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CPRI

CPRI
HOW TO SAFE GUARD
THE TRANSFORMER..???

Efficient and Effective network planning,


Design and Forecasting
Highly Reliable and Stable Protection system
and co-ordination
Measures to mitigate various faults and
abnormal conditions
Safe, rugged, optimum, economical and energy
efficient design and manufacturing.
Condition monitoring and Reliability centered
maintenance
CPRI
QUALITY CONTROL
The totality of features and characteristics of a
product or service that bear on its ability to satisfy
stated or implied needs.

QUALITY SYSTEM MUST ENSURE


Uniformity of products
Consistency in performance
Reliability in service life
Customer satisfaction
CPRI
UNIFORMITY OF PRODUCTS:

Using standard fittings, components and accessories

CONSISTENCY IN PERFORMANCE:
Good manufacturing practice
Adequate testing at all stages
Close monitoring to control process variable
Ideal case of process control : zero-defect
Any defect to be followed by root-cause analysis and
necessary system level changes to be introduced
CPRI
RELIABILITY IN SERVICE LIFE:
Ensured by adequate design margins and over-load
capacity
Maintenance instructions & steps to be taken in case of
break down, contingency plans and recovery procedures
to be provided
CUSTOMER SATISFACTION :
Ease of operation, maintenance free
Inter-changeability, rapid restoration of operation
Clear documentation, availability of spares
Speedy redressal of complaints
RAW COPPER
MATERIAL
IRON
SUPPLY- CORE
CHAIN INSULATION
DESIGN

COSTING

ACCESORIES

CRADLE-GRAVE
RISK POOL
COOLING

MAINTENANCE
&RLA

DISASTERS
R&R
PROCESS
QUALITY
CONTROL

PROTECTION TESTING &


SHIPMENT
INSPECTION
FAULTS ERECTION STORAGE&
AND
HANDLING
COMMNG
TEST ON TRANSFORMER AS PER IS:1180-1, 2014
Routine Tests:
a) Measurement of winding resistance IS 2026 (Part 1).
b) Measurement of voltage ratio and check of phase
displacement IS 2026 (Part 1).
c) Measurement of short-circuit impedance (principal
tapping, when applicable) and load loss at 50 percent and
100 percent load IS 2026 (Part 1).
d) Measurement of no-load loss and current IS 2026 (Part 1).
e) Measurement of insulation resistance IS 2026 (Part 1).
f) Induced over-voltage withstand test IS 2026 (Part 3).
g) Separate-source voltage withstand test IS 2026 (Part 3).
h) Pressure test (see 21.5).
j) Oil leakage test (see 21.5).
TESTS ON TRANSFORMER AS PER IS:1180-1, 2014

Type Tests:
a) Lightning impulse test IS 2026 (Part 3).
b) Temperature-rise test IS 2026 (Part 2).
NOTE - Maximum measured total loss (No load at rated excitation + load
loss at maximum current tap converted to 75 C reference temperature) at

100 percent loading shall be supplied during temperature rise test.

c) Short-circuit withstand test IS 2026 (Part 5) (up to 200


kVA).
NOTE Routine tests before and after short circuit test shall be conducted
as per IS 2026 (Part 1).

d) Pressure test (see 21.5)


TEST ON TRANSFORMER AS PER IS:1180-1, 2014

Special Tests:
a)Short-circuit withstand test IS 2026 (Part 5) (above 200
kVA)
NOTE Routine tests before and after short circuit test shall be conducted
as per IS 2026 (Part 1).
c) No load current at 112.5 percent voltage (see 5.9.3).
d) Paint adhesion tests. The test is performed as per ASTM
D3359 (Standard Test Methods for measuring adhesion by
Tape test).
a)Determination of sound levels IS 2026 (Part 10)
e) BDV and moisture content of oil in the transformer (IS
335).
NOTE Tests at d) and e) may be carried out on more than one unit subject
to agreement between user and supplier
Pressure test
Type test (for Routine test
30 minutes) ( for 10 minutes)
3, Non sealed 80 35
(Plain tank)
Corrugated tank 80 15

Sealed (upto 80 80
200kVA)
1, upto 25kVA) 100 35
Vacuum Test (Type Test)

