TRANSFORMER ERECTION & COMMISSIONING

1. GENERAL 1. Introduction The transformers are designed, manufactured and tested with care. With proper attention during Installation and use, the user should receive from it the service, which he may reasonably expect. The purpose of this Instruction Book is to explain how the transformer should be installed, commissioned and maintained. The book is necessarily very general in character. No transformer should have rated voltage applied to it until all the preliminary work and checks described hereunder have been completed. No high voltage tests should be made without making reference to the manufacture. A transformer which has been commissioned and later withdrawn from service for any considerable time should be re-checked as when first commissioned. 1.1 ARRANGEMENT FOR TRANSPORT 1.1.1 Transformers are thoroughly dried out before despatch. Oil, whether in the transformer tank or in separate drums, is clean and dry when despatched. 1.1.2 Parts that are liable to be damaged in transit; are removed, packed and despatched in separate leases. Radiators, bushings, explosion-vent/PRV dehydrating breathers, rollers and buchholz relays. It always removed during despatch, wheather proof blanking plates being provided where necessary. Transformers are despatched from the factory in either of the following conditions: a) With oil covering core and coils only This is the usual arrangement wherever transport limitations permit. The tank is made oil tight. Extra oil for filling up the tank, conservator and other fittings is sent in separate sealed drums. b) With no oil in the tank The transformer is filled with nitrogen. The gas pressure and temperature at the time of despatch from the factory are painted on the tank cover. Full quantity of oil is sent in separate sealed drums. 1.2. INSPECTON 1.2.1 Before Despatch The transformers are inspected and despatched from manufactirer works in first class operating conditions, suitably packed for transport to destination. 1.2.2 At Site 1.2.2. External A thorough external examination should always be made immediately on arrival at site. The various packages should be checked against the advice notes. Any discrepancies from the advice notes should be immediately reported to the insurance underwriters, transporters under intimation to supplier. In the event of outward damages, open delivery should be demanded from transporters. Thereupon claims should be lodged with transporters and underwriters under advice to supplier.

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1.2.2.2 Internal An internal examination should be carried out to the maximum possible extent through the inspection cover. The tightness of nuts and bolts should be particularly checked. Core and coils should not be lifted unless there is reason to suspect internal damage. 1.2.3 Damage/Loss 1.2.3.1 Damage or loss of any component should be reported to supplier immediately. Photograph or other useful evidence should be submitted where possible. 1.2.3.2 When the transformer is despatched filled with oil, a sample of oil should be taken from the bottom of the tank and tested to I.S. 335. If the di-electric strength is below 40 kV BDV when tested on a standard test gap as specified in I.S. 335, the matter should be reported to supplier along with insulation resistance values of the various windings to earth. 1.2.3.3 Drums containing transformer oil which have been despatched separately should be examined carefully for leaks or any signs of tampering. All drums are despatched filled up to their capacity and any shortage should be reported. The drums should be stored in horizontal (lying) position, with bung at 45 downwards. 1.2.4 Deterioration 1.2.4.1 The presence of rust or condensation anywhere within the tank indicates that moisture is present. The transformer should not be energised until it has been dried out by the method given in clause 2.5 of this booklet. 1.2.4.2 When transformers are despatched gas filled, the pressure and temperature, when received at site, should be checked against the despatch pressure and temperature painted on the tank cover. Pressure difference indicates that the seal is ineffective. If the pressure is the same as the atmosphere, breathing may have taken place or the pressure may have gone down because of temperature variations. In such a case the temperature of the transformer should be raised above that of the 5urrounding air and a second measurement taken. If the internal and atmospheric pressure are still the same, breathing is taking place and drying out may be necessary. This should be referred to supplier giving the pressure measured and the temperature at which the measurements were taken. 1.3 HANDLING 1.3.1 Apart from the main lifting points designed to take the total weight of the unit, transformers often have subsidiary lifting points suitable only for particular components. Care must be taken to distinguish between them. 1.3.2 When lifting a tank, whether empty or with core, coils and oil, the cover must always be bolted in position with the full complement of bolts. 1.3.3 Transformers should be jacked up using the projections specially provided for that purpose. Jacks should never be placed under any valves 1.3.4 To avoid undue mechanical stresses the transformers must be kept on reasonably level foundation. 1.3.5 Regarding oil please refer clause 2.3 of this booklet.

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1.4 STORAGE 1.4.1 After arrival at site, it is desirable to erect and commission the transformer with minimum delay. In Case this is not possible the transformer should be erected at its permanent location with conservator and breather filled und dry oil filled to the correct level. Whether in storage or in use, the dehydrating breather must be fitted on all transformers which are oil filled. The breather incorporates an oil sealing device which must be filled with oil to the level marked to be effective. The condition of silicagel must be checked periodically, particularly during monsoons. The floating arm of the oil gauge on the conservator which is locked during despatch should be released. The conservator and associated pipe work must be checked for rust or any foreign matter and then flushed with dry oil before fitting. Breather inspection should be carried out. Wherever possible, it is most desirable to keep the transformer energised even at a low voltage so that the .oil temperature is about 10/150C higher than the surrounding ambient temperature. 1.4.2 All other accessories should be stored in a covered dry place. It should be ensured that there is no damage to the gasketted joints and that all the blanked joints are tight. 1.4.3 Indoor type. transformers must be protect9d from the whether at all times. Outdoor transformers may be stored outside, but it is preferable to store all transformers in a warm room in which the temperature variation is small. 1.4.4 During the temporary storage, the tank should be kept on beams to enable free flow of air underneath, unless the construction of the tank and base itself permits such a flow of air. 1.4.5 The tap changer, if provided, should be operated at 6 monthly intervals. Two or three runs from one end of the range to the other and back are sufficient. 1.4.6 Heaters for marshalling kiosks, etc. should be kept energised. If, for this purpose, power supply at the appropriate voltage to suit the heaters is not available, temporary heaters should then be installed to suit the site voltage. The provision of heaters is important and failure to provide them may result in extensive damage to the contents of the kiosk because of condensation. 1.4.7 All exposed paint work should be examined periodically. If any touching up is required. it should be carried out as described under clause 2.22 of this booklet. 1.4.8 Parts despatched separately are generally packed in cases or crates, although certain major items are sometimes despatched without packing. All items should be stored unreceived in a dry and covered place provided there are no sign of damage or rough handling. 1.4.9 If oil received in drums is not likely to be used immediately the drums should be stored in a covererd space where the temperature variation is minimum, If it is necessary to store the oil outside, adequate protection must be provided at all times. Drums should not stand on end but should be placed on their sides with the bung at 45 downwards.

