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MAINTENANCE HANDBOOK
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TRANSFORMER OF AC EMU/MEMU
TARGET GROUP – TECHNICIANS & SUPERVISORS OF AC
EMU/MEMU CAR SHEDS, WORKSHOPS

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CAMTECH/E/2005/TFP-EMU/1.0

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October 2005

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Maharajpur, GWALIOR - 474 020

Maintenance Handbook on Transformer of AC EMU/MEMU October, 2005

CAMTECH/E/2005/TFP-EMU/1.0 2

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MAINTENANCE HANDBOOK
ON
TRANSFORMER OF AC EMU/MEMU
TARGET GROUP – TECHNICIANS & SUPERVISORS OF AC
EMU/MEMU CAR SHEDS, WORKSHOPS

Maintenance Handbook on Transformer of AC EMU/MEMU October, 2005

CAMTECH/E/2005/TFP-EMU/1.0 3

FOREWORD

With increasing passenger traffic in Metropolitans & their connected cities, reliability of
AC EMU/ MEMUs has become very important. Proper maintenance of transformer is vital to
ensure trouble free operation of EMU/MEMUs.

CAMTECH has prepared this handbook to cover all essential aspects of maintenance and
overhauling of transformer of AC EMU/MEMUs. It describes technical details, description of
different parts, various maintenance schedules including POH, failures, causes and their
remedies. It also describes transformer oil purification and condition monitoring of transformer
by dissolved gas analysis (DGA).

I am sure the handbook will prove to be very useful to our maintenance staff in EMU car
sheds/ workshops.

CAMTECH, Gwalior R.N.Misra

Date:24.10.2005 Executive Director

Maintenance Handbook on Transformer of AC EMU/MEMU October, 2005

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PREFACE

The transformer is one of the most important equipment of AC EMU/ MEMU. Proper
maintenance of transformer is essential to ensure reliability of AC EMU/ MEMUs in service.

This handbook on maintenance of transformer has been prepared by CAMTECH with the
objective of making our maintenance personnel aware of correct maintenance and overhaul
techniques to be adopted in field.

It is clarified that this handbook does not supersede any existing provisions laid down by
RDSO or Railway Board. The handbook is for guidance only and it is not a statutory document.

I am sincerely thankful to Exe. Director/ EMU, RDSO/LKO for his valuable comments. I
am also thankful to all field personnel who helped us in preparing this handbook.

Technology upgradation and learning is a continuous process. Hence feel free to write to
us for any addition or modification in this handbook. We shall highly appreciate your contribution
in this direction.

CAMTECH, Gwalior Randhawa Suhag

Date:24. 10. 2005 Director/Electrical

Maintenance Handbook on Transformer of AC EMU/MEMU October, 2005

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CONTENTS

Chapter No. Description Page No.

Foreword iv
Preface vi
Contents viii
Correction Slip xii

1. GENERAL DESCRIPTION 01
1.1 INTRODUCTION 01
1.2 TECHNICAL DETAILS 02
1.3 DIFFERENT PARTS OF TRANSFORMER 04
1.4 DESCRIPTION OF IMPORTANT FITTINGS 05
1.5 COOLING EQUIPMENT 08
1.6 FACTORS AFFECTING LIFE OF TRANSFORMER 09

2. MAINTENANCE 10
2.1 TRIP INSPECTION 10
2.2 IA SCHEDULE/ IB SCHEDULE 10
2.3 IC SCHEDULE 11
2.4 POH 14
2.4.1 GENERAL 14
2.4.2 INCOMING TESTS/ INSPECTION 14
2.4.3 TRANSFORMER OIL TESTING 16
2.4.4 PURIFICATION OF TRANSFORMER OIL 17
2.4.5 INTERNAL INSPECTION 17
2.4.6 INPECTION OF FITTINGS 19
2.4.7 FINAL FITMENT OF TRANSFORMER ON MOTOR COACH 21
2.4.8 FINAL CHECKING 21

3. TRANSFORMER FAILURES 22
3.1 COMMON FAILURES OF EMU TRANSFORMER 22
3.1.1 OIL LEAKAGE 22
3.1.2 LOW BDV 23
3.1.3 BUSHING FAILURE 23
3.1.4 FLEXIBLE (METALLIC) EXTENSION COUPLING FAILURE 23
3.1.5 WINDING FAILURE 24
3.1.6 TEMPERATURE RISE/ACTUATION OF THERMOSTAT 24
3.1.7 ACTUATION OF PRV 25
3.1.8 LOW IR VALUE 25
3.1.9 HUMMING SOUND 25

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4. PURIFICATION OF TRANSFORMER OIL 26

4.1 INSULATION RESISTANCE DURING DRYING OUT 27

5. CONDITION MONITORING OF TRANFORMER BY

DESSOLVED GAS ANALYSIS 28
5.1 INTRODUCTION 28
5.2 SENSITIVITY LIMITS 28
5.3 ESTABLISHMENT OF REFERENCE VALUES/BENCH MARKS 28
5.4 ESTABLISHMENT OF NORMS 28
5.5 DIAGNOSIS OF FAULTS 29
5.6 WORD OF CAUTION 29
5.7 PROCEDURE FOR FAULT DIAGNOSIS 29

6. DO’S AND DON’TS 30

6.1 DO’S 30
6.2 DON’TS 30

ANNEXURE-1

LIST OF MODIFICATIONS AND SPECIAL MAINTENANCE

INSTRUCTIONS 31

REFERENCES 32

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ISSUE OF CORRECTION SLIP

The correction slips to be issued in future for this handbook will be numbered as follows:

CAMTECH/E/2005/TFP-EMU/1.0/ C.S. # XX date---

Where “XX” is the serial number of the concerned correction slip (starting from 01
onwards).

CORRECTION SLIPS ISSUED

Sr. No. Date of issue Page no. and Item no. Remarks
modified

Maintenance Handbook on Transformer of AC EMU/MEMU October, 2005

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CHAPTER 1

GENERAL DESCRIPTION

1.1 INTRODUCTION

Transformer is one of the most important traction equipment of AC EMU/MEMU. It

is double wound with primary and secondary windings interleaved together to give a
sandwich construction.

Figure 1.1 TRANSFORMER

Current at 25 kV is taken from OHE to its primary winding via the pantograph, the
vacuum circuit breaker and the high tension main bushing. The return path for this current is
via the earthing brushes mounted in the axle cap of each traction motor and the running
rails.

The secondary winding of the transformer is in two sections, one section having five
tapped sections, other being untapped. This arrangement gives a total twenty-two voltage
steps by various connections of transformer tappings and voltage dropping reactors. This
voltage, which is controlled by the tap-changing switchgroup, is applied to the silicon
rectifiers, the full wave output of which is fed to the traction motors via the smoothing
reactor.

Two tertiary windings, auxiliary I and II are provided. Auxiliary I, 266 V winding
feeds the single phase a.c. auxiliary machines. Auxiliary II, 141 V winding supplies power
to normal lights & fans, head lights stabilizer, the auxiliary rectifier for main compressor
motor.

