POWER TRANSFORER

PARTS OF POWER TRANSFORMER

1. Tank.

2 Core

3. Winding

4. Oil

5. Busing insulator

6. Buchholz Relay

7. Cooling Tube

8. Radiator

9. OLTC

9. Conservator

10. Breather

11. Explosion Vent

12. Cable Box

13. Oil Level Indicator

14. Sudden Pressure relay

15. Temperature Gauge

16. Wheel

17. Drain Valve

18. Name Plate

19. Earth Point

20. Lifting Hook.

 TANK

1. PLAIN SHEET STEEL TANK

These types tanks are generally used with small transformers of rating
less than 50 KVA for normal voltages.

2. TUBED TANK

∆ This type of tank is used for all sizes of distribution

transformer.

∆ Oil circulates naturally through the external tubes which are welded
on the inside of the tank walls.

3. CORRUGATED TANK

∆ This types so tanks have corrugations or fins welded between the

cover flange and the tank base. This type of construction provides
insufficient cooling surface on larger unit and hence, are limited to
distribution transformer only.

4. RADIATOR TANK

∆ This types of tanks have radiators mounted directly on to

transformer tank.

∆ The radiator consists of elliptical tubes or oil channels welded to

header pipes and flanges which are bolted directly on to tank.

∆ These are used with transformers of rating higher than 200 KVA.

5. TANK WITH SEPARATE COOLER

∆ With increase in transformer ratings, it become necessary to mount

the coolers separately from the tank as the tank is not large enough
 to permit the required number of radiators to be mounted on tank
side.

∆ The separate coolers consists of a larger number of detachable

radiators mounted vertically to horizontal headers.

CLASSIFICATION OF TRANSFORMER

AS PER RATING
∆ Power Transformer
∆ Distribution Transformer

AS PER TRNSFORMER RATION

∆ Step Up
∆ Step Down
∆ Isolation

AS PER CORE CONSTRUCTION

∆ Core Type
∆ Shell Type
∆ Berry Type
∆ Wound Core Type

AS PER WINDING
∆ Cylindrical winding
∆ Continuous disc
∆ Sand witch
∆ Helical

AS PER APPLICATION
∆ Sub Station Transformer
∆ Pole Mounted Transformer
∆ Control Transformer
∆ Centre Tap Transformer
∆ Variac (Dimerstat)
∆ Constant voltage Transformer
AS PER COOLING
∆ Air Cooled
∆ Oil Cooled
∆ Water Cooled
∆ Gas Cooled

TRANSFORMER CORE (Properties)

1. Material :- Silicon Steel (3-5%)

2. Lamination Thickness 0.33 – 0.5 mm

3. It should be highly permeable to reduce magnetizing current

4. Flux density of hot rolled steel is 1.45 wb/sq.m

5. Flux density of cold rolled steel is 1.6 wb/sq. m

6. Cold rolled steel is 25 to 30% costlier.

7. Now a days cold rolled grain oriented steel is used in many transformer.

8. Losses in CRGO or CROSS Steel is minimum.

COMPARISION BETWEEN CORE TYPE AND SHELL TYPE CORE

1. Simpler Design 1. Complicated Design

2. Poor mechanical strength 2. Greater capability to withstand

against short circuit fault the force which is produced due
to short circuit

3. Leakage more 3. Low Leakage

4. Better cooling for winding 4. Better cooling for core

5. All large transformer are core 5. Small transformers are shell type
type

6. It has only one magnetic circuit 6. It has two magnetic circuit.

 Winding and Insulation

Winding form the electrical circuit of a transformer. For core-type

transformers, the windings are cylindrical and are arranged
concentrically. Circular coils offer the greatest resistance to the radial
component of electromagnetic forces, since this is the shape which
any coil will tend to assume under short-circuit stresses.

1. Types of windings.

The choice of the type of winding is largely determined by the rating of

the winding. Some of the common types of windings as described
below.
1.1 Distributed Cross-over Windings.

These windings are suitable for current not exceeding about 20A. They
comprise wires of circular cross section (Fig 1) and are used for HV
windings in small transformers in the distribution range. A number of
such coils are joined in series, spaced with bock which provide
insulation as well as duct for cooling.

1.2. Spiral Winding

This types of winding is normally used up to 33 kV and low current ratings. Strip
conductors are wound closely in the axial direction without any radial ducts
between turns. Spiral coils are normally wound on a bakelite or pressboard
cylinder (Fig. 2).
Though normally the conductors are wound on the flat side, sometimes they are
wound on the edge. However, the thickness of the conductor should be sufficient
compared to its width, so that the windings remains twist-free.

Spiral windings may be made as single layer or multi layer type. Figure 4 shows
a double-layer spiral coil where an oil dust separates the two layers. For such a
coil, both the start and the finish lead lie at one end of the coil and may at tikes
prove to be advantageous for making the terminal gear.

Normally it is not necessary to provide any transposition between the parallel

conductor of a spiral winding as the lengths and the embracing of leakage flux
are almost identical.

Normally it is not necessary to provide any transposition between the

parallel conductors of a spiral winding as the length and the embracing
of leakage conductors of a spiral winding as the length and the
embracing of leakage flux are almost identical.

1.3 Helical Winding

This type of windings is used in low-voltage and high-current ratings. A

number of conductors are used in parallel to form one turn. The turns
are would in a helix along the axial direction and each turn is
separated from the next by a duct Helical coils may be single-layer
(Fig.5) or double layer (Fig. 6) or multi-layer, if the number of turns are
more.

Unless transposed, the conductors within a coil do not have same length and
same flux embracing and therefore have unequal impedance, resulting in eddy
losses due to circulating current between the conductors in parallel. To reduce
these eddy losses, the helical windings are provided with transposition of the
conductors which equalize the impedance of the parallel conductors.

1.4 Continuous Disc Winding

This type of winding is used for voltage between 33 and 132 kV and
medium current ratings. These oils consists of a number of sections
placed in the axial direction (Fig. 7), with ducts between them. Each
section is a flat coil, having more than one turn, while each turn itself
a my comprise one or more conductors (usually not more than four or
five0, in parallel. The sections are connected in series, but without any
joints between them.
This is achieved by a special method of winding. It is not necessary to provide a
cylindrical former for these coils, as these are self-supporting.

Each disc is mechanically strong and exhibits good withstand of axial forces.
Another particular advantage of these coils is that, each section can have either
integral or fractional number of turns (for example 4-15/18 turns per section.)

Voltage Regulation and Tap Changer

Voltage variation in electrical systems is normal phenomenon, because

or rapid growth of industries and distribution network. It is very
essential to maintain the system voltage within prescribed limits for
the better health or electrical equipments. Voltage or the system can
be varied by changing the turn ratio or transformer. The device tap
changer is used for adding or cutting out turns or primary or secondary
winding or the transformer. Basically tap changing equipment can be
divided in two categories :

a) Off-circuit tap changer,

b) On – Load tap changer.

1 OFF-CIRCUIT TAPCHANGER

The cheapest method or changing the turn ratio of a transformer is the

use or off-circuit tap changer. As the name implies, it is essential to
de-energize the transformer before changing the tap.

An off-circuit tap changer, as shown in Fig. 1, consists of principally the following

three parts :

(a) Operating handle projecting outside the transformer

(b) fixed contact with connecting terminal

( c) Fixed contact with connecting terminal

The basic transformer winding circuit arrangements using off-circuit tap change
are as shown in Fig. 2 They are :
(a) Linear

(b) Single-bridging

( c) Double-bridging

Depending upon the requirement any of the above arrangement of the winding
can be made use of to get desired voltage regulation. To prevent unauthorized
operation of an off-circuit tap changer, a mechanical lock is provided. Also to
prevent inadvertent operation, an electromagnetic latching device or micro switch
is provided to open the circuit breakers to de-energize the transformer while
operating the handle of tap changer before movement of contacts on tap switch.