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Fig. 2 Typical Unloading Arrangement of the Transformer

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2 INSTALLATION 2.1 PRECAUTIONS 2.1.1 Workmen having access to the interior of a transformer should empty their pockets of all loose articles. Any spanners or other tools used should be securely tied with a tape so that they can be recovered, if accidentally dropped. 2.1.2 Fibrous cleaning material should not be used. The presence of loose fibers in suspension in transformer oil can reduce its insulating properties. If any cleaning or wiping is necessary, this should be done with clean and dry oil, using soft-non fluffy cloth. 2.1.3 All components despatched separately should be cleaned inside and outside before being fitted. Rusted internal surfaces should receive special attention. 2.1.4 Transformer oil is inflammable and, under certain circumstances in a confined space, may become explosive. Naked lights and flames should never be used near a transformer. 2.1.5 Transformer oil and the cellulose-based solid insulations normally used in transformer construction absorb moisture easily, particularly when cold. Condensation can be caused if the interior of a tank is exposed to atmosphere. But by taking adequate precautions this can be minimised. 2.1.6 Whether despatched with or without oil, a transformer is best protected, from damp hazards by circulating warm, dry, deaerated oil through it until its temperature is 5C to 10C above ambient. This should be done before allowing external access to the interior of the tank. The warm oil should be circulated all the time the transformer is open to atmosphere. 2.1.7 Any air entering a transformer through leaky joints or with the oil may get lodged in vulnerable places such as windings. To prevent this, the oil pump and all joints in the oil pipe work should be air tight. 2.2 LOCATION AND SITE PREPARATION 2.2.1 No special foundation is necessary for the installation of a transformer except a level floor strong enough to support the weight and prevent accumulation of water. Foundation incorporating special oil drainage facilities during fire and emergency is strongly recommended for large transformers. 2.2.2 Transformer should be placed on the foundation so that easy access is available all around and diagram plates, thermometers, valves, oil guages, etc., can be easily reached or read. Adequate electrical clearances are also to be provided from various five points of the transformer to earthed parts. 2.2.3 Type ON transformers depend entirely upon the surrounding air for carrying away the heat generated due to losses. For indoor installation, therefore, the room must be well ventilated so that the heated air can escape readily and be replaced by cool air. Air inlets and outlets should be of sufficient size and number to pass adequate air to cool the transformer. The inlets should be as near the floor as possible and outlets as high as .the building will allow. Where necessary, exhaust fans can be installed for the purpose. 2.2.4 The transformers should always be separated from one another and from all walls and partitions to permit free circulation of air. In this connection reference is also drawn to clause 7.3 of I.S. 1886-1967.