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The transformer is oil-immersed type and oil is forced circulated and cooled in
radiator by blower set.
T8

M12
OHE

PANTOGRAPH T9
OL6

M29
P1
T7
OL5
ABB/VCB

TL
LA
P2

EAS
T5
a8
TO RECTIFIER
T4 BLOCKS
CT a7
P3

0.05µF
T3
a6
LP2
LP1

T2
a5
OLP
T1
100A a4
M11
a12 T6
AUX.I M10
100A a11 266V a3
W2
PRIMARY

W1

250A a22 AUX.II a2

a21 141V M9
250A

0.05µF
TO RECTIFIER
G P4 BLOCKS
DL

a1

Figure 1.2 CIRCUIT DIAGRAM

1.2 TECHNICAL DETAILS

Make BHEL

Continuous Rating 1000 KVA at 25 kV

Primary winding 25 kV/40 Amp.

Secondary winding 782 Volt/ 1280 Amp.

Auxiliary winding I 266 Volt/55 Amp.

Auxiliary winding II 141 Volt/250 Amp.
Frequency 50 Hz
Cooling OFAF

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Secondary winding

Across Voltage kVA

a3 – a4 78.2 100
a3 – a5 156.4 200
a3 – a6 234.6 300
a3 – a7 312.8 400
a3 – a8 391.0 500
a1 – a2 391.0 500
a1 – a4 469.2 600
a1 – a5 547.5 700
a1 – a6 625.6 800
a1 – a7 703.8 900
a1 – a8 782.0 1000

Thermostat setting 75°C

Approximate Weight (in Kg)

Core and winding 1375
Tank and fittings 715
OFAF cooler 460
Oil in conservator 40
Total oil 795
Total weight 3402

Oil quantity (in Litres)

Oil in tank 668
Oil in Radiators & Pipe works 87
Conservator 77
Pipe work 100
Total oil 675

Cooling pump
Capacity 363.6 litres/minute at 70°C against a 7.32 meter head.
RPM 1430
Size of suction branch 76 mm
Size of delivery branch 73 mm
Pump motor
BHP 1.5
RPM 1430
Rating 240 ± 22.5%V, 1 phase, 50 Hz.

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1.3 DIFFERENT PARTS OF TRANSFORMER

1.3.1 Core
The core is a three limbed shell type construction,
each limb being inter-leaved with the top and bottom yokes.
The laminations are made from high-grade non-ageing
silicon alloy cold rolled grain-oriented steel. After cutting
and punching the sheets are deburred, stress relieved and
varnished.
Figure 1.3

1.3.2 Windings

H.V. (primary), L.V. (secondary), and auxiliary

(tertiary) windings are arranged on the centre limb and are
inter-leaved to give a robust mechanical construction.
Tapings are provided on secondary for voltage variation and
are brought out individually for connection to an external tap
changer switch group.

Figure 1.4

1.3.3 Terminal Arrangement

The H.V. (primary) line terminal is brought out to the H.V. turret through the cover
& connection is made to condenser bushing/ cable head bushing.

The L.V. (secondary) terminals, 8 in number each capable of carrying 1280 amperes,
are taken from the side of the tank through epoxy resinated terminal boards with copper bars
embedded into it.

Figure 1.5

Four terminals of two auxiliaries are taken through another epoxy resinated terminal
board in a similar fashion as in the case of L.V. The primary earthing terminal is taken
through a 6.6 KV porcelain bushing and is connected to earth.

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1.3.4 Tank

The tank is of welded mild steel plate

construction, shot blasted on the inside and
outside to remove the scale before painting.
The tank is designed to withstand a pressure of
0.55 kg/sq.cm. Inside of the tank is coated
with Copal varnish and the outside with three
coats of high quality paint, comprising of a
primary coat of anti-corrosive paint, an
intermediate coat and a finish coat of
battleship grey.
Figure 1.6
1.3.5 Fittings

The following fittings are provided with transformer.

1. Conservator with oil gauge.
2. Silica-gel breather mounted on the conservator.
3. Buchholz relay
4. Thermostat
5. Relief vent
6. Drain valve
7. Filling holes
8. Filter valve
9. Oil inlet and outlet valves.
10. Drain plug with locking valves.
11. Air release plug.
12. Pressure Relief Valve (PRV)
13. Turret
14. Main Bushing

1.4 DESCRIPTION OF IMPORTANT FITTINGS

1.4.1 Conservator With Oil Gauge

It is a drum containing transformer oil and is

mounted in the HT compartment. It is connected to the
transformer via the Buchholz protection relay. As the
volume of oil of transformer tank expands and contracts
according to heat produced, this expansion and
contraction of oil causes the level of the oil in
conservator to rise and fall. The aim of conservator is to

- Maintain the oil level in tank

- Provide space for the expansion of oil.

An oil gauge indicator is also provided on one

side of conservator drum with a scale having marking
according to temperature. Figure 1.7

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1.4.2 Breather

It is attached to conservator tank and contains silica gel,

which prevents the moist air from entering into the tank during
contraction of oil. When oil is hot there is expansion and gas
passes to atmosphere through it. When oil is cooled, there is
contraction and the air enters in it.

Air entering the breather is first drawn through an oil

seal and passes upwards through the silica gel crystals to the
connecting pipe at the top. During this upward passage of air,
any moisture present is absorbed by the dry silica gel. The oil
seal ensures that the gel absorbs moisture only when the
transformer is breathing. Thus it prevents transformer oil from
moisture contamination.
Figure 1.8

1.4.3 Buchholz Relay

A gas actuated double element Buchholz device

(BUD) is fitted in the pipe connection between the
conservator and the transformer tank in which the metal to
metal (silver) contacts are used. Under normal conditions, it
is full of oil.

Buchholz relay is provided with an indicating flag and

a mechanical latch so that when it is closed by operation of
either FAST or SLOW contacts of the Buchholz device, it
remains closed until the reset button is pressed. Contact
BIR/1 is connected in the air blast circuit breaker (or VCB)
Figure 1.9
circuit to trip in the event of a Buchholz operation and red
ABB/VCB ‘OFF’ light is lit in the faulty unit.

Relay BIR trips permanently and the transformer is disconnected from the supply
through circuit breaker tripping if any of the following faults occurred:
a. Broken down core bolts.
b. Shorted laminations.
c. Bad contacts
d. Over heating of some part of the windings.
e. Falling of oil level arising from leakage.
f. Ingress of air, through defects in the oil circulating system.
g. Puncture of bushings.
h. Short circuit between phases.
i. Earth faults.
j. Winding short circuits.
k. Oil level falling below height of mounting position of the protector.

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1.4.4 Thermostat

The thermostat fitted is a type GM thermostat

of Teddingation control with a range of 57/ 99 deg. C
continuously adjustable and is set at 75°C.

Undue rise in temperature of the transformer

oil causes the transformer thermostat to operate, which
in turn picks up the transformer thermostat relay
(TTR). Operation of the relay TTR interrupts the feed
to the motor contactors and also lights unit fault lamps
in the faulty unit.

When the transformer oil has cooled, the

thermostat TT and the relay TTR return to normal
position, allowing traction power to be restored, but
leaving the flag indication to show that a trip has Figure 1.10
occurred. The flag can be reset by operation of a
button on the relay.

1.4.5 Relief Vent

A major fault inside the transformer causes instantaneous vaporization of oil, leading
to extremely rapid build up of gaseous pressure. If this pressure is not released with in few
milliseconds, the transformer tank can rupture, spilling oil over a wide area. This relief vent
provides instantaneous releasing of such dangerous pressure and protects the transformer.

1.4.6 Pressure Relief Valve

In case of severe fault in the transformer,

the inter pressure may built up to a very high
level which may result in an explosion of tank.
To avoid such a contingency, a pressure relief
valve is fitted on the transformer. It is spring-
loaded and has contacts for giving visual
indication and ABB/VCB tripping.

