CAMTECH/E/10-11/Trg.-AT/1.

1
/

dsoy dk;Zky;hu mi;ksx gsrq

(For Official Use Only)

Hkkjr ljdkj GOVERNMENT OF INDIA

jsy ea=ky; MINISTRY OF RAILWAYS

vkWfDtyjh VklQkWjej ij Vsfuax iSdst

Training Package on Auxiliary Transformer
Transformer
y{; lewg % VhvkjMh vuqj{k.k deZpkjh
TARGET GROUP: TRD Maintenance Staff

dSeVsd@bZ@10&11@Vhvkjth&,Vh@110&11@Vhvkjth&,Vh@1-0
CAMTECH/ E/ 10-11/ Trg-AT/ 1.0

vxLr 2010
August 2010

egkjktiqj, Xokfy;j & 474 005

Maharajpur, GWALIOR - 474 005
Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

vkWfDtyjh VklQkWjej ij Vsfuax iSdst

Training Package on Auxiliary Transformer

xq.koRrk uhfr
jsyksa esa ;k=h vkSj eky ;krk;kr dh c<+rh ekx dks iwjk
djus ds fy, xq.koRrk ca/k .kkyh esa vuqla/kku]
fMtkbuksa vkSj ekudksa esa mRd`"Vrk rFkk lr~r lq/kkjksa ds
ek/;e ls lkafof/kd vkSj fu;ked vis{kkvksa dks iwjk djrs
gq, lqjf{kr] vk/kqfud vkSj fdQk;rh jsy kS|ksfxdh dk
fodkl djuk A
QUALITY POLICY
To develop safe, modern and cost
effective Railway Technology complying
with Statutory and Regulatory
requirements, through excellence in
Research, Designs and Standards and
Continual improvements in Quality
Management System to cater to growing
demand of passenger and freight traffic on
the railways.
August 2010

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

kDdFku
Vsuksa ds lqpk# ifjpkyu ds fy;s dyj ykbZV flXuy] dsfcy] dsfcy gV] ,lih]
,l,lih] yscy kWflax bR;kfn dks fo|qr dh vkiwrhZ djus esa vkWDthyjh VkalQkeZj cgqr
egRoiw.kZ Hkwfedk vnk djrk gSA blfy, bl midj.k ds mfpr vuqj{k.k dk lgh Kku cgqr
t:jh gSA
dSeVsd us vkWDthyjh VkalQkeZj ij ;g Vsfuax iSdst cuk;k gS ftlesa cukoV]
vuqj{k.k vuqlwfp;k] vksojgkWfyax fof/k] foQyrk,sa ,oa muds funku] d.Mhku ekWuhVfjax
bR;kfn fn, x;s gSaA bl Vsfuax iSdst esa ekWMy u Hkh fn, x;s gSaA
eq>s vkkk gS fd ;g Vsfuax iSdst VhvkjMh foHkkx esa gekjs vuqj{k.k deZpkfj;ksa ds
fy, mi;ksxh fl) gksxkA

dseVsd] Xokfy;j
fnukad % 27 vxLr 2010

Training Package on Auxiliary Transformer

,l?ky
,l- lhlh- fla?ky
dk;Zdkjh funskd

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

FOREWORD

Auxiliary Transformer plays very important role in smooth running of trains as it

provides electrical supply to colour light signals, cabins, cable huts, SPs, SSPs, level crossings
etc. Therefore knowledge of proper maintenance of this asset is essential.
CAMTECH has prepared this training package on Auxiliary Transformer which contains
construction, maintenance schedules, overhauling procedures, failures and their remedies,
condition monitoring etc. Model questions are also given in the training package.
I hope this training package will prove to be useful for the maintenance personnel
working in TRD department.

CAMTECH, Gwalior
Date : 27th August 2010

August 2010

S.C. Singhal
Executive Director

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

Hkwfedk
fo|qrhd`r [k.M+ esa dyj ykbZV flXuy midj.kksa] fLofpax LVskuksa vkSj VSDku lc LVskuksa
bR;kfn dks 240 oksYV] 50 gVZt] flaxy Qst fo|qr dh vkiwrhZ djus ds fy, vkWDthyjh VkalQkeZj dh
vko;drk gksrh gSA ;g dsfcu] LVsku] Cykd gV] vkj vkj vkbZ vkSj yscy kWflax xsV flXuy dks Hkh
lIykbZ nsrk gSA
dSeVsd }kjk vkWDthyjh VkalQkeZj ij ;g Vsfuax iSdst vuqj{k.k deZpkfj;ksa dks lgh vuqj{k.k ,oa
ejEer rduhdksa ls voxr djkus ds ms; ls rS;kj fd;k x;k gSA
;g Li"V fd;k tkrk gS fd ;g Vsfuax iSdst vkjMh,lvks ;k jsyos cksMZ ;k ,lh VSDku eSuqvy }kjk
fofuZfn"V fdlh Hkh fo/kku dks foLFkkfir ugha djrk A ;g Vsfuax iSdst dsoy ekxZnkZu gsrq gS ,oa ;g ,d
oS/kkfud nLrkost+ ugha gSA
eSa] dk;Z{ks= ds mu lHkh deZpkfj;ksa dk vkHkkjh gw ftUgksus bl Vsfuax iSdst dks cukus esa gekjh
lgk;rk dh A
rduhdh mUu;urk vkSj lh[kuk ,d lrr~ izfdz;k gSA vr% bl Vsfuax iSdst esa tksM+us@lq/kkjus ds
fy;s gesa fy[kus esa Lora= eglwl djsa A bl fnkk esa ge vkids ;ksxnku dh ljkguk djsaxsA

dseVsd ]Xokfy;j
fnukad % 27 vxLr 2010

Training Package on Auxiliary Transformer

ih;w"k xqIrk
la- funskd]
kd] fc/kqr

bZ&esy direlcamtech @gmail.com

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

PREFACE

Auxiliary Transformer in Electrified section is required for supplying 240 V, 50Hz

single phase supply for colour light signal equipment, switching stations and traction sub
stations etc. It also provides supply for cabins, stations, block-huts, RRIs and level crossings
with gate signals.
This training package on Auxiliary Transformer has been prepared by CAMTECH
with the objective of making our maintenance personnel aware of correct maintenance and
repair techniques.
It is clarified that this training package does not supersede any existing provisions
laid down by RDSO, Railway Board or AC traction manual. This training package is for
guidance only and it is not a statutory document.
I am sincerely thankful to all field personnel who helped us in preparing this training
package.
Technological up-gradation & learning is a continuous process. Please feel free to
write to us for any addition/ modification in this training package. We shall highly appreciate
your contribution in this direction.

