Transformer: Inspection and Maintenance Information 1) General

Recently power transformer are getting larger in their capacity to meet increasing power demand. So emergency or unexpected power ouage due to transformer trouble cause much loss of production as well as inconvenience. Therefore it is essential to assure trouble-free performance by a well planned maintenance program. Daily or periodical inspection will result in detecting abnormal condition a transformer and prts before they cause any more serious troubles. A regular program is inspection should be established and rigidly carried out for preventive maintenance of power transformer. 2) Recuirements for inspection and maintenance

The inspection items are calassified into three categories. (a) Roution inspection

The roution inspection should be made, preferably daily, on every transformer in service. Especially, oil temperature and/or winding temperature, load current, ambient temperature and oil level in transformer should be daily checked and recorded. (b) Periodical inspection items

The periodical inspection should be made occasionally, one every six months to once every three years in order to ascertain the good performance os a transformer and its parts. Most of the periodical inspections should be made in detail when the transformer is de-energised. (c) Additional inspection items

Some additional inspections or measurement of electrical characteristics of a transformer are recommended as preventive maintenance actions and when any transformer trouble should be investigated throughly. Repaintaing of radiators and transformer tanh and exchange of parts, gaskets and bearings of motor should be planned and prepared previously for preventive maintenance, which will result in continous good performance aof transformer. If any protective relays given alarm, investigate the trouble causes according to Table 5 and Table 6. It is essential in investigating the right causes to check whenever differential relay, overcurrent relay and/or ground fault relay have operated or not, in combination with other relays such as Buchholz relay sudden pressure relay and pressure relief device, which have phisically operating mechanisms. Transformers should be inspected internally whenever they have subjected to unusually severe operating conditions such as overloads and frequent short-circuits aor outer bus ar transmission line. Any symtoms such as unusual noises, high or low oil levels, rupturing or bursting palte, etc. should be investigated throughly. 3) Inspection record

(a) The establishment of the report and recording of the condition and repair of the transformers is required for a good maintenance program. (b) i. A preventive maintenance system will operate satisfactorily with the following records. An equipment record

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This may be simply a card which contains the basic information of a transfoemer itself such as the serial number, the location, site etc. ii. A reapair record card. This may keep a running record as to cost of maintening a transformer. It is essential diagnostic record for avoiding future difficaulties.

An inspection check list or inspectors record. This may be simply a listing of the points to be checked on a transformer and the establishment of the time that these check should be made. iii. Without these records it would be very difficult for a preventive maintenance program to work, because the knowledge from regular inspections would be quickly lost.

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4)

Routine inspection

All least item should be checked daily and recorded. Table 1 No Items 1. Oil temperature and winding temperature

Method Read indication of dial and/or alcohol thermometers and winding thermal relays, if provided. Compare them with the data previously obtained. When oil and/or winding temperature are much higher or lower considerating load current and ambient temperature, thermometers should be inspected.

Action Check if indicate of thermometer is correct or not. If the thermometer is not correct, exchange with a new one. If oil temperature is too high due to dust and other foreign materials on the finned area of radiatos, or the inner surface of cooling water tube clean up them.

Load current and Ambient temperature

Load current and ambient temperature should be recorded at the same time. Read indication of the dial oil level gauge or the conservator. Compare it with the oil level-oil temperature curve for the transformer. Oil level is deemed to be normal when its difference is within one graduation of the gauge on the curve. When the indicated oil level is constant with the changing oil temperature, inspect the dial gauge and check the actual oil level. If the oil level is abnormal, adjust it according to instructions.

2.1

Oil level in transformer: See note.

2.2

In bushing.

Check the oil level with the oil level gauge. Check oil leaks visually from radiators, flangepipe, transformer tank and so on. If oil leaks are due to gasket, tighten bolts or exchange gasket. In caes of oil leaks from welded parts, apply adhesive material or weld again on the leaking part.

3.

Oil leaks

4.

Abnormal noise and vibration.

Abnormal or unusual noise, especially from oil pump motors and fan motors, should be carefully listened to. Abnormal vibration can be checked comparatively easily by hand.

When oil pump or fan motor is getting noiser, exchange the bearings, etc. with new one.

When any supporters, pipes and other parts are vibrating due to loose bolts, tighten them. When any loose bolts are found, tighten them.

5.1

Appearance bolt connection

Confirm tighness of bolts with a test hammer.

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5.2

Discoloration

Check visually that all connections are normal without any discoloration due to local heating.

When any connections show signs of having been hot, clean and tighten bolts and nuts.

5.3

Dust

Inspect visually for dust, especially on radiators. Inspect visually for rust, especilly on radiators.