2. On-Load Tap changer (OLTC)

On-load tap changers are employed to change turn ratio of transformer

to regulate system voltage while the transformer is delivering normal
load. With the introduction of on-load tap changer, the operating
efficiency of electrical system has considerably improved, Now-a-days,
almost al the large power transformer are fitted with on-load tap
changer.

All forms of on-load tap changing circuit posses an impedance, which is

introduced to prevent short circuiting of tapping section during tap changer
operation, The impedance can be either a resistor or a centre-tapped reactor,
The on-load tap changer can in general, the classified as resistor or reactor type.

2.1 Reactor Transition Type OLTC

In early designs, the use of centre-tapped reactor as tap changing
impedance, was in general more popular inspite of the inevitable
shorter contact life, one of the principal advantages of mid-point
reactor transition is that, twice as many active workings positions as
that of transformer tapping could be obtained. This can be of
considerable advantage where large number of tapping positions are
required. Reactor transition type on-load tap changers are
manufactured and used only in the United States of America. In other
parts of the world, resistor transition type on-load tap changers are
being manufactured and used.

2.2 Resistor Transition Type OLTC

Resistor transition has considerable advantage of longer contact life;

due to relatively short arcing time associated with unity power factor
switching. W ith the introduction of high speed resistor transition tap
changing, it is possible to break the arc at first to current zero,
Furthermore, the introduction of contacts using copper/tungsten alloy
arcing tips has brought about a substantial improvement in contact life.

Transition resistor type tap changers can be divided into two types,
those which carry out selection and switching on the same contacts,
and those which have tap selectors and a separate diverter switch,
The first category is known as single compartment type. While the
second one as double-compartment type.

2.3 Single-compartment type OLTC

The single-compartment type employs a rotary form or selector switch

with single-transit on resistor or double-transition resistor. Figure 6,3
illustrates the switching sequence in moving from one tap to the next
tap employing single-transition resistor. This switching cycle is known
as “asymmetrical pennant cycle” Tap changers constructed with one
transition resistor are suitable for power flow in one direction only.
This particular contact arrangement is not suitable for power flow in
reverse direction.

Figure 4 illustrates the switching sequence in moving from one tap to

the next employing two transition resistors. This switching cycle is
known as flag cycle and the arrangement is suitable for bi-directional
power flow. Single compartment tap changers available presently are
suitable for currents up to 600A and 66 kV voltage class with certain
limitation up to 132 kV class) winding of transformers.
a) Tap position No. 2. the main contact
carrying the load current. The transition
contact is open and rests between the
fixed contacts 2 and 3.

b) Transition contact makes on the fixed

contact 3, the transition resistor
circulating current.

c) The main switching contact breaks and

the transition resistor carries the load
current.

d) The main switching contact makes on

contact 3 and carries the load current.

e) The transition contact opens. The tap

change operation complete.

a) Tap position no. 2 The main

contact is carrying load current the
resistor contacts M1 are open,
resting between fixed contacts.
b) The resistor contact M1 has made
on the fixed contact 2 and the main
contact has broken the transition
resistor contact M1 carries load
current.

c) The resistor contact M2 has made

on the fixed contact 3. The load
current is divided between resistor
contacts M1 & M2. The circulating
current is limited by resistors.

d) The resistor contact M1 has broken

from the fixed contact 2. The
transition resistor contact m2
carries the load current.

c) Position No. 2 the main contact

has made on fixed contact 2. The
resistor contact M2 has broken
from the fixed contact 3 the main
contact is carrying load current.
 Transformer Auxiliaries and Oil Preservation
System
Transformer auxiliaries play a vital role in ensuring proper functioning
of the main equipment. Some of the auxiliaries provide protection
under fault conditions.

Transformer oil being a major insulation requires special attention

against contamination by moisture and oxygen for preservation of
quality.

Transformer auxiliaries

Gas operated (Buchholz) relay

The relay serves as main protection for any minor or major faults that
may develop inside a transformer. Such faults always result in
generation of gases which causes the operation of mercury switches
giving signal for audible alarms or isolate the transformers from the
network.

Figure 1 (Plate 4) shows the internal view of a relay. It comprises a

cast housing which contains two pivoted buckets, each bucket being
counter-balanced by a weight. Each assembly carries a mercury
switch, the leads from which are taken to a molded terminal block.

Operation

The relay is mounted in the pipe at an inclination of 3-7° as shown in.

fig. 2 In healthy condition of the transformer, the relay is full of oil and
both the mercury switches are open. In the event of a minor fault like
damage to core bolt insulation, local overheating, etc., the arcing
causes slow generation of gas in the oil, which passes up in the pipe
and gets trapped in the relay housing. As gas accumulates, the oil
level in the relay, falls, leaving the top bucket full of oil.

When a sufficient volume of gas is collected in the relay, the top

bucket, because of its extra weight due to oil contained, tilts,
overcoming the balance weight which closes the mercury switch and
initiates an audible alarm.

With a major fault like short-circuit between turns, coils or between

phases; the generation of gases is rapid and the gas and the
displaced oil surges through the relay and impinges on the baffle
plates, causing the lower assembly to tilt and close the mercury switch
and provide signal for tripping the circuit breaker, which disconnects
the transformer from the network.

1. Temperature indicators

Temperature indicators are precision instruments, specially designed

for protection of transformers and perform the following functions.

— Indicate maximum oil temperature and maximum or hottest spot

temperature of winding.

— Operate an alarm or trip circuit at a predetermined temperature.

— Switch on the cooling equipment when the winding attains a

present high temperature switch it off when the temperature
drops by an established differential (so as to avoid too frequent
on and off operation of the switch)

Normally two separate instrument are used for indicating oil and
winding temperatures.

1.1 Construction and Principle of Operation

These indicators normally work on the principle of liquid expansion,

the liquid being sealed in the bellows. Figure 3 shows a sectional view.
The indicator is provided with a sensing bulb place in an oil filled
pocket on the transformer tank cover. The bulb is connected to the
instrument housing by means of flexible connecting tubing consisting
of two capillary tubes. One capillary is connected to the operating
bellow of the instrument and the other to a compensating bellow. The
operating system is filled with a liquid which changes volume with
varying temperature. The compensating acts upon the operating
bellow through a linkage compensating for variations in the ambient
temperature. W ith change in the volume, of the liquid the bellows
expand or contract, transmitting the movement through a linkage
mechanism to the indicating pointer and switching disc. Up to four dry
electrode mercury switches, each mounted on a steel carriage, are
provided on a winding temperature indicator. The make-and break
temperature of each switch can be independently adjusted.

Oil and winding temperature indicators work on the same principle,

except that winding temperature indicator is provided with an
additional bellow heating element. As it is not possible to measure tue
winding temperature directly, it is done indirectly by mean of thermal
image process

The heating element is fed by a current transformer, with a current

proportional to the load in the winding whose temperature increase of
the winding over top oil temperature. As bulb of the instrument is
located in the hottest oil zone, it senses the maximum oil temperature.
The operating below thus sets additional movement, simulating the
increment of winding temperature above maximum oil temperature
thus indicates hottest spot temperature of winding.

2. Pressure relief valve

The pressure relief value plays a significant role in the protection of

power transformer systems. As mentioned before, a major fault inside
the transformer causes instantaneous vaporization of the oil, leading
to extremely rapid build-up of gaseous pressure. If this pressure is not
relieved within a few milli seconds, the transformer tank can get
ruptured, spilling oil over a side area. The consequent damage and
fire hazard possibilities are obvious. A pressure relief device provides
instantaneous relieving of dangerous pressure.