CAMTECH, Gwalior
Date:27th August 2010

August 2010

Peeyoosh Gupta
Jt. Director Electrical
e - mail id : [email protected]

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

fo"k; lwph
e la[;k

fooj.k

kDdFku
Hkwfedk
fo"k; lwph
lakks/ku iphZ
1-0
2-0
3-0

4-0

5-0

6-0
7-0

Lrkouk
dk;Z fl)kar
fofHkUu {kerk ds vkW
Dthyjh Vkl
a QkeZjksa ds rduhd
vkWDthyjh
rduhdh vkdM+s
3-1 5 dsOgh, vkWDthyjh VkalQkeZj
3-2 10 dsOgh, vkWDthyjh VkalQkeZj
3-3 25 dsOgh, vkWDthyjh VkalQkeZj
3-4 100 dsOgh, vkWDthyjh VkalQkeZj
lajpuk
4-1 lkekU;
4-2 VkalQkeZj ds fofHkUu iqtsZ vkSj vo;o
vuqj{k.k
j{k.k
5-1 ekfld vuqj{k.k
5-2 =Sekfld vuqj{k.k
5-3 v)Zokf"kZd vuqj{k.k
5-4 okf"kZd vuqj{k.k
ihvks,p
6-1 vksoj gkWfyax fof/k
vkWDthyjh VkalQkeZj ds thou dks Hkkf
Hkkfor djus okys
okys dkjd
7-1 VkalQkeZj ds thou ij ueh dk Hkko
7-2 vkWDlhtu dk Hkko
7-3 Bksl vkq)rkvksa dk Hkko
7-4 okfuZk dk Hkko
7-5 okbfUMax ds <hys gksus dk Hkko

Training Package on Auxiliary Transformer

i`"< la[;k
iii
v
vii
xi
01
01
03
03
04
06
07
09
09
09
13
13
13
14
14
15
15
18
18
19
19
19
19

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

CONTENTS
Item No.

Description

Page No.

Foreword
Preface
Contents
Correction Slip

iv
vi
viii
xii

1.0

INTRODUCTION

01

2.0

WORKING PRINCIPLE

01

3.0

TECHNICAL DATA OF AUXILIARY TRANSFORMERS OF

4.0

5.0

6.0

DIFFERENT CAPACITY

03

3.1

5 kVA AUXILIARY TRANSFORMER

03

3.2

10 kVA AUXILIARY TRANSFORMER

04

3.3

25 kVA AUXILIARY TRANSFORMER

06

3.4

100 kVA AUXILIARY TRANSFORMER

07

CONSTRUCTION

09

4.1

GENERAL

09

4.2

DIFFERENT PARTS & COMPONENTS OF TRANSFORMER

09

MAINTENANCE

13

5.1

MONTHLY SCHEDULE

13

5.2

QUARTERLY SCHEDULE

13

5.3

HALF YEARLY SCHEDULE

14

5.4

YEARLY SCHEDULE

14

POH
6.1

7.0

August 2010

15
STEPS FOR OVERHAULING

15

FACTORS AFFECTING LIFE OF AUXILIARY TRANSFORMER

18

7.1

EFFECT OF MOISTURE ON TRANSFORMER LIFE

18

7.2

EFFECT OF OXYGEN

19

7.3

EFFECT OF SOLID IMPURITIES

19

7.4

EFFECT OF VARNISHES

19

7.5

EFFECT OF SLACKNESS OF WINDING

19

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

e la[;k
8-0

9-0
10-0

11-0

12-0

13-0

fooj.k
VkalQkeZj rsy
8-1 VkalQkeZj rsy dk ijh{k.k
8-2 ;ksx esa vk jgs Vkl
a QkeZj rsy ds ijh{k.kksa dk
vuq;ksx vkSj mudh O;k[;k
8-3 fuekZrk ds dkj[kkus esa ijh{k.k ds le; u;s rsy dh
egRoiw.kZ xq.k/kkfeZdrk,sa (REF: IS 335)
8-4 VkalQkeZj rsy dk ifj'kks/ku
8-5 rsy dk uewuk
foQyrkvksa ds dkj.k vkSj muds funku
9-1 lkekU; foQyrk,sa
dUMhku ekWuhVfjax
10-1 Qk;ns
10-2 foyhu xSl foys"k.k Mhth,
10-3 Mhth, ds ifj.kkeksa dk foys"k.k
10-4 LoLFk VkalQkeZj esa foyhu xSlksa dh vuqKs; lkanzrk
10-5 fofHkUu nks"k voLFkk esa xSl dk Lrj
D;k djsa vkSj D;k u djsa
11-1 D;k djsa
11-2 D;k u djsa
ekWMy u
12-1
fo"k;ijd dkj
12-2
fjDr LFkku Hkjsa
lakks/ku
lanZHk

Training Package on Auxiliary Transformer

i`"< la[;k
19
19
20
20
21
21
22
22
25
25
26
26
27
27
28
28
28
29
29
31
32
33

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

10

Item No.
8.0

10.0

19

8.1

TESTING OF TRANSFORMER OIL

19

8.2

APPLICATION AND INTERPRETATION OF TESTS ON

TRANSFORMER OIL IN SERVICE

20

SOME IMPORTANT CHARACTERISTICS OF NEW OIL

WHEN TESTED AT THE MANUFACTURERS
WORKS (REF: IS 335)

20

8.4

PURIFICATION OF TRANSFORMER OIL

21

8.5

OIL SAMPLING

21

FAILURES, CAUSES AND THEIR REMEDIES

22

9.1

22

12.0

13.0

August 2010

COMMON FAILURES

CONDITION MONITORING

25

10.1

ADVANTAGES

25

10.2

DISSOLVED GAS ANALYSIS (DGA)

26

10.3

ANALYSIS OF DGA RESULTS

26

10.4

PERMISSIBLE CONCENTRATION OF DISSOLVED

GASES IN THE OIL OF A HEALTHY TRANSFORMER

27

GAS LEVEL FOR DIFFERENT FAULT CONDITIONS

27

10.5

11.0

Page No.

TRANFORMER OIL

8.3

9.0

Description

DOS AND DONTS

28

11.1

DOS

28

11.2

DONTS

28

MODEL QUESTIONS

29

12.1

OBJECTIVE TYPE

29

12.2

FILL IN THE BLANKS

31

MODIFICATION

32

REFERENCES

33

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

11

lakks/ku ifpZ;ksa dk izdkku

bl iqfLrdk ds fy;s Hkfo"; esa izdkfkr gksus okyh lakks/ku ifpZ;ks dks fuEukuqlkj la[;kafdr fd;k
tk;sxk %
dseVsd@bZ@10&11@Vhvkjth&,Vh@1-0 lh] ,l@# XX fnukad --------tgkW XX lEcfU/kr lakks/ku iphZ dh ze la[;k gS 01 ls izkjEHk gksdj vkxs dh vksj A
izdkfkr lakks/ku ifpZ;kWa
lakks/ku iphZ
iphZ izdkku dh
dh la[;k
rkjh[k

lakksf/kr I`k"B la[;k

,oa en la[;k

Training Package on Auxiliary Transformer

fVIi.kh

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

12

ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be numbered as follows :
CAMTECH/E/10-11/Trg.-AT/1.0 C.S. # XX date--------Where XX is the serial number of the concerned correction slip (starting from 01 onwards).
CORRECTION SLIPS ISSUED
Sr.
No.