Clean up dust if it may reduce cooling capacity of radiators. Re-painting is recommendable once every five years. Anti-rust and final paint should be applied after rubbing off rust and old paint.

5.4

Rust

5.5

Dew

Inspect visually for dew in the terminal box, control cabinets and protective relays.

If any dew is found, dry it our and ensure space heaters are in use if they are provided.

Note: In case of a self-cooled transformers, there is some difference between top and average oil temperatures depending on loading conditions and ambient temperature. Strictly speaking, the average oil temperature should be referred to for checking oil level.

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5.

Periodical inspection

The recommended inspection frequency is described in parenthesis under each inspection item. Table 2 No Items 1. Breather (Once every six months)

Method Check the discoloration of silicagel in breather due to moisture in breathed air.

Action If the color of silicagel has turned to pink by more than two thirds of total quantity, dry out or exchange it. If the color became to pink from upper side, find out the air leaks and fix it up.

2 2.1

Insulating oil: Dielectric strength

Measure dielectric strength with a oil tester and confirm it is more than 40kV/2.5 mm gap. Measure moisture content in oil with Karl-Fisher method and confirm that it is less than 30 ppm. Measure acid value and judge it with the criteria of Table 7. (1) Measure insulation resistance of fan motor and/or oil pump motors with a 500V megger.

If any measured valus are not satisfactory, filtering and/or degassing of insulating oil are recommended.

2.2

Moisture content

2.3

Acid value (Once every three years) Fan motors and/or oil pump motors (once every three years)

3.

If insulation resistance is less than 2M , check balancing of load currents of three phase and dry out the interior of fan motors. If it is more than 10 , check its insulation, resistance, winding resistance and three phase balancing of load current. If any characteristics are not satisfactory according to the criteria shown in Table 8, shorten inspection interval of coolers. If any heavy scalae is found on the inside of the cooling tubes, clean them up.

(2) Check if temperature rise of oil pump motors cases, based on oil temperature, is less tahan 10 .

4.

Cooler of watercooled type (Once every three years)

(1) Analyse the characterities of cooling water as shown in Table 8. (2) Check scale deposit on the inside of the cooling tube to reduce the water flow required, resulting in excessive heating of a transformer at normal load.

5.

Control panel and terminal box and cables (Once every three years)

(1) Check the water-tighness of a control cabinet and a terminal box. (2) Ascertain the tighness of all control wiring connections. (3) Operate all switches, annunciators and lamps to observe proper functions according to schematic diagram.

If the rubber gasket it worn out, exchange it with a new one.

Tighten the loose bolts.

If any part maloperates, adjust or exchange them with new one.

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(4) Measure insulation resistance of cable. Check any crack or abrading on cable insulation. 6 Protective relays (1) dial thermometer (3) dial oil gauge (5) Buchholz relay (7) sudden pressure relay (9) bursting plate beaking device

If such defect is found, put tape on it or exchange it with new one.

(2) winding thermal relay (4) oil flow indicator (6) gas detector (8) differential pressure relay (10) leak detector Note: (8) and (10) for oil/water cooler

6.1

Insulation resistance (Once every three years) Operation

Measure insulation resistance of protective relays including their wirings with a 500V megger. Operation test should be made only when protective relays operated even if no troubles of a transformer occured. All connectors outside of a transformer should be inspected to see whether they are in good conditions without any discoloration, which indicates hot connection.

When the insulation resistence is less than 2M , check dews in the terminal box. The cause of malopertion should be investigated by operation test according to instruction books for protective relays. Any connection that shows signs of having been hot should be thoroughly cleaned and bolted together tightly.

6.2

7.

Connections (Occasionally)

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6.

Additional inspection

Sometimes the following inspection and measurings are recommended for a preventive maintenance and in investigating a transformer trouble. Table 3 No Items 1 Insulating oil. 1.1 Analysis of gas dissolved on oil.

Method After a transformer is put into service, a periodic analysis of gas dissolved in oil is recommended every one or two years. Using an appropriate air tigh container, oil should be taken from transformer. The dissolved gas should be extracted from the oil and analyzed.

Action or remarks When the quantities of combustible gases are obtained, evaluations can be made to a probable location and type of trouble which may be present in a transformer. (Refer to Table 10) If there is an indication of moisture, sludge formation, low dielectric strength and low rsistivity, an inspection should be made on the inside of the tank for possible cause of the trouble.

1.2

Resistivity

Measure resistivity of insulating oil when a periodic test shows that the oil is in bad condition. Measure the insulation resistance between a pair of winding and between each winding and ground with a 2kV megger. The megger test should be made to check if the transformer is in suitable condition for operation or application of the dielectric test

2.