2.1 Construction and Operation

Figure 4 shows a cross – sectional view of the valve. The valve is

generally mounted on the tank cover above and opening. The valve
has a corresponding port which is normally sealed by a stainless still
diaphragm (4). The diaphragm rests on an ‘O’ ring (3) and is kept
pressed by two heavy duty springs (6). As the pressure inside the tank
rises above a present limit due to a major fault, the diaphragm gets
lifted instantaneously and excessive pressure drops, the diaphragm
then restores to its original position. The lift of the diaphragm is
utilized to operate a flag indicator (10) and micro-switch with the help
of a rod (8). Figure 5 (Plate 4) shows the photograph of the spring
loaded type of pressure relief device.

1. Base

2. Basket Ring

3. O Ring

4. Diaphragm

5. Cover

6. Spring

7. Rod Retaining Spring

8. Switch operating Rod

9. Flag carrier Plate

10. Flag indicator

Another type of device which is also used for the same purpose is
called explosion vent. Figure 6 shows the general construction fan
explosion vent. In the event of a serious fault, due to excessive
pressure, the top diaphragm ruptures, thus releasing the pressure.

Due to certain superior feature of spring loaded pressure relief value

like smaller size, elimination of equalizer pipe and provision of a
switch for alarm annunciation in the event of its operation, is finding a
widespread preference over the explosion vent.

3. Oil level indicator

Normally all transformers are provided with an expansion vessel called

conservator to take care of expansion in the oil volume due to rise in
temperature, when the load on the transformer increases or due to
increase in ambient temperature. The oil level in the conservator
consequently goes up. Conversely, it falls when the temperature or
load reduces. It is essential that the oil level in the conservator is
maintained above a pre-determined minimum level. All large
transformers are, therefore, fitted with a magnetic oil level gauge
which also incorporate a mercury switch. The switch closes and
actuates an audible alarm in the event of oil level dropping to near
empty position in the conservator. Figure 7 (Plate shows the
photograph of such an indicator.

3.1 Construction and operation

Figure 8 shows a cross-sectional view of the inner details and a

schematic diagram. A float is used as a sensor which moves with the
rise and fall of the oil bevel. Its movement gets transmitted to the
switch mechanism by means of a bevel gear and magnetic coupling,
which ensure, a complete seal between the conservator and switch
compartment. The pointer is also magnetically operated and picks up
the correct oil level.

4. Bushing and cable sealing Box

It is necessary to bring the low and high voltage leads out of

transformer tank, to be able to make connection between transformers
are generator or transmission lines, etc. This is accomplished by
terminating these leads through what the known as bushings or cable
box.

1. Float

2. Float arm

3. Bevel gear

4. Limit stoppers

5. Main body

6. Switch housing

7. Mercury switch

8. Dial body

9. Driving magnet (for pointer)

10. Cam

11. Driving magnet (main coupling)

12. Driving magnet (main coupling)

13. Magnet with pointer.

A bushing is a structure carrying a conductor through a partition in the
tank and insulating the conductor from partition.

4.1 Type of Bushing

Two types of bushing are commonly employed, namely porcelain and

condenser. In its simplest form a porcelain bushing consists of a
current carrying conductor passing though a hollow porcelain insulator.
The space between conductor and insulator is filled with an insulating
medium like oil, air or a gas. The use of porcelain bushings is
generally limited to the highest system voltage of 36 kV, beyond which
they become very bulky.

In the porcelain type of bushing, the concentration of electric does not

permit efficient use of insulating material. This difficulty is overcome
by using the principle of condenser. The insulation wall thickness is
divided into a number of capacitors by concentric conduction
cylinders.

(a) Bushing Assembly

1. Central metallic tube

2. Condenser core

3. Conducting layers

4. Porcelain insulator

5. Cable thimble

6. Oil

7. Oil level gauge

8. Terminal cap

9. Gasket

10. Mounting flange

11. Arcing horn

12. Stress shield

13. Oil drain plug

14. To terminal

15. Test tap

This is illustrated in Fig. 9, which also shows components of a

bushing. The core insulation of a condenser bushing generally
consists of the following types. :

— Synthetic resin bonded paper

— Oil impregnated paper

— Resin impregnated paper

Synthetic resin bonded paper (SRBP) bushing

In this type, the core of bushing is built-up the winding resin coated
paper on a central metallic tube with interleaving of layers of
condenser foils at specified diameters. The resin used on the paper is
of thermosetting type and is therefore wound under temperature and
pressure. The core surface is treated with special anti-tracking epoxy
varnish to provided glossy finish and to prevent moisture ingress. The
annular space between condenser core and porcelain insulator is filled
with transformer coil.

Oil impregnated paper (OIP) and resin impregnated paper (RIP)

bushing

In the OIP type bushing, the condenser core is built-up per on a

central metallic tube, whereas in the RIP type, crepe Kraft paper
impregnated with epoxy resin is used for making the core. The
condenser core with or without porcelains dried under vacuum and
degassed oil is impregnated the bushing are hermetically sealed. The
partial discharge levels of these bushings are much lower compared to
SRBP bushings.

4.2. Cable Sealing Box

Generally used for termination of lead of low voltage, a cable sealing

box is designed for the purpose of receiving and protecting the end of
a metal-sheathed cable or cables and containing a suitable insulating
medium.
It is a unit complete with bushings, to which the terminals of the
transformer an be connected. The insulating medium in a cable box
can be air or a bituminous compound. Figure 10 shows a typical 3-
Pole, 9-gland cable sealing box.

1. bushing

2. shell

3. cable gland

4. cable (Insulate)

5. cable (bare)

6. flexible connect

7. connector

8. cable ferrule

9. opening

10. filling material

 Transformer Oil Preservation System

Transformer oil deterioration takes place due to moisture an appear in

transformer from three sources, viz by leakage past gasket, by
absorption from air in contact with the oil surface, or by its formation
within the transformer as a product of deterioration as insulation ages
at high temperature. The effect of moisture in oil is to reduce the
electric strength, especially if loose fibers or dust particles are
present. Method available to reduce oil contamination from moisture
are silica gel breather, thermo-siphon filter, sealed conservator tanks
using gas cushion, rubber diaphragm or air-cell seals and refrigerated
dryers.
5. SILICAJEL BREATHER
A silica gel breather is most commonly employed as a means of
preventing moisture ingress. It is connected to the conservator tank,
which is fitted to transformers to allow for changes in volume due to
temperature variations. As the load reduces, air is drawn into the
conservator through are cartridge packed with silica gel desiccant,
which effectively dries the air. Freshly regenerated gel is very efficient,
it will dry the, air down to a dew point of below –40 0 C,but quickly falls
in efficiency. A well maintained silica gel breather will generally
operate with a dew point of –35 0 C, as long as a large enough quantity
of gel has been used for the cycling duty. Figure 11 shows such a
breather.
6. GAS SEALED CONSERVATORS
In this method, the contact between transformer oil and atmospheric
air is eliminated by providing cushion of an inert over oil surface in
the conservator vessel. The gas pressure is always higher than
atmospheric pressure to avoid ingress of air. The gas normally used
for this purpose is nitrogen having high purity and dryness.
Construction and operation.
Figures 12 (Plato 5) and 13 show respectively, a photo graph and a
schematic diagram of nitrogen sealing system. High pressure nitrogen
gas at 15 M Pa flows out of the cylinder and is admitted in the
conservator after passing through multi stage pressure reducing
valves. The pressure reducing valves automatically cut off the nitrogen
gas supply when the pressure in the conservator reaches 3-5 k Pa.
Due to increase in ambient temperature and load the gas pressure
build up. The system is designed to relieve any excessive pressure
through a relief value provided for the purpose. When the pressure
drops below 3-5 k pa, the valves open to admit nitrogen from cylinder
and this cycle continues until the cylinder becomes empty. The
system may be provided with switches in the pressure gauges to
operate alarm under the following abnormal operation conditions :
a) When the pressure in transformer exceed relief over valve pre-
set operating pressure.
b) When the pressure in transformer drop below 3-5 k pa.
c) When the cylinder pressure is reduced to around 1 m pa.
 CHARACTERISTICS OF TRANSFORMER OIL (IS 335-1983)