August 2010

Date of
issue

Page no. and

Item no.
modified

Remarks

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

1.0

Lrkouk@
Lrkouk@INTRODUCTION
Auxiliary Transformers in electrified sections are required for colour light signal
equipment for signal lights, switching stations and traction sub stations. Auxiliary
transformer provides 25kV/ 240V, 50Hz single phase supply for cabins, substations,
feeding and switching posts, stations, block-huts, RRIs and level crossings with gate
signals.
Auxiliary transformer is a static device and works as a step down transformer
which transforms power from one ac circuit to another ac circuit at the same frequency.
These circuits are conductively disjointed but magnetically coupled by a common time
varying magnetic field. It can raise or lower the voltage with a corresponding decrease or
increase in current.
The windings which form the electrical circuits must fulfill certain basic
requirements, particularly the di-electric, thermal and mechanical stresses imposed on it
during testing as well as in service and cater for over loads under adverse conditions.

2.0

dk;Z fl)kar@ WORKING PRINCIPLE

In general, working principle of a transformer can be expressed on the basis of law
of electromagnetic induction as following:
a.

When a conductor cuts the magnetic flux or magnetic flux cut the conductor, an
emf is induced in the conductor.

b.

The magnitude of this emf is proportional to the rate of change of flux.

LAMINATED CORE

PRIMARY

SECONDARY

When the primary winding is connected to an ac supply mains, current flows

through it. Since this winding links with an iron core, so current flowing through this
winding produces an alternating flux in the core. Since this flux is alternating and links
with the secondary winding also, therefore it induces an emf in the secondary winding.
The frequency of induced emf in secondary winding is the same as that of the flux or that
of the supply voltage.

Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

The induced emf in the secondary winding enables it to deliver current to an

external load connected across it. Thus the energy is transformed from primary winding to
the secondary winding by means of electro-magnetic induction.
The flux of the iron core links not only with the secondary winding but also with
the primary winding, so produces self-induced emf in the primary winding. This self
induced emf in the primary winding opposes the applied voltage and therefore sometimes
it is known as back emf. The induced emf in the primary winding limits the primary
current in the same way that back emf in a dc motor limits the armature current.

vkDthyjh VkalQkeZj dk js[kk fp=

Line Diagram of Auxiliary Transformer

1.1

2.2

PRIMARY 25kV

SECONDARY 240V

1.2

2.2

EARTH
I

1.1

2.1 (PHASE)

3
4
240 VOLTS

5
6
7
2.2 (NEUTRAL)
1.2
EARTH

Connections
5-4
4-6
6-3
3-7

August 2010

Tap No
1
2
3
4

Primary
26250 V
25000 V
23700 V
22500 V

Secondary
240 V
240 V
240 V
240 V

Ratio
109.375 105%
104.166 100%
98.75
95%
93.75
90%

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

3.0

fofHkUu {kerk ds vkW

Dthyjh VkalQkeZjksa ds rduhd
vkWDthyjh
rduhdh vkdM+
M+s@

TECHNICAL DATA
OF AUXILIARY TRANSFORMERS OF DIFFERENT CAPACITY
The technical details of different capacity auxiliary transformers used in TRD are as
following:

3.1

5 dsOgh, vkW
Dthyjh VkalQkeZj@5 kVA Auxiliary Transformer
vkWDthyjh

The rating and other particulars of the auxiliary transformer are as follows:
i.

Type

ii.

Rated voltage of primary winding 25 kV

iii.

Rated voltage of
winding
Rated current
a. Primary winding

iv.

v.

Double wound, single phase, oil immersed

natural air cooled and step down transformer
for outdoor installation.
secondary 240 Volt.

b. Secondary winding
Rated frequency

vi.
vii.

a.

0.2 A

b. 21 A
50 Hz 3%

Rated power
Insulation level of winding
a. Rated lightening impulse
withstand voltage peak
b. Rated short duration power
frequency withstand voltage
c. Rated induced over voltage
viii. Tapings

i. 5 kVA
Primary
a. 190 kV

ix.

Subtractive

Polarity

Training Package on Auxiliary Transformer

b. 70 kV rms

Secondary
3 kV rms

c. 80 kV rms
Off-circuit tap changer to give rated
secondary winding voltage for a primary
winding voltage variation of plus 5% to minus
10% in steps of 5%. Tapings may be provided
either on primary or on secondary winding.
All tapings are capable of carrying full load
current continuously.

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

x.

Temperature rise limits

The temperature rise over an ambient

temperature of 45C at rated load conditions
shall not exceed the value indicated below :a. Winding: 50C (measured by the resistance
method)
b. Insulating oil : 40C (measured by
thermometer)
c. Current carrying parts in air : 40C.
d. Hot spot temperature : not to exceed 115C.

xi.

Impedance voltage at rated 5%

current at 75C.

xii.

Type of cooling

xiii

Temperature class of insulation Class A for all the windings.

ONAN

xiv. Current density for primary & 2.5 A/mm2

secondary windings (max)
xv.

Maximum permissible losses

a. No load loss.
b. Load loss at 75C.

a.
b.

50 W
200 W

xvi. Minimum creep age distance i. 900 mm for 36 kV class.

of the porcelain housing.
ii. 90mm for 3.6 kV class.

3.2

10 dsOgh, vkW
Dthyjh VkalQkeZj@10 kVA Auxiliary Transformer
vkWDthyjh

i.

Type

ii.

Rated voltage
winding.

iii.

Rated voltage of secondary 240 Volt.

winding.

iv.

Rated current
a. Primary winding.
b. Secondary winding.

a. 0.4 A
b. 42 A

v.

Rated frequency

50 Hz 3%

vi.

Rated power

10 kVA

August 2010

Double wound, single phase, oil immersed

natural air cooled and step down transformer for
outdoor installation.
of

primary 25 kV

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

vii.

Insulation level of winding

a. Rated lightening impulse
withstand voltage peak.
b. Rated short duration power
frequency withstands voltage.
c. Rated induced over voltage.

Primary

Secondary

a. 190 kV

b. 70 kV rms

3 kV rms

c. 80 kV rms

viii.

Tapings

Off-circuit tap changer to give rated secondary

winding voltage for a primary winding voltage
variation of plus 5% to minus 10% in steps of
5%. Tapings may be provided either on
primary or on secondary winding. All tapings
are capable of carrying full load current
continuously.

ix.

Polarity

Subtractive

x.

Temperature rise limits.

The temperature rise over an ambient

temperature of 45C at rated load conditions
shall not exceed the value indicated below.
a. Winding: 50C (measured by the resistance
method).
b. Insulating oil: 40C (measured by
thermometer).
c. Current carrying parts in air: 40C.
d. Hot spot temperature: not to exceed 115C.

xi.

Impedance voltage
current at 75C.

xii.

Type of cooling.

ONAN

xiii

Temperature class of insulation.

Class A for all the windings.

xiv.

Current density for primary & 2.5 A/mm2

secondary windings (max).

xv.

Maximum permissible losses.

a. No load loss.

a.

60 W

b.

b.

300 W

at

Load loss at 75C.

rated 5%

xvi.