Figure 1.11

When pressure in the tank rises above predetermined safe limit, this valve operates
and performs following function:

a. Allows the pressure to drop by instantaneously opening a port of about 150mm dia.
b. Gives visual indication of valve operation by raising a flag.
c. Operates a micro switch which gives PRV trip indication by glowing LED and
ABB/VCB tripping in the faulty unit.

The valve restores its position as soon as the pressure in the tank drops below set
limit. The flag and switch remain operated until they are reset manually.

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1.4.7 Main Bushing

25 kV condenser type bushing assembly are in service in most of the AC
EMU/MEMU. On some AC EMU/ MEMU cable head type termination is in service.
The 25 kV condenser type bushing assembly consists of three major parts viz. roof
bushing, condenser sleeve and transformer bushing. Originally this type of bushing is oil
filled. But due to failure of condenser bushing resulting in its bursting and splashing of hot
oil on to the floor of motor coach and this hot oil often leads to the fire in the motor coach.
In order to avoid such fire cases on EMUs/ MEMUs, RDSO has issued SMI No.
RDSO/WAU/01 dt. 20.05.98. According to this SMI, oil is to be removed from condenser
bushings and use of cable head terminations in lieu of condenser bushings.

1.5 COOLING EQUIPMENT

The cooling equipment is common for both transformer and reactors and consists of
the following:
a. Pump
b. Forced air blast oil cooler (radiator)

Transformer oil from main transformer is pumped by means of a centrifugal pump to

an air blast cooler (radiator) through 63.5 mm nominal bore pipe work fitted with flexible
stainless steel couplings to make into account the expansion of pipe due to heat. The force-
cooled oil is admitted into the reactors tank and then back to transformer tank as shown in
figure given below.
The pump used for this transformer is a glandless centrifugal pump with all moving
parts completely enclosed and sealed. The pump and driving motor are built as a unit on a
common shaft. A window is fitted in the shaft end to enable direction or rotation to be
observed.
DRAIN PLUGS
CONSERVATOR BREATHER
AIR RELEASE PLUGS

FILTER VALVES

BUCHHOLZ RELAY FLEXIBLE CONNECTIONS

GATE VALVES

TRANSFORMER

PUMP

CHOKE RADIATOR

Figure 1.12 OIL CIRCUIT

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1.6 FACTORS AFFECTING LIFE OF TRANSFORMER

Life of transformer is affected by the following factors:

1. Moisture
2. Oxygen
3. Solid Impurities
4. Varnishes
5. Slackness of winding

1.6.1 Effect of Moisture on Transformer Life

Presence of moisture in oil is highly undesirable as it affects adversely the dielectric
properties of oil. The moisture present in oil also affects the solid insulation of transformer.
As paper insulation is highly hygroscopic in nature, when transformer is filled with oil, it
absorbs the moisture from oil which affects its insulation properties as well as reduces its
life. Solubility of moisture in oil increases with increase in temperature and oxidation
products of oil. When the oil in service oxidizes, acids are formed. These acids increase
moisture solubility of oil. Acids coupled with moisture further decompose the oil forming
more acids and moisture. Thus the rate of deterioration of oil increases.

Check the colour of silicagel in each inspection and if found pink, replace or
reactivate crystals at 150 to 200 degree C. Test transformer oil for electric strength and
water content in IC schedule & POH and carry out purification with high vacuum type
transformer oil filteration plant if required. Arrest the oil leakage if any.

1.6.2 Effect of Oxygen

Oxygen may be present inside the transformer due to air remaining in oil. The
oxygen reacts and decomposes the cellulose of insulation. This forms an organic acid
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.
Carry out oil purification with high vacuum type transformer oil purification plant
periodically to remove atmospheric gases (air) and sludge.
1.6.3 Effect of Solid Impurities
The solid impurity present in the oil reduces its dielectric strength considerably. A
good remedy is to filter the oil periodically.
1.6.4 Effect of Varnishes
Some varnishes having oxidizing effect, react with transformer oil and precipitate
sludge on windings. Synthetic varnishes having acid inhibiting properties, generally delay
the natural formation of acid and sludge in the oil.

1.6.5 Effect of Slackness of Winding

After few months of service, the transformer coils may suffer natural setting. This
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 conditions, which
may result in electrical and magnetic unbalance and produce even greater displacement. A
good practice is, therefore to lift the core and windings to take up any slackness present at
the first major schedule.

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CHAPTER 2

MAINTENANCE

Periodic maintenance of transformer is essential to ensure safety, reliability and

trouble free operation of EMU/ MEMU over a long time period. Maintenance schedules are
given as under.

Schedule Periodicity

Trip inspection 10 Days

IA Schedules 45 Days
IB Schedules 90 Days
IC Schedules 180 Days
POH 18 Months

Work to be carried out under different schedules is given as under.

2.1 TRIP INSPECTION

S. Work/ Inspection to be done Standard value

No
1. Check transformer oil level in conservator tank and top up 15 degree C.
with 50 kV oil, if required. (min.)
2. Check transformer for oil leakages. No leakage
3. Check colour of silica gel crystals and replace if found pink. Blue in colour

2.2 IA SCHEDULE / IB SCHEDULE

S. Work/ Inspection to be done Standard value

No
1. Check transformer oil level in conservator tank and top up 15 degree C. (min.)
with 50 kV oil, if required.
2. Check transformer for oil leakages. No leakage
3. Check colour of silica gel crystals and replace if found pink. Blue in colour
4. Check radiator and its pipe line connections for any oil No leakage
leakage.
5. Open the radiator protective net and blow the dust of radiator Clean
with compressed air and clean it with high pressure water jet.
Provide the radiator net.
6. Release the gas of transformer from Buchholz device (BUD) No gas
and check the operation. OK

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S. Work/ Inspection to be done Standard value

No
7. Check the Buchholz device, conservator, MPH, gate valves No leakage, no
and flexible couplings for any oil leakage or damage. damage.
8. Check the Buchholz device for intactness of glass, operation No abnormality.
of vent cocks, condition of drain plug.
9. Check terminal blocks for any oil leakage, flash mark etc. and No leakage,
also check intactness of each connection. intact.
10. Check main bushing visually for any damage and clean Clean, Intact
porcelain roof bushing insulator & complete bushing surface
thoroughly. Also check intactness of roof bushing connection.

2.3 IC SCHEDULE

S. Work/ Inspection to be done Standard value

No
1. Check transformer oil level in conservator tank and top up 15 degree C.
with 50 kV oil, if required. (min.)

2. Check transformer for oil leakages. No leakage

3. Check colour of silica gel crystals and replace if found pink. Blue in colour

4. Check radiator and its pipe line connections for any oil No leakage
leakage.

5. Open the radiator protective net and blow the dust of radiator Clean
with compressed air and clean it with high pressure water jet.
Provide the radiator net.

6. Release the gas of transformer from Buchholz device (BUD) No gas

and check the operation. OK

7. Check the Buchholz device, conservator, MPH, gate valves No leakage, no

and flexible couplings for any oil leakage or damage. damage.

8. Check the Buchholz device for intactness of glass, operation No abnormality.

of vent cocks, condition of drain plug.

9. Check terminal blocks for any oil leakage, flash mark etc. and No leakage,
also check intactness of each connection. intact.

10. Check main bushing visually for any damage and clean Clean, Intact
porcelain roof bushing insulator & complete bushing surface
thoroughly. Also check intactness of roof bushing connection.