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2.2.5 Where rollers are not fitted, level concrete plinth with bearing plates of sufficient size and strength can be adopted for outdoor transformers. To prevent the formation of rust, it is essential to avoid presence of air and water in the space between the plinth and the base of the transformer by use of cretex or similar bituminous compound. 2.2.6 Where rollers are fitted, suitable rails or tracks should be used and the wheels locked to prevent accidental movement of the transformer. Where walls are provided it should be ensure that the transformer gets a good ventilation as mentioned above for indoor transformers. Provision should be made for the emergency drainage of the oil from the transformers (e.g. in case of fire in neighbouring apparatus or bushing or the transformer tank). by surrounding the transformer plinth with sump filled with small pebbles. 2.3. Oil 2.3.1 When. Transformer oil is despatched to site separately. it is usually in sealed steel drums. At the time of filling the drums it is ensured that the oil is filtered clean and dry. 2.3.2 If the drums are stored outdoors, they should be on their sides with the bungs downwards at 45 to vertical. 2.3.3 Specification The oil to be used for filling or topping up the transformers should be as per IS : 335 . 3.2.4 Precautions 2.3.4.1 Oil is easily contaminated. It is very important when sampling the oil and filling the tank, to keep the oil free from contamination. 2.3.4.2 All equipment used for handling the oil should be cleaned and flushed with clean transformer oil before use (the oil used for washing must be discarded). Particular attention should be paid to the cleanliness of bungs, valves and other points where dirt or moisture tends to collect. 2.3.4.3 For sampling, glass containers with glass stoppers are to be preferred over the metal type which are susceptible to contamination by dirt. etc. Cleanliness is essential as even small amounts of dirt and water will affect the accuracy of test results. Wax should not be used for sealing the oil sample bottles, However, the stopper can be covered by a pack of silicagel tied in a piece of cloth. 2.3.4.5 Flexible steel hose is recommended for handling insulating oil. Some kinds of synthetic rubber or PVC hoses are also suitable but only those known to be satisfactory should be used. Ordinary rubber, hose should not be used for this purpose as oil dissolves the sulphur from the rubber and is thereby contaminated. Hose used for handling oil should be clean and free from loose rust or scales. 2.3.4.6 Transformers must always be disconnected from the electricity supply system before the oil level in the tank is lowered. . 2.3.4.7 Oil must not be emptied near naked lights as the vapour released is inflammable. 2.3.4.8 Minute quantities of moisture (particularly in the presence of fibres or dust) lower the di-electric strength of the oil. To reduce the risk of condensation and moisture entering the oil. containers taken into a warm room should not be opened until the entire body has attained the same temperature as the room.
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2.3.5 Sampling and Testing Oil takes up moisture readily and its condition should always be checked before use. Oil of a muddy colour is certain to be wet. Water and water saturated oil are both heavier than dry oil and sink to the bottom of any container. Samples should therefore, be taken from the bottom. Sample should not be taken unless the oil has been allowed to settle for 24 hours if from a drum and for several days, if from a large transformer. 2.3.6 Samples from tank Dirt from the draw-off valves or plug should be removed. To ensure that valve is clean, some quantity of oil should be allowed to flow into a separate container before collecting sample for testing. Samples should be collected in clear glass receptacles so that any water present will settle at the bottom of the receptacles and will be clearly visible. Only glass bottles with stoppers should be used for sampling. 2.3.7 Samples from drum The drum should first be allowed to stand with bung vertically upwards for atleast 24 hours. The area around the bung should be cleaned. A clean glass or brass tube long enough to reach within 12 mm of the lowermost pmt of the drum should be inserted, keeping the uppermost end of the tube sealed with the thumb whilst doing so. The thumb should be removed, allowing oil to enter the bottom of the tube. The tube is to be resealed and an oil sample withdrawn. The first two samples should be discarded. Thereafter the samples should be released into a suitable receptacle. 2.4 PROCESSING OF OIL In case when transformer is supplied with gas, it is customary to supply oil in drums. It is not possible to filter each and every drum and test it before filling in transformer. It is therefore necessary to have a container with suitable fittings so that the oil can be processed to the required quality. The figure 5 shows a typical arrangement of oil storage tank along with the fittings required. This storage vessel can be transported on a truck and can be lifted empty through the lifting holes provided on the base channel. 2.4.1 Oil Filling of Transformer Tank Before filling oil in the tank, it should be tested to meet the following requirements: BDV PPM (i) For transformers upto 132 kv class 60 kv 15 (ii) For transformers above 132 kv class 70 kv 10 In case the oil does not meet the requirements, it should be processed and should only be used when it meets the requirements. For transformers despatched gas filled, the filling of oil inside the tank should be done under vacuum. Transformers of high voltage ratings have their tanks designed to withstand partial or full vacuum. The safe vacuum as consistent with the tank design should be used for filling the oil. When filling a transformer with oil, it is preferable that the oil is pumped from the bottom of the tank and that a filter press or other reliable oil drying and cleaning device is interposed between the pump and the tank. If the maximum suitable vacuum is maintained in the interior whilst oil is being pumped in, the hazard of bubbles lodging in inaccessible corners of winding is very much reduced. Any air that remains will
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dissolve in the partially ceaerated oil when the vacuum is broken. It should also be ensured that the tap changer board, condenser bushing, relief vent diaphragm, buchholz relay, conservator, etc., are not subjected to full vacuum as they are not designed for the same. 2.5 DRYING OF TRANSFORMERS 2.5.1 The process of drying out a transformer is one requiring care and good judgement. If the drying out process is improperly performed, great damage may result to the transformer insulation through overheating, etc. A properly dried out and correctly installed transformer is one of the most reliable electrical appliances. 2.5.2 In no case should a transformer be left unattended during any part of the dry out period. Transformer should be carefully watched throughout the dry out process and all observations carefully recorded. 2.5.3 Drying of core and coils using oven 2.5.3.1 Where a suitable oven is available the core and coifs can be effectively dried in it by raising the temperature to a level not exceeding 80C. This applies to oil-soaked transformers also. A large volume of air should pass through the oven to remove moisture and vapour. An insulation resistance check will indicate when the coils are dry. The speed at which air impinges on the core and coils must not exceed 600 metres per minute. The oil, in which the dry core and coils will subsequently be immersed, must be processed and must meet the requirements la ill down in clause 2.3.1. 2.5.3.2 An alternative method can be used where transformer is to keep the core and coils in its own tank in an oven. This method can be used where the tanks are designed for full vacuum. The vacuum will be drawn from the top of the tank by connecting a suitable pump to any valve fitted at the top of the tank. The temperature in the interior of the tank should not exceed 75C. Care should be taken that the heating and application of vacuum should be alternated in sequence. Dry nitrogen gas should be used whenever vacuum is required to be broken. 2.5.4 Drying out a transformer using Streamline filter machine 2.5.4.1 The most practical method of drying out is by circulation of hot oil through a Streamline filter machine incorporating oil heater and vacuum chamber (or other oil cleaning and moisture removing device). Before using any filter machine it should be ensured that any other oil filled in the filter machine is first drained and refilled with oil supplied along with the transformer. The oil should be circulated through the filter machine several times and oil sample should be tested. If test results are in order, the filter machine can then be used for circulating the oil through transformer. The vacuum pump of the filter machine should have the capacity of creating vacuum as high as possible, but not less than 710 mm of Mercury. Where possible a vacuum pump can be connected to the top tank cover to keep the oil in tar1k under vacuum consistent with tank suitability. This may speed up the drying out process. It is preferable to lag or blanket the transformer tank to prevent loss of heat. To start with, oil is drawn from the bottom and let into the transformer at the top. This will remove any settled moisture/impurities. After about 8 to 12 hours circulation in this manner, the cycle is reversed i.e., oil is drawn from the top and fed at the bottom.

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2.5.4.2 The oil temperature as measured by the oil temperature indicator should be of the order of 75C it should be seen that the oil temperature at the filter machine in no case exceeds 85C. The circulation should be continued till the insulation resistance and oil samples taken from various points test satisfactorily. 2.5.4.3 The IR values taken at regular intervals should be plotted against temperature readings. It will be observed that, in the beginning, IR values drop down as the temperature goes up. The IR values will be low till moisture is present inside. Once the moisture is removed, the IR values will start rising and then become steady.

CURVE SHOWING VARIATION OF INSULATION RESISTANCE WITH TIME OF DRYING

Fig.3 Curve Showing Variation of Insluation resistance with time of drying

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IR-TEMPERATURE CURVE

Fig.4 IR - Temperature Curve 2.5.4.4 If necessary equipment is available, the power factor reading can be taken, which gives a reliable check on the condition of the solid insulation in a transformer. Capacitive power factor angle is different for each transformer design and the factory tested figure at a suitable reference temperature can be made available to the user, on request at the order stage. 2.5.4.5 The transformer can also be heated up by short circuiting the low voltage wind inn and supplying a reduced voltage at high voltage terminals. The supply voltage should be maintained in such a way that the current in the windings does not exceed 70% of normal full load current and the oil temperature, as mentioned above, is about 75C. In this case, temperature of oil should be measured at the bottom of the tank also. Constant watch is to be kept to ensure that the temperature limits are not exceeded. The temperature of the windings which can be measured by the following formula should in no case exceed 90C. R2 (235 + T1)-235 T2 = ---R1 Where T2 = final average temperature of the copper. T1 = Initial temperature of the copper. R2 = Final resistance of the windings. R1 = Initial resistance of winding. This method is more effective in drying the insulation but requires care und supervision of an experienced engineer.
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277

Fig. 5

2.5.4.6 IR Temperature relation It has always been the question from our customers as to how the IR value can be converted at different temperature. We have drawn a curve (fig. 4) for guidance of the operating staff on the basis of our experience, so that they can judge the IR Value at any temperature. This curve cannot be taken for absolute value but will serve as a good guide for conversions of IR values at different temperatures. A simple example is given as to how to calculate the value at different temperatures. Suppose IR value at 70C is 300 M. Ohms and we want to convert at 40C, the curve will give you a factor K for difference in temperature i.e. (70 - 40) = 30C K for 30C temperature difference = 4.2 So the value at 400C = 4.2 x300 = 1260 M. Ohms. Value thus converted fairly tally with the actual value when cooling the transformer. The factors are tabulated as below: Difference in temp. ( C) Factor K 10 1.65 20 2.6 30 4.2 40 6.6 50 10.5

