STANDARD MAINTENANCE PRACTICES

Oil Filled Transformer (≥5MVA)

Document No: SSTG/SMP/ELEC/0001

Revision History

Revision Approvals
Date Reason of revision
no Prepared by Checked by Approved by
Mr. Jagannath Mr. Ved Prakash
0 New Document Mr. U. Prasad
Mr. Sandeep Thakur
1. Change in Frequency of Transformer Inspection as
recommended by ETD
29-10- 2. Testing to be done as & when required as Mr. Jagannath Mr. Ved Prakash
1 Mr. U. Prasad
2013 recommended by ETD. Mr. Sandeep Thakur
3. Changes due to revision in oil testing standards.
IS:1866

1. OLTC Counter reading at MB and RTCC

15-05- 2. Introduction of noise level checking of the
2 Mr. Sandeep Mr. U. Prasad Mr. Rajesh Mishra
2021 transformer
3. Specific values for IR with different voltage levels

New clause I added for Core coil assembly inspection

31.12.2 Mr. Ranjan Mr. Umesh
3. of transformer for electrical and mechanical Mr. N. Rajesh Kumar
022 connection integrity.
Kumar Prasad
 Oil Filled Transformer DOCUMENT NO. REV
(≥5MVA) SSTG/SMP/ELEC/0001 3
Date:31.12.2022 Page 2 of 8

Revision Approvals
Date Reason of revision
no Prepared by Checked by Approved by

31.05.2 Mr. Ranjan Mr. Arnab

4. Recommendations of LEAP workstream-1 Team Mr. N. Rajesh Kumar
024 Kumar Bhattacharya

A. Introduction: Three phase transformers are meant to transfer power from one voltage level to other voltage level. It
can be classified into following categories.
i. Power transformer: That supplies bulk power to wide area or lot of load centers
ii. Distribution transformer: That supplies power to small area or load centers
iii. Converter transformer: This transformer is meant for power supply to rectifier loads or VFD loads
B. Operating Parameter/Working Condition/Basic condition:
Ambient Temperature: 30 - 40 Degree C
C. Scope: The document covers the standard Inspection & maintenance Guideline & procedure for Oil filled power
transformer above ≥ 5 MVA
D. Safety:
a) Safety Interlock: Within Fencing
b) Protection Interlock: Emergency Push button trip
E. Failure mode / Reason of Failure:
Failure modes Referral points in the SMP
Sl. No
Deviation of Winding resistance >5% G. b) 19.1
1.
Low Oil Level G. a) 9, 10
2.
Evolving of gas in Oil H.
3.
Low IR Value G. b) 19.2
4.
F. Guidelines from OEM: Refer OEM Operational manual
G. Inspection Guidelines:
a) Running Inspection (Daily/Weekly/Monthly)
b) Periodic Inspection

a) Running Inspection:
Sl.
Check Point Details Frequency How to Check Criteria Action (if out of criteria)
No.
1 Transformer Loading: D/W Ammeter on Should not be >100% Take action to reduce load on the
• HV Amps SWGR/RCP transformer
• LV Amps
2 Winding Temperature D/W Temp. meter on • Should not be >85 oC • If Winding Temp. >85oC, analyze
• At field Marshalling Box • Variation between & take action
• At RTCC panel near RTCC and field should • If variation found >5oC check the
(If provided) Transformer & not be > 5oC. repeater at RTCC panel
on RTCC

D : Daily, W : Weekly, M : Monthly, Q : Quarterly, HY : Half Yearly, Y : Yearly

Shares Services Technology Group 2
 Oil Filled Transformer DOCUMENT NO. REV
(≥5MVA) SSTG/SMP/ELEC/0001 3
Date:31.12.2022 Page 3 of 8

