GE POWER TRANSFORMER

TRAINING MANUAL – TRANSFORMER

DATE: 19-09-24
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Introduction
Our objective is to provide training on the Power transformer and Earthing Transformer
operation &
maintenance. Power transformer rating is of 132kV, 35/50 MVA, manufactured as per the IEC
standard
60076.Make Japan AE power System Corporation, Japan and 500 kVA Earthing Transformers
are from
AREVA Turkey.

Following Transformers are in Adani Substation.

1. 31.5MVA Power Transformer
2.
Power Transformer:

A 66/11 kV, 31.5 MVA Star-Delta (Vector Group of Dyn11) Transformer with On Load
tap changer 17 Tap positions. Highest voltage at maximum tap position is 72.6 kV and
Low Voltage at minimum Tap is 59.4 kV. (Please refer to name plate).

Rated Primary current at 275A ,31.5 MVA LV Amps is 1581 with impedance Voltage HV/LV at
75 °C (at ONAF) >
11.56 %. Short Circuit rating of HV side is 40 kA for 1 Sec and LV side 25kA for 3 Sec.
12 Nos radiators are provided on each Transformer and 08 cooling Fans in two Groups (04
Fans in one
Group) fully automatic control through Oil Temperature Indicators and Winding Temperature
Indicators.

Each radiator is fixed with Tank through Butterfly Valve and individual radiator can be
replaced in case of
any rectification during maintenance.

01 Conservator Tank is fixed on IDT having enough capacity to accommodate the expansion
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and
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MV Cable Boxes are designed such free standing and self supported that incase of any
problem Transformer can be removed without disturbing cables.

Transformers are designed to operate satisfactorily in parallel of other Transformer on same

tap position.
Adani has standard Master- Follower scheme which is controlled by Automatic voltage
regulator (AVR)
installed in RTCC (Remote Transformer control cubicle) in control room.

Transformer Tap change control is also affected from the substation control room with
facilities for remote
control from supervisory control center.

Following are the main protection of Transformer:

Mechanical Protection:
A.1 Buchholz Relay
A.2 Oil Temperature Trip
A.3 Winding Temperature Trip
Electrical Protection:
B.1 Differential Protection
B.2 REF Protection
B.3 O/C and E/F Protection

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Earthing Transformer:

500 kVA (11/0.4kV) earthing Transformer with ONAN cooling system is installed to provide
the earthing
of Power transformer (11kV winding is delta connected).

Layer type windings and Primary is in Zigzag and LV side is Star connected and having
ZNyn11 vector
Group. Short circuit rating on 11kV is 12.7 MVA for 30 Sec.

Voltages are regulated through Off Load tap changer and LV winding is used for substation
load. All
utility of the substation is fed by ETs through LVAC switchgear.

Following are the Protections for ETs:

1. Buchholz relay
2. OIL and Winding Temperature Trip
3. LV REF and LVAC REF
4. O/C & E/F Protection for both MV and LV windings

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Manufactured as per the IEC standard 60076

General Data for Power Transformer

- Make : CGL India

- Rating : 25/31.5 MVA
- Rated Voltage : 66000/11500
- Guaranteed Max. Temp. Rise : Windings 55 °K, Oil 50 °K
- Type and Make of OLTC : MS III 300Y (MR)
- Total Mass : 57500 Kg
- Mass of Oil : 13400 kg
- Total quantity of Oil : 15056 liter
- Zero Sequence Impedance : 11.56%
- Impedance Voltage at tap 10 : 12.10 %
- No of Radiators : 12
- No of Cooling Fans :8
- Type of Cooling : ONAN/ONAF (Oil Natural Air Natural /Oil Natural Air Forced)

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List of Accessories/Protective Devices installed in the Power Transformer

Rubber Cell Type Conservator

To ensure many years of stabilized operation for oil immersed transformer without
sacrificing a high dielectric strength. In order to achieve this it is essential to ensure
prevention of deterioration of insulating oil and watch out the behavior of gases dissolved in
oil. The most eminent cause of deterioration is a phenomenon of oxidation.

Pressure Relief Device

The pressure relief device is generally a spring loaded valve having a unique means of
providing instantaneous amplification of actuation force. Pressure relief valve having the
single pole double throw switch, provides 2 contacts one for normally closed and another
one is normally open

Oil Temperature Indicator

The Oil temperature indicator series 34 measures the top - oil temperature. It is a standard
instrument for cooling, control and protection for all transformers.
It provides contact for fan start, alarm and trip contract.

Winding Temperature Indicator

The life of the transformer depends on the winding temperature which determines the
deterioration of the insulating material due to the high electric potential of the winding
temperature directly.
It provides contact for fan start, alarm and trip contract.

Buchholz Relay
Most of the faults in the transformer are accompanied by the generation of gases due to
decomposition of oil and insulating material. However if such a fault is limited within a small
scale, gases are generated slowly and collected at the ceiling of the tank cover while rising
in the oil in the form of bubbles. If a serious faults happens gases are generated abruptly to
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It operates the alarm contact against slowly generating gas or the trip contact against
abruptly generating gas.

Rubber Bag Rupture Relay

Rubber bag rupture detector relay is the protection equipment for finding damages of rubber
bag inside oil conservator. It should be attached to upper side of oil conservator which is fixed
to transformer. If rubber bag is damaged, inside gas will get out and go to upper side of
conservator and stay there. Rubber bag rupture relay will detect the gas and find the
abnormality of the rubber bag.

Dial Type Oil Gauge

The dial type oil gauge is of outdoor type and used for transformer conservator oil level
indication and its alarm for low/and or high level condition.
Unlike conventional direct reading of actual level dial type indicator is provided with the
needle pointer through permanent magnet coupling so that oil level can be seen easily from
ground level even it is located in the high position.

Dehydrating Breather
The breather is installed on the ventilating pipe on the upper part of such units as
transformer, oil filled equipment and insulation oil storage tanks.
The breather completely removes parts of moisture and fine floating substances out of the
flowing air by means of the absorbent and filter. Humidity is almost completely removed by
silica gel, a desiccating agent.

