MVA rating at OFAF or ONAF a) MVA rating at OFAF or a) MVA rating at a) MVA rating at ONAF a) MVA rating at a) MVA rating at ONAF a) MVA rating at AN/
b) Impedance at Principal or ONAN or ODAF ONAF or ONAN or ODAF OFAF or ONAF or or ONAN ONAF or ONAN or ONAN ONAN
Tap at Rated Frequency b) 12% to 16% (to be decided b) 12% to 16% (to be ONAN b) 12-20 % b) 10-14 % For b) 10-14 % b) 4-10%
and 75°C winding considering the requirement decided considering the b) 12-20 % For three winding
temperature to evacuate the total generated requirement to evacuate three winding transformers,
power within the operating range the total generated power transformers, impedance value to
of generator power factor and within the operating range of impedance value to be decided based
also to limit the short circuit generator power factor and be decided based on the system
contribution to grid) also to limit the short circuit on the system requirement
contribution to grid) requirement
F SYSTEM EARTHING
27. HV side Solidly earthed Solidly earthed Solidly earthed Solidly earthed Non effectively Non effectively earthed Non-effectively earthed
earthed
28. LV side Non Effectively Earthed Non Effectively Earthed Non Effectively Non Effectively Non effectively Non effectively earthed Effectively earthed
Earthed Earthed earthed
G SYSTEM FAULT LEVEL
29. HV side 40/50/63 kA for 1/3 sec (To 40/50/63 kA for 1/3 sec (To 40/50 kA for 1/3 sec 40/50 kA for 1/3 sec Magnitude of fault Magnitude of fault 50/44/40 KA (r.m.s.)
be defined as per grid system be defined as per grid system (To be defined as (To be defined as per current& Withstand current &Withstand time for 1 Sec
fault level) fault level) per grid system fault grid system fault level) time depends depends upon system
level) upon system configurations
configurations
30. LV side As per short circuit calculation As per short circuit As per short circuit As per short circuit As per short circuit As per short circuit 50/65 KA (r.m.s.) for
at LV side calculation at LV side calculation at LV side calculation at LV side calculation at calculation at LV side 1 Sec
LV side
H SHORT CIRCUIT WITHSTAND TIME WITHOUT INJURY DUE TO TERMINAL FAULT WITH RATED VOLTAGE MAINTAINED ON THE OTHER SIDE
31. With 3 phase dead short 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec
circuit
32. With single phase short 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec
circuit
555
plants
I CONSTRUCTION
33. Transformer tank cover Bell type Bell type Bell type/ Bell type/ Conventional Bell type/ Bell type/ Conventional Conventional
type Conventional Conventional
34. Cooler type & capacity 120% capacity radiator banks 120% capacity radiator banks 2 X 60 % Banks 2 X 60 % Banks 2 X 60 % Banks 2 X 60 % Banks 2 X 50 % Banks for oil
(minimum two (2) banks) with (minimum two (2) banks) immersed
arrangement of isolating 20% with arrangement of isolating
capacity of banks at a time so 20% capacity of banks at
that in case of leakage in one a time so that in case of
section, only that section will be leakage in one section, only
isolated not the whole bank. OR that section will be isolated
120% capacity Unit Coolers (min not the whole bank.
six (6) nos. coolers so that in
case of failure of one cooler also,
100% capacity is available)
Stand-by Fan & Pumps One number stand-by fan per One number stand-by fan One number stand-by One number stand-by One number stand- One number stand-by Not applicable
bank and one number stand-by per bank and one number fan per bank and one fan per bank by fan per bank and fan/ Bank
pump per bank for radiator banks stand-by pump per bank for number stand-by one number stand-
radiator banks pump per bank for by pump per bank
radiator banks for radiator banks
Noise level Max 85 dB Max 85 dB Max 85 dB Max 85 dB Max 85 dB Max 85 dB Max 85 dB
Finishing paint type Epoxy paint Epoxy paint Epoxy paint Epoxy paint Epoxy paint Epoxy paint Epoxy paint
Paint shade As per projects requirement As per projects requirement As per projects As per projects As per projects As per projects As per projects
requirement requirement requirement requirement requirement