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S. Work/ Inspection to be done Record value

No
11. Check the insulation resistance of winding between

A. Primary to earth by 2.5 kV megger.

B. Secondary to earth by 1000V megger.

C. Primary to secondary by 1000 V megger.

D. Primary to Aux.I by 1000V megger.

E. Primary to Aux.II 1000V megger.

F. Aux.I to earth by 1000V megger.

G. Aux.II to earth by 500V megger.

H. Secondary to Aux.I by 1000 V megger.

I. Secondary to Aux.II by 1000 V megger.

J. Aux.I to Aux.II by 1000V megger

12. Ensure tightness of all connections including TFP earthing Tight

and roof bushing connection.

13. Collect oil sample of transformer oil and send it to the lab for
testing as per Annexure ‘A’. Confirm the report from lab
before releasing the rack for service.

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Annexure ‘A’

As per RDSO SMI no. RDSO/ELRS/SMI/ 158 dt. 19.01.1995, following tests to be
carried out on the transformer oil during IC schedule.

i. Draw a sample of the oil from the transformer as per the method given in IS: 6855-
1973 or IS: 9434-1979 depending upon the characteristics to be evaluated. The
quantity of oil drawn should be 4 litres instead of 2 litres prescribed in these
standards.

ii. Check the oil characteristics for tests given in table given below.

Sr. Tests Test methods Permissible limits Requirement of new

No. filtered oil
1. Visual inspection As per IS --- The oil shall be clear
12463-1988 & transparent and
free from suspended
matter or sediments.
2. Dissolved gas SMI-138 As per SMI-138 ---
analysis
3. Electrical strength IS:6792-72 30 kV (rms) (min.) 60 kV (rms)
(break down voltage)
4. Water content (PPM) IS:335-1983 35 PPM (Max.) 25 PPM (Max.)
5. Specific resistance at IS: 6103-71 0.1 x 10 ohm-cm 35 x 1012 ohm-cm
12

90 degree C (Ohm- (Min.) (Min.)

cm)
6. Total acidity IS:1448-67 0.5 mg KOH/gm. 0.08mg. KOH/ gm.
(Max.)

iii. If the colour of the oil has became dark brown, which is indicative of presence of
dissolved copper, change the oil with new filtered oil meeting characteristics given in
Annexure I of SMI 158.

iv. For interpretation of results of dissolved gas analysis, follow the instructions given in
RDSO SMI No. 138.

v. If dielectric strength and water content are beyond the permissible limits given in
above table, the oil is likely to be cloudy with acrid smell and it should be filtered
under vacuum as per IS:10028 (III) 1981 & IS: 1866-1983.

Filtration of EHV grade oil to be carried out at a vacuum level of 98% at a

temperature of 60 degree C and of inhibited oil at a pressure of 0.15 torcillie at a
temperature of 60 degree C, provided the specific resistance is within limits.
Filtration should continue till such time the oil is completely dried. Check the
filtered oil sample for electrical strength and water content and if these parameters
are within the limits, the oil is fit for use and if not, repeat filtration till electrical
strength and water content are within limits.

vi. If the specific resistance is beyond permissible limit, replace the oil with new filtered
oil meeting characteristics given in Annexure 1 of SMI 158.

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2.4 POH

Details of work to be carried out during POH is given as under:

2.4.1 General

First of all remove as much dirt as possible particularly around the transformer tank,
radiator protective net, terminal block covers & PRV etc. Open the radiator protective net
and blow the dust of transformer & radiator with compressed air.

2.4.2 Incoming Tests/ Inspection

Before carrying out any incoming tests, disconnect following connections.

Disconnect roof bushing connection from HT primary cable/ condenser bushing.

Disconnect the earth leads from the transformer primary earth bushing terminal block.

Disconnect all the power cable connection from secondary winding side terminal blocks.

Disconnect all the cables from auxiliary windings terminal blocks.

2.4.2.1 Visual Inspection

Clean the body of the transformer and tightened all the bolts in the body of the
transformer.

Check the complete tank for any deformation and crack.

Check the oil leakage from transformer tank, radiator, the oil pipes, the flange joints,
flexible couplings, conservator, Buchholz device, drain plugs, vent plugs and both side
terminal blocks.

Check the thread condition of filter valve, drain plug and oil sample valve, air release
vents and replace all gaskets/washers.

Check the conservator for any bend and damage.

Check the under frame oil pipe lines, gate valves, tank etc. for any hitting mark,
damage etc.

Note all the defects and deficiencies.

2.4.2.2 Meggering

Check the insulation resistance of windings between:

A. Primary to earth by 2.5 kV megger.

B. Secondary to earth by 1000V megger.
C. Primary to secondary by 1000 V megger.
D. Primary to Aux.I by 1000V megger.
E. Primary to Aux.II 1000V megger.
F. Aux.I to earth by 1000V megger.
G. Aux.II to earth by 500V megger.
H. Secondary to Aux.I by 1000 V megger.
I. Secondary to Aux.II by 1000 V megger.
J. Aux.I to Aux.II by 1000V megger.

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2.4.2.3 Continuity Test

Check the continuity of the following windings with the multimeter:

Primary winding across P3 & P4

Secondary windings across a1& a2, a3 & a8

Auxiliary winding I across a11 & a12

Auxiliary winding II across a21 & a22

2.4.2.4 Ratio test

Apply 225 V a.c. to the primary winding of the transformer and measure the voltage
appearing at the following terminals of the terminal blocks.

TAP Nominal voltage Range (volts) Terminal no.

1 0.704 0.700-0.708 a3 - a4
2 1.408 1.400-1.412 a3 - a5
3 2.112 2.100-2.125 a3 – a6
4 2.816 2.800-2.825 a3 – a7
5 3.52 3.500-3.535 a3 – a8
6 3.52 3.500-3.535 a1 – a2
7 4.220 4.200-4.240 a1 – a4
8 4.928 4.900-4.955 a1 – a5
9 5.632 5.600-5.660 a1 – a6
10 6.336 6.300-6.365 a1 – a7
11 7.04 7.00-7.075 a1 – a8
12 Auxiliary winding-I = 2.40 V at terminals a11 & a12
13 Auxiliary winding- II = 1.27 V at terminals a21 & a22

The above tolerances are ± 0.5% of the stated voltage ratio of the transformer at no load.

Note:- For taps 7 upwards, it will be necessary to short terminals a2 & a3 with a piece of
insulated conductor.

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2.4.3 Transformer Oil Testing

As per RDSO SMI No.RDSO/ELRS/SMI/158 dtd. 19.01.95, following tests to be carried out
on the transformer oil during POH.

i. Draw a sample of the oil from the transformer as per the method given in IS: 6855-
1973 or IS: 9434-1979 depending upon the characteristics to be evaluated. The
quantity of oil drawn should be 4 litres instead of 2 litres prescribed in these
standards.

ii. Check the oil characteristics for tests given in table given below.