Axial Fans for Cooling

Cooling fans are used for the cooling of the power transformer running under load. Refer the
manual TAE-981, page 25-1- 1/3 for the reference.
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Oil Surge Relay

The protective relay responds only if oil flows occur from the on load tap changer head to the
oil conservator. The flowing oil actuates the flap valve which trips over into position OFF. The
reed switch is thereby actuated, the circuit breakers are tripped and transformer is de-
energized.

On Load Tap Changer with Motor Drive Unit

On load tap changer is comprised of diverter switch and selector switch for changing the tap.
From the winding all the tapings are connected to the selector switch. Diverter switch
compartment shall be taking care of each tap changing operation. Arc developing during
operation shall be quenched by the oil present in the compartment.

Type of On Load Tap Changer:

Motor drive unit is installed on the transformer to drive the on load tap changer for each tap
operation. Motor drive unit is coupled with the on load tap changer through the bevel gear
arrangement.

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Maintenance and Inspection of Transformer

Inspection under Service Interruption

When intending to perform inspection under service interruption it is absolutely necessary to
examine pilot lamps and indicating plates of various disconnecting switches, circuit breakers,
molded case circuit breakers etc. to confirm whether the equipment under inspection is totally
separated from live circuits. In order to prevent careless re-closure on the other hand it is
essential to lock the equipments by switching off the control power supply or evacuating the
compressed air if the equipment is of pneumatically operated type.

Daily Maintenance and Inspection

Temperature of Insulating Oil and Winding

As stated in the specification, the temperature of insulating oil and winding is limited. It must
be confirmed whether the temperature is proper or not.

Inspection of Oil Level

Check whether the oil level is in proper position.

Noise
In order to find out faults at their early stage pay attention to any abnormal noises having
generally high frequency during the daily inspection. These noises are likely to be produced
as a result of faults in the transformer.

Looseness on Locking or Bindings

In case of any looseness is found on various bindings bolts along the outside surface, tighten
it again directly.

Oil Leakage
Any oil leakage may lead to the deterioration of oil and will spoil the outside appearance of
transformer very much. Check carefully the parts where gaskets are applied.
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Dehumidifying Breather
The breathing action of the breather can be observed exactly at its oil cup, even while running
whether
either the ambient temperature or oil temperature changes. Check whether the breathing
action is going on
normally or not.

Silica gel is adopted as the standard dehumidifying agent, that looks blue in dry condition by
mixing cobalt
chloride and it will become light pink when it has absorbed moisture. Special attention should
be paid to the
changes of color. It is desirable to replace it with new one at suitable opportunity.

Periodical Maintenance and Inspection

Dial Thermometer
Check whether the alarm contact is good.

Buchholz Relay
Check whether its float moves smoothly or not using of float checking device and further
whether its contact
function is good or bad.

Bushings
Check whether the following damages or trouble is observed on the bushing:
Dirty spot, crack and trace of discharge on porcelain insulator.
Loosened bolt, nut and irregular tightness on fixing terminals or studs.

On Load Tap Changer

It is recommended a periodic inspection of the tap changer equipment to maintain a high
PRESENTATION TO ADANI - MUNDRA Slide - 10
reliability in
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The schedule of the tentative frequency of the periodical inspection

N Inspection Item Frequency of Remarks

o
1 Buchholz relay & dial type Periodic Inspection
2 Thermometer Every 3 years
3 Bushing Every 3 years Check only the
appearance
4 Dehumidifying breather When necessary Replacement of
dehumidifying agent
and also of oil in oil
cup.
5 Measurement of Every 3 years
insulation Resistance for
each winding
6 Measurement of acid Every 3 years
value for insulating oil
7 Internal Inspection Every 10 years
8 Cooling Fans/or Oil Pump Every 3 years
9 On Load Tap Changer As per the inspection
manual
1 Gas in Oil Analysis Every 1 year
The0 outlines on daily and periodical maintenance and inspection have been described up to
the proceeding
paragraph. In this paragraph, several Inspections which are essential and it needs detailed
data.
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Earthing Transformer

General Data

- Make : Areva
- Rating : 0.5 MVA
- Insulation Level : L11 75AC 281L1 –AC3
- Rated Voltage : 11000/400 V
- Cooling Method : ONAN
- Impedance Voltage at Tap 3 : 3.87%
- No of Radiators :2
- Total Weight : 5700 KG
- Oil Weight : 1770 KG
- Type of Oil : Nynas nytro 10 XN
- Vector Group : ZNyn11
- Designed Ambient Temperature : 55 deg °C

List of Accessories/Protective Devices installed in the Earthing Transformer

- Oil Temperature Indicator

- Winding Temperature Indicator
- Pressure Relief Valve
- Buchholz Relay
- Oil Level Indicator

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Site Acceptance test

The following Pre commissioning tests shall be carried out on the transformer:
▪ IR value check on winding
- Insulation resistance measurements are performed to verify the dryness of the various
winding and core.
Insulation resistance test also reveal the concealed damage of the bushings. Measurements
are made
at 15th, 60th, 600th second IR value is determined. PI value should be more than or equal
to 1.5.

▪ Insulation resistance of core and core clamp

- To determine the insulation resistance of core & core clamp and between core & core
clamp.
▪ 2kV AC test on core and core clamp
- To ensure that the insulation is capable to withstand the specified test voltage of 2kV.
▪ Ratio and vector group or phase displacement check
- The turn’s ratio of the transformer is the ratio of number of turns in a higher voltage
winding to that in a
lower voltage winding. Ratio error is the ratio of the difference between ratios of the
measured value and
actual value (design/actual).
- To ensure the phase placement or vector group of the Transformer is designed /
manufactured as per
the specification.
▪ Measurement of magnetizing current
- The exciting current test is very useful in locating problems like the magnetic core
structure, shifting of
winding, failure in turn to turn insulation or problems in the tap changer.
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▪ Measurement of short circuit Impedance

- Short circuit impedance is the voltage required to drive the rated current under short
circuit condition.
- To ensure the guaranteed values of the short circuit impedance at rated and extreme taps.
- To compare the values of all taps with the factory test reports.
- To check the occurrence of any interturn shorting or disc replacement of winding during
transportation.