1. Density At 27 0 C 0.89 g/cm

2. Viscosity At 27 0 C, Max 27 cSt

3. Interfacial Tension 0.04 N/m

4. Flash Point 140 0 C

5. Pour Point Max. -9 0 C

6. Neutralization value (Total Acidity) 0.03 mg KOH/g

7. Corrosive Sulfur Non – Corrosive

8. Electric Strength (Break down voltage)

a) As received 30 kv (rms)

b) After Filtration 50 kv (rms)

9. Dielectric dissipation factor (Tan Delta) 0.005 At 90 0 C

10. Specific resistance, min

At 90 0 C 30 x 10 * 12 OHM
cm

At 27 0 C 500 x 10 * 12 OHM
cm

11. Oxidation stability

a) Neutralization value after oxidation max 0.40 mg KOH/g

b) Total sludge after oxidation 0.10% by weight

12. Water content (as received) max 50 ppm by weight

13. Permittivity 2.2

14. Specific Heat 2.06 Kj/Kg 0 C

15. Thermal Conductivity 0.13 W/m 0 C

Test Result

S. Test Test Require Test Confi

No Method ment IS: Value mity
1866

1 Electric Strength IS 6792 30 63 yes

(Break Down voltage) kv rms

min

2 Water content(ppm) Max IS 1356 35 18 Yes

3 Di-electric Dissipation IS 6262 1.00 0.0167 yes

Factor(Tan ) at 90°c max

4 Specific resistance IS 6103 0.1x10* 0.58x10 yes

(resistivity)ohm-cm at 90°c 13 *13

5 Neutralization value total IS 0.30 0.19 yes

acidity (mg KOH/gm. max 1448P2

6 Sludge content(% by mass IS 1866 Nil Nil yes

7 Flash point °c (Min) Is 1448 125 150 yes

8 Inter Facial Tension at 27°c IS: 0.015 0.038 yes

(min) 6104

9 Dissolve gasses Analysis ( p pm )

Methane (CH4) -120 IS 32

:9493
Ethylene (C2H4)- 50 14
IS
 10593
Ethane (C2H6) - 65 33
Ratio
Acetylene(C2H2)- 35 Method 0

Hydrogen (H2) – 100 2

350

Carbon Mono Oxide (CO) - 1101

CO2 1524

As per IS 1866 it is mandatory to carry out all the 9 test on transformer

oil at least once in a year

CH4- Local Over heating

C2H4 - Thermal Degradation of oil

C2H6- Over heating

C2H2 - Arcing and sparking

H2- Electrical / Thermal Fault

CO - Thermal aging of paper

CO2 - Cellulose decomposition

 STANDARD VECTOR GROUPS OF 3 PHASE TRANSFORMER

In 3 phase transformer polarity alone it insufficient to represent the

relation between HV and LV windings. In addition to the terminal
markings on HV side and LV side voltage vector diagrams are required
to show the angular displacement between HV and LV winding.

The angular difference between vectors representing the voltages

indeed between HV and LV terminals having the same marking letters
and corresponding neutral point (real or imaginary) expressed with
reference to HV side is termed as phase displacement for the
transformer.

Even under normal condition the line to line voltage on HV side are
displaced from corresponding voltages on LV side. Also line to neutral
voltage on HV is are displaced from corresponding voltages on LV
side. This displacement depends upon transformer connection
(star/delta). IS 2026-1972 gives four vector groups standard
connections. These whole groups are explained below :
Group Phase Displacement Connection
1. Zero Yyo, Dd0, Dz0
2. 180 degree Yy6, Dd6, Dz6
3. 30 deg. lag Dy1, Yd1, Yz1
4. 30 deg. lead Dy11, Yd11, Yz11

The phase different is indicated by the angle in terms of clock face.

The HV vector being at 12 O’Clock (zero) and the corresponding LV
vector at hour number thus.

Phase displacement zero = 0

Phase displacement 180 = 6

Phase displacement 30 deg. lag = 1

Phase displacement 30 deg lead – 11

Letter Y represents star – connected HV

Letter Y represents star – connected LV

Letter D represents star – connected HV

Letter d represents star – connected HV

Letter z represents star – connected zig-zag.

Thus the symbol Yy0 represents ad star/star winding with 0 deg

displacement.

— Sub – station layout, voltage levels and fault – levels

— Transport facilities, roads, etc. between the manufacturers

premises final site. Road, rail permits availability of suitable
trailers, wagons

— Civil engineering requirements such as the room, foundation for

cabling ventilation aspects, etc.

The data regarding transport requirements and handling facilities

should be obtained. This information includes : overall dimensions,
weight, lifting arrangements, transport facilities, special trailers, the
transport route, roads, bridges, culverts arches, etc, throughout the
route, rail route and requirements of special wagons etc.

Information to be furnished by Manufacturer to the user. The following

information is generally furnished by the manufactures to the user at
the time of the inquiry :
Information to be furnished in all cases

1. Name of the Manufacturer ……….

2. Service continuous/short time etc.

3. Ratings Rated KVA…….. Rated voltage of LV…KV

Rated voltage of LV…..KV

4. Number of phase

5. Connection HV : LV :

Vector Group :

6. Tapping HV…..per cent; LV ……….. Per cent

7. No-load current at rated voltage and rated frequency…….KW

CHECK LIST OF INSTALLATION, TESTING AND COMMISSION OF

TRANSFORMERS

A. Inspection of Transformer w.r.t following points.

1. Tank sides or cooling tubes dented.

2. Protruding fittings damaged.

3. Oil sight glass broken

4. LT & HT Sides Bushings cracked or broken.

5. Loss of bolts due to vibration in transit.

 6. Oil leakage particularly along welds (for oil filled
transformer.) or reduction in gas pressure of gas filled
transformer)

7. Damage to auxiliaries.

8. Check for Rut.

9. Compare name plate and rating with project specification.

10. Size of inspection cover shall be adequate to check

bushing and tap changer connections.

11. Condition of connecting lead.

12. Tap changer.

13. I.R. value of transformer.

14. Checking of core.

15. CT winding, the secondary leads and their passage

through metal parts.

16. Core ground (To check with megger after removing

ground).

17. All loose objects to be removed.

18. Oil sample to be tested.

B. INSTALLATION :

1. To ensure that the civil work (Trans. Foundation) as per

drawing and compare with the dimensions of transformer.

2. To check the clearance between the wall and the

transformer shall be maintained below :
 a) If wall is on one side – 0.5 M

b) If wall are on two side – 0.75 M

c) If walls are on three sides – 1 M.

d) if walls are no four sides – 1.25 M.

3. The minimum vertical clearance between conservation

tank top and ceiling shall be 0.5 m.

4. The transformer shall be positioned inside thee cell such a

manner that the name plate, oil level indicator, dial type
thermometer should be visible from the front.

5. Suitable detachable wheel stoppers shall be provided near

all wheels.

6. As per I.E rules oil soak pit to be provided for transformer

containing oil of 2000 litters or more with drainage facility.

7. Earthing of transformer cell are to be earthed as per I.E.

Rules

8. Fire bucket fillet with sand/foam type fire extinguishers

and shock treatment chart in English and Hindi language
shall be kept in a conspicuous place inside the transformer
cell.