Sr. Tests Test methods

Permissible Requirement of new
No limits filtered oil
1. Visual inspection As per IS --- The oil shall be clear &
12463-1988 transparent and free
from suspended matter
or sediments.
2. Dissolved gas SMI-138 As per SMI- ---
analysis 138
3. Electrical strength IS:6792-72 30 kV (rms) 60 kV (rms)
(break down (min.)
voltage)
4. Water content IS:335-1983 35 PPM (Max.) 25 PPM (Max.)
(PPM)
5. Specific resistance IS: 6103-71 0.1 x 1012 35 x 1012 ohm-cm
at 90 degree C ohm-cm (Min.) (Min.)
(Ohm-cm)
6. Dielectric IS: 6262-71 1.0 (Max.) 0.002 (Max.)
dissipation factor
(Tan Delta) at 90
degree C.
7. Total acidity IS:1448-67 0.5 mg 0.08mg.KOH/ gm.
KOH/gm.
(Max.)
8. Sediments and IS:1866-88 0.05% by wt. No sediment or
perceptible sludge Appendix-A perceptible sludge shall
be detected.
9. Flash point IS: 1448-1970 125 deg. C 100 deg. C (Min.)
(Min.)
10 Interfacial tension IS: 6104-71 0.018 N/m 0.04 N/m (Min.)
at 27 degree C (Min.)
11 Oxidation IS: 335-1983 0.3% by mass 0.3% by mass (Max.)
Inhibitor Appendix ‘D’ (Max.)

Compare the results with the result recorded earlier on the same oil. Any abrupt
change in the value of the parameters is indicative of the unhealthiness of the
transformer. The transformer should be opened for detailed internal inspection for any
incipient fault. However, if the flash point falls by 15 degree C from its initial value,
replace the oil with new filtered oil without opening the transformer.

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iii. If the colour of the oil has became dark brown, which is indicative of presence of
dissolved copper, change the oil with new filtered oil meeting characteristics given in
Annexure I of SMI 158.

iv. For interpretation of results of dissolved gas analysis, follow the instructions given in
RDSO SMI No. 138.

v. If either of the parameters i.e. flash point, interfacial tension, specific resistance, total
acidity and dielectric dissipation factor are beyond the permissible limits, replace the
oil with new filtered oil.
vi. Measure and record the inhibitor content in the oil, if inhibited.

2.4.4 Purification of Transformer Oil

If transformer is not due for core lifting and other test results are satisfactory,
connect the transformer for oil purification. The oil should be purified under vacuum as per
IS: 10028 (III) 1981 & IS: 1866-1983.

Filtration of EHV grade oil is to be carried out at a vacuum level of 98% at a

temperature of 60 degree C and of inhibited oil at a pressure of 0.15 torcillie at a
temperature of 60 degree C. Filtration should continue till such time the oil is completely
dried. Check the filtered oil sample for electrical strength and water content and if these
parameters are within the limits, the oil is fit for use and if not, repeat filtration till electrical
strength and water content are within limits.

2.4.5 Internal Inspection

In order to obtain optimum service life from the EMU transformer, it is suggested
that transformer is opened and core is lifted at an interval of 6 to 8 years of service. Core
should also be lifted during first POH after commissioning for tightening of the pressure
bolts.

Following work is to be carried out if transformer is due for internal inspection.

2.4.5.1 Removing of Active Part (Windings) From Tank

Close all the gate valves of transformer and its pipes lines.

Drain oil from transformer pipe lines.

Disconnect all electrical connections of transformer.

Disconnect and remove main bushing.

Disconnect all pipe line connections to the transformer.

Open all base parts from transformer tank.

Provide hydraulic trolley below the transformer tank and lift the transformer by the
trolley.

Remove all the foundation bolts fixing transformer to the motor coach.

Remove the transformer with the help of hydraulic trolley.

Bring the transformer in transformer repairing section.

Clean thoroughly the transformer body.

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Drain the transformer oil completely.

Remove all the bolts from the transformer tank top covers.

Remove all three number inspection covers.

Disconnect all windings connections from terminal blocks and also remove the
earthing connection of active part.

Lift the active part (windings) with top cover with the help of crane.

Place the active part on wooden blocks and remove the top cover by removing its
fixing bolts.

2.4.5.2 Inspection of Active Part (Windings)

Lower and raise the active part 4 to 5 times in a dry oil bath so as to remove the
sludge from the ducts in the core/ windings.

Place the active part (windings) in a large vessel vertically on wooden blocks and hose
down with clean dry oil. Do not impinge hot oil jet on the transformer windings.

Check all the core support bolts for any crack at the welded joint and replace them if
required.

Check the tightness of yoke bolts by torque wrench.

Check the spacers and wedges for proper position and thickness.

Check the lead paper insulation for any damage and reinsulated if necessary.

Check the distance between the bus bars and yoke.

Check the bushing stud and insulator for any damage and replace if necessary.

Check the tightness of bus bar leads and also crimping terminal joints.

Check the condition of insulating separators.

Tighten all pressure bolts until Belleville washers are flattened and then rotate by 1/6
turn in opposite direction.

Bake the active part (windings) in oven at a temperature of 60 degree C.

Check insulation resistance with 1 kV megger between end frame and core.

2.4.5.3 Attention on Tank

Clean the tank thoroughly from inside and outside.

Check visually inside of tank for any flash mark, hit mark, damage etc.

Check the tank from outside for any damage, welding crack of angles/ channel and
repair if required.

Do the varnishing of the tank inside area with Copal varnish.

Paint the tank from out side with battleship gray paint.

Check the oil drain cocks and change washers by a new one, tight and lock them.

Remove the terminal blocks and check visually for any damage. Repair them if
required.

Check the secondary and auxiliary terminal blocks fixing studs for tightness and they
should be oil leak proof.

Check the P4 bushing fitting surface, it should be clean and plain.

Check the top and bottom gate valves for their proper working and check for oil
leakage.

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2.4.5.4 Top Cover Attention

Clean the top cover (plate) thoroughly from the top-side, bottom side and turret area.

Check visually for any flash mark on bottom side and welding cracks of
channels/angles.

Check the vent plugs (3 nos.) and replace nylon/ copper washer with new one, if
required.

Top cover bottom side to be varnished properly with copal varnish and top side to be
painted with battleship grey paint.

Check active part holding suspension device for straightness and uniform ness.

2.4.5.5 Re-Tanking of Active part

Fit the top cover on active part

properly.

Replace all gaskets with new one
before re-tanking the active part.

Re-tank the clean, dry active-part in
tank.

Tighten all the bolt of the top cover.

Connect all winding connections on
terminal blocks including earthing
connection of active part and fit the
inspection covers.

Check, clean and re-fit all
accessories of the transformer tank Figure 2.1
cover.

2.4.5.6 Testing of Transformer After Re-tanking

Carry out the following tests on the transformer after re-tanking of active part in tank.

Meggering

Continuity test

Ratio test

2.4.6 Inspection of Fittings

2.4.6.1 Buchholz Relay

Clean the complete assembly with fresh transformer oil.

Check the Reed switch on test bench for its healthiness.

Check manually the free operation of BUD floats.

Check visually the glass indicator for any damage.

Check the operation of assembly by allowing the oil flow.

Check the pet cock for free operation.

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2.4.6.2 Silica Gel Breather

Check the silica gel breather visually for any abnormality/ damage.

Reactivate silica gel by heating in a shallow pan at a temperature of 150 deg. C to 200
deg. C for two or three hours until the crystals should have regained their original blue
tint.

Clean and dry all parts of the breather before filling the container with silica gel.

Fill the fresh or reactivated silica gel crystals.

Verify that the oil level in the oil cup is correct after reassembly.

2.4.6.3 Thermostat

Clean the thermostat assembly with petrol.

Check the contact closing temperature with the help of thermo-meter.

Check visually the presence of transformer oil in thermostat pocket.

2.4.6.4 Pressure Relief Valve

Check the diaphragm visually for healthiness.

Check the springs visually for any defect and ensure their tention.