▪ Measurement of Tan delta & capacitance of windings

- Dielectric loss is the power dissipated by the insulation when subject to the alternating
voltage.
- Capacitance is defined as charge per unit current. It is usually mentioned in pico-farad (pf).
- To ensure the condition transformer insulation.
- To check any physical /shifting of the transformer winding/internal parts during
transportation.
- The Dielectric factor for oil filled transf. and reactor in good condition shall not exceed
0.5% at 20°C.

▪ Measurement of Tan delta & capacitance of Bushings

- To ensure the condition of bushing insulation.
- Bushing test tap is used for this measurement and only possible to do the condenser
- Type bushing with test taps arrangement.
- The Dielectric factor of bushings in good condition, value shall not exceed 0.7% at 20 °C.

▪ Calibration of Temperature Indicators

- To ensure the proper working of temperature indicators according to the actual sensing
temperature of
the oil and winding.
- The temperature reading between standard bath and indicator is > 2 °C at any of
calibration steps.

▪ Hot spot gradient checking of winding temperature indicator

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▪ Ratio check of BCT’s for winding temperature indicator

- To ensures the ratios of BCT s are correct and manufactured as per the specifications.
- This test is done to verify the primary to secondary current ratio of WTI BCT’s without
connecting a
burden. The principle is the primary ampere turns and secondary ampere turns in the BCT
are same.

▪ Measurement of Transducer output for remote temperature Indicator

- To ensure the transducer is working properly according to the actual sensing of temperature
indicators in
terms of DC milliamps.
- This test can be done along with the calibration .The milli ampere output are measured for
the different
steps of calibration and results extrapolated to temperature in degrees. The readings are
compared with
bath temperature and local indicators.

▪ Operation check of on load tap changer

- To ensure the proper operation/performance of on load tap changer and its compliance with
the
requirements.
- On load tap changer is a device used to enable the transformer to serve a constant voltage
in the load
dispatch grid as per the input supply or demand variation by changing the tap position on
the
transformers on the loaded condition. The operation of OLTC can primarily by the
operations from MDU.

▪ Tap position Indication check

- To check the tap position indication on OLTC, MDU, AVR, DCS and SCADA are same at every
tap.
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▪ Operation check of cooling equipments

- To ensure the performance of cooling equipments.
- To ensure the operation of cooling fans are according to the start/stop temperature setting
at WTI.
Start/stop set of values cooling fans are given by the manufacturer according to the factory
temperature
rise test results and these values are set in each of the indicators.

▪ Protective devices wiring /operation check

- To ensure correct operation of protective devices at DCS/SCADA before energization of
substation.
- To check the wiring and terminal identification at MK/LCC/RCP/RP are as per the approved
drawings.
- Buchholz relay shall be checked with the N2 injection.

▪ Cable box Inspection

HV Cable box Inspection

To ensure the entire requirement are met as per the drawing/documents before and after
conducting the
cable high voltage test at HV and LV cable inside the respective cable boxes.

If the test preparations are found satisfactory, the separately processed oil with good test
values shall be
filled in the cable box. Following are the required specification of oil.

PRESENTATION TO ADANI - MUNDRA Slide - 16

BDV of Oil ≥ 70
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LV Cable box Inspection

Ensure the insulation resistance of the supporting insulators provided on the bus bar at the LV
side. Ensure
the tightness of LV cable and connection at bus bar. Ensure the tightness of LV bushing
terminal end.
Ensure that the connections are per the drawing/documents and all are connection are locked
with the
torque tightening.

▪ Check on Automatic Voltage Regulator

To check and ensure the operation and performance of AVR as per the specification and
documents
/ requirements.

Automatic voltage control shall be initiated by voltage regulating relay. The relay shall be
operated from the
normal reference voltage stated in the requirements from the circuit mounted on the LV
voltage transformer.
The relay shall be insensitive to the frequency variation from 47 to 51 Hz the relay shall also
be incorporate
the under voltage blocking facility if reference voltage falls below the 80% of the nominal
value and
automatic restoration of control when the reference value varies 85% of the nominal value.
The relay
bandwidth shall be adjustable of to any value between 1.5 and 2.5 times transformer tap step
% the
nominal setting being twice the transformer tap step %.

▪ Operation
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a. Put AVR in auto mode and MDU in remote and check the following:
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c. Put MDU in local position and check the following:

1. Operation possible from MDU.
2. Operation not possible from AVR, DCS and SCADA.

d. Put MDU in remote position and check the following:

1. Operation possible from MDU.

e. Put MDU and AVR in remote and check the following:

1. Operation possible from AVR.
2. Operation not possible from DCS and SCADA.

f. Put AVR in supervisory and MDU in remote and check the following:
1. Operation possible from MDU and AVR.
2. Operation not possible from DCS and SCADA.

g. Under and Over Voltage blocking of MDU

1. No operation possible from any point.

AVR Display

1. Ensure that AVR display has parameters like Voltage, Current, Frequency, Tap no.,
Master/Follower/Independent mode, Paragramer functions (Breaker status).

2. Operations, Indication and Alarm Checks on each AVR Relay

Following procedures are to be carried out in each AVR. Also the safety precautions should
be followed
before starting the test.

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2.a. R/L Control (Hand) & AVRs Independent mode

