IS I 10028 (Part III) - 1981

( Reaffirmed 1993 1

Indian Standard ( Reaffirmed 1998 )

CODE OF PRACTICE FOR

SELECTION, INSTALLATION AND
MAINTENANCE OF TRANSFORMERS
PART Ill MAINTENANCE

Fwtih Reprint APRIL 1997

( Incoprating Amendment No. 1)

UDC 621*314*21-7

BUREAU OF INDIAN STANDARDS

MANAK RHAVANU. 9 RAHAVUR SHAH ZAFAR MARG
NEW DELHI 110002

(;r 6 May 1982

 IS : 10028 ( Part III) - 1981

Indian Standard
CODE OF PRACTICE FOR
SELECTION, INSTALLATION AND
MAINTENANCE OF TRANSFORMERS
PART III MAINTENANCE

Code of Practice for Power Installation and Maintenance Sectional

Committee, ETDC 20

Chairman Representing
SHRI K. K. BOSE The Calcutta Electric Supply Corporation Ltd,
Calcutta
Mtmberr
SHRI A. CHATTERJEE( Alternafe to
Shri K. K. Bose )
SHRI B. c. ALVA Karnataka Electricity Board, Bangalore
SWRI T.N;R. RAO ( Alternate )
SHRI M. J. ANANDALIURTHY Chief Electrical Inspector to the Government of
Tamil Nadu, Madras
ELECTRICAL I N s P E c T o R
(TECHNICAL ) TO THE
GOVERNMENTOF TAMIL NADU
( Alternate )
SHRI P. D. BAOADE Tata Consulting Engineers, Bombay
SHRI R. C. BAJPAI ( Alternate )
SHRI V. S. BHATIA Siemens India Limited, Bombay
SHRI K. K. PANT ( Alternate )
SHRI K. V. CHAUBAL The Federation of ElectricityUndertakings of India,
Bombay
SHRI K. S. JOSHI ( Aftsrnate )
CHIEF ENGINEER ( ELEC )-I Central Public Works Department, New Delhi
SURVEYOR OF WORKS ( ELEC)-I
( Alternate )
SHRI RANES RAY CHOUDHURI Engineering Construttion Corporation Limited,
Bombay
SHRI L.E.D. CRUZ (Alternate)
CHIEF ELECTRICALENGINEER Railway Board, Ministry of Railways
DEPUTY DIRECTOR STANDARDS
( ELEC )-IV, RDSO ( Alternate )
( Continued on page 21

(9 Copyrrght 1982
BUREAU OF INDIAN STANDARDS
This publication is protected under the Indian Copyrtghr Acr (XIV of 1957) and
reproduction in whole or in part by any means except with written permission of tbe
publither shall be deemed to be an infringement Of copyright under the raid Act.
IS : 10028 ( Part III) - 1981
( Continurdfiompage1 )
Members Representing
SHRI DEVENDER NATH Larsen & Toubro Ltd, Bombay
SXRI T.P.R. SARMA ( AIkmak )
SHRI B.L. DESXPAND~ Electrical Engineer to the Government of
Maharashtra, Bombay
SXRI K. V. DHARYADHIKARI Jyoti Ltd, Vadodara
SHRI D. J. HASTAK Maharashtra State Electricity Board, Bombay
MEMBER ( HYDRO-ELECTRIC ) Central Electricity Authority, New Delhi
DIRECTOR ( HED )-1 ( Alternate )
SHRI D. R. NEELAPPA REDDY NGEF Limited, Bangalore
SHRI G.S.N. MURTHY ( Alkmak)
SXRI K.P.R. PILLAI Fact Engineering and Design Organization, Udyoga-
mandal
SHRX C.R.R. MBNON ( Alkmak )
LT-COL B.B. RAJ~AL Engineer-in-Chief’s Branch, Army Headquarters
( Ministry of Defence )
SHRI S. K. SHANQAW ( Alternate )
SHRI B. M. SAXANT The Bombay Electric Supply and Transport Under-
taking, Bombay
Sxar S. R. UGRANKAR ( Alkmatc )
SXRI I. C. SAXQER Delhi Electric Supply Undertaking, New Delhi
Sxm P. S. SAWXNEY ( AItemate )
SHRI P. K. SAXRNA Rural Electrification Corporation Ltd, New Delhi
SHRI G. L. DUA ( Alternate )
SHRI SARDUL SINQX Chief Electrical Inspector to the Goyqtb)ltnt of
Punjab, Chandigarh
SHRI D. S. UPPAL ( Alkmate )
Sxar V, SA~HYANATWAN Tamil Nadu Electricity Board, Madras
SXRI S. KRISXNARAJ (Aftemote )
SXRI R. SATYABAL Tariff Advisory Committee, General Insurance Asso.
ciation of India, Bombay
SXRI K. K. MANDAL ( Alternate )
DR T. C. SIDXAN Chief Electrical Inspector to the Government of
Kerala, Trivandrum
SHRI K. S. SUI)RI(XMANIYAM Bharat Heavy Electricals Ltd, Secunderabad
SXRI G. P. PAHWA ( Altcmafc)
SXRI G. N. TXADANI Engineers India Limited, New Delhi
SXRI S. G. GO~WALE ( Alkmate)
SXRI S. VAIDYANAIXAN Kerala State Electricity Board, Trivandrum
SXRI R. VARADARAJAN ( tillernate)
SXRI S. P. SACHDEV, Director Genepal, I$l ( Ex-oficio Mcmbrr )
Director ( Elec tech )