2.6 GASKETS AND GASKET JOINTS 2.6.1 Transformer gaskets are of neoprene bonded cork and when supplied loose, have no bolt holes in them. They are usually cut to the size and shape required, although they may be supplied as straight, angled, or in U-shaped pieces from which complete gaskets can be built up. 2.6.2 Only scared joints should be used i.e. a 40 mm scarf in 5 mm thick material is recommended. Joints should be located away from corners and bolt halos, and should be well bonded smooth and free from local thickening, Neoprene solution is used as an adhesive for joints. 2.6.3 Gaskets are best stored in hermetically sealed containers in a cool place. They must be protected from damp, oil and grease. 2.6.4 To make a gasket joint first clean the metal surfaces ensuring that they are free from oil, rust, scale, etc. Using one of the flanges as a template, punch the necessary bolt holes. Insert the bolts and tighten the bolts sequentially, a little every time so that uniform pressure is exerted on the gasket until the gasket is compressed to about 2/3 of its original thickness. Joints should not be subjected to pressure until tightening is complete. If care is taken in making joints, and in handling the gasket, it is possible to break and re-make a joint several times, using the same gasket.

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2.6.5 For making leak proof and good gasket joints, it is necessary that uniform pressure is achieved all over the gasket after mating rims/flanges have boon clamped with bolts/studs. Following instructions be followed for proper tightening of bolts/studs. (i) Tighten lightly the bolts/studs diagonally in the sequence as shown in the figure given below:

Fig. 7 (ii) Tighten again bolts /studs in the same sequence with full pressure till gasket thickness is reduced to 2/3 of original thickness. (iii) Do not overtighten otherwise gasket will get crushed. 2.7 BUSHINGS 2.7.1 Bushings are usually removed for transport and the bushing holes blanked off. Before fitting, bushing should be examined for damage or cracks which may have occurred during transit. They should be cleaned with a dry non-fluffy cloth. Bushings are normally despatched fully assembled and filled to the correct level with the appropriate filling medium. Where a fluid filling is used, a check of the level must be made and the bushing filled up to the correct level, if necessary. Any leakage should be checked and stopped before the bushing is fitted. 2.7.2 Bushings should be assembled with their adaptors. if supplied, using the proper gaskets for the various joints. When clamping the bushings to the tank, care should be taken to ensure that an even pressure is obtained on the flange of the porcelain and its gasket by tightening the diagonally opposite nuts alternatively. The line connections to all types of bushings should be flexible to ensure that there is no strain exerted on the bushings because of line movement such as swing, expansion. contraction. etc. If arcing horns are fitted, the gaps should be carefully checked and reset to the values shown on the outline drawing or give in the instruction book supplied along with the transformer. For condenser bushing, please refer separate leaflet. 2.8 CABLE BOX 2.8.1 The laying of cables, connecting up and filling the cable boxes are usually the responsibility of the cable contractor and as such have not been dealt with here. 2.8.2 The cable box should be filled to the correct level with suitable filling medium (I S : 7084 class III) before energizing. lf the transformer is delivered to site with the cable box detached, this should be assembled on the transformer before filling with compound and allowed to stand with full oil head behind it for 24 hours. This is to check against possible oil leaks into the compound.

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Fig. 9

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2.8.3 The cables should be supported separately to ensure that no undue strain is exerted on the porcelain terminals in the cable box. The filling holes should be made weatherproof. 2.8.4 Hot compound should never be poured directly on the porcelain of insulator. 2.9 CONSERVATOR 2.9.1 As the temperature of the transformer oil increases or decreases, there is a corresponding rise or fall in the oil volume. To account for this. an expansion vessel (conservator) is connected to the transformer tank. 2.9.2 Conservator, where fitted. should be assembled with its pipe work. etc., making sure that all gasket joints ,He oil-tight and the pipe work is clean and free from moisture. The mechanism of the float type oil gauge inside the conservator is locked to prevent damage during transit. After placing the conservator in position, it should be released by turning the locking bolt in the direction indicated on the plate. 2.9.3 While topping up oil in the transformer. it should be ensured that oil is filled to the level indicated by the oil gauge on the conservator and commensurate with the oil temperature at that lime. 2.10 SILICAGEL DEHYDRATING BREATHERS Silicagel breaths arc despatched as loose items to prevent silicagel getting wet by oil in the breather cup. The plug sealing the top of the breather should be removed and connected to the associated pipe work. The oil cap at the bottom of the breather should be removed filled to the mark on the inside wall with transformer oil and the cap replaced. The oil seal ensures that silicagel is prevented from absorbing moisture when the transformer is not breathing (refer to separate leaflet on breathers). 2.11 EXPLOSION VENT 2.11.1 A temporary cover is provided over the explosion vent flange on the tank cover. This should be removed and the explosion vent fitted with suitable gaskets, care being taken to ensure that the top diaphragm with its gaskets makes on air tight joint. The explosion vent is sent blanked from works and the top blanking plate should not be removed till the oil level inside the transformer comes above the tank cover. 2.11.2 Where a transformer is provided with a buchholz device, a bottom paper diaphragm which acts as deflector plate, is fitted at the base of the explosion vent to ensure that any gases liberated in the transformer will pass through the buchholz relay and not collect in the vent. A hole in the side permits the oil to enter the vent and equalise the pressure on either side of the deflector diaphragm.

Arrangement of Explosion Vent Fig. 9

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2.11,3 In transformers of large ratings the space above the oil in the vent is usually connected by n pipe to the top conservator to equalise the pressure and vent it to tip. atmosphere through the breather. For transformers supplied without equalising pipe an air-cock is fitted at the top which must be opened when the tank is being filled with oil and closed again. 2.12 PRESSURE RELIEF VALVE In some of the temperature where explosion vent is not provided, Pressure Relief valve is provided. Pressure relief valves are usually removed for transport and the mounting holes on the transformer tank over blanked off. Examine the valve for damages, if any, before mounting. Check the continuity of contacts with Avometer. The flag operation should be checked manually by lifting the switch operating rod. The following checks should be observed before installation of Pressure Relief Valve on the transformers: (1) Use gasket supplied along with the valve. (2) Before P. R. V. put to service each valve should be cleaned with compressed air. The rubber gasket supplied with the valve should be cleaned and located properly in the recess carefully. All the bolts should be tightened evenly and sequentially so that equal pressure is exerted on gasket and base. The details of the pressure relief valve are as per figure no. 8 2.13 BUCHHOLZ RELAY 2.13.1 The buchholz relay is connected in the oil pipe work between the transformer tank and the conservator: It a valve is fitted to isolate the conservator, the buchholz relay is usually on the transformer tank side of the valve. The buchholz relay should be mounted in the pipe work only alter oil level inside the transformer is above the tank cover. 2.13.2 To ensure successful operation of the relay, the pipe work on either side of the relay and the relay itself, are all set at the same angle (3 - 7 to the horizontal for double float relay). A machined surface is provided on the housing of the relay to check the level. The arrow on the housing should point towards the conservator. The gas release pipe, when provided, is connected to the top petcock of the buehholz relay. In service, the top petcock should be kept open and the gas release pipe should be full of oil. When the gas is to be collected through the gas release pipe oil will flow out initially followed by the gas.