- Switch on AVR & MDU control supply, DC supply and MDU motor supply. Identify and
verify the
terminal where CB status inputs are connected.
- All the CB status inputs be temporarily short circuited.
- Select paragrammer screen of all AVRs and ensure that all CB status are closed in all
AVRs.
- Switch of control supply of AVR 1 and observe whether there is any status disturbance in
the
paragrammer of other AVRs.
- Keep MDU in Local and ensure that the tap positions are same in MDU, OLTC, AVR
Display and Bus
Bar diagram.
- Keep AVR in “Hand” (manual) and Independent mode and ensure the following
Indications/operations
- Check that Tap Changer in Local indication lamp glows.
- REMOTE / SUPRY try color LED off and MDU local LED glows.
- LED in the Hand push button glows and Raise/Lower operation not possible. Also
Independent LED
glows.
- AVR VT supply absent message in the status line.
- Keeping MDU in remote ensure that tap operation is not possible from MDU.
- Keeping AVR in “REMOTE” ensure that “REMOTE / SUPRY” tri-color LED glows in green
and MDU
local LED off. Also LED in the “Hand” push button glows.
- Raise/Lower operation possible from AVR and Independent LED glows.
- AVR VT supply absent message in the status line.
- Give Raise/Lower commands from AVR and ensure simultaneous tap raising/lowering of
the tap
positions at MDU, OLTC, AVR display & Paragrammer.
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▪ During tap operation ensure that “Tap 0” display is not coming at any point.
▪ Bring the OLTC in extreme tap positions and observe the message “Tap changer in extreme
position”
in the status line is displayed and tap operations are blocked at extreme positions.
▪ Check “T.C. Incomplete” alarm in the status line when tap operation is stopped midway.
This can be
simulated by switching off the MDU control supply during tap operation In- progress. Reset
TC
Incomplete alarm by doing further tap operations after switching on the MDU control supply.
▪ Ensure “T.C. Motor Supply Faulty” alarm in the status line by switching off the MCB of TC
motor
supply at LVAC panel. Ensure T.C. Control Supply Faulty alarm in the status line by switching
off the
MCB of TC control supply at AVR panel.
▪ Put the AVR in “SUPRY’ and ensure the following:
- Put the AVR in SUPRY and ensure that Red color LED of REMOTE /SUPRY push button
glows.
- Raise/Lower operation not possible from AVR panel.
- Tap changer in “LOCAL’ indication lamp off.
- MDU Local LED off.
- Independent LED glows.
- AVR VT supply absent message in the status line.

2.b. R/L Control (Auto) & AVRs in Independent mode

▪ Identify the Terminals where VT Secondary connections are to be given.

▪ Disconnect the wires from the terminals after noting the TB andPRESENTATION
ferrule Nos.
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▪ Put the AVR in “AUTO” mode.

▪ Ensure that Raise/Lower operation from the AVR panel is not possible manually.
▪ Keep AVR in REMOTE position.
▪ Also ensure following indications and display:
- LED in the Hand push button off.
- LED in the AUTO push button glows.
- Measuring value display “11kV” in the home screen.
- Voltage deviation display approximately zero.
- Deviation pointer in balanced position.
- Time bar remains unfilled.
- AVR VT supply absent alarm message vanished.
- No Alarm Display and alarm indication.
- REMOTE / SUPRY try color LED glows green.

▪ Gradually raise the voltage output of the variac and observe the voltage deviation in the
home screen
display. Also observe the deviation pointer moves upwards.
▪ Increase the voltage by 4% of the (band width) the reference level (110V) and ensure the
following:
- Time bar in the home screen display starts filling and at the end of the filling, LED in the
“Lower”
command push button starts glowing.
- Tap change in progress message in the status line as long as the operation is in
progress.
- After green LED of lower Command goes off, tap position is seen reduced by one tap.
- Tap position in MDU, OLTC, AVR display and programmer are same.
- As soon as the lower tap operation starts, bring the variac output back to 110 V.
- Repeat the above automatic tap lowering for two or three tap operations.

▪ Decrease the voltage by 4% of the (band width) reference level (110V) and ensure the
following:
- Time bar in the home screen display starts filling and at the PRESENTATION
end of the filling,
TO ADANI LED in
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▪ As soon as the Raise tap operation starts, bring the variac output back to 110 V.
▪ Repeat the above automatic tap raising for two or three tap operations.
▪ Keep the variac output at 110V and ensure the alarms.
▪ Reduce the voltage by 20% of the reference value and ensure the following:
- Red LED glows against “< U”.
- Under Voltage message in the status line.
- Automatic tap raising operation is seen blocked from AVR.
- Ensure that in Manual mode both Raise and Lower operations are blocked when AVR is in
Under
Voltage condition.
- Put AVR in AUTO mode.

▪ Bring back the variac to 110V and increase the output by 20% of the reference value and
observe the
following:
- Red LED glows against “> U”.
- Over Voltage message in the status line.
- High speed automatic tap lowering command issued by the relay.
- Bring the variac output less than 30% of the reference value and observe that all alarm
indication
vanished except “AVR VT Supply absent” message in the status line.
- Put AVR in SUPRY mode and in AUTO.
- Ensure that automatic tap operation and signaling take place in SUPRY mode also as
described
above.

3. Parallel Operation, Indication and Alarm checks

3.a. Parallel Manual – R/L control in Manual:

▪ Identify and verify the Terminals where CB status inputs are connected.
▪ All the inputs to be temporarily short circuited. PRESENTATION TO ADANI - MUNDRA Slide - 22
▪ Select all AVRs in HAND mode.
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▪ Ensure the tap position at MDU, OLTC, AVR display and Programmer is same.
▪ Select parallel control of all AVRs in Manual.
▪ Select AVRs in REMOTE.
▪ Select AVR 1 in Master and others in Followers (i.e. M F F)
▪ Ensure the following:
- Master LED of AVR 1 glows.
- Follower LED of AVR 2 & 3 glows.
- LED against “Parallel” symbol glows in all AVRs.
- Master message in the status line display of AVR 1.
- Follower message in the status line display of AVR 2 & 3.
- No alarm display and alarm indications in any AVRs.
- All circuit breaker are in closed status in programmers of all AVRs.
- Programmer shows the correct indication of the parallel selection.
- Raise/Lower the tap from the master AVR and ensure proper parallel tap operation in all
IDTs.
Check tap positions at MDU, OLTC, AVR display and Programmer of all IDTs.
- Ensure that tap operations are not possible from the AVRs selected as Followers.
- Select AVR2 as Master and Others as Followers and do the tap operations as done in
AVR1 and
ensure satisfactory operations and indications (F M F).
- Then select AVR3 as Master and others as Followers and repeat the procedure as
mentioned
above (F F M).
- Do tap operations and indication checks on all possible combinations as suggested in
the test
format for OLTC Operation Checks – Parallel Manual mode.
- Ensure that operation shall not be possible from Follower AVRs.
- Parallel operation shall not be possible from any of the AVRs if more than one master is
selected.
- Parallel operation shall not be possible from any of the AVRs if Followers are selected
without
any Master. PRESENTATION TO ADANI - MUNDRA Slide - 23
- Switch off AVRs one by one and observe “Failure Par. Control” message in the status
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- Again operate the same AVR in Independent mode and create one step tap difference
and switch
off the MDU control supply.
- Then put this AVR again in parallel mode and then observe that Raise/Lower command
initiated
from the AVR but tap operation is not taking place at MDU and OLTC.
- Meantime ensure an “Out of step” alarm message an the status line of each AVR after
time delay.
- Repeat this check in other AVRs also
- Create two-step tap difference and put the AVR in parallel mode and observe an “out of
step”
alarm message immediately.
- Select AVR in SUPRY mode and ensure that operations are not possible from AVR panel.