3 Transformers 250mm of Hg. for


Upto 200 kVA 30 minutes

3 Transformers 500mm of Hg. For


>200kVA & upto 30 minutes
2500kVA
Oil Leakage test (Type test)
Non-sealed &sealed Type Transformers:
Pressure of Twice the normal head
measured at base of tank for 8 hours
Tank with corrugations:
Pressure of 15kPa measured at top of the
tank for 6 hours.
Paint Adhesion test (Special Test)
Major steps of the procedure:

Criss-cross marks are made on tank painted


surface using Criss-Cross cutter.
Adhesion tape is pasted on this area.
After few minutes, pasted adhesion test is
forcefully pulled off from one length.
No paint shall come out along with
adhesion tape.
CPRI
Implementation
QUALITY CHECKS AT ALL STAGES OF MANUFACTURE :
From receipt of raw materials to finished
product. ----- Stage inspection
Select samples randomly by batch, by lot
Identify vendors and assess them
Even the qualified vendors are subjected to
surprise audit to short-list a few. This is called
vendor qualification.
Check for calibration of meters and and other
measuring devices for valid calibration
CPRI
Quality Check Schematic

WINDING COMPLETE CORE

ACTIVE PART ASSEMBLY

COMPLETE TRANSFORMER
WINDING CPRI
Phenol resin
Insulation Paper Hard Paper Press Board paper tube
Mechanical tests Phenol resin
Mechanical tests Mechanical tests paper test
Electrical tests
Electrical tests Electrical tests Mechanical,
Machining test
Chemical tests Chemical tests Electrical tests
Punching tests
on tubes

Cu wire conductor Al. Wire conductor


Visual & Dimension Visual & Dimension
Control tests Control tests
OR
Mechanical tests Mechanical tests
Electrical tests Electrical tests

Winding
Visual & Dimensional Control
Check for no. of turns
Inspection control after winding assembly &
winding finishing
Visual & Dimensional Control after winding
impregnation and pressing
CPRI
QUALITY CONTROL CHECKS
FOR TRANSFORMER
A. PAPER COVERED CONDUCTORS
(ALUMINIUM OR COPPER)

Check visually and dimensionally for


both bare and insulated conductors
Test for percentage elongation and
tensile strength (mech. Department)
Test electrical conductivity and
resistance
CPRI
ACTIVE PART ( WINDING)

Visual and dimensional check


Check for correct number of turns
Inspection of joints
Dimensional check after impregnation and
coil Compression
COMPLETE CORE CPRI
Tests On Materials
Visual And Dimensional
Laminations Control During Process Of
Slitting, Shearing, Punching,
Deburring Of Laminations

Assembly of core
Complete core Visual and Dimensional Control
High voltage test on core bolts

Type test Core loss test of naked core


CPRI

CORE LAMINATION (MATERIAL)

Watt loss
Stacking factor
Surface insulation
Visual and dimensional checks
CPRI
LAMINATION (PROCESSING)

Visual and dimensional check during slitting,


Cutting, punching deburring

CORE ASSEMBLY
Visual and dimensional checks
Verticality
Dielectric test on core bolt
Core loss test
ACTIVE PART ASSEMBLY
Core coil
CPRI
Lid complete assembly Active part Ratio Test
Visual & Transformers above
Visual &
Dimensional 500 kVA after
Dimensional Inspection Control
control Vaccum driving
control
High voltage test

Insulator & LV & HV


Lid Condenser connections.
Visual & bushings
Dimensional Inspection Control
Visual &
control of steel sht. Visual & Dimension
Dimensional
Mechanical test Control tests
control
chemical test
Tap changer Tap changer
(off-load) (on-load) Ratio Test
Visual & Dimension OLTC Assembly
Control tests Inspection Control Power transformers
Mechanical tests Mechanical Test
Milli volt drop test Electrical Test
CPRI
B. COMPLETE ACTIVE PART &TANK

Dye penetration test for lifting lugs


Ratio test on windings
Visual and dimensional check on insulators
Tap changer : torque test, operation test,
Millivolt drop test, combined electrical operation
Visual and dimensional checks for connections
and joints
Core bolt test
Ratio test at terminals
C. TANK ASSEMBLY CPRI
MATERIAL
Visual and dimensional checks on tank steel
sheets
Mechanical test on steel sheet
Chemical composition