Insulation resistance of winding

The insulation resistance is subject to wide variation with temperature, humudity and cleanness of bushing porcelains. It may be low due to the leakage current through the weakest case gases dissolved in oil should be anaylyzed. Compare the test results with these in the test report. If it is difficult to measure because of fluctuation of voltmeter pointer or because of unbalance of a bridge circuit, more detailed investigation should be made.

3.

Ratio test

Measure the ratio of a transformer by two voltmeter method or with a ratio tester. If the transformer has taps, the turn ratio should be measured for all taps as well as for the full winding. The test voltage may be between 100 and 200V at the rated frequency.

4.

Winding resistance

Measure the winding resistance by bridge method or by drop-ofpotential method. If oil pumps are provided, they should be operated in measuring winding resistance. The oil temperature should be also record at the same type.

If the winding resistance corrected to a specified temperature, is different from the data obtained previously, more detailed investigation should be made.

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5.

Exciting current at low voltage

Measure the exciting current at low voltage (100-200 volts) applied on the lower voltage winding with other windings being open-circuited. The voltage wave shape should be sinusoidal. (Note (1))

If the measured exciting current is much larger than the original data at installation, more detailed investigation should be made. (Note (2))

6.

Impedance voltage

Measure the impedance voltage at low current (5-10 amperes) applied on the higher voltage winding with lower voltage winding being shortcirduited. (Note (3)) Exciting current and winding resistance should be measured in the same way as items 4 nad 5.

If the measured impedance voltage is much different from the original data at installation, more datailed investigation should be made.

7.

Bushing current transformer

Same as above 4 and 5.

Note: (1) the ammeter should be conneted inside of voltmeter as shown below to avoid error to high impedance measurement.

(2) If the measured values satisfy an expression below, the transformer may not get serious injury such layer shorting.

10

: Rated current : Measured current : Rated voltage : Measured voltage (3) The shorting cable should be more than 100 possible in its length, to avoid measuring error. in its section and be as shorter as

Shorting cable

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7.

Maintenance

Maintenance of parts and materials should be planed according to the following tables. Table 4 No Material and parts 1. Grease of fan motors

Maintenance frequency Grease them up once a year, with the grease gun.

Remarks Refer to items No.6. It is no necessary when a bearing is sealed type. According to instruction book.

2.

Porcelain insulator such as bushing, lightning arrester, supporting insulator.

Cleaning should be done periodically. Interval depends on actual circumstane condition at site. Recommended cleaning frequncy is once every two yares. Dust and other foreign materials, accumulated on the finned area, should be blown out to maintain the efficiency of the cooler. Internal compartment check and cleaning should be done once every two years. Repainting should be done once every five years. Bursting plate is recommended to be re[placed once every five years. Expected life is ten years. Expected life is three years, when bearing is sealed type. (Only fan motors)

3.

Cooler: (1) Radiator type (2) Forced air type

With compressed air and/or water.

(3) Water cooled type

4.

Paint

After cleaning the painting surface.

5.

Bursting plate of transformer Bearing of fan motors and oil pum motors.

6.

Exchange with new ones, if a motor becomes noisy due to broken bearings.

7.

Gasket (corkneoprene) Thermometer (oil, winding) Pressure relay (water, nitrogen, sudden pressure relay, water/oil differential pressure relay)

Expected life is ten years.

Exchange with new gaskets, if oil leaks from gasket are serious.

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8.

Trouble shooting

If any protective relay gives an alarm, investigate its causes according to the following table. Table 5 No Relay 1. Dial type thermometer

Function The dial type thermometer indicates the top oil temperature and highest oil temperature experienced. It gives an alarm when oil temperature gets to the alarm stting (80 for example). The thermal relay detects and indicates maxikum oil or winding temperature of a transformer. It also has protective functions to give an alarm or tripping signal and automatic functions to control cooling system.

Cause 1. Overloading. 2.Insufficient efficiency of cooler units due to dust and other foreign materials accumtlated on the finned area or due to heavy scale in the water cooling coils. 3. Maloperation of thermometer or thermal relay due to their own defects.

2.

Thermal relay for oil temperature or winding temperature.

3.

Oil flow indicator

The magnetic oil flow indicator checks the operating condition of an oil pump. When an oil pumps stops, the pointer returns to the stop position and the microswitch contact closes to give an alarm

1. Trouble of oil pump motor. 2. Trouble of wiring connection to oil pump motor. 3. Radiator valves are shut off.

4.

Oil level gauge-dial type

The dial type oil level gauge indicates the oil level in a conservator of an oilimmersed transformer. When the oil level comes down to the bottom of a conservator, its poiter indicates zero and give an alarm.

