DISTRIBUTION TRANSFORMERS

Maintenance guide
for liquid filled
distribution
transformers
02

CONTENTS
1 : Introduction 03
1.1 : Cautionary note 03
1.2 : Health & Safety 03

2 : Transformer Components 04
3 : maintenance - BASIC procedures 06
4 : maintenance - the process 08
4.1 : Liquid Fillings For Transformers 08
4.2 : Mineral Insulating Oil 08
4.3 : Insulating Oil 09
4.4 : Transformer core & windings 12
4.5 : External – outdoor / indoor terminal bushings 12
4.6 : Cable boxes 13
4.7 : Conservator & other means of oil preservation 13
4.8 : Cooling systems - radiators 13
4.9 : Sealing Gaskets 14
4.10 : Gauge(s), indicators & relays 14
4.11 : Temperature Indicators 15
4.12: Buchholz Relay 15
4.13 : Explosion vent or pressure relief device 16
4.14 : Dehydrating breather 16
4.15 : Control cabinets 16
4.16 : Current transformers 16
4.17 : Onload tap changers 17
4.18 : Off circuit selectors 17
4.19 : Surge arrestors 17
4.20 : Protection fuses 18
4.21 : Auxilary transformers 18
4.22 : Valves 18
4.23 : Bolts, nuts & fasteners 18
4.24 : Paint-work 18
4.25 : Anti vibration pads 18
4.26 : General Notes 18

5 : TESTING Of The TRANSFORMER 20

5.1 : Transformer checks that may be required 20
5.2 : Transformer testing following maintenance 22
5.3 : Post-maintenance recommendations 25
5.4 : Transformer life cycle 25
5.5 : Warranty Conditions 25

6 : contact details 25
7 : about us 27
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1. Introduction
All transformers supplied by Wilson Power Solutions (WPS) UK,
are designed, manufactured and tested with the latest
technology and under strict quality controls, in order to
provide you with a long and trouble free service.

To secure a long lifespan for the transformer it is important to follow proper installation, commissioning and
protection procedures and to ensure that timely maintenance is carried out during transformer operation.

The purpose of this Maintenance Manual is to provide guidance on required and recommended maintenance of
liquid-filled (mineral and synthetic ester) transformers.

This guide is necessarily generic in nature, so specific features or parts listed in this guide may be missing from your
transformer, and accessories or auxiliary units on your transformer may be omitted from this guide.

In the event of any doubt, arising questions or any irregularities / deviation from IEC / BS (or equivalent) standard
observed, please refer to WPS for clarification and assistance.

The transformer, along with all its accessories and fittings, should be installed, commissioned and operated under the
supervision of a competent electrical engineer in accordance with relevant statutory requirements and good
engineering practice, as well as being operated within the terms of the specification.

For the UK and International Standards, reference should also be made to the current edition / publication of BSI:
Standards Catalogue, ENA-TS, and IEC: Catalogue of Publication, etc.

1.1 Cautionary note 1.2 Health & Safety

No transformer should have rated service voltage Materials or components that are liable to be exposed
applied to it until all preliminary work and pre- or handled in normal operation and maintenance and
commissioning tests and checks have been could present a hazard to health are covered here.
satisfactorily completed.
Electricity at Work Regulations - 1989 applies to the
No high voltage tests should be applied to any UK Electrical Installation as per ‘Memorandum of
transformer without making reference to the original Guidance on the Electricity at Work Regulation’ from
supplier (WPS). HMSO.

A transformer which has been commissioned and Also, refer to the ‘Regulations for Electrical
then removed from service for any length of time Installation’ BS: 7671 for installation up to 1000V AC
should be re-checked to the same standard as when and ‘Safety in Electrical Testing’ HS (G) 13 from HMSO,
it was first commissioned prior to being re-energised ISBN 011 883 283 0.
and placed back into service.
In addition to the instruction given in this manual, BS /
IEC / equivalent standards and local regulation should
also be referred for other details regarding the design,
materials and performance.

Excessive or prolonged skin contact with transformer

oil (mineral oil) should be avoided. For further
information regarding oil handling, please refer to
‘Effect of Mineral Oil on the Skin [SHW295]’

A list of standards applicable to distribution

transformer is given as below:

• Power Transformers IEC:60076 and and all

relevant parts therein.
• Distribution Transformers: ENA 35-1
04

2. Transformer Components
This section helps the user to identify individual parts of the transformer
which will be referred to throughout this document. The following images
will indicate the approximate location and style on several different designs.
Items labeled with a letter (A, B, C etc.) indicate standard components are present on all standard transformers,
numbers (1, 2, 3 etc.) indicate optional extras or accessories that may not be on your version.

Standard components and accessories: Optional components and accessories:

A. Connection point for air dehydrating breathers (Figure 1a) 1. Oil temperature indicator (OTI)/ Winding temperature
B. LV connection (standard cable connection) (Figure 1a) indicator (WTI) (Figure 1a)
C. Marshalling Box (Figure 1a) 2. Ring main units/ACB/ other connections (Figure 1a)
D. Drain valve (Figure 1a) 3. Thermometer, to install on the thermometer pocket
(Figure 1a)
E. De-energised tap-changer (Figure 1a & Figure 2)
4. Pressure relief device (PRD) (Figure 1b)
F. Thermometer pocket (Figure 1a)
5. Current transformer connection box (Figure 1b)
G. Rating plate (Figure 1a)
6. Conservator (Figure 1b)
H. Jacking points (Figure 1a)
7. Buchholz relay (Figure 1b)
I. Transformer lifting eyes (Figure 1b)
8. Off circuit dual ratio changer (Figure 2)
J. Tank earthing terminals (Figure 1b)
9. Oil level indicator (Figure 2)
K. Transformer lid lifting eyes (Figure 1b)
L. Radiators (Figure 1b)
M. HV connection (standard cable connection) (Figure 2)

A E
B 2
1 F,3
C G
D H
Figure 1a - Transformer View from Tap Switch End
 05

4 6

5 7

i k

j l
Figure 1b - Transformer View from LV Side

A
9
8

e m

Figure 2 - Dual Ratio Transformer

06

3. Basic maintenance procedures

If a transformer is to give long and trouble-free service, it
should receive a reasonable amount of necessary maintenance

As a guide, following the CIGRE ‘Guide for Transformer Maintenance’, published in 2011, alternative methods given
below could be chosen or selected to achieve a satisfactory result for a given transformer. Alternative methods that
should be considered are:

• Time Based Condition Monitoring

• Condition Based Monitoring
• On-Line Condition Monitoring
• Time Based Maintenance

Time Based Condition Monitoring (TBCM)

To be TECHNICALLY feasible a condition assessment should have the ability to detect initial changes in condition for
any items that are relatively small compared to the deterioration necessary for failure. This requires that measurement
or inspect intervals that are smaller than fail point to allow detection before failure occurs. This may be too complex
for transformers of smaller power rating.

Condition Based Monitoring (CBM)

Condition Based Monitoring (CBM) - simply monitoring the change in condition of any item on an ’as & when’ basis,
long term experience being the main governing principal coupled with perceived usage, i e loading, particularly if any
overloads. A FAIL condition may occur with this approach.