Clean the PRV contacts with petrol and check its operation manually.

Ensure free movement of PRV plunger manually.

2.4.6.5 Radiator

Clean the radiator tubes thoroughly by compressed air and high pressure water jet.

Check radiator tubes and fins for any damage.

Replace both side cover gasket of radiator with new one.

2.4.6.6 Pipe Lines And Couplings

Clean all the pipelines and coupling thoroughly.

Check all the pipelines, flexible couplings for any damage, hitting marks etc.

Check all the supporting clamps and brackets of the pipelines for any damage, welding
crack etc.

Paint all the pipelines with grey paint.

2.4.6.7 Conservator

Clean conservator and glass indicator thoroughly.

Check the conservator for any damage, intactness of indicator glass and condition of
glass.

Check flexible coupling below conservator for any damage, oil leakage etc.

Paint the conservator with grey paint.

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2.4.6.8 Main Bushing

Clean the roof bushing insulator, condenser sleeve and transformer bushing thoroughly.

Check visually roof bushing porcelain insulator for any crack, flash mark etc.

Check condenser sleeve for any damage, crack etc.

Remove oil from the condenser bushing if provided.

Check and record tan- delta of the bushings (without oil at 1,2 and 5 kV). If the value of
the tan delta is greater than 3%, replace the bushing.

Check flange to flange distance in the condenser bushing, it should be of 2200± 5 mm.
If this gap is found to be less, carry out modification as advised vide RDSO
modification sheet No. RDSO/WAU/3/ Dated 24-07-1981.

Note:- Replace the condenser bushing with cable head termination system as per RDSO
specification No. ELRS/SPEC/BL-0003 –May 99 and SMI No.193.

2.4.7 Final Fitment of Transformer on Motor Coach

Fit the transformer on motor coach with the help of hydraulic trolley.

Fit all the fitting such as Buchholz device, main bushing, conservator, breather etc.

Connect all the pipe lines, flexible couplings and pipe lines support.

Connect all electrical connection, earthing leads etc.

If transformer oil has been replaced due to any reason, replace the oil of choke tank also.

Fill the transformer oil up to proper level.

Ensure open condition of all gate valves.

Connect the transformer to the oil purification plant for purification of transformer oil
and carry out purification as described under section 2.4.4.

Check the transformer, conservator, Buchholz device, pipe lines, couplings, gate valves,
radiator etc. visually for any defect or deficiency.

2.4.8 Final Checking

Check visually for any oil leakage from any point, coupling, joints etc.

Ensure the open condition of all the gate valves.

Check and ensure oil level in conservator, it should be minimum 15 degree C mark.

Release air from vent plugs.

Check the function of Buchholz relay.

Ensure connection of thermostat and oil in TT pocket.

Ensure operation of PRV plunger and its connections.

Check the transformer fuses.

Provide all terminal block covers.

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CHAPTER 3

TRANSFORMER FAILURES

3.1 COMMON FAILURES OF EMU TRANSFORMER

Some of the common failures/ defects occurred in EMU/MEMU transformer are as

under:

Oil leakage

Low BDV

Bushing failure

Flexible (metallic) expansion coupling failure

Winding failures

Temperature rise/ actuation of thermostat.

Actuation of PRV

Low IR value

Humming sound

3.1.1 Oil Leakage

Location Possible causes Remedial action

From screw ‫־‬ Foreign material in threads ‫־‬ Remove the foreign material.
joints ‫־‬ Poor threads ‫־‬ Check the threads & replace
if required.
‫־‬ Improper assembly ‫־‬ Ensure proper assembly.
From gasket ‫־‬ Insufficient or uneven compression. ‫־‬ Tight gasket joints uniformly.
joints ‫־‬ Improper preparation of gaskets and ‫־‬ Provide proper gaskets.
gasket surfaces.
‫־‬ Old gaskets ‫־‬ Provide new gaskets.
From weld ‫־‬ Shipping strains, imperfect weld. ‫־‬ Repair welds following
joints proper procedure as per SMI
102.
From flexible ‫־‬ Cracks in flexible couplings. ‫־‬ Replace flexible couplings
couplings & and secure the pipe lines near
their joints couplings properly.
‫־‬ Defective coupling joints. ‫־‬ Make proper coupling joints
and tight the screws.
From drain ‫־‬ Defective thread portion. ‫־‬ Check the threaded portion.
plugs. ‫־‬ Defective oil seal. ‫־‬ Replace the oil seal and tight
the drain plug.

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3.1.2 Low BDV

Type of failure Possible causes Remedial action

Low BDV Moisture contamination in Reactivate silica gel crystals or
transformer oil due to inactive replace them. Purify the transformer
silica gel (pink colour). oil to restore dielectric strength.
Leaks around cover Attend leaks, regasket if necessary.
accessories, breathing air from Purify the transformer oil to restore
leaks. dielectric strength.
Humid atmosphere in rainy Purify the transformer oil to restore
season. dielectric strength and check the
BDV & water content.

3.1.3 Bushing Failure

Types of failure Possible causes Remedial action

Power contact ‫־‬ Tilted bushing. ‫־‬ Check for any tilting and correct if
nearest to condenser required.
sleeve flashed. ‫־‬ Flange to flange ‫־‬ Check and maintain flange to flange
distance less. distance of 2200 ± 5 mm. If this gap
is found to be less, carry out
modification as advised vide RDSO
modification sheet No.
RDSO/WAU/3/ Dated 24-07-1981.
Roof bushing flash ‫־‬ Lightening. ‫־‬ Gapless lightening arrestor may be
over. provided.
‫־‬ Dirty bushing. ‫־‬ Ensure cleaning of porcelain bushing
during each inspection.
Roof bushing ‫־‬ External hitting. ‫־‬ Ensure proper cleaning and visual
porcelain insulator checking of porcelain bushing during
petticoat broken / each inspection.
cracked.

3.1.4 Flexible (metallic) Expansion Couplings Failure

Types of failure Possible causes Remedial action

‫־‬ Couplings ‫־‬ External hitting or ‫־‬ Check the pipelines near couplings
broken/ cracked continuous for proper support. Provide
from flexible vibrations. additional support if required.
portion.
‫־‬ Coupling joints ‫־‬ Loose joint ‫־‬ Ensure tightness of joints during
loose and oil each schedule.
leaking. ‫־‬ Gasket worn out. ‫־‬ Provide new gaskets during POH.

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3.1.5 Winding Failures

Types of failure Possible causes Remedial action

‫־‬ Primary winding ‫־‬ Short circuit Check the setting of over load relay and its
lead open circuited due to CT. Investigate for over loading and take
/ earthed. overload. corrective action accordingly.
‫־‬ Bulging and inter ‫־‬ Coils shrink During manufacturing/ rewinding of the
turn short. and in between transformer, the coils should be pressed
insulation down, heated and cooled repeatedly until the
failure. coil height stablises.
‫־‬ Shorting between ‫־‬ Insulation Nomex paper insulation sheet should be
LV and HV coils. failure. provided between H.V. & L.V. coils so as to
strengthen the insulation level. Ensure that
this insulation sheet does not cause any
obstruction in the passage of oil flow.
‫־‬ Shorting between - Insulation Additional pressboard separator barrier of
secondary bus failure. suitable thickness should be provided in
bars. between LV bus bars at locations where
shorts generally have occurred

Note :
Actuation of PRV, BIR and OLR takes place during failure of transformer winding
and circuit breaker is tripped. Circuit breaker should not be reclosed as it might result in
additional internal damage and fire hazard.
Check transformer for any external mechanical or electrical damage to bushings,
terminal board connections and other parts. Take oil sample for DGA, BDV and other
tests. Check the transformer thoroughly and take corrective action according to
observations and oil test results.
3.1.6 Temperature Rise/ Actuation of Thermostat.