Secretary
SXRI K. GANEW
Assistant Director ( Elec tech ), TSI

( Contind on pugs 22)

 rS:leO28(PartIII)-1981

Indian Standard
CODE OF PRACTICE FOR
SELECTION, INSTALLATION AND
MAINTENACE OF TRANSFORMERS
PART III MAINTENANCE

0. FOREWORD
0.1 This Indian Standard (Part III) was adopted by the Indian Standards
Institution on 25 November 1981, after the draft finalized by the Code of
Practice for Power Installation and Maintenance Sectional Committee had
been approved by the Electrotechnical Division Council.
0.2 The code of practice on installation and maintenance of transformers
was originally published in 1961 as, IS ; 1886, intended as a guide to
installation engineers, contractors and others engaged.in the installation
and maintenance of power and distribution transformers. It was made up
to date subsequently in 1967, with additional details regarding internal
inspection of transformers. Apart from the information concerning
transformers themselves, the code covered ancillary work, such as ventila-
tion, cabling and isolation of transformers.
0.3 The present version of the code is being brought about to include
‘additional details on criteria for selection of transformers, transportation
to the point of installation, taking into view also the latest thinking on the
methods of supervision and maintenance of insulating oils in service.
Specific details on maintenance aspects of special purpose trahsformers are
intended to be added at a later date.
0.4 This standard closely follows the earlier version thougn currently being
presented in three parts mainly in order to identify information and to
consolidate them in functionally coherent sections. This standard is hence
brought out in three parts, viz:
Part I Selection (under preparation)
Part II Installation
Part III Maintenance
These parts shall be read in conjunction with each other. This standard
(Part III) partly supersedes the provisions of IS : 1886-1%7* which will
be withdrawn when all the parts are made available.
*Code of practice for installation and maintenance of transformers (J;rsr reoirirn).

3
IS : 10028 ( Part III ) - 1984

0.5 In view of the consideration of this code required to be in conformity

with the prevailing statutory regulations in the country, reference to the
relevant provisions of the Indian Electricity Rules, 1956 has been made at
the appropriate places.
0.6 In the preparation of this standard, considerable assistance has been
derived from the following:
IS : 6600-1972 Guide for loading of oil-immersed transformers
IS : 8478-1977 Application guide for on-load tap-changers
IS : 4146-1967 Application guide for voltage transformers
IS : 4201-1967 Application guide for current transformers
Specification for Power and Distribution Transformers, Section K,
Erection, Maintenance and Commissioning Manual, issued by the
Central Board of Irrigation and Power.
0.7 For the purpose of deciding whether a particular requirement of this
standard is complied with, the final value, observed or calculated, express-
ing the result of a test or analysis, shall be rounded off in accordance with
IS : 2- 196Cr*. The number of significant places retained in the rounded off
value should be the same as that of the specified value in this standard.

1. SCOPE
1.1 This standard ( Part III ) covers guidance on maintenance of distribu-
tion and power transformers covered by IS : 1180-1964t and IS : 2026
( Parts I to IV )-1977# respectively.
1.2 Special purpose transformers, such as gas cooled, synthetic, liquid
insulated, dry type and mining transformers and instrument transformers
are excluded from the scope of this code and in all such cases, the manu-
facturer’s instructions shall be followed.

2. TERMINOLOGY
2.1 For the purpose of this code, the definitions given in IS : 1180-1964t
and IS : 2026 ( Part I)-1977$, shall apply.
*Rules for rounding off numerical values ( revised ).
tSpecification for outdoor type three-phase distribution transformers up to and inclu-
ding 100 kVA 11 kV ( rsviscd ).
$Specification for power transformers :
Part I General rfirsf revision ).
Part II Temperature-rise (jrsr revision).
Part III Insulation level and dielectric tests ( fir.rf rwisiw ).
Part IV Terminal marking, tappings and connertcrs ( jrst rc&iun ).

4
 IS : 10028 ( Part III ) - 1981

3. GENERAL INFORMATION
3.1 As compared with most electric apparatus, transformers require relati-
vely little attention. The extent of the inspection and maintenance required
will be governed by the size, importance of service continuity, the location
on the system, and operating conditions, such as ambient temperature,
unusually dirty atmosphere, heavy fogs and water supply ( in the case of
water-cooled units ). The supply authority shall be consulted if heavy loads
on single phase or unbalanced loads are to be connected.
3.2 Distribution transformers and small power transformers ordinarily
require and receive less attention than large transformers which represent a
much greater investment. However, small transformers sometimes supply
power to industrial loads where continuity‘ of service is of the utmost
importance. In these cases, a greater degree of attention is justified.
3.3 The suggestions in the following pages should prove helpful to
operators. Full information on installation and operation are contained
in the instructions sent with each transformer and are referred to on the
transformer nameplate.
3.4 Generally the causes of breakdown of transformers may be classified
as follows:
a) Faulty design or construction,
b) Incorrect installation or use,
c) Overload and peculiarity of loading conditions,
d) Neglect,
e) Wear and tear and other deterioration,
f) Accidents, and
g) Failure of auxiliary equipment.
3.4.1 A rigid system of inspection and preventive maintenance will ensure
long life, trouble-free service and low maintenance cost. Maintenance
shall consist of regular inspection, testing and reconditioning, where
necessary. The amount of attention and maintenance vary with the
service conditions and load cycle of the transformers.
3.4.2 Records shall be kept of each transformer giving details of all
inspections and testing made and of unusual occurrences.
3.4.3 The principal object of maintenance is to maintain the insulation
in good condition. Moisture, dirt and excessive heat in contact with
oxygen, are the main causes of insulation deterioration and avoidance of
these will, in general, keep the insulation in good condition. The
limiting factor is the ageing of the insulation and decline in the quality of
the insulation during the ageing process due to chemical and physical
effects. The decay of the,insulation follows the chemical reaction rate, and