Minimum creep age distance of i. 900 mm for 36 kV class.

the porcelain housing
ii.90mm for 3.6 kV class.

xvii.

Mass of core & winding.

80 kg.

Mass of oil

98 kg.

Total mass

300 kg.

Volume of oil

110 lts.

Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

3.3

25 dsOgh, vkW
Dthyjh VkalQkeZj@25 kVA Auxiliary Transformer
vkWDthyjh

i.

Type

ii.

Rated voltage
winding.

iii.

Rated voltage
winding.

iv.

Rated current
a. Primary winding.
b. Secondary winding.

a. 1.0 A
b. 105 A

v.

Rated frequency

50 Hz 3%

vi.

Rated power

25 kVA

vii.

Insulation level of winding

a. Rated lightening impulse
withstand voltage peak.
b. Rated short duration power
frequency withstands voltage.
c. Rated induced over voltage.

Primary

Secondary

a. 190 kV

3 kV rms

viii.

Tapings

Off-circuit tap changer to give rated secondary

winding voltage for a primary winding voltage
variation of plus 5% to minus 10% in steps of
5%. Tapings may be provided either on primary
or on secondary winding. All tapings are
capable of carrying full load current
continuously.

ix.

Polarity

Subtractive

x.

Impedance voltage
current at 75C.

August 2010

Double wound, single phase, oil immersed

natural air cooled and step down transformer for
outdoor installation.
of

of

primary

Normal- 25 kV
Min - 19 kV
Max - 27.5 kV

secondary 240 Volt.

at

b. 70 kV rms
c. 80 kV rms

rated 5%

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

xi.

Temperature rise limits

The temperature rise over an ambient

temperature of 45C at rated load conditions
shall not exceed the value indicated below.
a. Winding: 50C (measured by the resistance
method).
b. Insulating oil: 40C (measured by
thermometer).
c. Current carrying parts in air: 40C.
d. Hot spot temperature- not to exceed:115C.

xii.

Type of cooling.

ONAN

xiii

Temperature class of insulation

Class A for all the windings.

xiv.

Current density for primary & 2.5 A/mm2

secondary windings (max.)

xv.

Maximum permissible losses

a. No load loss
b. Load loss at 75C.

xvi.

Minimum creep age distance of i. 900 mm for 36 kV class.

the porcelain housing
ii. 90 mm for 3.6 kV class.

xvii.

Mass of core & winding.

220 kg.

xviii. Total mass

3.4

a. 60 W
b. 300 W

515 kg.

100 dsOgh, vkW

Dthyjh Vkl
a QkeZj@100 kVA Auxiliary Transformer
vkWDthyjh

i.

Type

Double wound, single phase, oil immersed

natural air cooled and step down transformer
for outdoor installation.

ii.

Rated voltage of primary winding.

25 kV

iii.

Rated voltage
winding

iv.

Rated current
a. Primary winding.
b. Secondary winding.

a. 4.0 A
b. 416.66 A

v.

Rated frequency

50 Hz 3%

vi.

Rated power

100 kVA

of

Training Package on Auxiliary Transformer

secondary 240 Volt.

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

vii.

Insulation level of winding

a. Rated lightening impulse
withstand voltage peak.
b. Rated short duration power
frequency withstands voltage.
c. Rated induced over voltage.

Primary

Secondary

190 kV

70 kV rms

3 kV rms

80 kV rms

viii.

Tapings

Off-circuit tap changer to give rated secondary

winding voltage for a primary winding voltage
variation of plus 5% to minus 10% in steps of
5%. Tapings may be provided either on
primary or on secondary winding. All tapings
are capable of carrying full load current
continuously.

ix.

Polarity

Subtractive

x.

Temperature rise limits.

The temperature rise over an ambient

temperature of 45C at rated load conditions
shall not exceed the value indicated below :a. Winding: 50C (measured by the resistance
method).
b. Insulating oil: 40C (measured by
thermometer).
c. Current carrying parts in air: 40C.
d. Hot spot temperature: not to exceed 115C.

xi.

Impedance voltage at rated current 5 .19%

at 75C.

xii.

Type of cooling.

ONAN

xiii

Temperature class of insulation

Class A for all the windings.

xiv.

Current density for primary & 2.5 A/mm2

secondary windings (max).

xv.

Maximum permissible losses.

a. No load loss
b. Load loss at 75C.

a. 60 W
b. 300 W

xvi.

Minimum creep age distance of i. 900 mm for 36 kV class.

the porcelain housing.
ii. 90mm for 3.6 kV class.

xvii.

Mass of core & winding

360 kg.

Mass of oil

275 kg.

Total mass

880 kg.

Volume of oil

310 lts

August 2010

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

4.0

lajpuk@
puk@CONSTRUCTION

4.1

lkekU;@
lkekU;@General

Auxiliary Transformer transfers power from 25 kV OHE, single phase 50 Hz.

system to 240 volt system. It consists a HV winding and a LV winding. Both windings are
separated electrically but magnetically coupled. Primary and secondary windings are
wound on a common magnetic core. One end of primary winding is connected to 25 KV
system through a bushing and other end is connected to tank (Earth) through bushing and
link. Secondary terminals (both) are mounted on the tank through bushings. One terminal
is used as phase and other is earthed and used as neutral. Windings along with core are
immersed in insulating oil in a tank. For contraction and expansion of air in conservator
tank, there is a silica-gel breather. Oil level indicating glass window is provided on the
side of conservator tank. Two nos. of valves are provided on top & bottom side of tank for
centrifuging of oil or drainage. There is a tap changer on primary or on secondary side of
transfomer for suitable out-put voltage as OHE voltage is varying in nature.

4.2

VkalQkeZj ds fofHkUu iqtsZ vkSj vo;o@DIFFERENT PARTS & COMPONENTS OF

TRANSFORMER
Auxiliary Transformer consists of the following parts and components.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

4.2.1

Transformer tank
Core
Winding
HV bushings and LV bushings
Conservator
Breather
Tap changer
Radiator
Oil outlet valve
Oil inlet valve
Oil level indicator.

VkalQkeZj VSad@ Transformer Tank

The tank for the auxiliary transformer is constructed from
good commercial grade low carbon steel suitable for welding with a
single tier construction, so as to reduce welding to the minimum
while fabricating. The tank is adequately strengthen with lifting lugs
to permit hoisting of the transformer filled with oil through lifting
lugs by a crane or other means.

Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

10

4.2.2

dksj@

Core

The core is made of high permeability cold rolled grain

oriented/non aging electrical silicon steel laminations
conforming to IS: 3024.
The laminations used for stacking the core are free from
defects due to storage/atmospheric effects. Both sides of the
laminations are coated with suitable insulation capable of
withstanding stress relief annealing. In assembling the core, air
gaps are avoided.
The core is electrically connected to the tank to drain off
any electrostatic potential that might have been built up.
4.2.3

okbZUMx@
UMx@Windings
The primary and secondary windings are of
spiral/helical type. These windings are made of continuous
electrolytic copper conductor, paper insulated to class A
insulation.
Normally, no joint is used in the winding conductor. If a
joint becomes inescapable, it is brazed with high silver alloy
grade Ba, Cu Ag 6 conforming to IS: 2927 or electrically buttwelded.
The ratio of width to thickness of copper conductor used for winding is kept as
small as possible but shall not exceed 5:1 so as to avoid tilting of conductors when the
windings are subjected to axial and radial forces during short circuits.
The auxiliary transformer windings have following insulation levels.

a.

b.

c.

d.