J INSULATION
35. Type of Winding HV- Non uniformly graded LV- HV- Non uniformly graded HV- Non uniformly HV- Non-uniformly HV- uniformly HV- uniformly graded HV- uniform LV- uniform
Insulation uniformly graded LV- uniformly graded graded LV- uniformly graded LV- uniformly graded LV LV- uniformly graded
graded graded uniformly graded
36. Class of winding Class-A Class-A Class-A Class-A Class-A Class-A Class-A (Oil filled) Class-
insulation F(Dry Type)
37. SI (Switching impulse)/ As per IS 2026& IS: 2099 As per IS 2026& IS: 2099 As per IS 2026& IS: As per IS 2026& IS: As per IS 2026& IS: As per IS 2026& IS: As per IS 2026& IS:
LI (Lightning impulse) / (Insulation level of HV winding (Insulation level of HV 2099 (Insulation level 2099 (Insulation level 2099 / IEC 60076 2099 / IEC 60076 2099 / IEC 60076
AC (Power Frequency & bushing to be verified with winding & bushing to be of HV winding & of HV winding &
AC withstand voltage) insulation co-ordination study) / verified with insulation co- bushing to be verified bushing to be verified
a) HV Bushing b) HV IEC 60076 ordination study) / IEC 60076 with insulation with insulation co-
Winding co-ordination study) / ordination study / IEC
IEC 60076 60076
plants
38. LI (Lightning impulse) / As per IS 2026& IS:2099 / IEC As per IS 2026& IS:2099 / As per IS 2026& As per IS 2026& As per IS 2026& As per IS 2026& IS:2099 As per IS 2026& IS:2099
AC (Power frequency 60076 IEC 60076 IS:2099 /IEC 60076 IS:2099 /IEC 60076 IS:2099 /IEC 60076 /IEC 60076 /IEC 60076
withstand voltage) -HV
Neutral
39. LI (Lightning impulse) / As per IS 2026& IS:2099 / IEC As per IS 2026& IS:2099 / As per IS 2026& As per IS 2026& As per IS 2026& As per IS 2026& IS:2099 As per IS 2026& IS:2099
AC (Power frequency 60076 IEC 60076 IS:2099 / IEC 60076 IS:2099 / IEC 60076 IS:2099 / IEC 60076 / IEC 60076 / IEC 60076
withstand voltage) -LV
K BUSHINGS
40. Reference standard IS : 2099 / IEC 60137 IS : 2099 / IEC 60137 IS : 2099 / IEC IS : 2099 / IEC 60137 IS : 2099 / IEC IS : 2099 / IEC 60137 IS : 2099 / IEC 60137
60137 60137
41. HV Bushing (a). OIP condenser with test tap a. OIP condenser with test tap a. OIP condenser a. OIP condenser with a. Porcelain bushing a. Porcelain bushing a. Porcelain bushing/
(a). Type (b). As per IS 2026-III for rated b. As per IS 2026-III for with test tap test tap/ Porcelain b. As per IS 2026-III b. As per IS 2026-III for Cast Resin
(b). Voltage Class HV system voltage rated HV system voltage b. As per IS 2026-III bushing for rated HV system rated HV system voltage b. As per IS 2026
(c). Creepage distance (c). 31 mm/kV c. 31 mm/kV for rated HV system b. As per IS 2026-III voltage c. 20 mm/kV (for IPBD c. 25 mm / kV d. Cable
(d). Terminations (d). Suitable for terminating d. Suitable for terminating voltage for rated HV system c. 20 mm/kV (for terminations)
ACSR/AAC/AAAC overhead ACSR/AAC/AAAC c. 31 mm/kV voltage IPBD terminations) d. Bus duct terminations
conductors or IPS tubes (in overhead conductors or d. Suitable for c. 31 mm/kV d. Bus duct
case outdoor cable sealing IPS tubes terminating ACSR/ d. Suitable for terminations
arrangement is provided) AAC/AAAC terminating ACSR/
overhead conductors AAC/AAAC overhead
or IPS tubes (in case conductors or IPS tubes
outdoor cable sealing
arrangement is
provided)
42. LV Bushing (a). Oil communicating a. Oil communicating a. Porcelain bushing a. Porcelain bushing a. Porcelain bushing a. Porcelain bushing a. Porcelain bushing/
(a). Type condenser condenser b. As per IS 2026-III b. As per IS 2026-III b. As per IS 2026-III b. As per IS 2026-III for Epoxy Cast
(b). Voltage Class (b). As per IS 2026-III for rated b. As per IS 2026-III for rated for rated LV voltage for rated LV voltage for rated LV system rated LV system voltage b. As per IS 2026
(c). Creepage distance LV voltage LV voltage c. 25- 31 mm/kV c. 25- 31 mm/kV voltage c. 25- 31 mm/kV c. 25 mm / kV
(d). Terminations (c). 20 mm/kV (for IPBD c. 20 mm/kV (for IPBD d. SPBD d. SPBD c. 25- 31 mm/kV d. SPBD/ Cables d. Non Segregated Phase
terminations) terminations) d. SPBD Bus Duct (NSPBD)
(d). Bus duct terminations d. Bus duct terminations