1. Shortage of oil. 2. Abnormally low ambient temperature in winter season. 3. Oil leakage.

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9.

Relay function

If any protective relay operates, investigate the causes of a trouble according to the following relays function. Table 6 No 1. Relay Buchholz realy (1) First stage Function The first stage of a Buchholz relay detects the gas formation due to minor troubles in transformer tank. The type and location of trouble may be predicted by gas analyses of oil. Note: Nitrogen gas dissolved in oil at high pressure could accumulate in the relay and actuate the relay because of the rapid oil-temperature drop on a cold day in case a gas-sealed transformer. (2) Second stage The second stage of a Buchholz relay detects the rushing oil due to a serious trouble in the transformer tank. If other protective relays such as over-current relay or differential relay, operate at the same time, a serious internal damage is suspected. 2. Sudden oil pressure relay. The sudden oil pressure relay detects the high rate of oil pressure increase in a transformer tank due to the gas generation and oil vapour caused by serious troubles. The type SP-3 sudden pressure relay detects the high rate if nitrogen pressure increase in a tank due to the gas generation and oil vapour caused by serious troubles in the transformer tank. The pressure relief device operates when the pressure in the relief vent rises abnormally high enough to reach the pressure of approximately 0.85 kg/ caused by serious failure in a transformer. It also operates when the pipe of air breather is choked so as to incresse the pressure in the relief vent. 5. Differential relay The differential relay detects the differece between the input current and the output current of a transformer converted by a current transformer. It also operates sometimes with the inrush current when a transformer is excited. 6. Overcurrent relay and ground fault relay These relays detect faults in the electrical system including transformer.

3.

Sudden pressure relay (Type SP-3)

4.

Pressure relief device

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Fig 1. Allowable value of transformer insulation resistance

Fig 2. Reaction between dielectric strength and amount of water in insulating ( )

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Table 7. acid value criteria No 1. 2. 3. Acid value (mg KOH/g) Less than 0.2 From 0.2 to 0.4 More than 0.4 Action Good Filter or exchange with new In earlier stage oil. immediately

Table 8. Criteria of cooling water characteristcs No 1 2 3 4 5 6 7 8 9 10 Test item Hydrogen ion concentration (PH) Electrical conductivity Chlorine ion Total hardness Surfurid acid iron M-Alkaliniry Sulfur ion Ammomium ion Total iron ion Silica Criteria 6.0 8.0 at 25 Less than 500 ( /cm) at 25 Less than 100 ppm Less than 150 ppm Less than 200 ppm 15 60 ppm Undetectable Undetectable Undetectable less than 0.5 ppm Less than 30 ppm

Table 9. Resistivity criteria of insulating oil at 80 No 1 2 3 Resistivity (ohm-cm) More than 1 x From 1 x to 1 x Less than 1 x Judgement Good Precaution Poor

Table 10. Combustible gas and type of fault with dissolved gas analysis of insulating oil. No 1 2 3 4 Decomposed gases , , , , , , , , , , , , , , , , , , , Type of fault Local heating in the oil Local haeting in the oil impregnated solid insulation Discharge in the oil Discharge in the oil impregnated solid insulation

, ,

, ,

Note: Underline means a significant gas.

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APPENDIX I: Action for safety and quality Table 11 No 1. 2. Working condition Exterior check Electrical test and remedial work Action for safety 1) Be careful not to approach live parts. 1) De-energise the transformer by circuit breakers and line switch. 2) Ground the line terminals and the transformer. 3) Attach caution tags not to operate switches for circuit breakers and line switches. See note. 4) De0energise the control cabinets for coolerd and tap changer by AC and DC switches. 5) Attach caution tag on switch boxes. Same as above except the following additional items. 1) Replaced nitrogen gas completely with dry fresh air, if it was filled in the transformer. 2) Make sure there is 18% or more oxygen to sustain life ia a transformer tank. 3) Make sure your pocket are empty. 4) Take off a wrist watch and any other accessories on your body. 5) List up name and quantity of all tools to be brought into a transformer tank. 6) Spread out clean cloth on coil groups when repairing. 7) Protect lamps with guards not to break them in a tank. 8) Be carefull not to drop any tool and foreign material into the transformer. Secure all tools wiyh hand lines. Any metallic item dropped into a transformer must be removed to prevent serious trouble in future. 1) Make sure all foreign materials are clear before closing manhole and energizing. 2) Check the quantity of all tools brought out from tang. 3) Remove the grounding wires on the line terminals of the transformer.

3.

When internal inspection is to be made.

4.

After inspection work.

Note: when test the remedial work must must be carried out under the live conditions for any special reasons, pay attention to live parts to protect yourself against electrical shock.

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