Conservator tank oil pipe work showing the portion of buchholz protection Fig. 10
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2.13.3 Before putting the transformer into service. all air which may have collected in the relay should be allowed to escape through the top petcock. The alarm and trip terminals are clearly marked for function and polarity. When making the connection from these terminals in conduits. care must be taken that condensate should not drain into the terminal box. For details refer separate booklet on buchholz relay. 2.14 TEMPERATURE INDICATORS 2.14.1 Oil temperature and winding temperature indicators operate on the principle of liquid expansion and provide local indication of top oil and winding hot spot temperature respectively at the marshalling kiosk. The thermometer bulb is connected by capillary tubing to the local indicator. The bulb is enclosed in a pocket which is normally fixed in the transformer cover in the hottest oil region. The oil temperature and winding temperature indicators are provided with a maximum pointer and mercury switches as required by the customer. The oil temperature indicator is the same as the winding temperature indicator except for the CT circuit and heating element on the pocket. 2.14.2 In the case of WTI of the Heated Bellows type, heating element is incorporated in the instrument itself. thus eliminating the heating element in the pocket. 2.14.3 The steel capillary tube is protected by a copper tubing which is strong enough to withstand normal handling. It should not, however be bent sharply or repeatedly and should be supported by clips to prevent sagging. On no account should it be cut. The thermometer pockets for OTI and WT/ should be filled with transformer oil, 2.14.4 Normally winding temperature indicator is provided on one phase of the LV winding. Where required, WTI can also be provided on the HV winding and also on different phases. 2.14 5 Before installing. the accuracy of the instrument snou1d be checked by hot oil or water both. The mercury switches are adjusted to make contact at the desired temperatures depending upon site conditions i.e., ambient temperature, loading condition, etc. 214.6 The CT connection of the WTI is made to the thermometer pocket as per instructions given on the WTI terminal board. For details. refer separate book let on temperature controller. 2.15 COOLING EQUIPMENT 2.15.1 Radiators Individual radiator, pipe work and headers should be cleaned and flushed with clean dry oil before fitting. These should be assembled as shown in the outline drawing. The radiators should then be filled with...clean and dry transformer oil. Air should be release from top of the header and also from each radiator. The inter-connecting valves between the tank and radiators are opened only when dry out is completed. 2.15.2 The fans and pumps should be wired to the respective terminals in the marshalling kiosk and the direction of rotation should be checked. For details of pumps refer separate booklet. 2.15.3 OFW Coolers: Please refer separate booklet on OFW coolers.

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2.16 ON-LOAD TAP CHANGER 2.16.1 The tap changer, if despatched separately, is to be fitted onto the tank. The insulation resistance value of each tap changer lead to earth should be measured and the cause of low values, if any, investigated. The leads from the tap changer should then be connected to their respective positions on the terminal board provided on the tank. The tightness of all connections on the selector switch and terminal board should be ensured, Any protective taping on the diverter switch bushing is to be removed. 2.16.2 It is advisable to fit the tap changer on the transformer even during storage and connect it to the conservator and breather. 2.16.3 In some cases, it may be difficult to get good IR values if there is moisture in the tap changer terminal board or on any of the parts of the selector switch and diverter switch. It should, therefore, be ensured that the selector switch and diverter switch are filled with clean dry processed oil. To remove moisture from the terminal board, it will be preferable to circulate the oil in the selector switch tank and the main transformer tank simultaneously and at as high a temperature as permissible. If some other special instructions are provided, the same should be followed. 2.16.4 For internally mounted (type MR) tap changer please refer separate booklet. 2.17 OFF CIRCUIT TAP SWITCH Before changing taps on transformers designed for off circuit tap changing, isolate the transformer from supply on all windings. It is to be noted that tap change is complete only when the tap switch handle completes one full revolution. To prevent damage due to inadvertent operation, the tap switch handle should never be left halfway and/or unlocked. 2.18 CURRENT TRANSFORMERS All CT secondary terminals should be short-circuited or loaded before energising the transformer. This will prevent excessive voltages developing across the CT secondary which can damage the CT and be a hazard if touched. 2.19 EARTHING 2.19.1 The tank should be permanently and effectively earthed by means of connections to the earthing terminals provided for the purpose at the bottom of the tank. (Refer Indian Electricity Rules for details on earthing). 2.19.2 A good low-resistance earth is essential for adequate protection. The earthing connection should be of sufficient cross-section to carry the l V line current for 30 seconds. Stabilising winding, if supplied, for the suppression of harmonics, should have one point earthed to prevent it from developing a high potential. Other accessories such as fan motors, oil pump motors, etc., should be also earthed. 2.20 PAINT WORK 2.20.1 All metal parts are given three coats of high quality paint before despatch from the works. The first, which is applied to the clean metal surface, is a primary coat, followed by an intermediate coat and a final finishing coat. which is normally dark grey to shade no. 632 of 1.5. 5 or B.S. 381C unless specified differently by the purchaser. If the point work has been damaged during or erection, touching-up should be carried au with tl1o least delay.
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2.20.2 The following paints which are available from our approved suppliers should be used. FIRST AND SECOND COATS OF PRIMER

Sl.No. 1 2 3 4 5 6

Supplier Name Asian Paints Addisons British Paints Alkali Chemicals Garware Paints Goodlass Nerolac

Reference 32 / F 3257 LS 2907 BPL Primer Red Oxide Zinc chromate

32 781 RR 4460 205 /023

THIRD AND FINISHING COATS

1 2 3 4 5 6

Shalimar Goodlass Nerolac Asian Paints Jenson & Nicholson Alkali Chemicals British Paints

Superlac Synthetic Enemel 500 / 850 Apcolite Synthetic Enamel Robbialac Superlac Deluxe Synthetic Enamel LUXOL 3 HIGLOSS Synthetic Enamel