August 2010

Primary

Secondary

Rated voltage between

winding and earth.

25 kV

240 V

Rated short duration power

frequency withstand voltage

70 kVrms

3 kVrms

Rated lightning impulse

withstand voltage

190 kV peak

Induced over voltage

withstand.

80 kV rms

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

4.2.4

,p oh vkSj ,y oh cqfka
kax@

11

HV & LV Bushings

The bushings comply with IS: 2099 and IS: 3347. The line terminal of the primary
winding is brought out through a 36 kV class bushing for connection to the overhead
equipment and the neutral terminal brought out through a 3.6 kV class bushing and
connected to the tank externally be means of a suitable tin coated copper link. The steel
enclosure of the AT is connected to earth during service.

The 3.6 kV bushing and connection of the link to the tank is covered by sheet steel
of not less than 2 mm thickness welded on to the tank and locked up with bolted cover as
shown in fig a.
The porcelain housing of both bushing are comply with the requirements as per IS:
5621 and are of a single piece construction i.e. there is no joint in the porcelain housing.
The shed profile has a lip at the extremities, but free from ribs on the underside so as to
avoid accumulation of dust, pollutants and permit easy cleaning. The bushing is free from
corona.
Primary and secondary bushing are provided with identical tinned copper stems of
20 mm diameter for 36 kV class bushing and 12 mm diameter for 3.6 kV class bushing.
The stem is threaded to metric size at suitable places as per IS: 1367as shown fig. b

Fig a Steel Cover

Fig-b Terminal

The bushings shall withstand the following test voltages.

Primary

Secondary

a.

Highest test voltage for equipment

36 kV rms

3.6 kV rms

b.

Rated short duration wet power frequency

withstand voltage

70 kV rms

10 kV rms

c.

Rated lightning impulse withstand voltage

190 kV peak

40 kV peak

d.

Minimum creepage distance

900 mm

90 mm

Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

12

4.2.5

dUt+
+josVj@
dUtjos
j@Conservator
It is a drum containing transformer oil and mounted at the
top of the transformer and connected to the main tank by a pipe.
As the volume of oil of transformer tank expands and contracts
according to heat produced, this expansion and contraction of oil
causes the level of the oil in conservator to rise and fall. The aim
of conservator is to
-

4.2.6

Maintains the oil level in tank

Provides space for the expansion of oil.

czhnj@
nj@Breather
It is attached to conservator tank and contains silica gel,
which prevents the moist air from entering into the tank during
contraction of oil. When oil is hot there is expansion and gas
passes to atmosphere through it. When oil is cooled, it contracts
and the air enters in it. It prevents transformer oil from moisture
contamination.

4.2.7

Vsi pasUtj@
tj@Tap changer
The tap changer is used for regulate the output voltage
manually according to line voltage. The taps of the transformer
can be changed by the tap changer manually.

4.2.8

jsfM,Vj
M,Vj@
Vj@Radiator
Radiator tubes or fins provide better and effective cooling
of transformer oil by increasing the surface area of the tank to the
atmosphere.

4.2.9

fudkl okYo@
okYo@Outlet Valve
It provides passage to drain the oil during overhauling or as
and when required oil sample for testing.

4.2.10

osk okYo@
okYo@Inlet Valve
It provides passage to pour the transformer oil in the tank
during purification or in case of shortage found in the tank.

August 2010

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

4.2.11 vkW
;y
vkW;y

13

ysoy ladsrd@
d@Oil level Indicator

It indicates level of insulating oil in the transformer tank.

It has markings on transparent sheet for maximum & minimum
levels.

5.0

vuqj{k.k@
{k.k@MAINTENANCE

5.1

ekfld vuqj{k.k@
{k.k@Monthly Schedule
S.No
Maintenance
1
Visual inspection of transformer.
2
Clean the transformer externally
conservator, bushing and tank.
3
Check the condition of silica gel
& oil in the cup of breather.
4
5
6
7
8

5.2

Observation
Any sign of oil leakage, over heating
By clean cotton cloth.

Silica gel reactivates/ replace if colour is

pink.
Top up the oil in cup if less
Check all connections of HT and Tighten if loosen
LT bushing terminals
Check oil level in conservator.
Top up with new oil of 60 kV BDV up to
mark, if required.
Visual check of D. O. fuse and Over heating, connections etc.
assembly.
Clean the AT enclosure and Neat and clean
remove the vegetation.
Check the condition of pole - Overheating of lugs, use proper rating fuse
mounted ICDP switch and its
and loose connections.
fuses.
- Use fuse wire 20 SWG for 34 Amp. and
22 SWG for 24 Amp.
Check caution board and anti Availability and its conditions
climbing device.

=Sekfld
ekfld vuqj{k.k@
{k.k@Quarterly Schedule
S.No. Work To Be Carried Out
1
Check all points stated carried out
in monthly schedule.
2
Check the condition of the D.O.
fuse barrel and fuse element.
3
Measure the arcing horn gap for HV
bushing.
4
Check condition of foundation.
5
Check structure bond and earth
connection.
6
Check any unusual sound of
equipment.

Training Package on Auxiliary Transformer

Observation

- Breakage, overheating
- Use proper size fuse element for AT,s
Split horn gap maintain 82.5mm
(minimum).
Any crack or damages
Tightness
soundless

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

14

5.3

5.4

v)Z Okkf"kZd vuqj{k.k@

{k.k@Half Yearly Schedule
S.No.

Work To Be Carried Out

Observation

Check all points stated carried

out in monthly and quarterly
schedule.

Check the BDV of oil

BDV minimum- 30 kV (with 2.5mm gap).

Measure Insulation Resistance

between.
a.
HV- Earth
b.
HV- LV
c.
LV- Earth

-200 M ohm. Minimum (use 2.5 kV megger)

-200 M ohm. Minimum (use 2.5 kV megger)
-2 M ohm minimum (use 500 V megger)

Check secondary voltage on Permissible limit.

each tap.
a.
No load
b.
Full load

Measure the earth resistance and Not more than 10 ohm.

check earthing connections.

okf"kZd vuqj{k.k@
{k.k@Yearly Schedule
S.No.

Work To Be Carried Out

Observation

Check all points stated carried out in

monthly, quarterly and half yearly
schedules.

Check winding continuity on all By mulltimeter

tapings.

Check taps changer for smooth

operation.

Check dissolves gas analysis (DGA) of - Gases should be in permissible limit.

transformer oil and polatisation index.
- Time index is 600sec / 60sec.

Check the acidity of transformer oil.

Conduct ratio test by applying AC Measure the voltage.

supply to HV winding and LV side
winding.