5
IS t 10028 ( Part III ) - 1981

in case of oil-immersed transformers, if the sustained operating temperature

of the insulation exceeds the normal operating. -temperature: ?f FS:“C;
tf%e will be a shortening of the life of the transformer.
4. FACTORS‘AFFEC’TING THE LIFE OF A TRANSFORMER
4.1 Effect of Moisture -Transformer oil readily absorbs moisture from
the air. The effect of water in solution in the oil is to decrease the die-
electric strength of the oil as well as of the insulating paper which absorbs
and stores the moisture due to higher affinity of water to paper over oil.
All’ possible preventive steps should, therefore, be taken to guard against
moisture penetration to the inside of the transformers. This will include
blocking of all openings for free access of air in storage and frequent
reactivation of breathers in service.
4.3 Effect of Oxygen - Oxygen may be present inside the transformer due
to air remaining in oil, air pockets trapped in the windings, etc. The
oxygen reacts on the cellulose of the insulation and the decomposition
products of the cellulose lead to the formation of organic acids soluble in
oil and sludge which blocks the free circulation of the oil. The adverse
‘effect of oxygen, which may be aggravated by catalytic action between hot
oil and bare copper, increase the operating temperature.
r.3 Effect of Solid Impurities - The dielectric strength of oil is diminished
appreciably by minute quantities of solid impurities present in the oil. New
transformers may contain particles of insulating materials and other solid
*impurities. It is, therefore, a good practice to filter the oil after it has been
in service for a short time, especially for the units of higher voltage class.
4.4 Effect of Varnishes - Some varnishes particularly of the oxidizing type,
enter readily in reaction with transformer oil and precipitate sludge on the
windings. Synthetic varnishes having acid inhibiting properties generally
delay the natural formation of acid and sludge in the oil. This should be
borne in mind by the maintenance engineer when rewinding and replacing
the coils during repairs to transformers.
4.5 Effect of Slackness of Windings - Slackness of windings may cause a
failure due to repeated movement of coils which may wear the conductor
insulation at some places and lead to an inter-turn failure. The coils may
also get displaced under load conditions or momentary short circuit which
may cause electric and magnetic unbalance and produce even greater
displacement. It is, therefore, a good practice to lift the core and windings
of a transformer and take up any slackness which may have developed by
tightening the tie-rods or- pressure screws where provided for this purpose
at the first inspection. In all cases the instructions given by the manu-
facturers should be followed closely. However, the maintenance schedules
given in Tables 1 and 2 are recommended to serve as a general guidance.
Additional maintenance attention should be given where transformers are
working under abnormal conditions.

6
 5. MAINTENANCE PROCEDURE
5.1 Safety Precautions’- Arrangements shall be made to carry out the
maintenance of transformers in safety. Before starting any maintenance
work the transformers shall be isolated from the supply and the terminals
earthed. Oil level shall always be borne in mind when undoing nuts and
bolts and before unsealing the tank. No fire shall be kept .Oear the trans-
former while maintenance work is going on.
5.2 Oil
5.2.1 Transformer oil is subject to deterioration or contamination in
storage and in service. Accordingly, a periodic treatment to maintain it in
fit condition is required, and eventually, it may have to be replaced by
new oil. The causes of oil deterioration and recommendations for various
tests are ComprehensiveIy covered in IS : 1866-1978*. Reference shall be
made to the same regarding the maintenance of quality of oil in service.
The few short tips given below may serve as ready reference.
5.2.2 The oil level should be checked at frequent intervals and any
excessive leakage of oil investigated. There may be slight loss of oil by
evaporation, this need cause no concern if the tank is topped up at regular
intervals.
5.2.3 All leaks should be repaired as quickly as possible so as to avoid
possible trouble caused by low oil level.
5.2.4 Oil for toppling up should comply with IS : 335-1972t and should
preferably be from the same source as the original oil because the oil refined
from different crudes may not be completely miscible and may separate into
layers. Furthermore, there may be a greater tendency to form acidity or
sludge in a mixture than in an oil from a single source of supply. Used
oil shall not be mixed. New oil may be added as make up only, not
exceeding about 10 percent. It is desirable not to mix oil taken from a
transformer with that from switchgear equipment.
5.2.5 Samples of the oil should be taken at regular intervals and tested.
5.2.6 It may be mentioned that the dielectric strength does not give a
true indication of the deteriorated condition of the oil. Even an oil which
is highly deteriorated may give a high dielectric strength, if dry. Normal
method of oil purification only maitain the dielectric strength, but do not
give indication of the deteriorated condition of the oil. It is, therefore,
inadvisable, to rely solely on the dielectric strength of the oil by periodic
tests. In addition to chemical tests other tests as given in IS : 1866-1978*
should also be carried out.
*Code of practice for maintenance and supervision of insulating oil in service (Jr&
rrvisian ) .
$Specification for new insulating oils for transformers and switchgear( Ed r&ton ).

7
IS : 10028 ( Part III ) - 1981

5.2.7 It is recommended that the oil be kept under observation for

acidity. If the acidity is increasing rapidly, or exceeds limits the cover should
be removed to ascertain the condition of the interior of the tank and of
the core and windings. Oil should be treated or discarded, if sludge or
corrosion is evident. Advice should be obtained from the manufacturer.
5.2.8 It may be noted that reconditioning by centrifugal separation of
filtration does not remove the acidity from the oil but will remove sludge,
dust, diri, etc, and will tend to retard the process of deterioration.
5.2.9 Filters with fullers earth will help to reduce acidity in the oils and
in addition improve the resistivity.

5.3 Rollers
5.3.1 After a transformer has been in service for a long period, rollers
should be examined carefully. They should be greased.