FABRICATION
Visual and dimensional checks of tank
Pressure test
Dye penetration test on welded joints of tank

GASKET
Visual and dimensional check
D. OIL FILLING CPRI
Check for leakage in tank and at gaskets
Physical, chemical & electrical properties of oil
Volume resistivity
TRANSFORMER CPRI
Inspection control during /
Transformer after mounting of accessories
complete and devices

Lightning Impulse test, Temperature


Type tests Rise Test, Short circuit Test,
Pressure Test

Routine tests

Visual & Dimensional control after


painting & Final assembly

Packing & Dispatch control

CUSTOMER
CPRI
F. TESTS ON ACCESSORIES

Conservator - leakage test, dimensional


Verification
Radiators - dimensional checks
Buchholz relay - leakage test, operation
Pressure relief valve - operation
Breather - dimensional check
CPRI
Failure Modes During Short Circuit tests
Radial forces failure modes:
Spiraling:
Buckling: Characteristic
Characteristic failure mode
failure mode for inner and
for inner outer winding
winding

Axial forces failure modes:

Conductor Bending of cables


Collapse of end support tilting
Failure Analysis of Transformers
CPRI
Categories of failures generally observed and their probable
cause of failure of Transformers :
A) Major failures during or after Short circuit:
1.1 % change in % X after short circuit test beyond limits.
1.2) LV/HV bushing break during S. C test, subsequently oil comes
out.
1.3) PRV operate during short circuit test.
1.4) Oscillogram voltage & current wave shapes get distorted.
1.5) Flash in tap changer noticed during SC test.
1.6) Transformers Oil get carbonized.
CPRI
Failure Analysis of Transformers
1.7) Routine Test after Short Circuit test.
- During DVDF voltage get collapsed.
- No load current excessively high.
- High voltage power frequency voltage collapse.
- Magger (IR) value of winding gets zero.
1.8) After untanking of the transformer.
- Winding assembly get completely distorted.
- Spacers & blocks comes out from assembly.
- Top or bottom permawood ring breaks.
- Pressure bolts loosen, break or displace from its position.
- Tie Rods get loosen ,subsequently spacers and blocks also
get loosen.
- Base yoke channel loosen, subsequently core get disturbed.
- Supports for holding tap winding leads get break or loosen.
CPRI
Failure Analysis of Transformers

B) Minor failures : (Before S.C. test):


i) Megger (IR) of HV-E or LV-E zero.
ii) High Voltage power frequency test HV-E or LV-E do not
withstand.
iii) Ratio at one of the tap or more taps beyond the tolerance limits
as specified in the standard
iv) Induced over voltage test fail to withstand., Indicate failure of
inter turn in winding
v) No load looses or load losses or both beyond the guaranteed limit
as specified by the customer.
vi) Tap Switch operation problem in the test either due to pin broken
which connects handle rod and tap switch.
1.6MVA, 6.6/0.433 kV Transformer

Observations: %change in % x beyond limit after 5th shot,


No Load current abnormally high, carbonized oil came out
from PRV, arcing mark noticed on LV busbar, paper
insulation of winding burnt.
630kVA, 22/0.433 kV Transformer

Observations: %change in % x beyond limit after 7th shot,


No Load current abnormally high, end blocks & spacers
found loose, V phase winding HV winding deformed.
1.5 MVA, 33/ 0.69 kV Transformer

Observations: %change in % x beyond limit after 2nd shot,


abnormal sound noticed, oil carbonized, W ph HV winding
damaged & conductor burnt, end blocks & spacers found
displaced.
800KVA,33/0.433 kV Transformer

Observation: %change in % x beyond limit after 8th shot,


variation in resistance, Delta lead found opened.
1.0MVA,11/0.433 kV Transformer

Observation: waveform distorted, U & W ph LV busbar


found bent & shorting with core. Arcing noticed between
core & LV busbar.
1.0MVA, 11/0.433 kV Transformer

CENTRAL POWER RESEARCH INSTITUTE,

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