Sl.
Check Point Details Frequency How to Check Criteria Action (if out of criteria)
No.
3 Oil Temperature D/W Temp. meter on • Should not be >80 oC • If Oil. Temp. >80 oC take action to
• At field Marshalling Box • Variation between reduce load
• At RTCC panel near RTCC and field not • If variation found >5oC check the
(If provided) Transformer. & be> 5oC. repeater at RTCC panel
on RTCC
4 Oil leakages from D/W Visual No Leakage. In case of leakage assess the
flanges and welded severity and take corrective action
joints
5 OLTC counter reading M Counter in OLTC Readings at RTCC and Plan for inspection of connection
At field Marshalling Box OLTC MB should match from RTCC and OLTC MB during stop
and RTCC. and check inspection
6 HV/MV cable box M The temp. should be • Variation > 5oC from previous
By infrared
body temperature via consistent with previous record shall be investigated
thermal imaging
spot temperature record plus variation of
camera
measurement ambient temp.
7 Condition of clamps & M • Should not be >90 oC • If temperature found >90oC,
By infrared
connectors in power check the connection, clean or
thermal imaging
circuit. change the clamp at the earliest
camera
8 Condition of Silica Gel M Colour of Silica Colour shall be Blue • If colour found completely pink
breather Gel get the crystals dried or changed
• Check oil level in the pot below
the breather
9 Oil-level in the M Visual / The oil level shall be full • Take action if oil level is below the
bushing (for oil filled Binocular or above the marked marked level or not visible
bushings only) level • Clean gauge glass or replace
during shutdown if it is opaque
10 Main Tank Oil Level M Visual / Level should be Take action if oil level is below the
(Gauge Glass & MOG) Binocular between 35oC mark and marked level & fill with new oil
half mark on the MOG
11 OLTC Tank Oil Level M Visual / Level shall be above the Take action if oil level is below the
Binocular half mark of the gauge half mark level of gauge glass & fill
glass with new oil
12. Noise D/W dB meter Should be <75dB Inform sectional head and plan for
inspection

b) Periodical inspection/maintenance
Sl. Check Point Details Frequency How to Check Criteria Action (if out of
No. criteria)
1 Oil leakage from Y Visual No oil leakage • Proper tightening
Transformer of the inspection
covers to be
ensured
• Check condition
of gaskets
2 Cleaning of Bushing / Y Visual Shall be clean To be cleaned by
supporting insulators clean cotton cloth
(Jute should not be
used)
3 Tightness of Bushing Y By torque spanner Shall be tight Should be
clamps tightened with
proper torque
spanner

D : Daily, W : Weekly, M : Monthly, Q : Quarterly, HY : Half Yearly, Y : Yearly

Shares Services Technology Group 3
 Oil Filled Transformer DOCUMENT NO. REV
(≥5MVA) SSTG/SMP/ELEC/0001 3
Date:31.12.2022 Page 4 of 8

Sl. Check Point Details Frequency How to Check Criteria Action (if out of
No. criteria)
4 Condition of cable box Y Visual Shall be clean & no If moisture
moisture condensation or condensation or
contamination contamination is
found, it shall be
cleaned with petrol
or ether
5 Operation of Buchholz, Y Operation of alarm / trip Shall operate as desired Replace the relay if
Oil Surge relay (OLTC) contact by draining oil found defective

6 Operation of PRV Y Manually by operating at Shall operate as desired Adjust if found

the PRV defective
7 Oil-level in the bushing Y Visual The internal white strips Gauge glass shall
(for oil filled bushings shall not be visible be cleaned If
only) required
8 Replace oil of OLTC Y By portable oil pump To be replaced with new oil Check BDV of oil
diverter tank quarterly, replace
if found low.
9 OLTC tank oil level after Y Visual Between quarter and half- NA
oil replacement mark at the gauge glass
Lubrication of driving Y • Operate driving • The driving mechanism • Lubricate as per
10 mechanism mechanism & observe shall be smooth during OEM instruction
for any jamming or operation without Check the
abnormal sound abnormal sound operation of 1-
phasing
protection
• Check for
operation step-
by-step
11 Tightness of wiring Y • Visual & by pulling • Wiring shall be tightly • Tighten the
conditions & illumination sample cable from fitted with terminal loose cable with
in the DM Box and terminal • Illumination shall be Ok proper
Marshalling Kiosk screwdriver
• Fix the
Illumination
inside properly
12 Condition of space Y • Check functioning of • Space heaters shall be in • Replace heaters
heaters inside the DM space heaters by running condition if found
Box, Marshalling Kiosk switching on defective
13 WTI & OTI inside the Y • Check whether the • It shall not operate due • Mounting bush
Marshalling Kiosk contacts make on to vibration should be
vibration caused while replaced if
opening the door found defective
• Check for condition of • Mounting bush shall be
mounting bush of WTI in good condition
& OTI
14 Cooler control trial Y • Check operation of It shall function as per • Adjust the
through WTI fans manually first setting setting if found
• Then Check the wrong
operation through
WTI micro switch
manually at set point
in AUTO mode
15 Operational checks for Y • Operate cooling fan & • Shall be smooth running • Lubricate as per
cooling fan observe for any without any abnormality OEM instruction