5.4 Transformer Body

5.4.1 The transformer tank and other parts should be inspected periodi-
cally for any rust or leak. Rusted portions, if any, should be cleaned
thoroughly and repainted with proper paints. Transformer should be
completely painted at proper intervals. If any leak is found, it should be
investigated. If it is due to defective welding, the same should be rectified
after consulting the manufacturers. Leaking joints can be rectified by
tightening the bolts to the correct pressure or by replacing the gaskets.
5.4.1 Internal Inspection
5.4.2.0 The core and windings should be lifted from the tank, only
if necessary, in suitable Fonditions., The surrounding atmosphere should
not be humid and should be free from dust, dirt, etc. Suitable lifting
device depetiing on the weight of the core and coil should be arranged.
Before disturbing anything, the insulation resistance of the transformer
should be measured.
5.4.2.1 Opening the Transformer - The tank contains oil with oil ’
vapour and therefore care should be taken t6 prevent a fire. Naked lights
and flames should be kept well away while the tank is open. If an inspection
lamp is required, only a protected electric lamp, preferably an extra low
voltage lamp should be used. The lamp should be kept off when not in
use.
Before opening the tank cover, it should be properly cleaned removing
any dust, moisture, etc, from the top. The persons opening the tank cover
should not have anything in their breast pocket and should not wear a
watch or ring. The spanner should be clean of all metal fillings and should
be hold by a cotton strap or string tied securely round the waist or wrist of

8
 I!3 : 10028 ( Part III ) - 1981

the person opening the tank cover. Cast iron spanners should not be used
as they may break and fall inside the tank. All nuts and bolts, etc, should
be removed from top of the cover before removing it.
5.4.2.2 Removing the Cover - The method of removing the cover
depends on the construction of the transformer. If the core and windings
are separate from the cover and if there are bushings mounted on top, then
first bushings should be dismounted and stored carefully and then the
cover should be carefully removed. If however, the core and windings are
suspended from the tank cover, substantial lifting lugs, usually in the form
of eye bolts, are provided on the cover. While lifting the cores from the
eye-bolts care should be taken that the core is removed vertically. It
should also be ensured that spanners or other tools used in connection
with the work are not dropped into or left inside the tank.

5.5 Core and Winding

5.5.1 Lifting the Core and Coils-The core and coils, if not suspended
from the cover, are held in the tank by a bolt or other suitable fixing
devices at each end near the top. These should first be removed. If there
are bushings provided on the tank walls, these should also be removed by
undoing the connection. Mechanical connection ta the tap changing
switch handle, if provided, should be removed.
5.5.1.1 The core and coils should then be lifted vertically by slinging
it from the lifting lugs provided on the core, making sure that the sling
does not foul against bushing connections, tapping switch, etc, as it p 11s
tight.
5.5.1.2 After allowing the core and coils to drain into the tank, fcr
some time, they should be lowered preferably on beams placed in a metal
tray filled with saw dust or sand.
5.5.2 Inspection - After removing the core and coils from the tank, the
following should be carefully checked making sure that nothing is disturbed
unnecessarily and that the leads are not pulled out of their places unless they
are unsatisfactory:
a) All bolts and nuts should bc adequately tight. If they are too
tight clamps, etc, may bend.
b) The coils should be clean and free from sludge. Slight traces of
sludges should be cleaned by transformer oil. But if there are
heavy deposits, it is likely that the ducts are blocked. In such
a case the matter should be referred to the manufacturer.
c) The windings should be firmly clamped without any movements.
There should be no loose spacers or end blocks. If loose windings
or spacers are noticed, the vertical tie-bars which put pressure on

9
IS : 10028 ( Part III ) - 1981

the coil stacks should be adjusted. Special coil adjustment bolts

if provided should also be tightened properly.
d) Proper operation of tap changing switch may also be checked.
c) All connections should be tight and clear.
f) If the insulation resistance tests done before untanking gave low
value, it should be repeated. If now the test gives satisfactory
value, the low value is attributed to some other cause. However,
if the test still gives low value, the manufacturers should be
informed.
g) If there is sludge deposition at the bottom of the tank, it should
be removed while filtering the oil.
5.5.3 It is recommended that the core and winding be removed from the
tank for visual inspection as per time schedule given in the inspection table.
The ivindings should be examined to ensure that no sludge has been deposi-
ted blocking the oil ducts. Any loose nuts and bolts should be tightened.
5.5.4 Before lifting the core and winding from the tank, it is usually
necessary to disconnect the windings from the bushings are cable boxes
inside the tank to disconnect the off-circuit tap switch handle or leads of
the on-load tap changer and to remove any earthing strips between the core
clamps and the tank.
5.5.5 The core and windings shall be removed with great care. It should
be placed under cover and in a dry place.
5.6 Bushings
5.6 1 Clean the bushing porcelains and examine them for cracks and
chips, Very slight chips may be ignored but any serious damage will
require a new porcelain which must be obtaind from the manufacturer.
It is recommended to have a spare, in stock.
5.6.1.1 In some cases the porcelain only may be changed while in
other cases the conducting rod is cemented into the porcelain and the
complete bushing requires to be changed.
5.6.1.2 If the bushing is below oil level, the oil should be lowered
until it is below the bushing hole.
5.6.1.3 If only the porcelain is supplied it may not be necessary to
undo the internal bushing connection, for, in some cases the bushing stems
are joined by an insulated bar to prevent them from turning when the nuts
are undone. All the nuts at the top of the bushing should be removed and
the old porcelain lifted straight up over the central stem which remains in
place. Slide the new porcelain down over the stem and replace the nuts.
Too much strain on the porcelain should not be applied when tightening
the connections. Change ontv one porcelain at a time, replacing the nuts