9. Power and control cable are to be laid on separate trays or

control cables should be segregated from power cable in
the same tray.

10. Cable trench either to filled with sand plastered with

cement or covered with non inflammable slabs.

11. Neutral link of at least 50% capacity of full loads

secondary current be provided as per I.E. Rules.

13. Neutral links shall be installed at a height of 1.8 to 2.6 M.

level at a convenient location for easy operation inside
transformer cell.

14. If two transformer are installed side by side fire separation

wall is to be provided.

15. Surge protection installation and connection at two

different/distinct earthing station.
 16. Proper nomenclature such as KVA & voltage rating shall
be neatly inscribed by painting on transformer cell.

17. Outdoor transformer – marshalling box shall have weather

proofing arrangement such as gasket, canopy etc.

18. Copper flexible strip shall be provided between

transformer terminal and tubular bus bar in case of outdoor
transformer.

19. Emergency stop P.B. (type) shall be provided at a suitable

near entrance inside transformer cell.

20. H. T. of Caution as per TISCO Std. Shall be fixed in front

of transformer cell in a suitable location.

C. a) Testing (Pre – commissioning check):

1.1 To check coil and winding temp. indicator

1.2 Wiring for Buchholz relay. W inding and oil temperature

alarm and trip connection.

1.3 To check wiring between marshalling box to control relay

panel, (protective panel)

1.4 Tightness of connection of power cable and taping of

terminal/connecting legs and bus bar with full voltage tape.

2) TAP CHANGERS :

2.1 Check proper contacts while changing from one tap to

another tap with the help of doctor set (Drop Test at each
tap position for all the three phases).

2.2 In OFF – Locking of handle in respective tap position.

2.3 Do not operate Tap changer for “OFF POSITION”

2.4 Oil should be sealed drum and to be tested before filling in

the transformer tank.

2.5 All indicator and accessories fitted.

2.6 Oil filled through centrifuge and fit m/c. Rubber hose not to
be (because sulfur will attach copper windings).

2.7 To prevent erosion, should be filled – through bottom drain

valves.
2.8 Time of 24 hrs. for locked air bubbles to escape.

2.9 Vacuum filling for large transformer.

All test methods as specified in IS-335.

2.10 Drying of transformer.

a) If as a result of tests, presents of moisture is

indicated or oil does not with stand the tests or
insulating reading are not satisfactory, then drying of
transformer as per IS-10023 Parts II of selection,
inst. & maintenance of transformer.

b) Oil should be vacuum filtered separately at deg. – 70

deg. C using filtering M/c. as per IS – and check the
parameter with oil test certificate

2.11 If the silica gel of breather has absorbed moisture and

become pink in colour, it is to be heated is to be heated
and made moisture free. The colour of reconditioned silica
gel should be blue.

2.12 All the wiring to be checked for protection, closing and

tripping circuit.

2.13 Certificate from manufacturer for type the and routine tests
with all details as per ISP-2026 (Part I)

a) Primary and secondary injection test of all protective

relay of transformer and CTs.

b) Primary injection and secondary injection test of HV

side and LV side relays.

2.14 Ratio test of transformer (apply 415V dia power on HV side

and measure the voltage on LV side).

2.15 To check phase sequence.

2.16 Magnetic balance test (In case big transformer).

2.17 Tan-Delta Test (In case big transformer).

D) Pre-Commissioning Test :

1. Checking of HT breaker closing, Tripping

2. Checking of inter tripping between HV & LV breaker.

3. Checking of tripping of breaker with all protective relays.

4. Releasing of Air from transformer bushings, relay,

radiators etc.

5. Check the test angle of Buchholz relay.

6. Check the starting of cooling fan motors by simulating the

conditions (shorting different temp. contacts) and check
the protective O/L of motors.

7. Check the alarm circuit – Buchholz relay, oil & winding

temperature indication and cooling failure.

8. Ensure that all the radiator valves are open position in

cooling circuit.

9. Tap changing tests – mechanism position indicator (near

transformer as well as on control panel).

10. If Test HV of E. LV to E & LV to HV circuit.

11. Check the oil BDV as per standard i.e. with k2.5 mm. air
gap breakdown valve should not be less than 55 KV when
voltage raises slowly.

12. Before charging ensure that neutral earthing line/links

is/are closed.

13. Check transformer on equal taps before switching in.

14. Set down relays.

15. IR test of breaker, LV & HV

16. IR test Cables, LV & HV.

17. During charging remove the personnel from transformer.

18. Switch on the transformer.

19. Check secondary voltage in al three phase.

 20. Check any abnormal sound from transformer.

21. Check the parallel operation of the transformer w.r.t

existing source.

22. Keep the transformer in charge condition for 24 Hrs.

(Soaking time in case of big transformer0 before pulling on
load.

23. Put “ON” the transformer on load after checking parallel

operation with the existing system.

DRYING OUT OF POWER TRANSFORMER

Purpose : The transformer oil and insulation is hygroscopic (absorbs
moisture). If the transformer is dispatched without oil or is left idle for
a long period, the oil and insulating absorbs moisture and drying out is
necessary prior to recommending. The main purpose of drying out is to
expel the moisture from the oil, the winding insulating and the other
insulation parts. If the transformer is not dried out, it can not with
stand service for a long duration and its insulation may fail
prematurely.

Procedure is drying out

In the drying out procedure, the transformer oil/winding is heated by

one of the following methods for prolonged period (10 hrs to 4 weeks).
Periods reading :

1. Oil and winding temperature.

2. Power input

3. Insulation resistance are taken.

The temperature of oil is maintained at 80 degree and that of winding

at 90 degree.

The values of insulating resistance starts falling in the beginning of the

drying out process. This indicates that the moisture drops are getting
distributed in the winding and the oil in form vapour after several
hours. The insulation resistance becomes steady. The indicate that the
moisture is being expelled from the windings and oil.

The drying about process is stopped when the insulation resistance

value (hot) is more than the specified value, during the rising mode of
the drying out process and the polarization index, dielectric strength of
oil are satisfactory (P.I. 1.3, EDV 45 KV for 4mm gap) K.

Drying-out by circulation of Transformer oil through purifier (Filtering

Plant): The modern method of drying out of transformer consists of
circulation of the transformer oil through oil filtering plant. The modern
oil filtering and purifying plants are portable and have the following
components :

— Vacuum tank, vacuum pump

— Heating Chamber, Heaters

— Spray Chamber

— Centrifugal Blower

— Pump for circulation of oil.

The oil from the circulation tank is circulated through the filtering
plant fro :

i) removing moisture and

ii) for removing sludge, dirt and solid impurities.

While using the oil filtering plant for the purpose of drying out : the
thermo state of the filtering plant is set at outlet temperature of
Degree. The oil is drawn from the transformer tank through a pipe
dipped to the bottom of the tank. The outer of the filtering plant is
delivered back into the transformer tank at the top.

The purifier (filtering plant) is operated continuously except for one

our per day for cleaning the cones of centrifugal type of filter pads of
the vacuum type filter.

Preparation of drying-out

— Lagging the tank with fire resistance mat such as asbestos cloth,
glass sheet provide external shields to prevent drought of cold
air.

— Connecting thermo couple, placing thermometer, calibration,

arranging measuring instruments.

— To bring-cut the well insulated leads from the winding from the
terminal bushings for the measurement of the insulation
resistance.
— To bring out thermo couple lead through one of the opening of
the tank.

— To prepare a log book.

Precautions while drying out

1. Never leave the transformer unattended during any part of the

process. The transformer should be watched and observed.

2. Transformer oil temperature should never exceed 85 degree.

The maximum temperature of any thing in contact with the oil
should never exceed 90 degree.