Type of failure Possible causes Remedial action

Actuation of ‫־‬ Insufficient cooling due to ‫־‬ Ensure proper cleaning of radiator
Thermostat & dusty radiator tubes. tubes. Carry out one cyclic check of
TTR thermostat setting & TTR working as
pre summer precaution.
‫־‬ Insufficient cooling due to ‫־‬ Check and ensure fully open
partial close condition of condition of all gate valves.
gate valves.
‫־‬ Non working of MPH/ ‫־‬ Ensure working of MPH and both
MVRH. the MVRH.
‫־‬ Any internal fault such as ‫־‬ Replace the transformer and core to
short circuited core, core be lifted for thoroughly checking.
bolts/ clamps insulation Take corrective action according to
failure etc. (In this case TTR observations and oil test report.
will trip along with BIR.)

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Type of failure Possible causes Remedial action

‫־‬ Low oil level in ‫־‬ Check the oil level in conservator and top
conservator. up if required.
‫־‬ Sludged oil. ‫־‬ Carry out purification of oil to remove
sludge.

3.1.7 Actuation of PRV

Type of failure Possible causes Remedial action

Actuation of ‫־‬ Internal fault such as ‫־‬ Refer winding failures.
PRV winding failure,
insulation failure etc.
‫־‬ Obstructed oil flow. ‫־‬ Check all the gate valves for fully open
condition.
‫־‬ Obstructed breathing. ‫־‬ Check breather line for any obstruction.
‫־‬ Conservator oil level ‫־‬ Oil level should be adjusted to proper
too high. level (15 to 30 degree C.) to allow ample
space for expansion of oil.

3.1.8 Low IR Value

Type of failure Possible causes Remedial action

Low IR value ‫־‬ Moisture in oil. ‫־‬ Purify the oil with high vacuum type oil
purification plant and test the oil for
electrical strength and water content.
‫־‬ Insulation failure ‫־‬ Replace the transformer. Lift the active
between winding part and check the winding thoroughly for
and core. insulation damage and take corrective
action accordingly.
‫־‬ Internal ‫־‬ Check the internal connection leads by
connection leads lifting the active part and retape
insulation damage. insulation paper of damaged portion.

3.1.9 Humming Sound

Type of failure Possible causes Remedial action

Humming ‫־‬ Loose core ‫־‬ Lift the active part and tight all the pressure
sound bolts and clamping bolts.
‫־‬ Winding ‫־‬ During manufacturing/ rewinding of the
loose due to transformer, the coils should be pressed down,
shrinkage of heated and cooled repeatedly until the coil
coils height stablises.
‫־‬ The winding pressure bolts and core clamping
bolts should be tightened during the first POH
after commissioning to take care of shrinkage.

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CHAPTER 4

PURIFICATION OF TRANSFORMER OIL

The object of oil purification is to remove all contaminants such as water, carbon deposits,
dirt, sludge, dissolved moisture and gases. The most important quality to be preserved is the di-
electric strength, which is affected by the presence of moisture.

The insulating materials used in the winding are hygroscopic by nature and therefore
moisture is absorbed through defective breathers, gaskets and addition of untreated make up oil. It
is essential to remove these impurities by purifying the oil when the dielectric strength goes below
the permissible limits.

The purification plant should be capable of removing dissolved air/ moisture in the form of
free and finely dispersed water vapour and moisture in solution, sludge and fibers, gases,
carbonaceous products formed due to arcing and drum scale or any other solid particles from
insulating oil.

The plant should be capable of purifying the rated capacity of transformer oil to the
following parameters in maximum three phases.

a. Suspended impurities – maximum 1 micron particle size.

b. Water content – from 100 ppm to less than 5 ppm
c. Gas removal – from fully saturated i.e. 10 to 12% by volume with
air/gas down to less than 0.25%
d. Acidity correction – with addition of clay filters the neutralization
index should go down from 0.5 to 0.05 mg KOH/ gm
of oil.
e. Dielectric strength – Minimum 60 kV
f. Dissipation factor of oil/
tan delta at 90°C – 0.002

The switching ON & OFF of the heater groups should be thermostatically controlled
so that the temperature of the oil during treatment is not be permitted to rise above 60°C.
Operating vacuum should be better than 1 torr.

Filtration of EHV grade oil to be carried out at a vacuum level of 98% at a

temperature of 60 degree C and of inhibited oil at a pressure of 0.15 torcillie at a
temperature of 60 degree C, provided the specific resistance is within limits. Filtration
should continue till such time the oil is completely dried. Check the filtered oil sample for
electrical strength and water content and if these parameters are within the limits, the oil is
fit for use and if not, repeat filtration till electric strength and water content are within
limits.

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4.1 INSULATION RESISTANCE DURING DRYING OUT

Readings of temperature and insulation resistance should be recorded every two

hours, from commencement until the full operation is completed. If these readings are
plotted on a graph, the appearance will be as shown in fig 4.1.
INSULATION RESISTANCE IN MEG OHMS

TEMPERATURE
TIME IN HOURS

Figure 4.1 INSULATION RESISTANCE GRAPH

It is observed that there are four distinct stages:

A. Initially the insulation resistance drops down to a low value because of rise in
temperature of the oil up to about 60 degree C.

B. Insulation resistance will continue to remain at a low level despite temperature being
maintained at a high level until most of the moisture from the windings and oil has
been driven out.

C. The insulation resistance will thereafter rise gradually and level off, indicating that all
moisture has been driven out and the drying out operation has been completed. At
this point oil circulation should be discontinued.

D. As the oil cools off, the insulation resistance will rise much above the leveling off
point at the end stage (C). This is because the insulation resistance value doubles for a
fall in temperature of about 10°C to 15°C.

*****

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CHAPTER 5

CONDITION MONITORING OF TRANSFORMER BY

DISSOLVED GAS ANALYSIS

5.1 INTRODUCTION
In order to detect incipient faults in the transformer and to arrest deterioration/
damage to the transformer insulation, gases dissolved in the transformer oil are detected,
analysed and preventive measures adopted.
Gas Chromatography method is used for detection of the dissolved gases and
identification of incipient faults. The most significant gases generated by decomposition of
oil and deterioration of paper insulation on the conductor are hydrogen, methane, ethane,
ethylene and acetylene. The quantities of these gases dissolved in transformer oil vary
depending upon the type and severity of the fault conditions.

5.2 SENSITIVITY LIMITS

Gas Chromatography apparatus should be able to detect the following minimum
concentration of dissolved gases:
Hydrogen : 5 ppm
Hydrocarbon : 1 ppm
Carbon oxides : 25 ppm

5.3 ESTABLISHMENT OF REFERENCE VALUES/ BENCH MARKS

To establish a reference value/ bench mark, gas as generated from initial sample of
oil from each healthy transformer should be collected. Results of the analysis are taken as a
reference value/ benchmark. Results of later periodic analysis are compared with the
benchmark for each transformer.