10
 IS:10028(PartIII)-1981

at ,&e top of the stem befor removing those on the next bushing. If the
insulated bar between the bushing stems is not provided, the internal
connections should be undone and the whole bushing removed before the
porcelain is changed.
5.6.1.4 When a complete bushing is supplied the internal connection
to the bushing should be undone. If the replacement bushing has a socket
at the bottom end, the old bushing should be unclamped and withdrawn
from the tank, the internal lead being flexible and long enough to allow
this. This lead may now be unplugged from the old bushing and plugged
into the new one, which is then lowered into the hole in the tank and rec-
lamped firmly but not too tightly.
5.7 Cable Boxes
5.7.1 The seating arrangements for filling holes should be checked each
year. When screwed plugs are seated with a bituminous campound, the
compound should be examined for cracks. If the compound has cracked it
should be replaced as the cracks may lead to an accumulation of water
around the plug. Gasketed joints should be examined and tightened
whenever required.
5.8 External Connections
5.8.1 All connections should be tight. If they appear blackened or
corroded, undo the connection and clean down to bright metal qith emery
paper. Remake the connection and give it a heavy coating of grease. It
is particularly important that heavy-current carrying connections should be
properly maintained. If the metal has the characteristic bluish tinge
which indicates that it has been hot, then in most cases the connection
shall not be considered satisfactory. Either it has become loose OF dirty,
or the conductor is not suitable for carrying the current.
5.8.2 The earth connections shall be properly maintained. A small
copper loop to bridge the top cover of the transformer and the tank may
also be provided to avoid earthfault-current passing through the fastening
bolts when there is a lightning surge, high-voltage surge or failure of
bushings.
5.9 Conservator and Magnetic Oil Gauge
59.1 Conservators are so arranged that the lower part acts as a sump in
which any impurities entering the conservator will collect. A valve/plug is
fitted at the lowest point of the conservator for draining and sampling. The
inside of the conservator should be cleaned or flushed with oil every two to
three years. A removable end is generally provided for this purpose.
5.9.2 The oil level indicator should be kept clean. Generally the oil
level is visible through a transparent material. In case of breakage

11
IS : 10028( Part III ) - 1981

immediate replacement is essential. When conservator is stripped for

cleaning, the mechanism of the oil gauge should be inspected and cleaned.

5.10 Breather
5.10.0 There are generally two types of breathers used on a transformer:
a) plain breather, and
b) silicagel breather.
5.10.1 The end of the plain breather should be kept clean and the
ventilation holes free of dust. If an oil seal has been provided, the oil
should be wiped out and replaced to the correct level.
510.2 Silicagel dehydrating breathers are fitted with a sight glass so that
the colour of the crystals may be seen. The colour changes from blue to
pink as the crystals absorb moisture. When the crystals get saturated with
moisture they become predominantly pink and should therefore be reacti-
vated. The body of the breather should be removed by undoing the nuts.
If the crystals have been kept in an inner container, the container should
be removed, but if they are not, the crystals should be removed into a
shallow tray. The crystals should be backed at a temperature of about
200°C until the whole mass is at this temperature and the blue colour has
been restored. Clean the breather and replace the dry crystals and renew
the oil in the sealing cup at the bottom.

5.11 Buchholtz Relay

5.11.1 Routine operation and mechanical inspection tests should be
carried out at one and two yearly intervals respectively.
5.11.2 During operation if gas is found to be collecting and giving alarm,
the gas should be tested and aualysed to find out the nature of fault.
Sometimes, it may be noticed that the gas collecting 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 in inrtral stages only when no vacuum is
applied during filling of oil. The internal faults can be identified to a great
extent by a chemical analysis of gas.
5.11.3 Buchholtz may also give alarm/trip due to the oil level falling
below the Buchholtz level.

5.12 Explosion Vent

5.12.1 The diaphragm, which is fittgd at the exposed end of the vent
should be inspected at frequent intervals and replaced, if damaged. Failure
to replace the diaphmgm quickly may allow the ingress of moisture which,,
will contaminate the oil. Jf the diaphraem has broken because of a fault

12
 IS : 10028 (Part III) - 1981

in the transformer, an inspection shall be carried out to determine the

nature and cause of the fault.
5.13 Gaskets
5.13.1 Gaskets sometimes shrink during service. It is, therefore, neces-
sary to check the tightness of all bolts fastening gasketed joints. The bolts
should be tightened evenly round the joints to avoid uneven pressure.
Leaking gaskets should be replaced as soon as the circumstances permit.
5.14 Small Pipe Work
5.14.1 The pipe work should be inspected at least once a year. Leaks
may be due to slack unions, which should be tightened or to badly seated
joints caused by a misalignment. In the latter case, the pipes should be
aligned and joints remade.
5.15 Temperature Indicators
5.15.1 At each yearly maintenance inspection, the level of oil in the
pockets holding thermometer bulbs should be checked and the oil repleni-
shed, 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. Temps
rature indicators should be calibrated with standard thermometer immersed
in hot oil bath if found to be reading incorrectly.
5.16 Coolers and Cooling Fans
5.16.1 There is a variety of coolers. For radiator type coolers, mainte-
nance primarily consists of replacing damaged elements, cleaning the outer
surface to remove settled dust, repainting, etc.
5.16.2 Fan blades are cleaned to remove dust. Bearings of the fan
motors should be lubricated occasionally. Grease should not be added
while the motor is running. For other coolers, manufacturers, instructions
should be followed. Other precautionary measures, such as checking of
correct operation of pumps, gauges, indicators and differential pressure
between oil and water ( in case of water-coolers ) shall be taken.
5.17 On-Load Tap Changer
5.17.1 Since all on-load tap changers are not of the same design and
construction, special instructions of manufacturer’s should be followed.
However, a few points are enumerated:
a) Diverter Switch - The maintenance primarily consists of servicing of
diverter switch contacts, checking the oil level in the diverter
switch chamber, and replacement of diverter switch oil when the
same becomes unsuitable for further service.