3.b. Parallel Manual – R/L control in Auto:

Select all AVRs in REMOTE.

▪ Then connect variac output to the VT input of all AVRs as done earlier.
▪ Keep the variac output at 110V.
▪ Select all AVRs in AUTO mode.
▪ Select Parallel control of all AVRs in Manual mode.
▪ Select M F F mode.
▪ By varying variac output ensure tap operation as done earlier.
▪ Ensure proper parallel operation, i.e. Follower AVRs follow the Master.
▪ Ensure indications and tap positions at various locations.
▪ Ensure no alarm display and alarm messages at this condition.
▪ Create various alarm conditions as described earlier.
▪ Ensure Parallel operation blocking an alarm conditions.
▪ Ensure that VT wiring is done correctly such that cables comingPRESENTATION
from IDTTO1ADANI
VT -connected
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3.c. Parallel Auto – R/L control in Manual:

▪ Disconnect all shorting wires from the TB of CB status.

▪ Identify the CB open/close status condition input terminals in LCC and 11kV panel.
▪ Observe the programmers of all AVRs for correct busbar status.
▪ Select all AVRs in REMOTE and in HAND.
▪ Select all AVRs in Parallel AUTO mode.
▪ Observe AVR 1 automatically selected as Master and others as Followers (M F F).
▪ Meantime check all indications and alarms for proper display.
▪ Keep the Master IDT out of parallel control by opening respective CBs and then observe
that AVR
of another IDT, who’s CAN BUS ADDRESS is low, is selected automatically as Master.
Meantime
the AVR of the IDT which is out of parallel control becomes independent.
▪ Repeat the check as per the test format for Parallel Auto mode and observe that correct
selection
and indications take place automatically.
▪ Raise / Lower operations at each combination shall be done in HAND mode and tap
positions,
indications and display shall be checked for its correctness as described earlier.
▪ Create various alarm conditions as described earlier.
▪ Ensure parallel operation blocking on alarm conditions.

3.d. Parallel Auto – R/L control in Auto:

▪ Keep AVRs in Parallel Auto and Tap control in AUTO mode.

▪ Keep AVR 1 in Master and others in Followers.
▪ Check Raise/Lower operation by varying the variac output by ± 4% voltage.
▪ Ensure that parallel control is satisfactory in this mode also. PRESENTATION TO ADANI - MUNDRA Slide - 25
PRESENTATION TO ADANI - MUNDRA
 TRAINING MANUAL–TRANSFORMER

4. Communication with DCS / SCADA:

4.a Communication between AVR and DCS:

▪ Keep MDU in REMOTE.

▪ Select AVRs in SUPRY.
▪ Keep taps of all IDTs same.
▪ Select AVRs in Independent mode.
▪ Ensure correctness fro Tap positions, Indications and display as described earlier at MDU,
OLTC,
AVR display and Programmer of each IDT.
▪ Select DCS in Local.
▪ Ensure that tap positions and other indications in the Event list, SLD and TC control box of
DCS is
same as that shown in the AVRs of corresponding IDTs.
▪ Ensure that AUTO to MANUAL and MANUAL to AUTO selection is possible from DCS fro each
IDT.
▪ Following signals are to be ensured in DCS:
- Independent.
- Tap position.
- AUTO or MANUAL.
- AVR VT supply absent if variac output is less than 30V.
- Select MANUAL mode in DCS.
- Raise taps from 1 to 19 for each IDT and ensure correct feedback in DCS and in AVR.
- Ensure “Tap change in Progress” signal in the event list.
- Lower taps from 19 to 1 and ensure feedback as described above.
- Create various alarms in each IDT, as described earlier and observe the correct
feedback In the
Alarm list as well as in the Event list of DCS.
▪ Following are the list of alarms to be checked in DCS when AVRs are in Independent mode:
- TC Incomplete.
- Tap changer in extreme positions. PRESENTATION TO ADANI - MUNDRA Slide - 26
 TRAINING MANUAL–TRANSFORMER

- AVR faulty.
- AVR faulty alarm can be checked by switching off the AVRs one by one.
- Then ensure proper resetting of alarms.
- Now select AVRs in AUTO mode from DCS and ensure correct indications.
- Check Raise/Lower operation by varying the variac output by ± 4% of the reference
voltage.
- Ensure correct feedback in DCS for satisfactory tap operation and indication.
- Select AVR 1 in Master and others in Followers (M F F).
- Select AVRs in MANUAL mode.

▪ Ensure the following in the event list, SLD and TC control box of DCS:
- Tap changer IDT1, 2 & 3 parallel.
- Tap changer IDT1 - Master.
- Tap changer IDT2 & 3 - Followers.
- Tap position indication.
- Give a Raise command from DCS to the IDT selected as master and ensure that
satisfactory parallel
tap operation takes place in other IDTs.
- Ensure correctness of feedback and indication in DCS of all IDTs
- Give a lower command and check the operations and feedback as before.
- Then ensure that Raise/Lower tap operation is not possible from the IDTs selected as
Followers in
DCS.
- Select other AVRs one by one as Master and repeat the tap operations as described
earlier. (i.e. F M F,
F F M).
- Then create “out of step” alarm condition and ensure that parallel operations are blocked
from DCS.
- Parallel Auto selection is not possible from DCS.
PRESENTATION TO ADANI - MUNDRA Slide - 27
- Parallel Auto to Parallel Manual selection is not possible from DCS.
 TRAINING MANUAL–TRANSFORMER

4.b Communication between SCADA and AVR via DCS:

▪ Select DCS in Remote.

▪ Select AVRs in SUPRY.

▪ Ensure the following in SCADA:

- AUTO to MANUAL and MANUAL to AUTO selection possible.
- Master / Follower / Independent selection is possible if parallel manual mode is selected
from AVR
panel.
- Raise/Lower operation is possible.
- Correct feedback of tap positions and other indications as described in the case of DCS.
- Correct signaling of AVR alarms in both Independent and Parallel mode.
- All the operations, indications and alarms are to be checked simultaneously with DCS
and AVR.