2.20.3 It the recommended paints are not available. a high Quality alkyd resin-based paint may be used. The surfaces to be repainted should be clean and free from grease and rust. If rust has begun to form; the surrounding area should also be cleaned, thoroughly as rust tends to spread beneath paint work. 2.20.4 Failure to maintain the paint work in good condition will result in considerable deterioration of the apparatus during storage or service. 2.21 TOPPING UP OF OIL IN TRANSFORMER After completing mounting of all fittings on the transformer. the transformer should be topped up with clean and dry oil meeting the requirements as given in clause 2,3.3 through the bottom filter valve with the help of a filter machine. Care should be taken to keep all air release plugs and valves open to allow escape of trapped air. The filling is to be continued till the appropriate level, indicated on the conservator corresponding to the oil temperature, is reached. The filling should then be stopped and air release plugs and valves should be closed.
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2.22 COMPLETION OF ERECTION WORKS Any other work such as wiring of various alarm/trip contacts from various accessories of the transformer to marshalling kiosk. settings of relays, checking of protection scheme, etc., should be completed before the transformer is cleared for commissioning, 2.23 PARALLEL OPERATION 2.23.1 If it is desired to parallel a transformer which is not identical in design with BHEL transformer, it is preferable to refer the matter to BHEL for advice. 2.23.2 The voltage ratios and impedance values at all taps should match for the two transformers that are to be paralleled. Only certain combinations of vector groups are capable of being paralleled. The table below indicates the more common permissible combinations. 2.23.3 Reference to the connection diagrams of two transformers should indicate the terminals to be paralleled. 2.23.4 The reversal of two leads on either side of a three-phase transformer will reverse the polarity. Changing them in sequence (e. g. from A. B. C. to B.C.A. or C.A.B.) will swing the vectors through 1200 2.23.5 Phase sequence and polarity can be checked by energising both transformers on the primary side before paralleling, and measuring the open-circuit voltage appearing across each pair of terminals which will ultimately be paralleled. TRANSFORMER (B) HV LV H.V./L.V. Delta / Star TRANSFORMER (A) Star / Delta Delta / Star Star / Delta Yes Yes No No Yes Yes No No No No Yes No No No Yes Yes Delta Star Delta Star Delta Delta Star Star

3. COMMISSIONING 3.1 After the transformer is installed in accordance with Section 2 undernoted precommissioning tests and checks on instruments should be done before putting the transformer in service. 3.2 DRY OUT TEST 3.2.1 IR values of various windings to earth should be checked. While checking these values; no external lines. lightning arrestors, etc., should be in circuit. Bushings should be throroughly cleaned with a dry clean piece of cloth before taking I R values. The IR values obtained should
287

be comparable with those indicated in BHEI test report. In humid weather condensation on the sheds can affect IR values. 3.2.2 After filling the oil in the transformer, it will again be re-conditioned as per cl. no 2.4 till the following characteristics are obtained: BDV PPM (i) For transformer upto 132 kV 50 kV 15 (ii) For transfollllP.r above 132 kV 60 kV 10 3.3 RESISTANCE MEASUREMENT OF WINDINGS Winding resistance should be measured at all tap positions. 3.4 RATIO TEST Ratio test between HV and LV at all taps should be carried out. For 3 winding transformers ratio between other pairs of windings should also be taken. 3.5 PHASE RELATIONSHIP TEST Test for verification of phase relationship and vector group should be conducted at site. 3.6 TAP CHANGER TEST a) Manual operation. b) Local electrical operation. c) Remote electrical operation d) Parallel operation. e) The operations should be checked from one end of the range to the other to check for limit switch operations also. f) IR values of motor and control wiring should be checked with 500 V megger. 3.7 BUCHHOLZ RELAY TEST Buchholz relay operation for alarm and trip should be checked by injecting air through the test petcock. 3.8 LOW OIL LEVEL ALARM The low oil level alarm of the oil gauge should be checked. 3.9 TEMPERATURE INDICATORS The contacts of OTI and WTI for alarm, trip and control (where provided) should be checked and set at required temperature. 3.10 COOLING GEAR TEST a) The IR values and settings for operation of oil pump and fan motors should be checked. b) Alarm trip contact settings of differential pressure gauge, oil and water flow indicators, where provided, should be checked. 3.11 MARSHALLING KIOSK The wiring from various accessories to marshalling kiosk should be checked.

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3.12 PROTECTIVE RELAYS Tripping of the associated breakers is to be proved b actual operation of the differential relay, over current relay, earth fault relay and other protective relays as applicable. 3.13 MAGNETISING CURRENT The magnetising current can be measured by feeding 400 V. 3 phase, 50 Hz supply from HV side keeping LV side open circuited and the values in different phases could be compared. 3.14 ADDITIONAL CHECKS Checks should be made to see if : a) All oil valves are in correct position closed or opened as required. b) All air pockets are cleared. c) Thermometer pockets me filled with oil. d) Oil is at correct level in the bushings, conservator diverter switch. tank, etc. e) Earthing connections are made. f) Colour of silicagel is blue. g) Bushing arcing horn gap is set correctly. h) CT polarity is correct (when bushing mounted CTs are provided). If all the above tests/checks are found satisfactory a setting time of atleast 24 hours should be allowed for the oil and air released from all points at 6 hourly intervals, before commissioning the transformer. Wherever possible, while commissioning, the voltage should be built up slowly and brought to the full level in about 4 to G hours. If the breaker is tripped on differential. buchholz or any other device. the cause must be investigated before re-energising the transformer. Sometimes tripping may be because of magnetic inrush which depends upon the switching at a particular moment in the cycle. After commissioning magnetising current should be measured by connecting with a meter in metering CT circuit and the reading should be compared with the test report value. 4. MAINTENANCE 4.1 If a transformer is to give long and trouble -free service, it should receive a reasonable amount of attention and maintenance. Mi1intenance consists of regular inspection, testing and reconditioning where necessary. Records should be kept giving details of any unusual occurrence and also of any test results taken. The principal object of maintenance is to maintain the insulation in good condition. Moisture, dirt the excessive heat are the main causes of insulation deterioration and avoidance of these will, in general, keep the insulation in good condition. No work should be done on tiny transformer unless it is disconnected from all external circuits and all windings have been solidly earthed. Note: The general notes and information given under storage, handling and installation etc. are also applicable to routine maintenance. 4.2 TRANSFORMER OIL Oil is used as a coolent and di-electric in the transformer and keeping it in good condition will assist in preventing deterioration of the insulation which is immersed in it. The peremissible limits of various characteristics as per IEC : 422 are given as per Appendix A1 and A2 at the end.
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A few short notes on the subject are given below a) The oil level should be checked at frequent intervals and any excessive leakage of oil investigated. There may be a slight loss of oil by evaporation; this need not cause concern if the tank is topped up at regular intervals. All minor leaks or seepages should be repaired as quickly as possible.