3. maintain log sheet.

4. Use proper ventilation to remove the moisture given off by the

transformer oil. Duration of Drying-out

1 To 6 Days for KV transformer

10 Days to 30 Days for 220kV transformer.

15. Days to 40 Days for 400KV Transformer.

Details about transformers :

Details about method of drying out :

Date of Start : Date of completion :
Hrs. from Top oil Temp. Degree C Insulation Input Kw.
start bottom oil average Resistance
0 25 25 25 22 0
1 30 28 26 18 15
2 38 37 37.5 13 15
3 45 44 44.5 9 15
4 50 48 49 6 15
5 65 58 59 5 15
6 75 69 69.5 4 15
7 80 79 78 4 6
8 80 79 78 4 6
9 80 79 78 4 6
20 80 79 78 4 6
21 80 79 78 5 —
22 75 74 73 6 —
23 70 69 68 8 —
24 60 59 58 10 —
25 55 54 53 12 —
2 51 51 49 14 —
2 50 49 48 18 —
28 45 44 43 20 —
29 40 39 38 22 —
30 38 37 38 24 —

Stage Duration Average

(examp) temp. of oil

Initial heating up 4 to 8 Hrs. ambient to 80°c

Steady temperature 6 to 48 Hrs. 80°c

Cool down 48 to 60 hrs. 80 °c

In the first place of dying-out, the insulation resistance reduces.

This indicates release of moisture within insulation resistance is
contact.

In the third phase the insulation resistance increase

Steps in drying-out

1. Preliminary preparation of the machine, sources of heat,

measurement etc.

2. Arrange the set up

3. Apply heat by one or the suitable means gradually.

4. Take periodic reading of :
— Clock time
— Temperature of windings, body and air, ambient
— Insulation resistance values of 15 sec. Mugger reading and
60 sec. Megger reading
— Winding resistance (at the beginning and at the end).

5. Maintain steady temperature of specified value (winding temp.

not exceed 60 degree centigrade or 70 degree centigrade
depending upon insulation class). Measure periodically of the
insulation resistance values.

6. Initially during the first few hours (for medium motors), the
values of insulation resistance reduces even though the heat is
being applied for drying-out Why?

During initial heating period, the moisture trapped in the

insulation in form the small globules gets released within the
insulation. Hence the insulation resistance value starts reducing.

7. Intermediate stage. After a span of few hrs (for a medium sized

machine having good condition) or a few days )large machine or
a wet m/c.). The insulation resistance reaches steady value. This
indicate that the moisture has spread all over the insulation. The
input power is reduced to reduce the temperature rise.

8. Rising stage : after a few hours of steady value. The insulation

resistance starting rising. This indicates that the moisture has
vaporized and it being expelled (released from the winding. The
input power is reduced further.

9. The drying out process is stopped when the desired value of

insulation resistance (hot) and polarization index is reached. In
case of large machine both the insulation resistance and the
polarization index are equally important. The input power is
switched off.
 TESTING OF TRANSFORMERS

Testing is an important activity in the manufacture of any equipment.

While certain preliminary tests carried out at different stages of
manufacture provide an effective tool which assures quality and
conformation to design calculations, the final tests on fully assembled
equipment guarantee the suitability of the equipment for satisfactory
performance in service. The basic testing requirements and testing
codes are set out in the national and international standards. This
chapter, however, is intended to cover the purpose and the
methodology of performing the tests.

With a view to cover detailed information about impulse and partial

discharge tests, which are of great importance, separate sections have
been devoted to these tests. Also, the specific requirements of reactor
testing are dealt with in a separate section. All other test including
temperature rise test on power transformer are described in the first
section. Thus, the chapter has been divided into following three
sections.
1. Testing of power transformers

preliminary tests are carried out on the transformer before it is put into
the tank. Final tests are carried out on completely assembled
transformer.

1.1 Preliminary Tests

Following tests are carried out at works at difference stages, before

the core and coil assembly of the transformer is placed in its tank.
These checks help in detecting any fault at an early stage.

(a) Core insulation

After the core is assembled, 2kV test is done to ensure that the
insulation between clamp plates, core bolts and core is adequate.

(b) Core loss test

This is conducted on the core assembly to ensure its soundness. A

few, turns are wound over the core and it is energized at normal flux
density. Core loss and magnetizing current are noted and compared
with design value.

( c) Check of ration, polarity, vector relationship and winding

resistance of transformer assembly.

Ratio test is conducted to ensure the correctness of turns ratio

between different winding on each tapping. The tolerance allowed for
ratio is + 0.5% of the declared ratio or + 10% of the percentage
impedance voltage, whichever is smaller. The latter tolerance limit is
not applicable for auto transformers and booster transformers, where
impedance value is small. In order to get accurate ratio, a ratio meter
is employed. It also indicates the polarity of transformer windings.

For a three – phase transformer, it is more usual to carry out a vector

relationship test, in which one of the high – voltage and low – voltage
line terminals are joined together as shown in fig 14.1 Three-phase
400V supply is connected across high voltage line terminals. Voltage
between terminals 2U-IN, 2V-IN, 2W-IN 2V, 2W-1W and 2V-1W are
measured.
 Fig. 1 Vector relationship test for star-delta (YN,d11)

Connected step – down transformer.

For YN, d11 vector relationship

2U – IN > 2V-IN > 1U – IN

2V – 1W > 2V – 1V > 2W – 1W

The vector relationship for any other group can be checked in a similar
manner.

The dc resistance of each winding is measured by Kelvin’s double

bridge to check that there is no faulty joint.

(d) Preliminary load loss and impedance voltage measurement

Preliminary load loss and impedance measurements at reduced

current is carried out to ensure that these are within guaranteed limits.

Dos for power transformer

1. Connect gas cylinder with automatic regulator if transformer is to

be stored for long duration, in order to maintain positive
pressure.

2. Fill the oil in the transformer at the earliest opportunity at site

and follow storage instructions. It must be commissioned as
soon as possible.
3. Open the equalizing valve between tank and OLTC diverter
compartment, whenever provided, at the time of filling the oil is
the tank and close the same during operation.

4. Clean the oil conservator thoroughly before erecting.

5. Check the pointers of all gauges for their free movement before
erection.

6. Inspect the painting and if necessary fore touching.

7. If inspection covers are opened or any gasket joint is tightened,

tighten the bolts evenly with the proper sequence to avoid
uneven pressure.

8. Clean the Buchholz relay and check the operation of alarm and
trip contacts.

9. Check the oil level is oil cup and ensure that the air passages
are free in the breather. If oil is less, make up the oil level.

10. Check the oil in transformer and OLTC for dielectric strength and
moisture contact, and take suitable action for restoring the
quality of oil.

11. Attend to leakage on the bushing immediately.

12. Check the diaphragm of the relief vent. If cracked or broken,

replace it.

13. Remove the air from vent plug of the diverter switch before
energizing the transformer.

14. Check the gear box oil level in the tap changer. If less, top up
with specified oil.

15. Check the OTI and WTI pockets and replenish the oil, if
required.

17. Check the oil level in the diverter switch and if found less, top up
with fresh oil.

18. Examine diverter selector contacts of tap changer and if found

burnt or worn out, replace the same.

19. Check and thoroughly investigate the transformer whenever any

alarm or protection is operated.
20. Examine the bushings for dirt deposits and coats and clean them
periodically.

21. Check the protection circuit periodically.

22. Check all bearings and operating mechanism of the tap changer
and lubricate them as per schedule.

23. keep the valve connected between conservator of the tap

changer and its diverter compartment open, during transformer
operation.

24. Check the silicagel charge. If it is found pink, regenerate or

replace it with blue silicagel charge.