Painting to be done.

Check HT
connections.

August 2010

and

No obstruction during operation.

Maximum 0.5 mg KOH/gm.

If required.
LT

jumper

its Flash mark, loose connection and

overheating etc.

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

6.0

15

ihvks,p@
p@POH
Overhauling of a transformer is normally undertaken either if it is faulty or at the
end of 7 to 10 years of service. Overhauling (POH) of transformer can be done either in
repair shop or through trade.

6.1

vksoj gkW
fyax fof/k@Steps for Overhauling
gkWfya

6.1.1

lkekU; lQkbZ@General cleaning

First of all remove as much dirt as possible particularly around the transformer
tank, radiator, conservator, HV & LV bushing, neutral link block covers etc. Blow the dust
of transformer & radiator with compressed air.

6.1.2

ihvks,p
,p ds nk
nkSjku fd;s tkus okys dk;Z@Activities to be done during POH
The items which are required to be checked/ attended during overhauling are given
below:

6.1.3

a.

Record brief history of the equipment.

b.

Visual Inspection:

Check the complete tank for any deformation and crack.

Check HV & LV bushing for any cracks/chipped discs.

Check condition of silica gel container and silica gel.

Check the oil leakage from auxiliary transformer tank, oil pipes, flange
joints, conservator, drain plugs and vent plugs.

Check the thread condition of filter inlet and out let valves, drain plug and
breather socket.

Check condition of all gaskets/washers.

Check conservator tank, oil level indicator glass.

Check condition of arcing horn.

Note all the defects and deficiencies.

midj.k dks [kksyus ls igys

igys@Before opening of equipment
The following test to be carried out on transformer before opening of transformer.
a.

bUlqysku frjks/k@
k@

Insulation resistance

Check the insulation resistance of windings between .

a.
H V winding to earth by 2.5 kV megger.
b.
L V winding to earth by 500V megger.
c.
H V winding to L V winding by 2.5 kV megger.
b.

fujUrjrk ij
ijh{k.k@
{k.k@

Continuity Test

Check the continuity of the following windings with the help of multimeter.

Primary winding

Secondary windings
Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

16

c.

Vsi psUtj@
tj@

Tap changer

Check the condition and operation of tap changer at all tap positions.
d.

VkalQkeZj vkW;y dk chMhoh@

chMhoh@

BDV of transformer oil

Measure the BDV of transformer oil by automatic break down voltage kit.
e.

iksysjkbZtsku vuqikr@
kr@Polarization ratio
The test consists of applying dc high voltage 2500V, with the help of a
megger, continuously between winding and earth, and noting the insulation
resistance at the end of 10sec, 60sec.

f.

VkalQkeZj vkW;y dk Mhth,@

Mhth,@DGA of transformer oil
Dissolved gas analysis (DGA) of the oil of a transformer is a very useful
technique to assess the internal condition of the transformer.

g.

VkalQkeZj vkW;y dk ijh{k.k@Test on transformer oil

Measure the specific resistance (resistivity), water contents, dielectric
dissipation factor (Tan delta), flash point, neutralization value, sludge etc of
transformer oil.

h.

vuqikr ij
ijh{k.k@
{k.k@Ratio test
Conduct ratio test of auxiliary transformer.

i.

6.1.4

Before carrying out the work, the following works to be carried out.


Drain out the transformer oil from tank.


Disconnect all leads and remove tank top cover,
accessories, conservator, fitting etc.


Disconnect HV & LV bushings and store them
in a safe place.


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


Disconnect all the power cable connection from
secondary winding side bushing.

VkalQkeZj dks [kksyus ds ckn@

ckn@After opening the transformer
a.
b.
c.
d.
e.
f.
g.
h.

August 2010

Measure Insulation Resistance of winding.

Check all core support bolts for any cracks and replace them if required.
Check condition of core, winding and lamination.
Check for accumulation of water content/ sludge inside the tank.
Check earth connections.
Check condition of soldered joints.
Check the insulation paper for any damage and reinsulated if necessary.
Check the condition of tap changer contact tips at all tap positions.
Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

6.1.5

fd, tkus okys dk;ksZa dk fooj.k@

fooj.k@Details of Work to be Carried Out
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.

6.1.6

17

Clean winding and core with new filtered oil.

Tighten core bolts and other fasteners to secure the core and winding properly and
replace by new one if worn out.
Bake the winding and core by keeping in oven at a temperature of 60 C.
Observe daily improvement in IR values of winding.
Clean the tank thoroughly from inside and outside.
Check visually inside of tank for any flash mark, hit mark, damage etc.
Do the varnishing of the tank inside area with copal varnish.
Paint the tank from out side with battleship gray paint.
Check the oil drain cocks and change washers by a new one, tight and lock them.
Check the secondary terminal blocks fixing studs for tightness and they should be
oil leak proof.
Check the HV bushing fitting surface, it should be clean and plain.
Check the inlet and outlet valves for their proper working and check for oil
leakage.
Replace all gaskets, oil seal, O ring or other rubber/ neoprene items.
Tighten earth connection of the equipment.
Replace worn out contacts of tap changer.
Replace oil level indication glass, if required.

fQfVaxksa dk fujh{k.k@
fujh{k.k@Inspection of Fittings
a.

b.

c.

flyhdk tSy czhnj@

nj@Silica Gel Breather

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

Reactivate silica gel by heating in a shallow pan at a temperature of 150 C to

200 C for two or three hours until the crystals should have regained their
original blue tint.

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

Fill the fresh or reactivated silica gel crystals.

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

jsfM,Vj
M,Vj@
Vj@Radiator

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

Check radiator tubes and fins for any damage if applicable.

dut+
+josVj@
dutjos
j@Conservator

Clean conservator and glass indicator thoroughly.

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

Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

18

6.1.7

lw[kus ds ckn okbZfUM+ax dks yxkuk@

yxkuk@Reassemble after Drying Out the Winding
a
b.
c.
d.

6.1.8

Replace all gaskets with new one before assemble the equipment.
Fill the new filtered oil with 60 kV BDV in the tank.
Assemble the equipment and connect all winding connections of HV, LV
bushings, tap changer and HV earthing connection.
Check, clean and re-fit all accessories of the transformer.

vlsEcyh ds ckn vkW

Dthyjh VkalQkeZj dk ijh{k.k@Testing of Aux. Transformer
vkWDthyjh
After Assembling
Carry out the following tests on the auxiliary transformer after assembling of
winding and core in tank.
Meggering.
Continuity test.
Ratio test.
Voltage out put at different taps.
Magnetising current.

6.1.9

7.0

vfUre tkp@Final Checking

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

Check any unusual sound of equipment.

Check and ensure oil level in conservator, it should be maximum mark.

Release air from top screw of HV bushing.

Measure final IR values and compare with previous recorded values.

Measure BDV of oil and moisture content (ppm).