D : Daily, W : Weekly, M : Monthly, Q : Quarterly, HY : Half Yearly, Y : Yearly

Shares Services Technology Group 4
 Oil Filled Transformer DOCUMENT NO. REV
(≥5MVA) SSTG/SMP/ELEC/0001 3
Date:31.12.2022 Page 5 of 8

Sl. Check Point Details Frequency How to Check Criteria Action (if out of
No. criteria)
vibration or abnormal • Direction of rotation • The dust
sound shall be as marked on deposition on
• Check direction of the fan the fan blades
rotation with a piece shall be cleaned
of cloth with plain cloth
• Set right the
direction by
interchanging
any two-phase
connection
16 Neutral Grounding Y • Measure NGR • Resistance value of NGR • If Resistance
Resistor health resistance by Multi- shall be within ±10% of value more than
meter nameplate value ± 10%
• IR Value to Ground • IR value shall be more investigate for
after opening ground than rated system shorting/
connection voltage +1 MΩ loosening of
• Physical inspection for • Shall be clean some section &
cleanliness • All joint connection shall set right
• Connection tightness be tight • IR value is less,
by suitable spanner check for any
insulator
damage. Clean
or replace the
insulator to
improve the IR
17 Monsoon protection of Y (Before Visual Rain protection shall be in Take corrective
DM Box and Marshalling Monsoon) good condition action if required
Kiosk
18 Monsoon protection of Y (Before Visual Rain protection shall be in Take corrective
Buchholz and Oil-Surge Monsoon) good condition action if required
relay.
19.1 Winding Resistance 4Y • To be done as per • The variation in • In case
measurement standard procedures resistance between resistance value
of Elect. Testing dept. consecutive tap shall be exceed the limit
consistent further
• The variation in winding investigation to
resistance between be made
phases shall be ≤ 5%
19.2 Insulation Resistance & PI 4Y • To be done as per • > 30M Ω for up to 33 KV
• If IR values
Measurement standard procedures of • > 80M Ω for 132 KV
found less, then
Elect. Testing dept. • >142M Ω for 220 KV
refer to PI
• >255M Ω for 400 KV
HV-E+LV (5000 V) readings.
• > 100 M Ω (Core IR)
• For new
LV-E+HV (5000 V) • New Transformers: Transformers, If
IR of Core (1000 V) o PI of HV > 2 PI value found
o PI of LV > 2.2 less, consult the
• Old Transformers > manufacturer
10Years: • For old
o PI of HV >1.3 Transformers, If
o PI of LV > 1.3 PI is less than
that mentioned,
consensus
decision to be
taken

D : Daily, W : Weekly, M : Monthly, Q : Quarterly, HY : Half Yearly, Y : Yearly

Shares Services Technology Group 5
 Oil Filled Transformer DOCUMENT NO. REV
(≥5MVA) SSTG/SMP/ELEC/0001 3
Date:31.12.2022 Page 6 of 8

Sl. Check Point Details Frequency How to Check Criteria Action (if out of
No. criteria)
19.3 Core insulation 4Y • To be done as per
• The IR value shall be
measurement by 1000V standard procedures
megger >100
of Elect. Testing dept.
20 Calibration of WTI & OTI 3Y • To be done as per * *
at site standard procedures
of Elect. Testing dept.
21 Wash the OLTC diverter 3Y • To be done as per * *
assembly with oil. standard procedures
of Elect. Testing dept.
22 OLTC Tap changing 3Y • Check operation In case of deviation
operation after • The number of rotations it shall be set right
manually by counting
shall be same for each
overhauling the number of as per OEM
operation for guideline
rotations.
forward/reverse
• Check for consistency
of operation at each • They should be perfectly
tap position. matching. No
• Check whether the tap discrepancy is allowed.
no. at the top of
transformer is • Shall be consistent.
matching with the tap • Shall be around 2 – 3 .
position indicator at
DM Box & RTCC panel.
• Check the value of the
resistance.
23 Oil sample testing of Y • To be done as per IS N.A
transformer standard.
23.1 BDV of transformer or Y • As per IS 1866 If test Values
Up to system voltage of
OLTC oil crosses the limit,
• <=72KV: >30KV consensus decision
to be taken for oil
• >72 to <=170KV: >40KV filtration or
• >170 to <=420KV: >50kV replacement.