8. Don’t for power transformers

1. Do not use low capacity lifting jacks on transformer for jacking.

2. Do not allow WTI, OTI temperature to exceed 750C during dry

out of transformer, and filter machine temperature beyond 850C.

3. Do not re-energize the transformer, unless the Buchholz gas is

analyzed.

4. Do not re-energize the transformer without conducting all pre

commissioning checks.

5. Do not energize the transformer, unless the off-circuit tap switch

handle is in locked position.

6. Do not leave off-circuit tap switch handle unlocked.

7. Do not leave tertiary terminal unprotected outside the tank.

Follow manufactures recommendation in this regard.

8. Do not leave marshalling box doors open. They must be locked.

9. Do not leave any connection loose.

10. Do not meddle with the protection circuits.

11. Do not leave maximum temperature indicating pointer behind the

other pointer in OTI and WTI.
12. Do not change the settings of wti and oti alarm and strip
frequently. The setting should be done as per the site conditions.

13. Do not allow oil level in the bushings to fall: they must
immediately be topped up.

14. Do not allow conservator oil level to fall below one-fourth level.

15. Do not parallel transformer which do not fulfil and required

conditions.

16. Do not switch off the heater in marshalling box except in

summer.

17. Do not leave secondary terminals on an unloaded CT open.

18.. Do not allow water pressure more than oil pressure in differential
pressure gauge in OFW F cooled transformer.

19. Do not switch on water pump unless oil pump is switched on.

20. Do not leave ladder unlocked, when the transformer is

energized.

21. Do not allow unauthorized entry near the transformer.

22. Do not overload the transformer other than the specified limits
mentioned in national/international standards.

23. Do not allow inferior oil to continue in transformer.

24. Do not handle the off-circuit tap switch when the transformer is
energized.

9. Dos and don’ts for HV condenser bushings

9.1 Dos

1. Check the packing externally for possible transit damage before

unpacking.

2. Do unpacking the care to avoid any direct blow on bushing or

porcelain insulator.

3. Store the bushing in a shed or covered with tarpaulin to protect it

from moisture and rains. If removed from the crate, keep it
indoors with lower end protective intact.
4. Handle the bushing with manila rope slings without any undue
force on porcelain insulator.

5. Clean the porcelain insulator thoroughly.

6. Remove the wax tap protection on the oil end of the bushing 9at
the time of erection0 and clean the surface with hot transformer
oil.

7. Check the oil level and IR value of the bushing in vertical

position only, taking care that the bushing is cleaned and no
rope or sling etc., is touching the terminal and ground.

8. Check the breakdown value (BDV) of oil taken from drain plug or
siphoning from the bottom most portion of bushing. This should
not be less than the recommended value.

9. Check the IR value and tan Delta value (if possible) with bushing
in position on transformer with jumper connection remove.
Record these reading for reference and guidance for future
measurements.

10. Check BDV of oil and IR value of each bushing periodically

during maintenance shut down These value should be
comparable with the values recorded at the time commissioning.

11. Ensure to allow the air to escape from central tube to the
atmosphere while filling the transformer tank.

12. Maintain the log book records of periodical checks (i.e. tan Delta
and BDV of oil) up to date.

9.2 Don’ts

1. Do not unpack the bushing from the crate unless required to be

mounted on the transformer.

2. Do not remove the waxed tape protection/metal protective hood

from the oil end portion unless bushing is required for use.

3. Do not store the bushing outdoors without any protective

covering.

4. Do not measure the IR value and tan value without thoroughly

cleaning the porcelain and oil end portion.

5. Do not store the bushing without oil in porcelain.

6. Do not keep the top cap cover open for any longer time than
required as it contaminates the oil.

7. Do not tighten the nuts and bolts in excess to stop any leakage,
this could damage the cemented joints on porcelain.

Transformer protection
Transformer being a vital equipment, its protection is equally
important. The subject of transformer protection can be categorized
under two major headings.

a) Protection of the transformer against the erects of faults

occurring on any part of the system beyond the transformers.

b) Protection against the effects of fault arising in the transformer.

(a) Protection against external faults.

1.1 Short circuit

Short circuit across any two or all the three lines may occur in the
system. The over current produced because of such fault depend upon
system MVA feeding the fault, the voltage which has been short
circuited and upon the impedance of the circuit up to the fault. System
short circuits produce a relatively intense rate of heating of the feeding
transformer the copper-loss increase in proportion to the square of
per-unit fault as the copper-loss increase in proportion to the square of
per-unit fault current. The duration of external short circuit that a
transformer shall sustain without damage, if the current is limit only by
self impedance, is 2 as per IS : 2026. large fault currents produce
severe mechanical stresses in the transformer; the maximum stress
occurs during the first cycle of asymmetrical fault current and so
cannot be averted by automatic tripping of the circuit. The control of
such stress is therefore a matter of transformer design. The
transformers connected to a large power system have their windings
very securely braced in order to minimize the effects of the mechanical
forces to which they may be subjected, due to short circuit IS : 2026
specifies typical values of short circuit impedance, for different ratings
of transformers, to limit the short circuit current.

1.2 High voltage disturbances.

High voltage disturbances are of two kinds.

a) Transient surge voltages

b) Power frequency voltages

High voltage high frequency surge may arise in the system due to any
of the following:

i) Arcing grounds if neutral point is isolated

ii) Switching operation

iii) Atmospheric disturbances.

These disturbances principally take the form of traveling waves having

high amplitudes and steep wave fronts. On account of both their high
amplitudes and frequencies these surges may, upon reaching the
winding of transformer, break down the insulation between turns
adjacent to line terminal, causing short circuit between turns and
producing extensive damage to the transformer winding. The effects of
these surge voltages may however, largely be minimized by designing
the windings to withstand the application of a specified surge test
voltage and then ensuring that this test voltage is not exceeded in
service by the provision of a suitable surge diverter mounted adjacent
to the transformer terminals.

All type of surge deviators aim at attaining the same results, viz. of
shunting disturbing surge from the lines to earth to prevent their
reaching the transformer. In essence, the different kinds of valve-type
surge deviators employ several spark gaps in series with a nonlinear
resistor. These nonlinear resistors offer a low resistance path to high
voltage surge waves and hence these disturbances are discharged to
earth, through the diverter. As the surge voltage falls, the diverter
resistance automatically increases and prevents the flow of power
current to earth. Figure 18.1 shows schematically how tine various
dielectric path of a three-phase transformer should be shunted by
surge deviators in order to protect the transformer bushings and
windings against surge voltage. A surge protective should have the
following qualities :
 Fig. Schematic diagram showing connection of surge deviators.
i) Rapid response to impulse over voltage
ii) Independence of waved polarity
iii) Nonlinear characteristic
iv) High thermal capacity
v) High system follow current interrupting capacity
vi) consistent characteristic
Non, zinc oxide arrestors having high reliability and better
characteristic are also available in the market.

(b) Power frequency over-voltage

Power frequency over-voltage causes an increase in the stress on the

insulation and a proportionate increase in the working flux. The latter
effect causes an increase in the iron-loss and a disproportionately
large increase in magnetizing current. In addition, flux is diverted from
the laminated core structure into steel structural parts. In particular,
under conditions of over-excitation of the core, the core bolts which
normally carry flux, may be subjected to a large component of flux
diverted from the saturated region of core alongside.

Under such conditions, the bolts may be rapidly heated to a

temperature which destroys their own insulation and will damage the
coil insulation if the conditions continues.

Reduction of frequency has and effect, with regard to flux density,

similar to that of over-voltage.

The over fluxing, protection does not call for high speed tripping.
Instantaneous operation is undesirable, as this would cause tripping
on momentary system disturbance which can be born safely, but
normal condition must be restored or the transformer must be isolated
before significant damage is done to insulation structure. The
fundamental equation for the generation of emf in a transformer can
be arranged to give.