▪ After completing all the testing activities ensure the following:

- All disconnected wires are reconnected correctly and as per drawing.
- All the disconnected links reinserted properly and tightness checked.
- All the Circuit breakers kept in open condition.
- All the temporary arrangement for taking power supply from variac dismantled.
- All MCBs and Links are healthy.
- Availability of marked up drawing in the drawing folder.
- All AVRs in REMOTE and MANUAL mode.
- All AVRs in Parallel manual mode.
- Overall visual inspection conducted inside the panel.
- Front and Rear doors are closed. PRESENTATION TO ADANI - MUNDRA Slide - 28
 TRAINING MANUAL–TRANSFORMER

▪ Tap Changer and Cooler Alarm Indication Checks

To ensure the operation of tap changer indication and alarms, at DCS/SCADA when initiated
at device.

Alarm

1. Tap Changer Out of Step:

Tap changer out of step means the transformer taps are in different tap positions when the
AVR is in
parallel mode. This can be simulated by creating one step difference between the IDTs
when AVR in
parallel mode, then an out of step alarm will appear at DCS and SCADA.
Give a command for raise or lower the tap from AVR /DCS/ SCADA and tap operation does
not take
place at OLTC. Then alarm can be normalized in the same mode by putting all taps in same
tap position.

2. Tap Changer Incomplete:

Tap changer incomplete means, the tap operation has stopped at midway during tap
operation in
progress. This can be simulated by switching off the MDU control supply, immediately after
giving tap
operational signal. TC incomplete alarm message will appear at DCS and SCADA and further
tap
operation is not possible. The alarm can be normalized by switching on the MDU control
supply and the
OLTC tap will automatically go to next step as per earlier command.

3. TC Motor Supply Faulty:

PRESENTATION TO ADANI - MUNDRA Slide - 29
TC motor supply faulty means, the three phase supply input of MDU motor is not available.
 TRAINING MANUAL–TRANSFORMER

5. AVR Faulty:
AVR faulty means, the single-phase supply input of AVR is not available. This can be
simulated by
switching off the MCB of AVR input supply at AVR panel. AVR faulty alarm will appear in
DCS and
SCADA. The alarm can be accepted by switching on the same MCB.

6. VT Supply Faulty:
VT Supply Fail means, the reference voltage from the secondary side of the LV Voltage
transformer is
not available. This can be simulated by giving an AC 110V supply to the VT secondary
terminals after
disconnecting the wires actually coming from the VT secondary side to AVR and VT supply
fail will be
vanished. Bt switching off the above VT supply, VT supply fail alarm will appear at DCS and
SCADA.

7. Cooling Equipment Faulty:

Cooling equipment faulty means, the three-phase supply input for fan motors is not
available. This can be
simulated by switching off the individual MCB of fan control provided at MK. Cooling
equipment faulty
alarm will appear in DCS and SCADA. The alarm can be normalized by switching on the
MCB.

8. IDT-MK / MDU Heating / Lighting Supply Faulty:

IDT-MK / MDU Heating / Lighting Supply Faulty means, the single-phase supply input is not
available in
the circuit. This can be simulated by switching off the respective single phase MCB provided
in the circuit
PRESENTATION TO ADANI - MUNDRA Slide - 30
at MK. The related faulty alarm will appear in DCS and SCADA. The alarm can be normalized
 TRAINING MANUAL–TRANSFORMER

2. Tap Changer in Supervisory:

The tap changer in supervisory means, the AVR is in supervisory mode and the tap
changing operation
possible only at DCS and SCADA. This can be simulated by selecting supervisory mode in
AVR and
same will be indicated at DCS and SCADA and check the operation at DCS/SCADA,
AVR/MDU.

3. Tap Changer in Auto:

The tap changer in auto means, the AVR is in auto mode and no operation possible from
MDU, AVR,
DCS and SCADA. Auto operation is only in response with the VT secondary voltage. This can
be
simulated by selecting auto mode in AVR and same will be indicated at DCS and SCADA.
After
disconnecting the wires actually coming from the VT secondary side to AVR, AC 110V shall
be given. Set
the output voltage at exactly at 110V and note down the tap position. Ensure the
raise/lower operation
from the MDU, AVR, DCS and SCADA is not possible.
Gradually raise the voltage from the reference voltage of 110V (approx: 4% of 110V), the
Transformer
tap will automatically decrease, i.e. the transformer is selecting high voltage tap with
respect to the VT
secondary voltage. Decrease the voltage to 110V and then further decrease to approx. 4%
of the
reference voltage, then the Transformer will automatically increase the tap position with
respect to the VT
secondary voltage. PRESENTATION TO ADANI - MUNDRA Slide - 31
 TRAINING MANUAL–TRANSFORMER

6. Tap Changer (TC) in Independent Mode:

TC in independent means no parallel operation is intended to take place and TC in
independent will be
indicated at DCS and SCADA. This can be simulated by closing/opening HV and LV Breakers
or Bus
section Breakers.

7. Tap Changer (TC) in Master/Follower Mode:

TC in master/follower means transformers are in parallel operation and this indication will
indicate at DCS
and SCADA. This can be simulated by closing/opening HV and LV Breakers or Bus section
Breakers.

8. Tap Position Indication:

Tap position indication means the exact position of tap in which the Transformer is working
is indicated at
DCS and SCDA. This can be checked at any time while tap operation is going on.

9. Cooling Fan Running:

Cooling Fan Running will be indicated at DCS and SCADA when the cooling fans are
running.. This can
be simulated by switching on the cooling fans and checking the indication at DCS and
SCADA.

PRESENTATION TO ADANI - MUNDRA Slide - 32

 TRAINING MANUAL–TRANSFORMER

▪ OLTC Parallel Operation Checks

To ensure the performance of OLTC parallel operation through AVR at parallel manual mode
with master,
follower, and Independent selection independently. Parallel auto mode with master, follower
and
independent selection automatically with breaker status and same operation with auto to the
reference
voltage of VT secondary voltage.