557
plants
43. HVN/LVN Bushing HVN Bushing HVN Bushing HVN & LVN HVN & LVN Bushing HVN & LVN LVN Bushing LVN Bushing
a. Type a. Porcelain bushing a. Porcelain bushing Bushing a. Porcelain bushing Bushing a. Porcelain bushing a. Porcelain bushing/
b. Voltage Class b. As per IS 2026-III b. As per IS 2026-III a. Porcelain bushing b. As per IS 2026-III a. Porcelain bushing b. As per IS 2026-III epoxy cast
c. Creepage distance c. 25- 31 mm/kV c. 25- 31 mm/kV b. As per IS 2026-III c. 25- 31 mm/kV b. As per IS 2026-III c. 25- 31 mm/kV b. As per IS 2026-III
d. Terminations d. Flats d. Flats c. 25- 31 mm/kV d. Cable c. 25- 31 mm/kV d. Cable c. 25- 31 mm/kV
d. Cable d. Cable d. Cable
44. Minimum clearances

in air
a) HV Side As per IS 2026-5 / IEC 60076 As per IS 2026-5 / IEC 60076 As per IS 2026-5 / As per IS 2026-5 / IEC As per IS 2026-5 / As per IS 2026-5 / IEC As per IS 2026-5 / IEC
IEC 60076 60076 IEC 60076 60076 60076
b) LV Side As per IS 2026-5 / IEC 60076 As per IS 2026-5 / IEC 60076 As per IS 2026-5 / As per IS 2026-5 / IEC As per IS 2026-5 / As per IS 2026-5 / IEC As per IS 2026-5 / IEC
IEC 60076 60076 IEC 60076 60076 60076
L TRANSFORMER OIL
45. Type Mineral Oil (Uninhibited) Mineral Oil (Uninhibited) Mineral Oil Mineral Oil Mineral Oil Mineral Oil (Uninhibited) Mineral Oil (Uninhibited)
(Uninhibited) (Uninhibited) (Uninhibited)
46. Applicable standard IS 335/ IEC 60296 IS 335/ IEC 60296 IS 335/ IEC 60296 IS 335/ IEC 60296 IS 335/ IEC 60296 IS 335/ IEC 60296 IS 335/ IEC 60296
Appendix VIII
Test Windings for Bushing Current Transformers

Appendix VIII
Test Windings for Bushing Current Transformers
When bushing current transformers are provided in power transformers, a test winding (a one
turn winding over and above secondary winding) shall be provided to test the CT characteristics
without passing current through the primary (i.e., transformer bushing) which will be difficult .
This one turn test winding shall be suitable to carry 10A (minimum). In certain cases, it may be
more convenient to provide test tappings, one being at one end of the secondary winding and the
other at the center of the secondary winding. The test terminals should be physically separated
from output terminals of the secondary winding and preferably of slightly larger size.
When test winding is energized, the primary winding should be open circuited. Conversely,
when the primary winding is employed (i.e., when power transformer is energized), the test
winding should be kept open circuited. One of the test terminals shall be kept grounded in
service and shall be shown in rating & diagram plate.
Test winding is not recommended for current transformers for metering and for winding
temperature indication. Test winding terminals shall be marked as below:
Fig. 1 Current Transformer with two secondary Fig. 2 Current Transformer with two secondary
windings having Separate magnetic and Common Test Winding
coreswindings having Separate magnetic
cores and Test Winding
Fig. 3 Transformer with an intermediate tapping on

secondary winding with test taps
REFERENCE
(1) BS 3938: 1973 Current Transformers, Appendix H Current Transformer test windings.
561
Appendix IX
Pictures of Transformer Installations