Check arcing horn gap.

vkWDthyjh VkalQkeZj ds thou dks Hkkf

Hkkfor djus okys dkjd
FACTORS AFFECTING LIFE OF AUXILIARY TRANSFORMER
Life of auxiliary transformer is affected by the following factors:
1.
Moisture
2.
Oxygen
3.
Solid Impurities
4.
Varnishes
5.
Slackness of winding

7.1

VkalQkeZj ds thou ij ueh dk Hkko@

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

August 2010

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

19

Check the colour of silica gel in each inspection and if found pink, replace or
reactivate crystals at 150 to 200 C. Test transformer oil for dielectric strength and water
content in maintenance schedule and carry out purification with high vacuum type
transformer oil filtration plant if required. Arrest the oil leakage if any.
7.2

vkW
Dlhtu dk Hkko@
vkWDlhtu
Hkko@Effect of Oxygen
Oxygen may be present inside the transformer due to air remaining in oil. The
oxygen reacts and decomposes the cellulose of insulation. This forms an organic acid
soluble in oil and sludge, which blocks the free circulation of the oil. The adverse effect of
oxygen, which may be aggravated by catalytic action between hot oil and bare copper,
increase the operating temperature.
Carry out oil purification with high vacuum type transformer oil purification plant
periodically to remove atmospheric gases (air) and sludge.

7.3

Bksl vkq)rkvks
rkvksa dk Hkko

Effect of Solid Impurities

The solid impurity present in the oil reduces its dielectric strength considerably. A
good remedy is to filter the oil periodically.
7.4

okfuZk dk Hkko@
Hkko@Effect of Varnishes
Some varnishes having oxidizing effect, react with transformer oil and precipitate
sludge on windings. Synthetic varnishes having acid inhibiting properties, generally delay
the natural formation of acid and sludge in the oil.

7.5

okbZfUMax ds <hys gksus dk Hkko

Hkko@
kko@Effect of Slackness of Winding
After few months of service, the transformer coils may suffer natural setting. This
may wear the conductor insulation at some places and lead to an inter-turn failure. The
coils may also get displaced under load conditions or momentary short circuit conditions,
which may result in electrical and magnetic unbalance and produce even greater
displacement. A good practice is, therefore to lift the core and windings to take up any
slackness present at the first major schedule.

8.0

VkalQkeZj rsy@TRANSFORMER OIL

The auxiliary transformers are supplied complete with insulating oil conforming to
IS: 335. The transformer is shipped with windings and core under oil. In addition, 10 per
cent extra oil is supplied in non returnable sealed steel drums. The insulating oil is
procured from the manufacturers approved by RDSO. The manufacturers are submit test
certificates as per IS: 335 for oil.
The characteristics of insulating oil before energizing the AT shall be conforming
to the parameters stipulated in IS: 1866.

8.1

VkalQkeZj rsy dk ijh{k.k@

ijh{k.k@Testing of Transformer Oil
In order to improve the performance and to prolong the life of the transformers,
EHV grade oil is used as per the requirement laid down by RDSO. Application and
interpretation of tests on transformer oil in service is given below.

Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

20

8.2

;ksx esa vk jgs VkalQkeZj rsy ds ifj{k.kksa dk vuq;ksx vkSj mudh O;k[;k@
Application and Interpretation of Tests on Transformer Oil in Service
Sr.

1.

7.

Electric strength
(Breakdown voltage)
Below72.5 kV
Specific resistance
(Resistivity)
Ohm/cm at 27C
Water content
Below 145 kV
Dielectric dissipation
factor, Tan delta at
90C.
Neutralization Value
mg KOH/g of oil.
Interfacial
tension
N/m at 27C.
Flash point in C

8.

Sludge

2.

3.
4.

5.
6.

8.3

Tests
Permissible
limits
Min. 30 kV

Above
10 x 1012
Max. 35
ppm
0.01or less

0.5 or Less

Value as per IS: 1866

To be reTo be replaced
conditioned
Less than the
If minimum value
is not attained after
value specified
reconditioning.
Between
Below 1 x 1012
12
1 x 10 to
10 x 1012
Greater than the
value specified.
Above
Above 0.1
0.01 to 0.1
Above 0.5

Above 1.0

0.02 or more

0.015 and above Below 0.015

but below 0.02
140 or more 125 and above Below 125
but below 140
Non-detectable Sediment
Perceptible sludge

fuekZrk ds dkj[kkus esa ijh{k.k ds le; u;s rsy dh egRoiw.kZ xq.k/kkfeZdrk;sa

(REF: IS 335) Important Characteristics of New Oil when Tested at the
Manufacturers Works (Ref: IS 335)
S.No Characteristics

Test Method
(Ref. to IS: or
Appendix)
A representative
sample in 100
mm thick layer
IS: 6792-1972

1.

Appearance

2.

Electric strength
(break down voltage)
a. New unfiltered oil.
b. After filtration.

3.

Resistivity at
IS: 6103-1971
a. 90C
b. 27C
Dielectric
dissipation IS: 6262-1971
factor (tan delta) at 90C
Water content
Appendix E of
IS: 335-1983
Interfacial tension at 27C IS: 6104-1971
Flash point
IS : 1448

4.
5.
6.
7.
August 2010

Requirements
The oil is clear and transparent
free from suspended matter or
sediments.
a. Min. 30 kV (rms)
b. If the above value is not
attained, the oil shall be
filtered, 60 kV(rms), RDSO's
requirement.
Min. 35 x 1012 Ohm-cm
1500 x 1012 Ohm-cm
Max. 0.002
Max. 50 ppm
Min. 0.04 N/m
Min. 140C

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

S.No Characteristics

8.4

21

Test Method
(Ref. to IS: or
Appendix)

Requirements

8.

Dissolved gas content

4 8%

9.

Neutralization value
a. Total acidity
b. Inorganic
acidity/alkalinity

a. Max. 0.03 mg KOH/g

b. Nil

IS: 1448
- do -

VkalQkeZj rsy dk ifj'kks

ifj'kks/ku@
ku@Purification of Transformer Oil
The object of oil purification is to remove all contaminants such as water, carbon
deposits, dirt, sludge, dissolved moisture and gases. The most important quality to be
preserved is the di-electric strength, which is affected by presence of moisture.
The insulating material used in the winding are hygroscopic in nature and therefore
moisture is absorbed through defective breathers, gasket and addition of untreated make
up oil. It is essential to remove these impurities in purifying the oil when the di-electric
strength goes below the permissible limits.
For purifying the transformer oil, machine conforming to RDSO's specification
no.ETI/PSI/103 may be used.

8.5

rsy dk uewuk@Oil Sampling

8.5.1

lkekU; lko/kkfu;k@General precautions

8.5.2

i.

Use always clean, dry and amber glass bottles as per IS: 6855-1973

ii.

Take oil sample preferably in dry weather and avoid any external contamination.

iii.

Oil sample shall be at least as warm as the ambient air.

uewuk ysus dh fof/k@

fof/k@Sampling procedure
i.

First drain at least one liter oil to eliminate any contaminations which is
accumulated in the drain cock.

ii.

Rinse the bottles with the oil being sampled.

iii.

After taking the sample, ensure that the cock is correctly closed.

iv.

Check that the label marking are correct and complete.

v.