Procedure

Parallel - Manual Mode

- Switch on all AVR supply.
- Select all required parameters in all AVR.
- Put all AVR in hand/manual and remote mode.
- Manually select the first AVR in master and follower on second and third.
- With the above condition the operation of OLTC shall be checked from AVR, DCS and
SCADA and OLTC Operation Operation from
operation will be as given below:
Results
IDT1 IDT2 IDT3
AVR1/AVR2/AVR3 DCS SCADA

Operate as Operate as Operate as OK/OK/OK OK OK

Master (M) Follower (F) Follower (F) MFF/MFF/MFF MFF MFF

PRESENTATION TO ADANI - MUNDRA Slide - 33

 TRAINING MANUAL–TRANSFORMER

- MFF: MFF means AVR1 is the master of IDT1, AVR2 and AVR3 are the followers of IDT2,
IDT3
for the master.
- MF1: MF1 means AVR1 is the master of IDT1, AVR2 is the follower of IDT2 for the
master and
AVR3 is the independent for IDT3.
- Master: (M) Master means the OLTC operation is possible from the master only.
- Follower: (F) Follower means the OLTC operation not possible from the follower but
operation
followed by the master.
- Independent: (I) Independent means the operation of OLTC can be done individually.

▪ If all the breakers are closed as shown in figure, the scheme will be configured in such a
way that the
IDT1 as master and IDT2 & IDT3 are followers.

At the above condition, open Bus Section-1 (BS-1) breaker.

- IDT1 will be separated from the circuit and it will independent.

- IDT2 becomes Master.
- IDT3 becomes Follower.
- All operation with the above condition shall be checked at AVR, DCS and SCADA.
- Similarly all the operation mentioned in documents shall be checked.

Auto Operation check with VT secondary voltage

- Put AVR auto instead of hand (manual).
- Give the VT secondary voltage with slide arc to the terminals where the VT secondary
connections
are to the AVR after disconnecting the wires actually comingPRESENTATION
from theTOVT secondary
ADANI - MUNDRA Slide - 34
 TRAINING MANUAL–TRANSFORMER

Auto Operation check with VT secondary voltage

- Put AVR auto instead of hand (manual).
- Give the VT secondary voltage with slide arc to the terminals where the VT secondary
connections
are to the AVR after disconnecting the wires actually coming from the VT secondary
side.
- Set the voltage to 110V.
- Varying the voltage from 110V to approx. +4% and -4% for lower and raise operation of
the OLTC.
- With the above raise/lower conditions, the operation as stated in parallel auto mode
shall be
repeated and ensure the performance.

Parallel Auto Mode

- Select required parameters in all AVR.
- Put all AVR in hand (manual) and remote mode.
- Check the breaker status.

PRESENTATION TO ADANI - MUNDRA Slide - 35

 TRAINING MANUAL–TRANSFORMER

▪ Oil Leak test

To ensure the transformer is fully leak proof.

Remove main and OLTC breather connect the nitrogen cylinder parallel with the main tank and
OLTC
breather line so as to apply pressure in both tanks at a time

Pressure gauges shall be connected at the bottom and top of the main tank to monitor the
pressure level
during testing
- Ensure the rubber bag and rubber bag rupture relay are normalized.
- Ensure the main tank and the OLTC tanks are normalized.
- All the nuts and bolts are fully tightened and torque checked.
- Ensure new gaskets are used during erection.
- Ensure no oil trace at anywhere the Transformer.
- Ensure proper cleaning of the Transformer and its surroundings.
- Ensure the availability of nitrogen cylinder with regulator and pressure gauge.
- Ensure all gauges have proper valid calibration status.
- Ensure the availability of thermometer for ambient temperature.
- Ensure valves between main Buchholz relay and conservator and between HV cable
box/boxes and
conservator are open.
- Ensure all radiator valves are open.
- Ensure the valves between OLTC and conservator is open.
- Ensure the PRD operating pressure.
- Note down the pressure due to normal oil head at bottom and top of the tank.
- Note down the ambient and oil temperature.
- Slightly open the N2 cylinder valve and regulated N2 shall be allowed to pass and
pressured the
normal oil head. When the pressure reaches at as stated above by simultaneously
monitoring the
pressure gauges P1, P2 and P3 and maintaining continuouslyPRESENTATION
for 48 hours.
TO ADANI - MUNDRA Slide - 36
- During the pressurizing, ensure the pressure at tank top (P2) is less than the operating
 TRAINING MANUAL–TRANSFORMER

▪ Testing of Transformer Oil before and after filling in to the Transformer

To ensure the properties and characteristics of oil processed oil filling into the transformer.

Following are the properties and characteristics:

- Color : ≤ 2.0 (number)

- Appearance : Clean from sediments and suspended matters
- Break down voltage : ≥ 70 kV
- Water Content : ≤ 10 mg / kg at 20 °C
- Dissipation Factor : 0.010 at 90 °C
- Resistivity : ≥ 60 GΩm at 90 °C
- Neutralization Value : ≤ 0.03mgKOH / gm
- Interfacial Tension : ≥ 35 mN / m
- Oxidation Stability :
- Induction Period : ≥ 150 hours
- Flash Point : ≥ 140 °C
- Sulphur Content : ≤ 0.15 %
- Anti oxidant additives (DBPC) : 0.08 – 0.40 %

PRESENTATION TO ADANI - MUNDRA Slide - 37

 TRAINING MANUAL–TRANSFORMER

Following precautions and preparation shall be taken during oil sampling:

- It is suggested to take the oil sample directly to the sampling bottle.

- Special tools, gloves etc shall be used.
- Dry, clean and good atmospheric condition is better for taking sample.
- Do not speak during sampling.
- Do not allow air bubbles in the sampling oil.
- Care shall be taken to avoid entry of moisture, dust, metal parts etc to the sampling oil.
- Required quantity of oil shall be taken in the bottle at a time for each test.
- The cleaned sample bottle shall be washed two to three times with the oil to be tested.
- Check any air bubbles in the sampling oil.
- Sealed and identification mark shall be given to each sample.
- After sampling, immediately cover it properly to avoid entry of air / moisture through the
sampling
portion of the Transformer as well as the sampling.
- Test shall be conducted by independent laboratory.
- Laboratory test report shall be verified.