On-Line Condition Monitoring (OLCM)

On-Line Condition Monitoring (OLCM) – data, measurements or samples are collected whilst the subject transformer
is energized by visit to site. This can be developed to continuous monitoring by provision of suitable equipment to
capture real time data to provide information of developing trends in transformer condition. This will develop further
because of the appearance of ‘smart transformers’, resulting in the appearance of so-called ‘smart systems’.

Time Based Maintenance (TBM)

Time Based Maintenance (TBM) - this has been to this point in time the most popular form of maintenance, mainly
because many or most substations operate in reasonable isolation to each other with little feed back of information
to any central control. It consists of regular, programmed inspection, followed by any testing required and
reconditioning when necessary. Records should be kept giving details of any abnormalities during service, also any
periodic test results noted & any necessary actions arising. This demonstrates compliance with the general
requirements of ISO:9000. A FAIL condition may occur with this approach.

3.1 THE MAIN OBJECTIVE OF ANY MAINTENANCE IS TO PRESERVE THE ORIGINAL

PROPERTIES OF ALL MATERIALS USED IN GOOD WORKING CONDITION.
Moisture, dirt, excessive heat / over-loading, mishandling, etc., are the main causes of INSULATION deterioration.
Corrosion due to severe environment and weathering cause paintwork to deteriorate leading to rust formation
particularly serious for cooling radiators/fins. Terminal Bushings can become damaged particularly if outer porcelain
shell is used. The list is extensive.

A combination of all four techniques can be used or only one e g TBM. It depends on the level of RISK associated with
the transformer which can be defined as

• RISK = Likelihood of Failure * Failure Consequence

• Likelihood of Failure can be represented by the ‘Health Index’ of the unit
(service history, general condition, whether obsolescent etc.)
• Failure Consequence can be mitigated by various control measures.
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A Risk Level can be allocated to any transformer if this will help flag up the particular need for frequent maintenance
because of the importance of the particular unit to the general network.

3.2 NO maintenance work should be done on the transformer, unless all the
external circuits are disconnected / made dead and that all the windings
are solidly earthed.
There are, however, situations where the equipment may still be ‘live’. Qualified personnel ONLY following specific
rules to ensure safety at all times shall be permitted to work in these circumstances.

3.3 factors that can influence maintenance practice & effort

• the subject transformer characteristics & specifications
• the required duty of the transformer – load, OLTC operation etc
• the transformer working environment – temperature, humidity etc
• historical failure rate for transformer type & consequences of unavailability.
• availability & costs of skilled labour
• the presence of a maintenance optimisation programme

3.4 In broad terms transformer maintenance effort is related to component

selection regarding
• Bushings
• Oil Preservation systems
• Cooling Systems
• Gaskets
• Gauges, indicators & relays
• Control cabinets
• Current Transformers
• On Load Tap Changers
• Off Circuit Selectors
• Surge Arresters
• Transformer Active part
• All sensing & monitoring devices

3.5 ALL or ANY Maintenance work necessary should be accurately recorded to

form the essential history or verification that a given transformer has been
subject to the relevant procedures.
IF IN DOUBT RECORD for without accurate records it becomes increasing difficult over time to confirm what
maintenance procedure(s) have occurred or whether time related maintenance has been performed correctly.
08

4. Maintenance - THE PROCESS

4.1 LIQUID FILLINGS for TRANSFORMERS
Some liquids other than traditional insulating oil, have a very high flame ignition point & are considered environment
friendly – any leakage of traditional insulating oil MUST be contained to prevent contamination of surrounding area.
These alternative fillings tend to be used when the subject transformer is to be located inside buildings such as a
block of offices or places of manufacture particularly where food of any kind is produced. Fire precautions or need
to contain in event of leakage are not as strict hence resulting in potential reduced costs. Basic recommended
procedures to maintain the original properties of any liquid filling used with transformers manufactured by WPS are
given in the following sections.

4.2 MINERAL INSULATING OIL

4.2.1 Mineral insulation oil functions as a coolant, dielectric (insulant) & helps to extinguish any currents arcs in the
subject transformer. So keeping the oil in good, specified condition will help prevent/slow deterioration of the paper
& other such solid insulation materials immersed in it. Oil will deteriorate gradually with time – e. g. contact with air
causes oxidisation, a process accelerated by contact with metals such as copper & iron. Longer term, particularly if a
given unit operates at higher than normal temperature chemical reactions – decomposition & polymerization - occur
producing solids that are not dissolved & can collect within the core/winding structure. This is called sedimentation
or sludge formation. Another cause of deterioration is moisture or humidity. Hence it is usual to fit a dehydrating
breather to limit entry of moisture into a free breathing tank (it is important to ensure the dehydrating medium is
active at ALL times).

Other disadvantages are a relatively low ignition (fire) temperature & oil is now regarded as environmental
contaminant because of limited biodegradability which in the event of any leakage MUST be contained by suitable
means.

4.2.2 IEC:60422/2013 – ‘Insulating Oil – Supervision & Maintenance’ gives recommendations in detail for the
preservation of insulating oil. A few short notes on the subject are given as below;

a) Oil level should be checked at frequent intervals and any excessive leakage of oil must be investigated
thoroughly. There may be a slight loss of oil by evaporation; this need not cause concern if the tank is topped
up at regular intervals.
b) All minor leaks or sweating should be repaired as quickly as possible.
c) Oil shall be topped-up as per instruction of this manual. It is once again emphasized that any new oil to be
added will preferably be from the same source as the original oil. New oil from a different source may be
added as make-up only but not exceeding about 10% of existing oil volume. In this latter case, suitable records
must be kept.
d) Samples of oil should be tested at regular intervals and results are to be recorded & retained. Reduction in
voltage withstand capability, increase in moisture & acidity content can then be recognised & treated. In
addition a sample can be sent for DGA which can highlight other unwanted phenomena occurring.
NOTE : Dielectric strength alone does not give a true indication of oil condition. If dry, even highly
deteriorated oil can indicate a high dielectric strength.
e) Normal oil filtration methods can maintain the dielectric strength, but may not cater for the overall potential
deteriorated condition of the oil. It is NOT advisable to rely solely on the dielectric strength of oil by
periodic test, without verification of chemical contamination.
NOTE ; Reconditioning by centrifugal separation or filtration does not remove any acidity content from a
given oil but will remove moisture, sludge, dust, dirt, etc. and so tend to retard the processof deterioration.
Filtration with Fullers Earth will help to reduce acidity in oil and additionally improve the resistivity value of
the oil.
f) If the dielectric strength is below 30kV(rms), the oil should be reconditioned by passing it through either a
centrifugal separator or a filter. After reconditioning, the dielectric strength should be such that oil can
withstand a minimum of 40 kV(rms) in a standard test cell.
g) If acidity value is 0.5 to 1.0 mg KOH per gm of oil, it is recommended that the oil be kept under observation.
If the acidity is increasing rapidly, or exceeds 1.0 mg KOH per gm of oil, the cover should be removed to
ascertain the condition of the interior of the tank and of the core & windings. Oil is then to be treated or
discarded, if sludge or corrosion is evident. Advice should be obtained from the suppliers.
h) One of the most important & useful diagnostic tools is Dissolved Gas Analysis (DGA).
Gases commonly measured;
Hydrogen, Methane, Ethane, Ethylene, Acetylene, Carbon Monoxide, Carbon Dioxide, Oxygen & Nitrogen
 09