13
IS : 100% ( Part HI ) - 1981

b) Motor Driving. Mechanism

1. Do not allow dirt to accumulate between contact rings of notching
controller.
2. Do not use oil/grease on contacts rings on notching controller,
3. Check the operation of anti-condensation heater.
4. If the contacts of contactors are silver faced, no touching up shall
be done, but should be replaced when they are worn out. Copper
contacts may be lightly touched up with a Ale when they become
rough. The pole faces of,electromagnet shall be kept clean.
5. Do not oil/grease the contact surface of radial multi-contact
switches, unless a special contact lubricant is used. The space
between the rings should be cleaned occasionally. If necessary,
a few drops of benzine be used.
c) Selector Switch - The contacts do not make/break current. As such,
the wear is only due to mechanical movement of moving contacts.
These may be inspected once in 213 years.

5.18 Spares
518.1 It is a healthy practice to have essential spares like one member
of each type of bushings, one spare limb winding, one thermometer, one
cooling fan, etc, for each group of similar transformers. Suppliers’
recommendations may be followed in this connection.

6. MAINTENANCE SCHEDULE
6.1 Recommended maintenance schedules for all types of transformers of
rating less than 1 000 kVA and for ratings of 1 000 kVA and above are
given in Tables 1 and 2 respectively. The hourly and daily inspection
recommended are applicable for attended substations only. However, for
unattended substations, these items should be inspected as frequently as
possible.
6.2 In addition to the schedule recommended in Tables 1 and 2, it may be
necessary to inspect for other details in the case of specific types of trans-
formers. In all such cases, the manufacturers instructions shall be followed.

7. TROUBLESHOOTING IN TRANSFORMERS
7.1 Faults observed during the periodic maintenance schedules are to be
rectified as per the suggested action required. However, certain chance
troubles and major faults in performance of the transformer shall have to
be attended to in a desired sequence, as per manufacturer’s instructions or
ready reference manuals. Guidance to manage electrical and mechanical
troubles normally encountered in all types of transformers are provided in
Table 3.

14
 Is:loo28(PartIII)-1981

TABLE 1 ,RECOMMENDED MAINTENANCB SCHRDULR FOR TRANWORMgRs

OF CAPACITIES LESS THAN 1000 kVA
( C~auscs 4.5, 6.1 and 6.2 )
SL INSPECTION ITEMS ~0 BE INBPB~I~N AIXION REQVIPIID II
No. FREQUENCY INSPECTED NOTES INP.PE~~~~NSnows
umATl8?AuronY
CONDIYIONS

(1) (2) (3) (4) (5)

1. Hourly i) Load (amperes) Check against rated -
figures
ii) Temperature Oil temperature and
ambient tcmpera-
turc
iii) Voltage Check against rated
figures
2. Daily Dehydrating Check that air-pass- If silicagel is pink,
breather age are clear. change by SPZC
Check colour of charge. The old charge
active agent may be reactivated for
use again.
3. Monthly i) Oil level in Check transformer IL? top up with dry
transformer oil level Examme trans-
for’mer for leaks.
ii) Connections Check tightncu If loose, tighten.
4. Quarterly Bushings Examine for cracks Clean or replace.
and dirt deposits
5. Half yearly i) Non-conservator Check for moisture Improve ventilation,
transformer under cover check oil.
ii) Cable boxes, Inspect
gasketed joints,
gauges and
general paint
work
6. Yearly i) Oil in trans- Check for dielectric Take suitable action to
former strength and water restore qulity of oil.
content. Check for
acidity and sludge
ii) Earth resistance - Take suitable aactions if
earth resistance is high.
iii) Relays, alarms Examine relay and Clean the components
their circuits, etc alarm contacts, and replace contacts
their operation, and fuses if necessary,
fuses, etc. Check Change .$he setting, if
relay accuracy, ctc necessaiy.
7. 2 yearly Non-conservator Internal inspection Filter oil regardless of
transformers above core condition.
a. 5 yearly - Overall inspection Wash by hosing down
including lifting of with clean dry oil.
core and coils
NOTB - When inspection of core and coils are to be done, it is recommended the
manufacturer be consulted.
_____.~_
15
IS : 10028 ( Part III ) - 1981
..-
TABLE 2 RECOMMENDED MAINTENANCE SCHEDULE FOR
TRANSFORMERS OF CAPACITIES OF 1000 kVA AND ABOVE

( Clauses 4.5, 6.1 and 6.2 )

SL INSPECI~ON ITEMS TO BB INSPECTION ACTION REQUIRED IF

No. FREQUENCY INSPECTED NOTES INsPE~~~N Snows
UNSATISFACTORY
CONDITIONS

(‘1 (2) (3) (4) (5)

1. Hourly i) Ambient tempe- - -

rature
ii) Winding tempe-1 Check that tempera- Shut down the trans-
rature rature rise is reaso- former and investi-
iii) Oil temperature nable gate if either is
persistently higher
than normal.
iv) Load (amperes) -
Check against rated
figures
v) Voltage J
2. Daily i) Oil level in trans- Check against trans- If low, top up with
former former oil level dry oil, examine
transformer for
leaks.
ii) Oil level in bus- - -
hing
iii) Leakage of water -
into cooler
iv) Relief diaphragm - Replace if cracked
or broken.
v) Dehydrating bre- Check that air-pass- If silicagel is pink,
ather ages are free. Check change by spare
colour of active charge. The old
agent charge may be
reactivated for use
again.