PRESENTATION TO ADANI - MUNDRA Slide - 38

 TRAINING MANUAL–TRANSFORMER

▪ Dissolved Gas Analysis

Is used to identify the presence and quantity of gasses dissolved in the transformer oil.
Chemical names and symbols of gases

- Nitrogen : N2
- Oxygen : O2
- Hydrogen : H 2
- Carbon Monoxide : CO
- Carbon Dioxide : CO 2
- Methane : CH 4
- Ethane : C2 H6
- Ethylene : C2 H4
- Acetylene : C2 H2

▪ Check on small wiring

To ensure the items provided are confirming to the specification and drawings:

To check that the wiring of components are in order.

- Door Switch of MK.

- Heaters.
- Thermostat Setting – 30 °C.
- Hygrostat Setting – 60 %.

PRESENTATION TO ADANI - MUNDRA Slide - 39

 TRAINING MANUAL–TRANSFORMER

Frequency Response Analysis

Frequency Response Analysis (FRA) is a valuable tool to verify the geometric and mechanical
integrity of
electrical apparatus; especially transformers, providing accurate and repeatable
measurements. This is a
proven field diagnostic technique capable of detecting damage arising due to
dislocation/movement of core
and winding during transportation or after occurrence any fault.

FRA is based on the principle of measurement of steady electrical response against a steady
sinusoidal
input given to the test object.

The basis of the FRA technique is that the impedance of the transformer is a function of the
resistance,
inductance, capacitance and applied signal frequency. The resistance is related to the
physical construction
of the winding. Capacitance and inductance is related to the construction and geometry of the
windings.
Deformations and movements have an effect on both inductance and capacitance that may
be reflected in
the resulting frequency response.

There are two basic methods for conducting FRA test; Low Voltage Impulse method and
Sweep Frequency
Response Analysis (SFRA).

Low Voltage Impulse method relies on indirect measurement of the frequency response. An
PRESENTATION TO ADANI - MUNDRA Slide - 40
impulse or set
 TRAINING MANUAL–TRANSFORMER

SFRA measurement is done with the frequencies being swept in a wide range; usually from 20
Hz to 2
MHz. this is the simple direct measurement in frequency domain. Also a direct relationship
exists between
geometric configurations and RLC network constituted by winding and core assembly
identified by its
frequency dependent transfer function. Measuring the frequency response may be performed
by applying a
simple varying frequency signal to the transformer that covers the frequency range of
interest. Sweep
frequency method has far higher repeatability and consistency over impulse methods which
are prone to
variation due to lead arrangement and impulse shape.

Normally a factory FRA measurement is taken as reference (signature) and later on site
measurement
(after erection or any failure) is compared with the reference measurement. In practice
measurement after
erection at site is taken as reference for the future measurements done at site during the
operational period
of the transformer.

Possible damages in the winding are indicated in a relevant range of frequencies by shifting of
reference
points or by the introduction of new resonance, not being present in the reference
measurement.

The comparison of the traces belonging to different phases or different Transformer of same
PRESENTATION TO ADANI - MUNDRA Slide - 41
design (sister
 TRAINING MANUAL–TRANSFORMER

Possible damages in the winding are indicated in a relevant range of frequencies by shifting of
resonance
points or by the introduction of new resonance, not being present in the reference
measurement.
The comparison of the traces belonging to different phases or different Transformer of same
design (sister
unit) may be useful, but with limitations.

A shifting of the resonant point (if any) of the open circuited admittance is noted. The
difference (i.e. the
shifts of resonant points or the introduction of new resonance not present in the reference
measurement) is
evaluated as an indication of normal vibration or faults in the winding.

The plots of the admittance (reverse of impedance) verses frequency indicate a series of
resonance with
small value and anti resonance with high value. The resonance with low admittance
represents a parallel
resonance circuit. The resonance with high admittance represents a series resonance circuit.

Test Preparation
Measuring the frequency response of a winding within a transformer transfer function from
winding to
winding, gives a fingerprint for that winding or transformer. The process requires
measurement of both input
and output signals, which are then ratioed to give the response. This reduces the effect of the
measurement
of a three lead system involving input, measured input and measured response.
PRESENTATION TO ADANI - MUNDRA Slide - 42
 TRAINING MANUAL–TRANSFORMER

The test can also include voltage transfers between windings i.e. applying a signal to one
winding of a
transformer and measuring the response at another winding to determine the amplitude
change and phase
shift of the signal having been transferred along a winding, or from one winding to the other.

Transformer under test should be completely de-energized and isolated from the power
system. This shall
be solidly earthed which is common to FRA test equipment. FRA is performed as response to
electrical
measurement at the terminals connected to the starting and end of any winding. The test
leads must be first
connected to the FRA instrument and then to the Transformer Bushings.

Connect the color code cable to the instrument

i. Yellow : Excitation source cable

ii. Black : Measurement cable
iii. Red : Reference cable

The main cable clamps red and black are connected to bushing terminals accordingly. Also
connect the
ground clips for each cable, red and black to the corresponding Bushing flanges. The test set
up and actual
test shall be done as per the manufacturer’s manual.
PRESENTATION TO ADANI - MUNDRA Slide - 43
 TRAINING MANUAL–TRANSFORMER

Precautions / Safety

FRA measurement is sensitive to DC magnetization of the core and hence it has to be carried
out before
application of any DC voltage. If any DC measurement was carried out before FRA
measurement, it should
be properly demagnetized.

The resultant plot may distort from the actual one in case of a loose connection.

Interpretation

The exact comparison of the FRA measurement plots at site with the factory measurement
can be made
only if measuring equipments, measuring connection, setup, measuring lead etc are the
same. However
identical test equipments with the same connection and setup may give almost the same
results.

Frequency response plot provides a fingerprint for a transformer. Fingerprints from similar
transformers
have common features.

The core condition, in principle, cannot be checked by the FRA method. However
magnetization of core,
affects low frequency results.
PRESENTATION TO ADANI - MUNDRA Slide - 44
 TRAINING MANUAL–TRANSFORMER

Pictures of Transformers Devices:

PRESENTATION TO ADANI - MUNDRA Slide - 45

 TRAINING MANUAL–TRANSFORMER

Pictures of Transformers Devices:

PRESENTATION TO ADANI - MUNDRA Slide - 46

GE POWER TRANSFORMER

Thank You