Analysis is based on both gassing rates & dissolved content of the different gases. Commonly certain gas
ratios are used to match the DGA gas profile obtained to that established by years of thorough analysis on
faulting transformers. Depending on this profile gassing may be associated with:

• Thermal faults of low temperature

• Thermal faults of medium temperature
• Thermal faults of high temperature
• Discharges of low energy
• Discharges of high energy
• Partial discharge activity

It is frequently possible to identify with reasonable accuracy the position/location of a fault or faulty
component within the transformer using ratios provided by various gases. The relative ease with which taken
oil samples can be analysed & interpreted make this the most important aid available to assess oil condition &
to detect early notification of fault development. It is highly recommended by WPS as an effective tool for
assessing the existing condition of any transformer at a given point in time & with sampling performed at
different points in time will enable any deterioration to be detected BEFORE actual failure occurs.
Refer to section following 4.3 re technique for taking oil samples for test with minimum contamination

4.3 ALTERNATIVE LIQUIDS to MINERAL INSULATING OIL

4.3.1 There are 3 main variations:

• Silicone, fully synthetic (IEC 60836)

• Esters, derived chemically, synthetic (IEC 61099)
• Esters, derived naturally, plant seed oils (IEC 62770)

All function as a coolant & dielectric (insulant). All offer higher flash/fire points than mineral oil, silicone in particular
also exhibits a self-extinguishing behaviour & the best thermal stability. However silicone has disadvantages such as
poor lubrication properties & it readily absorbs moisture which affects its insulating properties (hence it is normally
protected/contained in a sealed tank). Finally, environmentally it has very limited biodegradability. For these latter
reasons it is not normally used by WPS.

Esthers, synthetic
Are used fairly extensively by WPS being available for over 45 years as an alternative to PCB’ s. They offer low
temperature capability, high temperature oxidation stability & good moisture tolerance (better than mineral oil).
Finally it offers agreat advantage – it is readily biodegradable hence environmentally friendly. However it is strongly
hygroscopic so may be housed in either a ‘free breathing’ tank with effective dehydrating breather or sealed tank
depending on client preference. The IEC Specification given applies to the unused fluid whereas the maintenance
guide. Is available as IEC 61203. Reference to the latter Standard is recommended.

Esthers, natural
Unlike their synthetic counterparts, natural esthers have been developed considerably later entering commercial
usage in the United States in the year 2000 or thereabouts. Whereas there is a guide for the ‘ Acceptance &
Maintenance of Natural Ester Fluids in Transformers ‘ published in the U S in 2008 there Is no corresponding IEC Std.
at the time of writing. It is reported that the natural ester results in a reduction in insulating paper aging when
compared to mineral oil, shows higher flash & fire points than the synthetic ester. It shows the best biodegradability
of all the liquids mentioned – hence again environmentally friendly.

Of the fluids mentioned, other than mineral oil, the only other fluid in reasonable usage is the synthetic ester usually
as Midel 7131 or as alternative SE-A from alternative source. Some of the disadvantages listed for Mineral Oil do not
apply, i e some of the chemical reactions listed & a greater tolerance of water content without loss of di-electric
capability. It is however the flash/fire points & the ability to be biodegradable which make the fluid attractive for
internal locations.
10

4.3.2 IEC:61203/1992 – ‘Synthetic organic esters for electrical purposes – Guide for Maintenance of transformer
esters in equipment’ gives recommendations in detail for the preservation of the fluid. A few short notes on the
subject are given as below;

a) Fluid level should be checked at frequent intervals and any excessive leakage of fluid must be investigated
thoroughly. There may be a slight loss of fluid by evaporation; this need not cause concern if the tank is
topped up at regular intervals.
b) All minor leaks or sweating should be repaired as quickly as possible.
c) Fluid shall be topped-up as per instruction of this manual. It is once again emphasized that any new fluid to
be added will preferably be from the same source as the original. New fluid from a different source may be
added as make-up only but not exceeding about 10% of existing oil volume. In this latter case, suitable record
must be kept.
d) Samples of fluid should be tested at regular intervals and results are to be recorded & retained. Reduction in
voltage withstand capability, increase in moisture & acidity content can then be recognised & treated. In
addition a sample can be sent for DGA which can highlight other unwanted phenomena occurring. IF
contamination is severe the fluid must be returned to the original manufacturer for possible treatment to
recover alternatively the subject unit washed with fluid & refilled using new/recovered fluid to the same
specification. NOTE : Dielectric strength alone does not give a true indication of fluid condition.
e) Normal oil filtration methods can maintain the dielectric strength, but may not cater for the overall potential
deteriorated condition of the fluid. It is NOT advisable to rely solely on the dielectric strength of oil by periodic
test, without verification of chemical contamination. NOTE ; Return to Producer for treatment to recover
essential characteristics.
f) If the dielectric strength monitored is below 30kV(rms), the oil should be reconditioned by passing it through
either a centrifugal separator or a filter. After reconditioning, the dielectric strength should be such that oil
can withstand a minimum of 40 kV(rms) in Std. Test Cell. IF after attempting reconditioning the fluid is still in
unsatisfactory condition then return to the Producer for suitable treatment (as e) above).
g) Again as with mineral insulating oil one of the most important & useful diagnostic tools is Dissolved Gas
Analysis. Gases commonly measured:
Hydrogen, Methane, Ethane, Ethylene, Acetylene, Carbon Monoxide, Carbon Dioxide, Oxygen & Nitrogen
Analysis is based on both gassing rates & dissolved content of the different gases. Commonly certain gas ratios
are used to match the DGA gas profile obtained to that established by years of thorough analysis on faulting
transformers. Depending on this profile gassing may be associated with:

• Thermal faults of low temperature

• Thermal faults of medium temperature
• Thermal faults of high temperature
• Discharges of low energy
• Discharges of high energy
• Partial discharge activity

Although the history of results is not as comprehensive as with mineral insulating oil it is still frequently
possible to identify with reasonable accuracy the position/location of a fault or faulty component within the
transformer using ratios provided by various gases. The relative ease with which taken fluid samples can be
analysed & interpreted make this the most important aid available to assess fluid condition. It is highly
recommended by WPS as an effective means of assessing the condition of any synthetic ester fluid filled
transformer ( provided facilities exist to take samples of fluid ).
Refer to section below re taking oil (liquid) samples from a transformer
 11

Taking oil (liquid) samples from a transformer

The results of any test or analysis of sample(s) taken it is essential to ensure the correct sampling procedures are
followed viz:

• ALL apparatus used for sampling must be clean & free of moisture, fibres & any other contaminant. Before use
all apparatus should be carefully inspected & flushed with clean oil.
• Cotton rags/paper towels should NEVER be used, only use clothes that are guaranteed not to shed fibres –
use in clean condition free of any contamination
• Before removing covers or breaking any gasket style joints etc. of unit to be sampled, take precautions to
exclude any ingress of dust, loose deposits or other contaminants.
• Outdoor sampling should preferably be done in dry weather. In inclement weather (wet) precautions must be
taken to ensure sample(s) are not affected by ingress of moisture.
• Ensure that oil di-electric & sampling equipment is at same temperature as ambient air. The temperature of
the oil sampled must be taken & recorded.
• Sample bottles should be amber glass or if clear then they should be covered with black polythene or similar
post sample. Bottles must be capable of being sealed gas tight with a hard plastic screw cap which houses a
conical polythene seal.
• Bottles of 500 or 1000ml volume are typically used. The bottle should always be filled to a level of 8/10 mm
below the rim (leaving sufficient space for expansion).
• Thieve tubes should be made of glass (no sharp corners to trap contaminants).
• The blanking flange or cover of the valve from which the sample is to be taken should be removed & the
sampling point cleaned to remove all visible dirt etc.
• Any rubber or plastic tubing used for connection to a sampling vessel should be as short as possible, suitable
to use with fluid being sampled & impermeable to gases.
• A thermocouple is placed in the end of the tube & the temperature of the fluid being sampled is taken &
recorded as approx. 1 litre of fluid is allowed to drain to waste. NOTE : inspect for the presence of free water
• Allow the sampling bottle to fill slowly in a quiet manner, displacing the air gently hence causing the minimum
disturbance to the fluid being taken. Allow some overflow & slowly withdraw tubing with the fluid still flowing.
• Close the sampling valve & disconnect the tubing.
• Tilt the sample bottle to allow the fluid level to fall to 18/20 mm from the rim & then screw the bottle cap
securely in position.
• Label any sample bottle(s) immediately with relevant details & carefully store/pack particularly if being sent
away for testing (e.g. DGA)..

Sampling of Insulating Oil from Transformers for Labatory Analysis.

This sampling kit uses an oil proog rubber bung with approximately 5mm metal tube for insertion into the tap in a tank.

Valve Rubber Bung with Small

Bore Tubes

Rubber Tube
Transformer
Tank
Air Vent
Oil Sampling Point Rubber Bung with 2
Small Bore Tubes

Fill Level

Oil Sample
Bottle

Schematic diagram of oil sampling process

12

4.4 TRANSFORMER CORE & WINDINGS

4.4.1 It is recommended that the core & windings ONLY be removed from the tank for visual inspection if
PARTICULARLY necessary (e.g. an internal fault involving coil or coils is detected). IMPORTANT : If removed, on
replacement a full test procedure must be performed PRIOR to recommission to ensure transformer connections
etc. are satisfactory for further service.

4.4.2 Following draining all oil from the tank, internal inspection should be done via opened top cover or side
inspection cover openings. DO NOT USE NAKED FLAME OR LIGHT but a suitable SAFETY LAMP for internal inspection.
IF inert gases are present in the tank it will be necessary to employ suitable breathing apparatus – in NO circumstance
must any person attempt to enter a tank where it is suspected inert gases, e g nitrogen, is present without aids to
survival.

4.4.3 Before lifting the core & windings from the tank it is necessary to disconnect the winding connections from
terminal bushings inside the tank and the earth connection between the core body and the tank. The core and
windings must be removed with great care, and when removed be stored under proper cover and in a dry place.

4.4.4. IF removed from tank, windings should be examined to ensure that no sludge/dirt has been deposited to block
the oil ducts / opening passages.

4.4.5 Off circuit selector (OCS) terminals shall be thoroughly cleaned and ensure no welds / dents exist at tapping
contacts. And that all the tapping leads are properly insulated / supported without any loose sag. Also ensure smooth &
full operation of OCS throughout tapping range.

4.4.6 Any loose nuts & bolts should be tightened and main clamping checked for tightness.

4.4.7 After completion of examination, CHECK to ensure no foreign items have been left inside the tank.

4.4.8 On replacement of core & windings within the containing tank, replacement of covers etc & refill with oil it is
necessary to retest the transformer using reduced test voltage levels (as detailed in the relevant standard specification).
IF coil(s) have been replaced it may be necessary (or desirable) to perform a load loss test to verify the replacement
coil(s).

4.4.9 AS an alternative to this ‘time consuming process’, a regular DGA (Dissolved Gas Analysis) of oil will give effective
indication of any potential problems beginning to occur. Also video camera technique can be used to carry out an
internal inspection quickly and with minimum problems, (camera suitable for use under oil). This technique avoids the
need for a full test procedure as core/windings remain in position – if any connections are removed/reconnected
some low voltage test technique WILL be required.

4.5 EXTERNAL – OUTDOOR / INDOOR TERMINAL BUSHINGS

4.5.1 Outdoor Porcelain insulators and rain sheds should be cleaned at regular intervals. A metallic scrubber can be
used effectively to remove dirt / stains provided surface NOT damaged. Intervals between cleanings will be very
dependent on the degree of contamination in the immediate area. The rate at which contamination occurs will have to
be gauged by regular observation in first instance.

4.5.2 During cleaning process, the outdoor porcelain (or moulded) bushings should be examined for oil leakage,
cracks or other defects and defective ones should be replaced.

4.5.3 Arcing horns, if fitted, shall be checked for any arcing dents / welds and correct gap setting, Any arcing horn
suffering distortion etc. is to be replaced or rectified.

4.5.4 Indoor Porcelain Insulators, usually placed inside the cable box, should not require cleaning under normal
circumstances & are very reliable whether in air or under oil. Composite/moulded Insulators entering service have not
established long term reliability. Some early examples have suffered from surface deterioration
 13

4.6 CABLE BOXES

4.6.1 In the case of a compound filled cable box, check regularly for leakage at weatherproof plugging / sealing with
bituminous compound, which shall be free from any cracks. Likewise for any oil filled box or disconnect chamber
when oil seepage is detected.

4.6.2 In case of air-filled cable box (for Heat-Shrink / Push-On / other such dry termination), though no maintenance
is required, it is advisable to check regularly for cleanliness, any damage to the bushings, tightness of termination, etc.
& ingress of moisture

4.7 CONSERVATOR & other means of OIL PRESERVATION

4.7.1 A conservator acts as an expansion space for a working transformer & is normally placed above the related main
containing tank. It tends to minimise surface area of oil in contact with outside air. It is normal to provide some form
of dehydrating device to connect to the outer atmosphere – this commonly contains gel but in some cases may be a
refrigeration device. working on a freeze (trapping moisture)/ melt (disposing of entrapped moisture) cycle.

4.7.2 Conservators are arranged so that the lower part acts as a sump into which any impurities entering the
conservator will tend to collect. A valve is fitted at the lowest point of the conservator for draining and sampling. When
sampling, care must be taken to run off any such sludge before taking oil sample for testing.

4.7.3 The inside of the conservator should be cleaned at intervals and a removable end is provided on each
conservator to allow access for this purpose.

4.7.4 Some conservators may be fitted with a flexible diaphragm or bag to ensure that the oil within the transformer
does not come into contact with air. This allows for the expansion of oil but avoids contact with air. Refer to special
instruction supplied with subject transformer.

4.7.5 For some transformers, lower power ratings e.g. distribution, a sealed, expansion space is provided at the top of
the main containing tank & acts in a similar role as 4.5.4

4.8 COOLING SYSTEMS - RADIATORS

4.8.1 Cooling Radiators are produced by a number of manufacturers, & although similar in general style one with
another tend to differ slightly in the detail. It is preferable (but not mandatory) that the radiators fitted all come from
the same source/supplier.
NOTE : In event that repair/refit is required it may be convenient to use radiators from differing sources.

4.8.2 Cooling Radiators should be frequently checked for any oil leakages along all the welded joints, gasket joints,
plugs, etc.