b)

4.3 CORE & WINDINGS It is recommended that the core and windings be removed from the tank for visual inspection as per time schedule given in clause 4.17. The windings should be examined to ensure that no sludge has been deposited blocking the oil ducts Any loose nuts and bolts should be tightened. Before lifting the core and windings from the tank it is usually necessary to disconnect the windings from the bushings or cable boxes inside the tank, to disconnect the off-circuit tap switch handle or leads of the on-land tap changer and to remove any earthing strips between the core and the tank. The core and windings must be removed with great care, under cover and in a dry place. 4.4 TAP CHANGER See separate instruction booklet. 4.5 BUSHINGS Porcelain insulators and rain sheds should be cleaned at convenient intervals when the transformer is out of service. A metal pan scrubber can be used effectively to remove grime. During cleaning, the porcelain should be examined for cracks or other defects and defective ones replaced. Oil level in oil filled bushings should be checked at frequent intervals. The cause of any serious loss of oil should be investigated. For details See separate maintenance booklet on Bushings. 4.6 CABLE BOXES The sealing arrangement for fillings holes should be chucked each year. When screwed plugs are sealed with a bituminous compound, the compound should be exnll1irwd for cracks. If the compound has cracked, it should be replaced as the cracks may lead to an accumulation of water around the plug. Gasket joints should be examined and tightened. 4.7 COOLING EQUIPMENT Please refer separate booklet. 4.8 CONSERVATOR Conservators are so arranged that the lower part acts as a sump in which any impurities entering the conservator will collect. A valve is fitted at the lowest point of the conservator for dri1ining and sampling. When sampling, care must be taken to run off any contaminated oil before taking a sample for testing. The inside of the conservator should be cleaned as per clause 4.17. A removable end is provided on each conservator for this purpose. 4.9 OIL GAUGES Oil gauge glasses should be kept clean so that the gauges can fulfil their purpose.
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Broken glasses should be replaced immediately; The gauges are normally fitted with armour plate glass which is unbreakable under normal service conditions. When the conservator is stripped for cleaning, the mechanism of the float type oil gauge, if fitted, should be inspected and cleaned. 4.10 DEHYDRATING BREATHER Breathers when fitted should be examined to ascertain if the silicagel requires changing. The frequency of inspection depends upon local climate and operating conditions. More frequent inspections are needed when the climate is humid and when the transformer is subject to fluctuating load. The crystals of silicagel in the breather are tinted to act as an indicator and change from blue to pink on becoming saturated with moisture. When the majority of the crystals have turned pink, the silicagel should be replaced or reactivated. To reactivate the gel, the crystals should be heated in a shallow pan at a temperature of 1500 C to 200C until the original blue colour is regained. This usually takes 2 to 3 hours. The oil level in the oil seal should be maintained up to the level indicated in the cup. (For full particulars see instruction booklet on breathers. 4.11 BUCHHOLZ PROTECTOR Routine operation and mechanical inspection test should be carried out as per clause 4.17. The operation is tested by injecting air into the protector through the air injecting pipe. After inspection, any air which has accumulated in the gas chamber must be released through the upper petcock leaving the chamber full of oil. To carry out mechanical inspection, the oil level should first be brought below the level of protector and the mechanism removed. The floats should be able to rise and fall freely, and the mercury switches should be tightly clamped and he in good order. If a switch is defective swing to the glass being cracked there will be clouding of the glass. In such cases the switch must be replaced, During operation, if there is an alarm and gas is found to be collecting, the transformer should be isolated and the gas should be tested and analysed to find out the nature of fault. Sometimes it may be noticed that the gas collected is only air. The reasons for this may be that the oil is releasing any absorbed air due to change in temperature or due to leakage on the suction side of the pump. The absorbed air is released normally when no vaccum is applied during filling of oil and also in the initial stages only. The internal faults can be identified to a great extent by a chemical analysis of gas. Buchholz may also give alarm/trip duo to oil level falling below the buchholz level. Also see separate leaflet of the buchholz relays. 4.12 EXPLOSION VENT The diaphragm, which is fitted at the exposed end of the vent, should be inspected at frequent intervals and replaced. if damaged. Failure to replace the diaphragm quickly move allow the ingress of moisture which, will contaminate the oil. If the diaphragm has broken because of a fault in the transformer, an inspection should be carried out to determine the nature and cause of the fault. 4.13 GASKETS Gaskets sometimes shrink during service. It is therefore, necessary to check the tightness of all bolts fastening the gasket joints. The bolts should be tightened evenly around the joints
291

to avoid uneven pressure. Leaking gaskets should be replaced as soon as the circumstances permits. 4.14 SMALL PIPE WORK The pipe work should be inspected atleast once a year leaks may be due to slack unions, which should be tightened, or due to badly seated joints caused by a misalignment. In the latter case, the pipes should be aligned and joints remade. 4.15 TEMPERATURE INDICATORS At each yearly maintenance inspection, the level of oil in the pockets holding thermometer bulbs should be chucked and the oil replenished if required. The capillary tubing should be fastened down again if it has become loose. Dial-glasses should be kept clear and, if broken, replaced as soon as possible to prevent damage to the instrument. Temperature indicators if found to be reading incorrectly, should be calibrated with standard thermometer immersed in hot oil bath. 4.16 PAINT WORK During storage and service the paint work should be inspected once a year and, where necessary, painting or retouching carried out. If the metal surface is exposed and becomes dirty, rusty or greasy because of delay in repairing the paint work, the surface must be thoroughly cleaned before repainting to ensure a good bond between metal and paint. If paints recommended by supplier are not available, any good quality alkyd resin-based paint may be used. 4.17 MAINTENANCE SCHEDULE The maintenance schedule given at Table-A is a good indication 01 the attention required to be given to the transformer under average conditions.

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TABLE-A

S.No.

Items to be inspected Ambient temperature Winding temperature Oil temperature Load amps Load voltage

Inspection notes HOURLY -Check that temperature rise is reasonable. Check against rated figures. DAILY Check the relief vent diaphragm to be intact. Check oil level from oil gauge. Check oil level from the gauge glass Check the oil level from gauge glass. Inspect the transformer for leakages.

Action required

-Shutdown the transformer and investigate, if either is persistently higher than normal. An improper tap position can cause excessive core loss. Voltage and tap position should be corrected. Investigate, replace if found broken. Top up, if found low. Top up, if found low.