Appendix IX
Pictures of Transformer Installations
PLATE 1: 1-PHASE GENERATOR TRANSFORMER- TOP VIEW
PLATE 2:1 PHASE GENERATOR TRANSFORMER-SIDE VIEW
565
PLATE 3: 3-PHASE GENERATOR TRANSFORMER-TOP VIEW
PLATE 4: 3-PHASE GENERATOR TRANSFORMER-FRONT VIEW

Test Windings For Bushing Current Transformers 567
PLATE 5: 3-PHASE GENERATOR TRASNFORMER- SIDE VIEW
PLATE 6:3D MODEL VIEW OF A BANK OF 3 1- PHASE GENERATOR

TRANSFORMERS WITH IPBD CONNECTIONS
PLATE 7: 3D MODEL VIEW OF 3 PHASE GENERATOR

TRANSFORMER WITH IPBD CONNECTIONS
PLATE 8:GENERATOR TRANSFORMER AT SITE

PLATE 9: GENERATOR TRANSFORMER INSTALLED AT SITE WITH LIGHTNING ARRESTERS
PLATE 10: STATION TRANSFORMER INSTALLED AT SITE

PLATE 11: DISTRIBUTION TRANSFORMER INSTALLED AT SITE
PLATE 12: SERIES UNIT OF PHASE SHIFTING TRANSFORMER

PLATE 13: SHUNT UNIT OF PHASE SHIFTING TRANSFORMER
PLATE 14: CONTROLLED SHUNT REACTOR INSTALLED AT SITE

PLATE 15: RECTIFIER TRANSFORMER ALONG WITH RECTIFIER CUBICLE INSTALLED AT SITE
PLATE 16: ARC FURNACE TRANSFORMER INSTALLED AT SITE

PLATE 17: SILICAGEL BREATHERS ASSEMBLY
PLATE 18: HV BUSHING WITH TERMINAL CONNECTION

PLATE 19: UNIT TRANSFORMER TAP-OFF OF IBPD & FIRE WALL
PLATE 20: RAIL GAUGE AND FLANGED TWIN ROLLER ASSEMBLY

PLATE 21: RADIATOR BANK ASSEMBLY WITH COOLING FANS
PLATE 22: TRANSFORMER OIL PUMPS AND OIL FLOW INDICATION

PLATE 23: TRANSFORMER OIL FLOW INDICATOR
PLATE 24: CONSERVATOR AND OLTC DRIVING SHAFT

PLATE 25: MARSHALLING BOX

CORE GROUP
Chairman LAN: 0532 -2699990-Extn 1408,
Shri M. Vijayakumaran Mob+91 9956390015
Sr. Technical Expert vijayakumaran.moorkath@alstom.com
ALSTOM T&D India Ltd
Naini, Allahabad 211008
Members T:+91 265 263 7291
Shri P. Ramachandran +91 265 260 4502
Sr. Advisor - Design & Development M: +91 97 243 32977
Power Transformers Division p.ramachandran@in.abb.com
ABB Ltd., Maneja, Vadodara – 390013
Shri V.K. Lakhiani Cell : +91-9687659750
Technical Director Landline : +91-2717-661565
Transformers and Rectifiers (India) Limited virendra.lakhiani@transformerindia.com;
Survey No. 427 P/3-4, & 431 P/1-2
Sarkhej-Bavla Highway, Moraiya,
Taluka: Sanand, Dist. Ahmedabad–382213
Shri Dinkar Devate M: 09650992237
General Manager dinkar@ntpceoc.co.in
NTPC Ltd.
A-8A, Sector 24, Noida - 201301
Shri M.M. Goswami Phone 0124 2571814
General Manager M : 9910378078
Power Grid Corporation of India Ltd. mgoswami@powergridindia.com
Saudamini, Plot No. 2, Sector 29
Gurgaon – 122001
Shri V.K. Kanjlia Phone 91-11-26115984
Secretary M : 9810137864
Central Board of Irrigation & Power Fax 91-11-26116347
Malcha Marg, Chanakyapuri Email kanjlia@cbip.org
New Delhi 110021
Shri P.P. Wahi Phone 91-11-24101592
Director M : 9810801555
Central Board of Irrigation & Power Email wahi@cbip.org
Malcha Marg, Chanakyapuri
New Delhi 110021
Shri S.K. Batra Phone 91-11-26876229 ext. 133
Sr. Manager (Technical) M: 9811943812
Central Board of Irrigation & Power Fax 26116347
Malcha Marg, Chanakyapuri Email batra@cbip.org;
New Delhi 110021 cbip@cbip.org