4.8.3 Any bend, dents, etc., should be suitably rectified as soon as possible. Also replace protecting surface paint.
Refer to WPS in the circumstance that a galvanised finish is provided.

4.8.4 Cooling Radiators or fins cater for ONAN cooling (natural cooling) but extra cooling can be achieved by use of
forced air. The principal is simple, fans are used to increase the air quantity moving thro’ the panels thereby increasing
the cooling effect. Fans can be arranged to blow air in an upwards direction (from the coolest to the hottest point in
each radiator). Alternatively a single fan could be used to blow thro’ a set of radiators – thereby saving a quantity of
fans, an increased resistance results in the fans selected having to overcome an increased ‘back pressure’.

This is known as ONAF cooling indicating the mass of air available for cooling is increased by action of the fans.

An additional effect may be obtained by use of an oil pump in the oil pipework, usually the cooled oil return
connection, to speed up the velocity of the oil employed in cool process. This is known by the designation of OFAF.
The use of forced cooling to increase the power transmission thro’ put is commonplace even for distribution ratings by
means of forced air.
14

4.8.5 Radiators may need to be cleaned from time to time particularly when located in areas subject to dust
contamination, dirt/deposits hamper heat transfer to surrounding cooling air. Compressed air should be a suitable
vehicle for cleaning in majority of instances.

4.8.6 Other means of cooling uses water instead of air, suitable means are required to either cool the heated water or
transfer it to waste. Accordingly use of this means of cooling is virtually unknown for distribution ratings

4.8.7 All means of additional cooling impose particular requirements to ensure performance is maintained.

4.9 SEALING GASKETS

4.9.1 Gaskets have several important jobs to perform

• a gasket must create an effective seal & hold it over a long period of time.
• it should be impervious & not contaminate the insulating oil or air/gas above oil.
• it should be easily removed & replaced.
• it must be elastic enough to flow into imperfections on the surfaces to be sealed.
• it must withstand temperature variation & remain resilient to cope with joint movement, contraction & vibration.
• it must be resilient enough to avoid taking a ‘set’ even when exposed for a long period to applied
pressure variation.
• it must maintain its integrity under handling or installation.

Failure to meet any of the above criteria will result in a leak or leaks.

4.9.2 Gasket material used by WPS is Cork – Nitrile (classified TD1120). It has a shelf life of approx. 2 years. It can
often be re-usable in the short term unlike Cork – Neoprene which is not recommended for use An alternative which
is also used in certain situations is Nitrile (buna N). It must be protected from sunlight, otherwise it will deteriorate e.g.
relief vent ring gasket.

4.9.3 Gaskets sometimes shrink during service & require replacement. Before doing so check the tightness of all
bolts fitted with gaskets. The bolts should be tightened evenly around the joints to avoid uneven pressure, follow
recognised tightening procedures. Damaged gaskets (for whatever reason) should be replaced as soon as possible.

4.10 GAUGE(S), INDICATORS & RELAYS

4.10.1 The simplest format of oil level gauge is just a reinforced glass or plastic window or block thro’ which oil level
can be seen. A label giving expected Cold Oil level (minimum) & Hot Oil level may be fixed into position. It is also
possible to include a ‘low oil’ contact for protection (separate item) if needed. Any oil gauge, if glass, should be kept
clean and any damaged glasses should be replaced immediately or without undue delay.

4.10.2 An alternative is an oil gauge of the visual magnetic type fitted with an operating arm having a float attached.
As oil level increases, the float rotates a magnet inside the tank or conservator. Outside the tank another magnet
follows (rotates) which moves the pointer of the oil gauge. High & low level points to indicate level changes (oil
expands when hot). This is a simple method of check – determine the top oil temperature & then look at the level
gauge, the pointer should be at a reasonable level corresponding to the determined top oil temperature. It is normal
practice to indicate ‘cold’ oil level to ensure the unit is correctly filled with req’d oil. The oil gauge may incorporate
electrical switches for alarm or trip purposes in the event that the tank level falls.

NOTE : It is IMPORTANT not to damage or distort this operating arm if the parent conservator vessel is opened or
entered.
 15

4.11 TEMPERATURE INDICATOR(S)

4.11.1 The simplest form of temperature measurement is provided by the alcohol thermometer (note not mercury in
glass) placed into a thermometer pocket or well located in the tank wall near the top of the tank IN the oil. This will
provide for the occasional reading.

4.11.2 For convenience to indicate top oil use a typically sealed spiral bourdon tube dial type with liquid filled bulb
sensor. Again the bulb is accommodated in a thermometer pocket or well in a suitable position in the tank wall. As oil
temperature increases, liquid expands which expands with the spiral tube. The tube is attached to a pointer that
indicates temperature, also incorporating electrical contacts to trigger alarms or start cooling fans as operating
temperature increases.

4.11.3 The companion to 4.11.2 is the winding temperature indicator based on a similar construction with the addition
of a heating coil placed around/adjacent to the operating pointer This is intended to simulate load amps taken in 1
phase of the transformer. The heating coil is supplied by a single phase current transformer – primary rated for load
amps relevant to the rating of the transformer. The net result is an instrument reading top oil temperature PLUS an
additional component relating to the load amps supplied by the transformer. The thermometer monitors the
approximate average working temperature of the coil from which it receives supply hence called a ‘thermal image’
device. Some means of adjustment to calibrate performance to approximately match the subject transformer is
provided. As for 4.11.2 the instrument incorporates electrical contacts to trigger alarms, start cooling fans or pumps or
supply information re temperature reading to a remote point.

4.11.4 Both oil & winding temperature indicators should be check calibrated at intervals & the functioning of the
switches checked as operational.

4.11.5 The level of oil in the thermometer pockets should be checked and the oil replenished if required (to ensure
good contact between indicator bulb & internal tank oil). The capillary tubing should be fastened down again if it has
become loose. Dial-glasses of temperature indicators should be kept clean and, if broken, replaced. Temperature
indicators, if found to be reading incorrectly, should be re-calibrated with standard thermometer immersed in a hot oil
bath or other calibrated reference.

4.12 BUCHHOLZ RELAY

4.12.1 This is only suitable for use with transformers fitted with conservators. Consists essentially of 2 oil filled
chambers equipped with floats & contacts; one to give an alarm the other a trip signal. It relies on the fact that gas(es)
are produced by various conditions in the transformer such as local overheating or partial discharge etc. A slow build
up of gas affects the top float & eventually an alarm signal will be generated. If however there is a rapid evolution of
gas (such as would be produced by a specific fault) the other float will be activated to give a trip signal e.g. to cause the
relevant switchgear to operate).

4.12.2 During service, if the relay is operated due to an accumulation of gas and not due to fall of conservator oil
level the accumulated gas can be analysed. Any internal faults can be identified to a great extent by a chemical analysis
of gases collected. Sometimes, on analyzing the gas, it may be noticed that the gas collected is only air. Providing this
is not a frequent occurrence it may be that the contained oil is releasing any absorbed air due to oil filtration or due to
change in temperature.