θ = k (E/F)

it is necessary to detect a ratio E/f exceeding unity, E and f being

expressed in per-unit values of rated quantities. An over fluxing relay
whose D/f characteristic closely matches with that of the transformer
should be used to give alarm and signal to correct the disturbance. If
the condition persists for a long time, the transformer should be
disconnected from the system to protect it from severe damage.

2. Protection against internal faults

Considering next the means to be adopted for protecting the

transformer against the effect of faults

Arising in the transformer, the principal faults which occur are :

i) Breakdown to earth-either of winding or terminal gear.

ii) Phase-to-phase fault

iii) Inter-turn fault

iv) Core faults

2.1 Earth faults

a) Start-connected winding with neutral point earthed through an

impedance. The fault current for the fault shown in Fig. 2.1 is
dependent on the value of earthing impedance and is also
proportional to the distance of the fault from neutral point as the
voltage at the fault point will be directly proportional to this
distance. The fault current in the primary winding will depend on
transformation ratio between primary winding and short circuit
turns, which varies with the position of fault in the winding.

From fig. 2. it may be noted that the fault in the lower third of the
winding produces very little current through the primary terminals.
 Fig. 2 Earth fault current in resistance earthed star winding.

(b) Star-connected windings with neutral point solidly earthed

In this case, fault current is controlled by the leakage reactance of the

winding which varies in a complex manner with the position of fault on
the winding. As in the earlier case, the voltage available for fault
current varies with the position of fault on the winding. As in the earlier
case, the voltage available for fault current varies with the position of
fault on the winding. It is seen the reactance decrease very rapidly for
the fault point approaching the neutral and hence the fault current is
highest for a fault near the neutral end of the winding. The variation of
current with fault position is shown in Fig. 3.

From Fig. 3 its can be noticed that the fault current magnitude stays
very high throughout the windings. Also, after transformer ratio the
input current curve remains at a substantial level for faults at most
points along the winding.

c) Restricted earth fault protection

A simple over – current and earth fault system will not give good
protection cover for a star-connected primary winding. Particularly if
the neutral is earthed through an impedance. The restricted earth fault
protection schematic shown in fig. 4 improve the degree of protection
very much. This scheme is operative for faults on the star winding of
transformer. The system will remain stable for all faults outside this
zone. As whole fault current is measured, a good degree of protection
of the winding is achieved even in the case of neutral being earthed
through impedance. In the case of solidly earthed neutral, fault current
remains at a very high value even to the last turn of the winding and
hence complete cover for earth fault is obtained with restricted earth
fault protection scheme.

22. Phase-to-phase Fault

Phase-to-phase faults in the transformer are rare. If such a fault does

occur, it will give rise to substantial current to operate instantaneous
over current relay to the primary side as well as the differential relay.

2.3 Inter-turn Fault

A high voltage transformer connected to and overhead transmission

system is very likely to be subjected to steep fronted impulse voltage.
A line surge which may be of a magnitude times the rated system
voltage will concentrate on the end turns of the winding, because of
the high equivalent frequency of the surge front. Also LV winding is
stressed because of the transferred surge voltage. It is reported that
at very high percentage of all transformer failures arise from faults
between turns. Interterm fault may also occur because of mechanical
forces on the winding due to external short circuit. Though there may
be high short circuit between few turns loop, the terminal current will
be very small because of the high ratio of transformation between the
whole winding and the short circuited turns. If this turn-to-turn is not
detected in the earliest stage, the subsequent progress may destroys
the evidence of evidence of the true cause.

a) Differential protection

A differential scheme can be arranged to cover the complete

transformer protection. This is possible because of the high efficiency
of transformer operation and the close equivalence of ampere-turns
balance on both primary and secondary windings. The rated currents
of primary and secondary windings differ in inverse ratio to the
corresponding voltages. Therefore, - current transformers should have
their primary rating to match the rated currents of the transformer
windings to which they are applied. To correct phase shift of current
because of star/delta-connection of transformer windings, the current
transformers secondary should be connected in delta and star as
shown in fig.

For correcting voltage variation, almost all transformers are provided

with tapping, which in turn change the ratio from the mean. This will
create an imbalance proportional to the ratio change. At maximum
through-fault current, the spill output produced by the small
percentage unbalance may be substantial. Therefore, differential
protection should be provided with a proportional bias of an amount
which exceeds in effect maximum ratio deviation. This stabilizes the
protection under through-fault condition while still permitting the
system to have good basic sensitivity.

b) Magnetizing inrush current phenomenon

The magnetizing inrush phenomenon produces current input to the

primary winding, which has no equivalent on the secondary side. The
whole of the magnetizing current appears, therefore, as balance. The
normal bias for the inrush current is not effective and increase of
protection setting to a value (which would avoid operation of Relay)
would make the protection of little value.

As the magnetizing inrush current phenomenon is transient, stability

can be achieved by providing a small time delay. This can be achieved
by various means. A kick fuse can be connected as shunt to an
instantaneous relay: This fuse is so rated that it carries inrush current
without blowing. However, for internal fault the fuse blow and permits
the relay to operate. An induction pattern relay may have both a
suitable time characteristic and also a through bias feature. Two
induction electromagnets operate on a single disc to produce opposing
torque.

In case of severe inrush of current, the set time delay might be

insufficient to give stability. Also, to minimize the damage to important
transformer, it may be essential to clear the fault without delay. For
these cases, another solution to the inrush phenomenon must be
found. It can be noticed that the waveform of inrush current and zone
fault current differs greatly. This distortion of waveform can be used to
distinguish between the conditions. The differential current is passed
through a filter which extracts the second harmonic current. This
component is then applied to produce a restraining quantity sufficient
to overcome the operating tendency due to whole of the inrush current
which flows in the operating circuit.
c) Combined differential and restricted earth fault scheme

A set of additional phase correcting auxiliary current transformers are

required as shown in fig.

2.4 Core Faults

If any portion of the core insulation becomes defective or the

laminated structure of the core is bridge by any conducting material
which can permit sufficient eddy current to flow, it will cause serious
over heating. The insulated core bolts are used for tightening the core.
If insulating of these bolts fails and provides easy path for eddy
current, this will lead to over-heating. This additional core-loss,
although it causes sever. Local heating” will not produce a noticeable
change in the input current and cannot be detected by the normal
electrical protection. However, it is desirable to direct over-heating
condition before a major fault has been create. Excessive heating of
core will break down transformer oil with evolution of gas. This gas
rises to the conservator.

Recognition of the above action by Buchholz, and the limitation of

other means of detecting certain types of fault, led to the development
of a protective device known by his name. Construction of Buchholz
relay has been described, electrical contacts are available in the
Buchholz relay, one for alarm and the other for trip. W hen the
generation of gas is slow, the gas while moving towards the
conservator gets trapped in the relay and displaces the oil. After a
certain amount of oil is displaced the alarm contact is made and gives
signal in the control room necessitating further investigation.

A violent action described above causes a surge of oil which makes

the trip contact and the transformer is isolated from the circuit.

Because of its universal response to faults within the transformer,

some of which are difficult to detect by other means, the Buchholz
relay is invaluable.

b) because of heavy arcing inside transformer, if excessive

pressure is Generated, it is released through the pressure relief
device. Also one electrical contact on the device is made which trips
the circuit breaker and isolate the transformer from electrical circuit.

c) The overload or persistent fault increase oil temperature or

winding temperature or both. If the temperature increases beyond safe
working limit, the electrical contacts provided on these devices are
made. W hen first contact is mad. It gives alarm signal in the control
room necessitating investigation. If temperature rises further, another
contact is made which trips the transformers.