23.2 Moisture content Y • As per IS 1866 -Do-

• <=72KV: ≤50PPM
• 72 to 170KV: ≤40PPM
• 170 to 420KV: ≤20 PPM
23.3 Acidity Y • As per IS 1866 Max. 0.3mg KOH/gm of oil -Do-

23.4 Resistivity at 900C Y • As per IS 1866 Min. 0.1X1012/cmat 90 ⁰C -Do-

23.5 IFT at 27 0C Y • As per IS 1866 Min. 0.015N / M -Do-

23.6 Tan at 900C Y • As per IS 1866 Max. 1% (up to 145 KV -Do-

transformers)
23.7 DGA Y • As per IS 1866 As per IS 10593 -Do-

H. Criteria for Oil filtration, oil replacement and winding dehydration:

D : Daily, W : Weekly, M : Monthly, Q : Quarterly, HY : Half Yearly, Y : Yearly

Shares Services Technology Group 6
 Oil Filled Transformer DOCUMENT NO. REV
(≥5MVA) SSTG/SMP/ELEC/0001 3
Date:31.12.2022 Page 7 of 8

Sl. No. Conditions Criteria Action (If out of criteria)

Up to system voltage of: • If value found low, refer other test results
BDV of Transformer oil given below
1 • <=72KV: <30KV
• If Acidity results are ok, filter the oil through
• 72 to 170KV: <40KV
high vacuum filter
• 170 to 420KV: <50KV
Up to system voltage of:
• If value found low, change the oil
2 BDV of OLTC (if applicable) • <=72KV: <30KV
• 72 to 420KV: <40KV

• <=72KV: >50PPM • If found more, then filter the oil through high
3 Moisture content • 72 to 170KV: >40PPM vacuum filter
• 170 to 420KV: >20 PPM

• Replace with new oil

• Clean the core and winding with clean hot oil
Max. >0.3mgKOH/gm of oil
4 Acidity jet
• Perform tests more frequently when the
value approaches 0.2mgKOH/gm.

• Check tan at 900C

Min. 0.1X1012/cm
5 Resistivity at 900C • If tan value is high, replace the oil
• Carry out periodic measurement

Tan at 900C • <=72KV: Max 1 • If tan value is high, replace the oil
6 • 72 to 170KV: Max 1 • Carry out periodic measurement
• 170 to 420KV: Max. 0.2

Min. 0.015 N / M • No conclusive result.

7 IFT at 27 0C
• Other test results to be consulted.

Periodic filtering of oil through • If all the test of oil is OK then filtering shall
8 Every 10 years
high vacuum filter. be done after every 10 years of service

I. Core coil assembly inspection of transformer for electrical and mechanical connection integrity.

Core coil assembly inspection of transformer for electrical and mechanical connection integrity shall be done for the
transformer having age>=30 years and rating more than equal to 10MVA on one time basis.
Priority shall be decided based on Electrical test, DGA, OST of oil, application and criticality.

Note:
If after oil replacement the winding IR value and PI value does not improve to the desired level, winding dehydration will be
required.
• Inspection frequency for Oil filled power Transformers of Voltage rating (Ul ≥ 132 KV) will be Daily.
• Inspection frequency for Oil filled power Transformers of Voltage rating (Ul< 132 KV) will be weekly.
• The following test to be done only during Transformer commissioning or if a transformer trips on any
transformer fault.
▪ Magnetic Balance Test.
▪ Ratio Test
▪ Tan Delta testing of transformer winding.
D : Daily, W : Weekly, M : Monthly, Q : Quarterly, HY : Half Yearly, Y : Yearly
Shares Services Technology Group 7
 Oil Filled Transformer DOCUMENT NO. REV
(≥5MVA) SSTG/SMP/ELEC/0001 3
Date:31.12.2022 Page 8 of 8

▪ Tan delta of transformer bushing (in case of oil filled bushings)

I. Storage Guideline:
Transformer should be stored at a place where it is designated as vital installation and remains within a barricaded
fencing boundary / gated transformer cell.
J. Installation protocol:
As per Indian Standard
K. Do’s and Don’ts
i. All required PPE to be used during inspection and maintenance.
ii. Do not start maintenance without positive isolation.
iii. Ensure that there is no power before maintenance.
iv. Do not use metallic torch and metallic brush.
L. UMC: To be created as per the installed capacity and size

D : Daily, W : Weekly, M : Monthly, Q : Quarterly, HY : Half Yearly, Y : Yearly

Shares Services Technology Group 8