4.12.3 The relay should be routinely inspected and the operation of relay is ensured by injecting air into the relay and
check that floats are able to fall / rise freely and that the mercury / magnetic switches are making / breaking the
contacts correctly.
16

4.13 EXPLOSION VENT OR PRESSURE RELIEF DEVICE (PRV)

4.13.1 In an explosion vent, the diaphragm is fitted at the exposed end of the vent, which should be inspected at
frequent intervals and replaced if found deteriorated / damaged. Failure to replace the defective diaphragm quickly
may allow the ingress of moisture, which will contaminate the oil. If the diaphragm has broken due to an internal fault,
a full inspection should be made to determine the nature and cause of the fault BEFORE replacing & re-energising the
transformer. NOTE : this style of PRV is obsolete being replaced by the spring loaded resettable device.

4.13.2 In a spring loaded `blow-off & self or manual reset’ type Pressure Relief Device, a set of springs are held in
compression by a cover & press on a disc which seals the opening in the tank top. IF the pressure in the tank is caused
to exceed the set operating pressure the disc moves upward & relieves pressure. As pressure decreases, the springs re-
close the valve (to prevent ingress of air/moisture). To indicate operation a brightly coloured flag is exposed, & can only
be reset manually. If the indicator, usually a flag, has operated then an inspection should be made to determine the
cause of any fault BEFORE cancelling indication & re-energising the transformer (PARTICULARLY if disconnected from
supply) e.g. send oil sample(s) for DGA so that suitable remedial measures can be taken.

4.14 DEHYDRATING BREATHER

4.14.1 Normally used when transformers are classed as ‘free breathing’. It is important to keep out insects & small
rodents & prevent excess moisture from entering the tank (i e rain). Excess water does not help the insulating
properties of insulating oil & is to be avoided hence some means of drying any air entering the tank, due the natural
expansion/contraction of oil, is used. A breathing device filled with a quantity of desiccant is used to fulfil this function.

4.14.2 The dehydrating breather should be regularly checked for colour of desiccant. When the majority of gel
becomes saturated, the same shall be replaced or reactivated. Also oil in the oil seal, if used, should be maintained up
to the level marked on the cup.

4.14.3 The frequency of inspection depends upon local climate and operating conditions. More frequent inspections
are needed when the climate is humid and when the transformer is subject to fluctuating load.

4.14.4 As an alternative to the above a refrigeration device may be used. This works on a freeze/thaw cycle basis &
does not contain gel that regularly needs to be replaced.

4.15 CONTROL CABINETS

4.15.1 If the subject transformer is provided with a control cabinet this will be the marshalling point for all connections
to other places whether local or remote

4.15.2 It will also contain items like the temperature indicators, cooler control (if provided), any specialised
control/monitoring equipment required (specific to customer requirement), terminal blocks to marshal all connections
whether local auxiliary or for connection to remote points.

4.15.3 It will normally be to a weatherproof standard containing anti condensation heater & light/switch for
convenience. The internal will normally be finish coated in an anti-condensation coating. The door is normally fitted
with a viewing window/windows.

4.16 CURRENT TRANSFORMERS

4.16.1 Any current transformers will be normally mounted over internal bar work or interconnect leads inside the tank
of the transformer. Secondary connections will be brought to moulded type terminal blocks for external connection of
auxiliary wiring for connection to a common collect point.
 17

4.16.2 Current transformers provided for protection or metering purposes are normally located adjacent to the
terminal bushings they intended to protect or meter. On occasion this may be external to the main containing tank e g
in a separate external compartment.

4.16.3 In the event that malfunction is suspected normal basic test procedure applicable to current transformers
should be followed (e g check ratio test).

4.17 ON LOAD TAP CHANGERS

4.17.1 Always sourced from others, the particular manufacturer’s maintenance instructions should ALWAYS be
followed. There are two main types

• the traditional mechanical switching arrangement

• the more recent vacuum or electronic methods of switching

4.17.2 For the former oil located in a compartment where current making/breaking occurs will need examination to
ascertain when it should changed or renewed with fresh oil.

Likewise with the contacts making/breaking current (amps) will eventually need renewal due to thousands of
operations, actual as recommended by manufacturer.

4.17.3 For the former other associated equipment should prove reliable but contactors initiating tapchange may
require some maintenance. ALWAYS follow original manufacturer instructions. WPS will provide corresponding
literature that applies.

4.17.4 For the latter ALWAYS follow original manufacturer instructions. WPS will provide corresponding literature that
applies.

4.18 OFF CIRCUIT SELECTORS (OCS)

4.18.1 Will come from a variety of manufacturing sources including the UK, some more established than others. If
used correctly little should go wrong – the operative form is selector NOT switching. IF used to switch (i.e subject
transformer still energised) this process can be dangerous due the stimulation of current arcing that the action of
changing tap position will cause to occur. In extreme circumstances personnel have been injured & equipment has
caught fire.

4.18.2 The only maintenance required – on a yearly basis de energise the transformer & operate the selector thro’ its
complete range 3 or 4 times finally re setting onto the desired tap connection. Once the desired tap connection is
selected & protecting padlock fitted the transformer can be re energised.

The purpose of this procedure particularly if the subject transformer operates on a fixed tap position is to prevent/clear
any film build up which may occur eventually causing a high resistance contact to develop. In such circumstance the
three phase selector would need to be replaced.

4.19 SURGE ARRESTORS

4.19.1 These may be provided particularly if outdoor terminal bushings are fitted to prevent sudden voltage surges
(caused by lightening affecting transmission lines during storms or switching surges etc.)

4.19.2 The recommendations made under 4.5 regarding Outdoor Terminal bushings will be applicable e g cleaning
outer porcelain etc.
18

4.20 PROTECTION FUSES

4.20.1 Where an auxiliary transformer, having considerably lower power rating than the main power unit, is mounted
directly onto and deriving its supply from the same it is normal to provide a set of fuses on the incoming side of the
same.

4.20.2 The fuses should be checked to ensure serviceability – any fuse appearing unserviceable must be replaced with
identical or equivalent unit(s) and correctly clamped into position. If immersed under oil then any oil removed for
convenience of replacement must be placed in a clean container which can then be sealed and finally replaced.

IMPORTANT Any suspected or actual failure should be fully investigated PRIOR to re commissioning the subject
transformer.

4.21 AUXILIARY TRANSFORMER

4.21.1 The procedure to be followed is essentially as given in Sects 4.1 -4.14 & 4.18 -4.20.

4.22 VALVES
4.22.1 All valves should be checked for any leakage and for open / close operation. Blind caps should always be kept
fitted on them if provided.

4.22.2 Valves that are faulty should be changed as soon as possible.

4.23 BOLT, NUTS & FASTENERS

4.23.1 All bolts, nuts, fasteners, etc., shall be thoroughly checked for proper tightness and any deteriorated parts
should be replaced.

4.24 PAINT-WORK
4.24.1 During storage and service, the paint-work should be inspected once a year, especially at the welded seams /
joints, and where necessary, repainting or retouching carried out. If the metal surface is exposed and becomes dirty,
rusty or greasy because of delay in repairing the paint-work, the surface must be thoroughly cleaned with a wire-brush
or similar abrasives, before repainting to ensure a good bond between metal and paint.

4.24.2 If paints recommended by supplier are not available, any good quality alkyd resin-based paint may be used.

4.25 ANTI VIBRATION PADS

4.2.1 Anti Vibration Pads should require little or no maintenance as they will remain unaffected unless specific
solvents which act to dissolve or attack vulcanized rubber or similar are introduced to the substation support base. In
such an unlikely event, replacement would become necessary (the whole Transformer would require lifting or jacking
to allow this to occur).