5.4 ESTABLISHMENT OF NORMS

The contents of various dissolved gases in the transformer oil vary with design and
operating conditions. It is desirable that the values of concentration of gases of healthy
transformers of different age groups are to be gathered by the Railways concerned to evolve
suitable norms. However, as a starting point, the permissible concentrations of dissolved
gases in the oil of a healthy transformer are given below as guidelines:

Gas Less than 4 years in 4-10 years in service More than 10 years
service (ppm) (ppm) in service (ppm)
Hydrogen (H2) 100/150 200/300 200/300
Methane (CH4) 50/70 100/150 200/300
Acetylene (C2 H2) 20/30 30/50 100/150
Ethylene (C2 H4) 100/150 150/200 200/400
Ethane (C2 H6) 30/50 100/150 800/1000
Carbon dioxide (CO2) 3000/3500 4000/5000 9000/12000

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5.5 DIAGNOSIS OF FAULT

Basic Diagnosis of DGA is based upon the quantities of gases generated. Types of
gases in excess of norms produced by oil decomposition/ cellulosic material depend upon
the hot spot temperature produced by faults.
Characteristics gases associated with various faults are as under :

Methane (CH4) Low temperature hot spot

Ethane (C2 H6) High temperature hot spot
Ethylene (C2 H4) Strong over heating
Acetylene (C2 H2) Arcing
Hydrogen (H2) Partial discharge
Carbon dioxide (CO2) Thermal decomposition of paper insulation
Carbon monoxide (CO)

5.6 WORD OF CAUTION

To start with the diagnosis, it is necessary to be satisfied that measured gas
concentrations are significant and high enough to warrant diagnosis, because some amount
of gases will always be there due to normal operating conditions without any fault but it can
be sufficient to be misleading. The reasons for the situation are:

 Gases formed during the refining processes and not completely removed by oil
degassing.
 Gases formed during drying and impregnating the transformer in sheds/ workshops.
 Gases formed in the event of previous faults and not completely removed from the oil-
impregnated insulation before being refilled with degassed oil.
 Gases formed during repairs by brazing, welding, etc.

5.7 PROCEDURE FOR FAULT DIAGNOSIS

 Obtain the results of concentration of various gases in terms of microlitre (ppm).
 Compare the concentrations with sensitivity limits. These should be at least ten times the
sensitivity.
 If it exceeds sensitivity limits, compare with benchmarks.
 If it exceeds benchmarks, compare concentrations with norms depending upon age and
design of transformer.
 If one or more gases are above norms, compare with the last sample results; if increase is
sufficient, obtain a check sample.
 If the check sample confirms the results, calculate the rate of increase of gas. If rate of
increase is more than 10% per month, it is considered rapid and warrants immediate
further investigations including lifting of core and internal inspection.
 If the gas production rate is medium, i.e., less than 10% per month, sampling frequency
to be increased from quarterly to monthly.
Take a planned shut down for further investigation.

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CHAPTER 6

DO’S AND DON’TS

6.1 DO’S
1. Check the protection system of transformer periodically.
2. Always use transformer oil procured from RDSO approved suppliers.
3. Check silica gel regularly.
4. Check and thoroughly investigate the transformer whenever any alarm or protection
system is operated.
5. Examine the bushings for dirt deposit, coating and clean them periodically.
6. Attend any type of oil leakage at the earliest possible.
7. Clean conservator thoroughly before refilling.
8. Ensure proper functioning of Buchholz relay.
9. Ensure periodic testing of transformer oil.
10. Ensure that oil has been removed from the condenser bushing.
11. Ensure oil in TT pocket.
12. Maintain record of transformer and oil, transformer wise for future reference.

6.2 DON’TS
1. Don’t use under capacity lifting jacks.
2. Don’t leave any loose connection.
3. Don’t meddle with protection system.
4. Don’t allow conservator oil level to fall below 15 degree C. level.
5. Don’t over tight the nuts & bolts to stop any leakage.
6. Don’t use fuses higher than the prescribed ratings.
7. Don’t tamper with earthing connections.
8. Don’t keep the breather pipe open or exposed.
9. Don’t re-energize the faulty transformer unless the oil test report including DGA is
satisfactory.
10. Don’t impinge hot oil jet on the transformer windings for cleaning.
11. Don’t use reclaimed oil in transformer.
12. Don’t mix old & new transformer oils.
13. Do not mix EHV grade & inhibited transformer oil.

*****

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ANNEXURE – I

List of Modifications and Special Maintenance Instructions issued by RDSO for Transformer
of AC EMU/MEMU.

Sr. No. Modification/ SMI No. Brief Description

1. RDSO/ELRS/SMI/102 Procedure for repairing the defective welds of

Dt. Dec. 1982 transformer fitted on AC electric locomotives.

2. Modification Sheet no. Provision of additional parmali wood cleats to support

RDSO/WAU/5 L.T. busbars of BHEL built BG AC EMU transformers.
Dt. Aug. 1982
3. Modification Sheet no. Modification to the mounting arrangement of
RDSO/WAU/3 condenser bushing for 25 kV AC EMUs.
Dt. 24.07.1981
4. RDSO/ELRS/SMI/120 Maintenance of main transformer oil in service.
Dt. 23.11.1984
5. RDSO/ELRS/SMI/121 Revised characteristics for new insulating oil for
Dt. 30.01.1985 locomotive/ EMU transformer and additional tests for
maintenance of oil in service.
6. RDSO/ELRS/SMI/127 Procurement specification for insulating oil &
Dt. 27.04.1985 Condition monitoring of insulating oil.

7. RDSO/ELRS/SMI/138 Condition monitoring of traction transformers by

Dt. 29.04.1991 dissolved gas analysis.

8. RDSO/ELRS/SMI/158 Code of practice for maintenance of transformer oil in

Dt. 19.01.1995 service.

9. RDSO/ELRS/SMI/159 Use of Inhibited transformer oil to IS: 12463 in electric

Dt. 02.12.1993 loco and EMU transformer.

10. RDSO/ELRS/SMI/164 Code of practice for maintenance of loco transformer.

Dt. 30.01.1995
11. RDSO/ELRS/SMI/179 Check points during commissioning for transformer
Dt. 1995 fixed with accessories.

12. RDSO/ELRS/SMI/193 Maintenance practices for improving reliability of

Dt. 12.01.1998 cable head termination system for 25 Kv AC locos/
EMUs.
13. RDSO/WAU/01 25 kV condenser bushing on AC EMU motor coaches.
Dt. 20.05.1998

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REFERENCES

1. Manual of AC Traction Maintenance and Operation Volume III 1994.

2. BHEL Maintenance Manual for 25 kV broad gauge AC and Main Line Electrical
Multiple unit (Electrical Equipment). Book Number : MM/AC-M/EMU/003, January,
2001.

3. SMIs and modification sheets issued by RDSO.

4. IS: 10028 (Pt.III) - 1981, reaffirmed 1993 & 1998 –Code of Practice for Selection,
Installation and Maintenance of Transformers (Part– III Maintenance).

5. Field study and literature collected from various EMU car sheds/ workshops.

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OUR OBJIVECTIVE

To upgrade maintenance technologies and

methodologies and achieve improvement in
productivity, performance of all Railway
assets and manpower which inter-alia would
cover reliability, availability, utilisation and
efficiency.

If you have any suggestions and any specific Comments

please write to us.

Contact person : Director (Elect.)

Postal Address : Indian railways

Centre for Advanced
Maintenance technology,
Maharajpur, Gwalior.
Pin code – 474 020

Phone : 0751 – 2470740

0751 – 2470803

Fax : 0751 - 2470841

Maintenance Handbook on Transformer of AC EMU/MEMU October, 2005