3. Quarterly i) Bushing Examine for cracks Clean or replace.

and dirt deposits
ii) Oil in transfor- Check for dielectric Take suitable action
mer strength and water to restore quality of
content oil.
iii) Cooler fan bea- Lubricate bearings. Replace burnt or
rings, motors and Check gear box. worn contacts or
operating mecha- Examine contacts. other parts.
nisms Check manual con-
trol and interlocks
iv) OLTC Check oil in OLTC
driving mecha-
nisms
v) Indoor transfor- Cheek ventilation
mers
( Continued)

16
 IS : 10028( Part III ) - 1981

TABLE 2 RECOMMJZNDED MAINTENANCE SCHEDULE FOR

TRANSFORMERS OF CAPACITIES 1000 LVA AND ABOVE - Conrd

SL INSPXTION ITsarS TO BE INSPBCTI~N ACTION REQUIRED IF

No. FRXQUENCY INSPECTED NOTES INSPECTION Snows
UNSATISFACTORY
CONDITIONS

(1) (2) (3) (4) (5)

4. Half Yearly Oil cooler Test for pressure -

5. Yearly (or i) Oil in transfor- Check for acidity Filter or replace.
earlier if, the mer and sludge
transformer
can conveni-
ently be
taken out for
checking)
ii) Oil filled bus- Test oil Filter or replace.
hings
iii) Gasket joints Tighten the bolts
evenly to avoid
uneven pressure.
iv) Cable boxes Check for scaling Replace gaskets, if
arrangements for leaking.
filling holes. Exa-
mine compound for
cracks
VI Surge diverter Examine for cracks Clean or replace.
and gaps and dirt deposits
vi) Relays, alarms, Examine relay and Clean the componc-
their circuits, etc alarm contacts, nts and replace con-
their operation, tacts and fuses, if
fuses, etc. Check necessary. Change
relay accuracy, etc the setting, if nece-
ssary.
vii) Earth resistance Take suitable action;
if earth resistance is
high.
6. (a) 5 yearly 1000 to 3 000 kVA Overall inspection Wash by hosing
including lifting of down with clean
core and coils dry oil.
(bj 7-10 yearly Above 3 000 kVA do do

NOTE 1 - With respect to on-load tap changers, the manufacturer’s recommendation

should be followed.
NOTE 2- The silicagel may be reactivated by heating it to 150 to 200” C.
NOTE 3 -Every time the drying medium is changed, oil seal should also be changed.
KOTE 4 -No work should be done on any transformer unless it is disconnected from
all external circuits and the tank and all windings have been solidly earthed.
NOTE 5 - In case of anything abnormal occurring during service, maker’s advice
should be obtained, giving him complete particulars as to the nature and the extent of
occurrence, together with the name plate particulars in order to assist identification.

17
I!3:10028(PartIII)-1981

TABLE 3 TROUBLESHOOTING CHART FOR ALL TRANSFORMERS

( clause 7.1 )

TROUBLE CAUBE REMEDY

(1) (2) (3)

Rise in Temprraturc
High temperatures Overvoltage Change the circuit voltage or trans-
former connections to avoid overexci-
tation.
Overcurrent If possible, reduce load. Heating
can often be reduced by improving
DOWCI factor of load. Check nara-
ilel circuits for circulating c&rents
which may be caused by improper
ratios or impedances. See Electrical
Troubles, below.
High ambient tempera- Either improve ventilation or relocate
tures transformer in lower ambient tempe-
rature.
Insufficient cooling If unit is attiticially cooled, make
sure cooling is adequate.
Lower liquid level Fill to proper level.
Sludged oil Use filter press to wash off core and
coils. Filter oil to remove sludge.
Short-circuited core Test for exciting current and no-load
loss. If high, inspect core and
repair. See Electrical Troubles,
below.
ihtrical Troubles
Winding failure Lightning. Short-circuit Usually, when a transformer winding
Overload fails, the transformer is automati-
Oil of low dielectric cally disconnected from the power
strength source by the opening of the supply
Foreign material breaker or fuse. Smoke or cooling
Core failure Gore-insulation brcak- liquid may be expelled from the
down case, accompanied by noise. When
(Core, bolts, clamps, or there is any such evidence of a
between laminations) winding failure, the transformer
should not be re-energized at full
rated voltage, because this might
result in additional internal damage.
Also it would introduce a fire hazard
in transformers.
After disconnection from both source
and load, the following observations
and tests are recommended :
a) External mechanical or elcct-
rical damage to bushings,
leads, potheads, disconnecting
switches, or other accessories.
( Continued )
 fS : 10028 ( Part III ) - 1981

TABLE 3 TROUBLE-SHOOTING CHART FOR ALL TRANSFORMERS - Conld

TROUBLE CAUSE REMEDY

(1) (2) (3)
1~) Level of insulating liquid in all
compartments.
c) Temperature of insulating
liquid wherever it can be
measured.
d) Evidence of leakage of insula-
ting liquid or scaling camp
ound.
Electrical Troubles
High cxciting current Short-circuited core Test core 10s~. If high, it is probably
due to a short-circuited core. Test
core insulation. Repair if damaged.
If laminations are welded together,
refer to manufacturer.
Open core joints Core-loss test will show no appreci-
able increase. Pound joints toge-
ther and retighten clamping
structure.
1 ncofrcct vol tagc Improper ratio Change terminal-board connection or
ratio-adjuster position to give
correct voltage.
SUPPlY voltage Change tap connections or readjust
abnormal supply voltage.
Audible internal arcing Isolated metallic part The source should be immediately
and radio interference determined. Make certain that all
normally grounded parts are grou-
nded, such as the clamps and core.
Loosc connections Same as above. Tighten all connee-
tions.
Low liquid level, cxpo- Maintain proper liquid level,
sing live parts
Bushing flashover Lightning Provide adequate lightning prote-
ction .
Dirty bushings Clean bushing porcelains, frequency
depending on dirt accumulation.
Mechanical Troubles
Leakage through screw Foreign material in
joints threads
Oval nipples Make tight screw joints or gasket
Poor threads joints.
Improper filler
Improper assembly i
leakage at gasket Poor scarfed joints 1
Insufficient or uneven
Compression Make tight screw joints or gasket
Improper preparation of I joints.
gaskets and gasket
surfaces 1
( Continued )