4.26 General notes

IT IS ESSENTIAL TO KEEP A RECORD OF OBSERVATIONS MADE REGARDING OPERATING CONDITION, ANY TEST
PARAMETERS & TEST RESULTS OBTAINED. IN CASE OF ANY ABNORMALITY OCCURRING DURING SERVICE, ADVICE
FROM THE SUPPLIERS SHOULD BE OBTAINED, GIVING THEM NAME-PLATE PARTICULARS AND COMPLETE DETAILS
AS TO THE NATURE & THE EXTENT OF OCCURRENCE.
 19
Maintenance Schedule for the attention required
MAINTENANCE SCHEDULE under average conditions is given below;

Sl. No Frequency Items to be Inspected Inspection Notes Action required for

of Inspection unsatisfactory conditions

01 Hourly / Daily Ambient Temp. For reference -

02 - do - Oil / Winding Temperature Check that temp rise is For any abnormal temp. rise
within normal range trip, investigate the cause.
03 - do - Load Voltage & Current Check against the For any abnormal tripping,
rated figures investigate the cause.
04 - do - Noise emitted by unit Assess whether Check tap position, incorrect
appears reasonable can cause over fluxing
05 Weekly Dehydrating Breather Check desiccant Replace the desiccant or make
colour & oil seal up the oil, as required.
06 - do - Oil level in Main Tank Check the observed level If low, investigate for oil leaks
or conservator, if fitted against oil temperature & top up with dry oil.
07 - do - Buchholz Relay Check for gas Analyse, take action to prevent
collection any potential fault.
08 - do - Gasket Joints & Radiators Check for tightness Re clamp or replace / repair as
& no oil leakage required.
09 - do - Explosion Vent / Pressure Check for proper sealing/ Rectify / Investigate the
Relief Device indication of operation damage / malfunction.
10 - do - External condenser Check to req’d level Low oil, measure tan d &
bushing if fitted, oil level capacity. Advise supplier
11 -do - Full External Check for any discolouration, If o/heat suspected, investigate
maybe local o/heat, also paintwork as req’d to establish cause(s),
retouch paintwork.
12 Quarterly Fluid fill (Oil etc.) Check dielectric strength, Take suitable action to restore
also moisture etc. quality of oil/fluid.
13 - do - Cable Box / Termnl. Check for tightness Tighten if req’d, clean as
Bushings / dirt / damage needed, replace where
damaged.
14 Half Yearly Earthing Terminals Check tightness & Earth Investigate / correct if
Resistance measurement resisistance to earth is high.
15 - do - Oil / Unit quality, Take sample(s) for test Monitor result(s), take
dissolved gas analysis as required corrective as / if needed.
16 - do - Accessories / Auxiliary Check operation & switching Clean the components, if
Circuits contacts. necessary, replace the item.
17 Yearly Buchholz relay / Surge relay Mechanical inspection /function Check floats, contact switches
Pressure Relief device / operation etc. If faulty, correct
rusting/ damage or replace.
18 - do - Unit Insulation Resistance Check IR values using Megger If low investigate & take action
or similar to restore insulation.
19 - do - Off Circuit Selector With unit de energised, Operation OK, no further
operate thro’ range 5 x action. Operation suspect,
replace if needed.
20 - do - Sample batch, fasteners, Check for tightness Tighten as req’d or replace.
screws, clamps etc.
21 - do - Temperature Indicator (s) Check oil level in bulb Pockets. Replenish oil if needed.
Check operation & contacts Adjust or replace as needed.
22 - do - Paint-work Check for peelings / Suitably clean, treat &
rusting/ damage repaint, as required.
23 - do - Marshalling box, Check waterproof seal, all If needed, replace seal,
c/t terminal box connections O K, verify I R, aux veriify cause of any low I R.
cables Correct if needed.
24 Two Years On Load Tap Changer Check active contacts re arc burn / Clean the components, if
(if used) wear also oil condition (switching) necessary, replace as req’d.
25 - do - Oil Gauge Check operation & switching Clean the components, if
contacts. necessary, replace the item.
26 - do - Oil conservator Internal inspection Clean if necessary

27 3-5 Years Overall paint-work Check for deterioration Consider full repaint to original
specification
28 - do - HRC Fuse Links Check for arcing / Displacement etc. Replace / Repair defective
components as necessary
29 - do - Core & Windings Check for tightness / cleanliness Replace / Repair defective
components as necessary.

IMPORTANT The above is a recommended schedule highlighting items to be checked under average operating conditions.
The suggested time scales may be variable depending upon the PARTICULAR site conditions & loading regularly seen.
20

5. Testing of the Transformer

IMPORTANT: All checks to be carried out by a suitably qualified technician or engineer.

5.1 Transformer checks that may be required:

CHECKLIST
part Item to be checked y/n

De-energised Tap The transformer was delivered with the tap position on the principle
Changer tap, you may alter this if another tap setting is required. Once the
desired tap has been chosen it must be locked and the key must be
stored in a safe place to reduce the chance of maloperation.
Tank Earthing Terminals Ensure that your earth mat is still connected to the transformer via
the tank earthing terminal.
Thermometer Pocket Ensure that all thermometer pockets are fitted with appropriate
equipment (such as a temperature sensor) or closed off via a cap.

Drain Valve The transformer will be delivered filled with insulating fluid, with the
drain valve closed and a cap covering it as shown below. The valve
may be used to take oil samples from the transformer.

Breather Confirm the breather has been installed correctly and is functional.
Oil temperature indicator The transformers will be delivered with a preset alarm and trip as
(OTI) shown below:
OTI: Alarm 90oC, Trip 100 oC
Check and maintain selected alarm and trip settings. If other alarm
and trip values are required, refer to their product manuals for
installation guidelines.
Winding temperature The transformers will be delivered with a calibrated, preset alarm and
indicator trip as shown below:
(WTI)
WTI: Alarm 100oC, Trip 110 oC
Check and maintain selected alarm and trip settings. If other alarm
and trip values are required, refer to their product manuals for
installation guidelines.
 21

CHECKLIST
part Item to be checked y/n

Buchholz relay Visually check that the device is completely filled with oil.

✔ ✘
Pressure relief device Ensure the device has not been operated. If operated, investigate.The
brass coloured pin should be in the down position, as illustrated
below:

Dual primary voltage The transformer will be delivered set to the lower voltage unless
changer requested otherwise. If lower voltage is not what you require, ensure
the tap is changed to the appropriate setting. The number that
corresponds to the tap position is indicated on the rating plate
“SELECTOR SWITCH CONNECTION” and “SWITCH POSITION” as
shown below:

Once the correct voltage has been chosen, check that the switch has
been secured into that position.

Oil level indicator The oil level indicator can either be a magnetic oil gauge (right) or a
standard visual indicator (left). Make sure that the oil is in line with the
expected temperature.

If no oil level can be determined stop all activities and inform WPS.
22

5.2 Transformer testing following necessary maintenance

CHECKLIST
Insulation Resistance (IR) Test
Commissioning Procedure y/n

Before starting this test ensure that all power terminal bushings have been thoroughly
cleaned with a clean, dry piece of cloth.
During IR test, no external power lines / cables, lightning arresters, neutral earthing, etc.,
should be in the power circuit. Ensure that the transformer is completely isolated at both
HV & LV sides and that all non-current carrying conductors are earthed.
The IR values of windings to earth (and between windings) shall be measured for all tap
positions.