Relief vent Oil level in transformer conservator Oil level in tap changer diverter switch. Oil level in bushings. Pipework and accessories for leakages Dehydrating breather

Top up, if found low. If leakages are observed, tighten evenly the gasket joints. Replace 'O' ring or washer suitably. Replace gasket if needed. Reactivate/replace with new charge, if found pink. Investigate and rectify after taking shutdown. Clean and tighten plugs. Cracked porcelain should be rectified/ replaced. Take suitable action to restore quality of oil.

Check colour of silicagel.

Leakages of water into -cooler MONTHLY Examine for dirt deposition and tightness of oil filling plugs, Examine for cracks in porcelain. Check for di-electric strength and moisture content.

Bushings

Transformer oil and tap changer oil

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S.No.

Items to be inspected

Inspection notes QUARTERLY Check contacts, manual controls and interlocks.

Ac

Cooler fan, bearing and controls

Examine contacts, check step by step mechanism operation, end position On load tap changer limit switches, emergency limit switches and brakes. Check oil level in the Clip Dehydrating breather and ensure air passages are free. Check that air passages NOTES : Ventilators are free. 1) In addition to the above instructions, reference should also be made to IS : 1886 - Code of Check the oil for practice for installation and maintenance of transformers. Bushings dielectric strength and 2) The inspection schedule specified for longer periods automatically includes those specified moisture content. for shorter periods. HALF YEARLY 3) All maintenance test results and observations should be specifically recorded. Oil cooler Check for pressure test. 4) Where matter given in the inspection book differs from that given in IS or BS referred to, Insulation resistance Compare the values with of transformer commissioning value. 294 Check the free flow of oil Tap changer filter in the filter. wherever provided Cooling fans Check vibrations of impellers and shaft.

Lu Re an Cl int Re bu sw Cl lil1 an To air Cl

Re filt an

--Pr

Cl wi oil Re is ba

5)

6) 7) 8)

the transformer user should follow the instruction book. In case of anything abnormal occuring during service, advice from suppliers should be obtained giving them complete particulars as to the nature and extent of occurence, together with the nameplate particulars in order to assist identification of the transformer. Di-electric strength of at specified in the instruction manual is breakdown values with 2.5 mm gap - as given in IS : 335/1972. As-efforts are being constantly made to improve designs and service, the transformer supplied may differ in minor details from data given herein. Any additional information required by the customer will be gladly supplied. DOS FOR POWER TRANSFORMER Check and thoroughly investigate the transformer whenever any alarm or protection is operated. Check the diaphragm of the relief vent, if cracked or broken, replace it. Attend the leakages on the bushing immediately. Examine the bushing for dirt deposits and coats and clean them periodically. Check the oil in transformer and OLTC for. di-electric strength and moisture content and take suitable action for restoring the quality of oil as per table-A of Maintenance Schedule. Check the oil level in oil Clip and ensure air passages are free in the breather. If oil is less, make up tile all. Check the oil for acidity and sludge as per table-A of Maintenance Schedule. If inspection covers are opened or any gasket joint is tightened then tighten the bolts evenly to ovoid uneven pressure. Check and clean the relay and alarm contacts. Check also their operation, and accuracy and if required change the setting. Check tile protection circuits periodically. Check the pointers of all gauges for their free movement. Clean the oil conservator thoroughly before erecting. Check the buchholz relay and adjust the floats, switches, etc. Inspect the painting and if necessary retouching should be done. Check the OTI and WTI pockets and replenish the oil, if required. Remove the air vent plug of the diverter switch before you energise the transformer. Check the oil level in the diverter switch and if found less, top up with fresh oil conforming to IS:335 Check the gear box oil level, if less, top up with specified oil. Examine and replace the burnt or worn out contacts as per table-A of Maintenance schedule Check all bearings and operating mechanism and lubricate them as per schedule. Open the equalising valve between tank and OLTC, wherever provided at the time of filling the oil in the tank. Close the equalising valve between tank and OLTC during operation. Connect gas cylinder with automatic regulator transformer is to be stored for long, in order to maintain positive pressure. Fill the oil in the transformer at the earliest opportunity at site and follow storage instructions.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

DONTS FOR POWER TRANSFORMER Do not energise without thorough investigation of the transformer, wt1enever any alarm or protection has operated. Do not re-energise the transformer, unless the buchholz gas is analysed. Do not re-energise the transformer without conducting all pre-commissioning checks. The results must be comparable with results at works. Do not handle the off- circuit tap switch when the transformer is energised. Do not energise the transformer unless the off-circuit tap switch handle is in locked position. Do not leave off-circuit tap switch handle unlocked. Do not overload the transformer. Do not leave tertiary terminals unprotected outside the tank, connect them to tertiary lightning arrestors protection scheme when connected to load. Do not allow WTI OTI temperature to exceed 750C during dry out of transformer, and filter machine temperature beyond 850C. Do not parallel transformers which do not fulfill the condition given in clause 2.25 Do not use low capacity lifting jacks on transformer for jacking. Do not move the transformer with bushings mounted. Do not overload the transformer other than the specified limits as per IS : 6600. Do not change the settings of WTI and OTI alarm and trip frequently. The setting should be done as per the site condition. Do not leave red pointer behind the black pointer in OTI and WTI. Do not meddle with the protection circuits. Do not leave any connection loose. Do not allow conservator oil level to fall below 1/4 level. Do not allow oil lewd to fall in the bushings, they must immediately be topped up. Do not leave marshalling box doors open, they must be locked. Do not switch off the heater in marshalling box except in summer. Do not allow dirt and deposits on bushings, they should be periodically cleaned. Do not allow unauthorised entry near the transformer. Do not leave ladder unlocked, when the transformer is ON in service, in case it is provided. Do not change the sequence of valve opening for taking standby pump and motor into circuit. Do not switch on water pump unless oil pump is switched all. Do not allow water pressure more than oil pressure in differential pressure gauge. Do not mix the oil, unless it conforms fully to IS : 335. Do not allow inferior oil to continue in transformer. The oil should be immediately processed and to be used only when BDV conforms to IS : 335. Do not continue with pink silicagel, it should immediately be changed or regenerated. Do not leave secondary terminals of an unloaded CT open Do not commission the transformer in case IR values are not satisfactory. Do not continue to run the transformer with relief vent diaphragm broken or cracked. Do not store transformer for long after reaching site. It must be erected and commissioned at the earliest. Do not keep the transformer gas filled at site for a longer period.

296