Manual On Transformers

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Manual On Transformers

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Publication No.

Central Board of Irrigation & Power

Shri P. Ramachandran Shri M.M. Goswami

Shri Dinkar Devate Shri Sanjay Kar Chowdhury

Shri Mata Prasad Shri V.K. Lakhiani

Shri Ratish Kumar Shri R.K. Tiwari

Shri S.K. Ray Mohapatra Shri Y.V. Joshi

Shri B.V. Raghavaiah Shri Ranjan Banerjee

Shri M.L. Jain Shri V.M. Varkey

Shri Amit Mittal Shri Anilkumar Bhatia

Shri R.K. Tyagi Shri Aseem Dhamija

Shri Sudhir Agarwal Shri S.K. Gupta

Shri T.K. Ganguly Shri N.K. Dahiwale

Shri Oommen P. Joshua Shri R.K. Mohapatra

Dr. K. Rajamani Shri Pradeep Singh

Shri B.M. Mehra Shri Manish Kumar

Shri Vibhu Tripathi Shri A.K. Panwar

Shri Gunjan Agrawal Shri Minal Kataria

Shri K. Jayakrishnan Shri Govind Srivastava

Miss Tanvi Srivastava Ms. Mary Mody

Shri Pramod Srivastava Ms. Anagha Dixit

Shri Abhilash Mishra Shri Meet Patel

Shri Pravin Jain Shri T. Murlikrishna

Shri Abhay Agrawal Shri Manish Yadav

Shri Maneesh Jain Ms. Shubhangi Kulkarni

Shri Surojit Roy Shri Prasenjit Paul

Shri Subrata Dutta Shri Sameer Gaikwad

Shri R.V. Talegaonkar Shri Rakesh Sardana

Shri S.A. Rajan Shri R. Prakash

Shri B.D. Raut Shri D.M. Jadhav

Shri Manish Kataria Shri S.K. Batra

Although the transformer is a matured product of Electrical Engineering with

The manual is reformatted and divided in to two Volumes: Vol. I to cover

In this revision, existing sections have been updated as recommended by the

Technology evolves dynamically. Full-fledged revision is a voluminous task. It

Core group shall welcome suggestions / improvements / amendment proposals

Vol I: Standard Specifications of Transformers

SECTION E Specifications for Power Transformers of

Vol II: Application, Standard Fittings and Accessories

1.1 Compliance with Specifications

1.2 Design and Standardization

1.2.4 Corresponding parts liable to be replaced shall be interchangeable.

1.3.1 Galvanising where specified shall be applied by the hot-dipped process or by

1.4.3 All plates shall be of material which is corrosion resistant.

1.8 Prevention of Acidity

2.0 ELECTRICAL CHARACTERISTICS AND PERFORMANCE

2.1 Type of Transformers and Operating Conditions

2.2 Continuous Maximum Rating and Overloads

2.3 Voltage Ratio

2.4 Electrical Connections

2.5 Duty under Fault Conditions

2.5.4 Transformers directly connected to generator (generator step-up transformers) shall be

2.6 Stabilising Windings

3.2 Mechanical Construction of Cores

4.2 Bracing of Windings

5.0 INTERNAL EARTHING ARRANGEMENTS

5.2 Earthing of Core Clamping Structure

(a) By connection through vertical tie-rods to the top structure

5.3 Earthing of Magnetic Circuit

5.4 Earthing of Coil Clamping Rings

5.5 Size of Earthing Connections

6.1 Tank Construction

Inspection covers shall always be bolted type.