Between HV Winding and Earth use 5000V or 2500V Insulation Tester (Megger)

Principle Tap Value:____________________________________

Between HV and LV Winding use 5000V or 2500V Insulation Tester (Megger)

Principle Tap Value:____________________________________

Between LV Winding and Earth use 1000V or 500V Insulation Tester (Megger)

Value:______________________________________________

The IR values obtained should be similar to those indicated in the manufacturers’ test
reports and other records. Be aware that in humid conditions IR values obtained may be
lower due to condensation on the terminal bushings.
If IR values are very low (Minimum value is 1000ohm per volt service voltage), then it may
be necessary to filter the oil / dry-out the winding till the insulation reaches satisfactory
values.

Break-Down Voltage (BDV) Test

Procedure y/n

Oil samples should be carefully taken from the tank bottom and tested for BDV value.

BDV value of oil should be more than 50kV (rms) for 1 minute in standard test cell.

Value:______________________________________________

If the BDV value is very low and unacceptable (30kV (rms) or less for 1 minute) then it may
be necessary to dry-out & clean the oil until the insulation reaches satisfactory values.
Note: For very low IR values and low BDV values, it is recommended to contact WPS for a
suitable recovery procedure based on available facilities at site.
 23

CHECKLIST
Voltage Ratio Test
Procedure y/n

Apply 3-Phase, 433V/415V AC or a single phase 240V/230V AC supply on the HV side and
record the Voltage Ratio at all tap positions. This can be derived using a suitable precision
voltmeter connected to the LV side. A ratio meter, if available, can be used for a more
accurate measurement.

Tap 1 ratio:____________________________________

Tap 2 ratio:____________________________________

Tap 3 ratio:____________________________________

Tap 4 ratio:____________________________________

Tap 5 ratio:____________________________________

Tap 6 ratio:____________________________________

The Ratio values obtained should be similar to those indicated in the manufacturer’s test
report, which will have been furnished with the handing-over documents.

Winding Resistance (or continuity) Measurement Test

Procedure y/n
Winding Resistance of every phase of each winding should be measured using suitable DC
Resistive Bridge or similar. Alternatively check continuity of each winding.

HV U Value:____________________________________

HV V Value:____________________________________

HV W Value:___________________________________

LV u Value:____________________________________

LV v Value:____________________________________

LV w Value:____________________________________

Winding Resistance values obtained should be similar to those indicated in the

manufacturer’s test report, which will have been furnished with the handing-over
documents. NOTE: In order to achieve a result with some accuracy only measure when a
transformer is in a stable condition e.g. ambient temperature. Potential large errors can
occur when attempting to define an average coil temperature.
24

CHECKLIST
Marshalling Box Scheme Check
Procedure y/n
All the auxiliary wiring from the various accessories to the marshalling box shall be checked
against the marshalling box scheme drawing provided.
Operation of all the alarm / trip contacts should be checked by simulating the alarm or trip
condition, checking that the alarm or trip signal appears at the correct terminal at the
marshalling box.

Buchholz Relay Test

Procedure y/n
The Relay operation for alarm and trip contacts should be checked by injecting air through
the test petcock. The air injected into the relay will allow the alarm float / flap and trip float
/ flap to fall thus operating their respective switches.

Temperature Indicator Test

Procedure y/n

Indicator operation for alarm and trip contact shall be checked by manual stimulation.

OFF CIRCUIT Selector (OCS)

Procedure y/n
During maintenance the OCS is not separated from the transformer, so it is not necessary
to recheck the internal connections of tapping and internal mechanism.
Means of protecting the OCS from unauthorised operation is provided by using pad locking
arrangement at designated tap position.

Flash Test on Winding (On the request of the customer)

Procedure y/n

If a flash test is required then it must be performed at reduced voltages only, which is value
calculated by subtracting the service voltage from the original test voltage as tested as per
the manufacturer’s test certificate, halving the obtained value and then adding the service
voltage as explained in this example:
Service Voltage 11kV
Half of Difference Voltage
Recommended Test Voltage at site (17 / 2 = 8.5kV) + 11 =19.5kV
 25

5.3 Post-maintenance Recommendations

It is recommended that the transformer is initially energised at No-load only and is checked for any abnormalities for
the next 6 to 8 hours.

After switching on No-load, if the primary side circuit breaker is tripped, investigate the cause thoroughly and re-
energise the transformer only after ensuring that any fault is properly identified and cleared.

If satisfactory (transformer on No-Load) then apply load gradually and observe for any abnormalities for the next 6 to
8 hours.

If the transformer is satisfactory on-load up to 50% for the first 4-8 hours, shut-down the transformer and ensure
that all air-release plugs of tank, radiator, conservator, buchholz relay, bushings, etc., are free of air pockets which
might have developed during initial loading.

5.4 Transformer Life Cycle

Transformers are made from a mix of ferrous and non-ferrous metals which are widely recyclable, as is the insulating
medium. We recommend that end of life units are disposed of by means of recognised waste handlers / dismantler.
This product does not come under WEE regulations.

NOTE: Suitable financial value can be obtained, particularly for copper. Alternatively, aluminium may be used as a
winding conductor.

5.5 Warranty Conditions

The manufacturers warranty is provided subject to the following conditions being met:

• All warranty seals are intact and untampered with

• Recommendations given in this maintenance schedule are followed
• Proof of maintenance activities can be provided
• Any work external to the transformer needs to be carried out by a suitably qualified professional engineer
• Where this work is carried out unsupervised WPS reserves the right to declare the warranty void

6. contact details
If you need to contact us for any reason please use the following:

telephone : +44 (0)113 271 7588

email : info@wilsonpowersolutions.co.uk
address : Westland Works, Westland Square, Leeds, West Yorkshire, LS11 5SS
26

OUR VISION
To be a family company with
a conscience providing
innovative, sustainable energy
infrastructure solutions.

OUR MISSION
We are committed to growing our
business by continuing to deliver
customer driven, tailored solutions
and outstanding levels of service,
whilst investing in the development
of new and improved power
distribution products and services.
 27

7. ABOUT US
Wilson Power Solutions is based on
a unique customer and professional
approach that has been developed
over 70 years in the industry.
Today, Wilson Power Solutions is managed by the
third generation of the Wilson family who like their
business to remain agile and friendly. Dedicated to
helping customers find the best power distribution
solutions for their individual needs, we are
passionate about our expert knowledge and
committed to giving advice with our customers’
best interests at heart.

We treasure our heritage and know that our

hard-earned reputation for service excellence
and superior product performance has grown
out of 70 years of experience in the power
engineering sector.

THE BEST SOLUTION FOR YOUR POWER NEEDS

Recognising the importance of integrity and
reliability, we believe in building lasting partnerships
with our customers that are based on a unique
service based on technical knowledge, superior
product performance and mutual trust.

“
We believe in building
lasting partnerships
with our people, our
customers, suppliers
and our communities,
both locally and
internationally.
ERIKA WILSON MANAGING DIRECTOR

”
 Wilson Power Solutions Limited
Westland Works
Westland Square
Leeds LS11 5SS UK
T: +44 (0)113 271 7588
E: info@wilsonpowersolutions.co.uk

001/102017

WILSONPOWERSOLUTIONS.CO.uk