19
IS : 10028 ( Part III ) - 1381

TABLE 3 TROUBLE-SHOOTING CHART FOR ALL TRANSFORMERS -Contd

TROUBLE CAUSE REMEDY

(1) 63 (3)
Mechanical Troubles - Contd
Leakage in welds Shipping strains, imper- Repair leaks in welds.
fect weld
Pressure-relief dia- Improper assembly. Replace diaphragm. Inspect inside
phragm cracked Mechanical damage of pipe for evidence of rust or
moisture. Be sure to dry out trans-
former if there is a chance that
drops of water may have settled
directly on windings or other vulne-
rable locations, as oil test may not
always reveal presence of free water.
Pressure-relief dia- Internal fault
phragm ruptured
In conservator transfor- Check to see that valve between con-
mer -obstructed oil servator and tank is open and that
flow or breathing ventilator on conservator is not
blocked.
In gas-seal transfor- Make certain that relief valve func-
mer - obstructed pre- tions and that valves in discharge
ssure relief valve line are open.
In sealed transformer Liquid level should be adjusted to
-liquid level too high that corresponding with liquid
temperature to allow ample space
for expansion of liquid.
Moisture condensation Improper or insufficient Make sure that all ventilator open-
in open-type transfor- ventilators ings are free.
mers and airfilled com-
partments
Moisture condensation Cracked diaphragm Sea remedies above for cracked and
in sealed transformers ruptured diaphragms.
Moisture in oil Filter oil.
Audio noise Leaky gaskets and joints. hiake certain all joints are tight.
Accessories and exter- Tighten loose parts. In some cases
nal transformer parts parts may be stressed into resonant
are set into resonant state. Releasing pressure and
vibration giving off shimming will remedy this condi-
loud noise tion.
Rusting and deterio- Abraded surfaces and Bare metal of mechanical parts
ration of paint finish weathering should be covered with grease.
Fractured metal or Unusual strains placed Cables and bus-bars attached to
porcelain parts of on terminal connec- transformer terminals should be
bushings tions adequately supported. In the case
of heavy leads, flexible connections
should be provided to remove strain
on the terminal and bushing
porcelain.
( Cminued )

20 ._
 IS : 10028 ( Part III ) - 1981

TABLE 3 TROUBLE-SHOOTING CHART FOR ALL TUNSFOlklbfERS - Contd

Taouer.z CAVSC R~VEDY

(1) (2) (3)

Oil Troables ( see also IS : 1866-1978’)

Low dielectric strength Condensation iq open- Make certain that ventilating open-
type transformers from ings are unobstructedt.
improper ventilation

Broken relief diaphragm Replace diaphragmt.

Leaks around cover Regasket, if neeessaryt.

accessories

Leaky cooling coil Test cooling coil and repair+.

Badly discolourcd oil Contaminated by var- Retain oil if dielectric strength is

nishes satisfactory.

Carbonized oil due to

Switching

Winding or core failure

Oxidation (sludge or Exposure to air ‘ Wash down ’ core and coils and
acidity) tank. Filter and reclaim or replace
oil.

High operating tempera- Same as above. Either reduce load

tures or improve cooling.

*Code of practice for maintenance and supervision of insulating oil in service (jrs1
rrvirion ) .
tin any event, filter oil or dry transformer by heating, or both, to restore dielectric
strength.

21
IS : 10028 ( Part III ) - 1981

Panel for Selection, Installation and Maintenance of

Transformers, ETDC 2O/P24
ciNwrn8r Reprwnting
SHRI C. R. VAR~R Crompton &eaves Limited, Bombay

Mrm bcrs
Snnr S. V. MANRRIKAR ( Alternate to
Shri C. R. Varier )
SHR~M. M. BANDRE Mgharashtra State Electricity Board, Bombay
~~EF&~~NEBR( ELEO -I Central Public Works Department, New Delhi
Swax A. MAZINDAR 1 Altematr )
SHR~ T. K. Gxosa Calcutta Electric Supply Corporation Ltd, Calcutta
SHRXG. ‘%ATl-ERJ~ ( AItmurtr )
SRRI M. M. Joao Voltas Limited, Bombay
Smzr N. R. SANTHANAM Tata Consulting Engineers, Bombay
f3~a1M.N. BAPAT(AI~&)
SWRlP.S.sAWHNEY Delhi Electric Supply Undertaking, New Delhi
SHRI P. D. SHARMA ( Akmatr)
SENIOR MANAGER Dav (E) Bharat Heavy Elcctricals Limited, Secunderabad
SHRI D. P. GIJPTA ( Altmate )
SHRIT. OMKUMAR NGEF Limited, Bangalore
SHRI K. V. JAYADEV ( Akrnate )
SHRI N. TXUKRAL Haryana State Electricity Board, Chandigarh
SHRI J. L. ARORA ( Alternate )

22
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