Store samples in a dark place.

vi.

Ensure that the sampling is done by an experienced person.

vii.

Ensure that each of sampling bottle is filled up to 95 to 98 percent of its capacity.

Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

22

9.0

foQyrkvksa ds dkj.k vkSj muds funku@

funku@CAUSES OF FAILURES AND THEIR
REMEDIES

9.1

lkekU; foQyrk,sa@Common Failures

Some of the common failures/ defects occurred in auxiliary transformer are as under:

9.1.1

Oil leakage

Low BDV

Bushing failure

Winding failures

Excessive overheating of oil

Low IR value

Humming sound

rsy dk fjlko@
fjlko@Oil leakage
Location
From screw
joints

Possible causes
Foreign material in threads
Poor threads
Improper assembly

Remedial action
Remove the foreign material.
Check the threads & replace if
required.
Ensure proper assembly.

From gasket
joints

Insufficient or uneven
Tight gasket joints uniformly.
compression.
Improper preparation of
Provide proper gaskets.
gaskets and gasket surfaces.
Old gaskets
Provide new gaskets.

From weld
joints

Shipping strains, imperfect

weld.

Repair welds following proper

procedure.

From
couplings &
their joints

Cracks in couplings.

Replace couplings and secure the

pipe lines near couplings
properly.
Make proper coupling joints and
tight the screws.

Defective coupling joints.

From drain
plugs.

August 2010

Defective thread portion.

Defective oil seal.

Check the threaded portion.

Replace the oil seal and tight the
drain plug.

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

9.1.2

fuEu chMhoh@
chMhoh@Low BDV
Type of failure
Low BDV

9.1.3

23

Possible causes

Moisture contamination in Reactivate silica gel crystals or

transformer oil due to inactive replace them. Purify the transformer
silica gel (pink colour).
oil to restore dielectric strength.
Leaks
around
cover
accessories, breathing air
from leaks.

Attend leaks, regasket if necessary.

Purify the transformer oil to restore
dielectric strength.

Humid atmosphere in rainy

season.

Purify the transformer oil to restore

dielectric strength and check the
BDV & water content.

Ckqfkax foQyrk,sa@Bushing Failure

Types of failure
H V Bushing flash over

H V Bushing porcelain
insulator petticoat
broken / cracked.

9.1.4

Remedial action

Possible causes
-

Lightening discharge
or over voltage

Arcing horn gap is

less.

Dirty bushing.

External hitting.

Remedial action

It may be a break in the

turns or end lead, flash
marks on the end coil and
earthed parts close to it.
Measure split type arcing
horn gap minimum 82.5
mm.
Bird electrocuted
Ensure cleaning of porcelain
bushing
during
each
inspection.
Ensure proper cleaning and
visual checking of porcelain
bushing
during
each
inspection.

okbZfUMa
UMax foQyrk,sa@Winding Failures
Types of failure
Primary winding lead
open circuited / earthed.

Possible causes
Short circuit due to
overload.

Remedial action
Check the winding in one or all
phases would show signs of
overheating and charring.

Bulging and inter turn Coils shrink and in Investigate for over loading and
short, inter layer short or between
insulation take corrective action accordingly.
inter coils short.
failure.
Shorting between LV
and HV coils.

Insulation failure.

Training Package on Auxiliary Transformer

During manufacturing/ rewinding

of the transformer, the coils should
be pressed down, heated and
cooled repeatedly until the coil
height stabilizes.
August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

24

Types of failure

Possible causes

Remedial action

Flash mark on the core Dead short- circuit - Nomex paper insulation sheet
and support.
due to lateral or
should be provided between
displacement of the
H.V. & L.V. coils so as to
coil.
strengthen the insulation level.
Ensure that this insulation
sheet does not cause any
obstruction in the passage of
oil flow.
- Replace the transformer and
- Winding loose on
core to be lifted for thoroughly
the core.
checking and take corrective
action accordingly.
- Repair the winding if possible
9.1.5

VkalQkeZj dk vR;kf/kd xeZ gksuk@

k@Excessive overheating of transformer
Type of failure
Temperature rise of
transformer oil.

9.1.6

Possible causes

Remedial action

Replace the transformer and

core to be lifted for thoroughly
checking. Take corrective
action
according
to
observations and oil test
report.

Low oil level in

conservator.

Check the oil level in

conservator and top up if
required.

Slugged oil.

Carry out purification of oil to

remove sludge.

- Any internal fault

such as short circuited
core, core bolts/
clamps insulation
failure etc.

fuEu vkbZvkj eku@Low IR value

Type of failure
Low IR value

August 2010

Possible causes

Remedial action

Moisture in oil.

Purify the oil with high vacuum

type oil purification plant and test
the oil for electrical strength and
water content.

Insulation
failure
between winding and
core.

Replace the transformer. Lift the

active part and check the winding
thoroughly for insulation damage
and
take
corrective
action
accordingly.

Internal
leads
damage.

connection
insulation

Check the internal connection

leads by lifting the active part and
re-tape insulation paper of
damaged portion.
Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

9.1.7

25

fHkufHkukgV dh vkokt@
vkokt@Humming sound
Type of failure
Humming sound

Possible causes

Remedial action

Loose core

Lift the active part and tight all the

pressure bolts and clamping bolts.

Winding loose due to

shrinkage of coils.

During manufacturing/ rewinding

of the transformer, the coils should
be pressed down, heated and
cooled repeatedly until the coil
height stabilizes.
The winding pressure bolts and
core clamping bolts should be
tightened during the first POH
after commissioning to take care of
shrinkage.

10.0

dUMhku ekWuhVjhax@CONDITION MONITORING

10.1

Qk;ns@Advantages
Condition Monitoring of Auxiliary Transformer involves monitoring of certain
parameters. Maintenance activities can be decided and carried out based on the
prescribed values of these parameters.
Normally, any equipment is maintained in three ways namely:
a) Routine Maintenance
b) Periodic Maintenance
c) Condition based maintenance
In Routine maintenance, activities are involved which are essential for day to day
working like checking of Oil level, colour of silica gel in breather, abnormal sound, oil
leakage, etc.
In Periodic maintenance, activities involved are those which ensure the working of
the transformer over a long period such as oil testing, IR measurement of the windings
etc.
It is established that over maintenance of any equipment leads to more number of
failures. Therefore the trend should be to minimise the maintenance which can be
achieved through Condition based monitoring.
A transformer never fails all of a sudden except due to short circuiting or
lightening surges. Normally fault is developed gradually and may lead to its failure if not
detected in incipient stage.
Dissolved gas analysis is very powerful tool to monitor the health of transformer
during service.

Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

26

foyhu xSl foys"k.kMhth,

k.kMhth,@
Mhth,@

10.2

Dissolved Gas Analysis (DGA)

The transformer oil acts as a coolant and insulating medium in the transformer. It
absorbs heat from the core and dissipates it to atmosphere. Also it insulates various parts
of the transformer which are at different potentials. The oil is possess the properties as
specified in IS: 335.
Condition of the oil indicates the health of the transformer. If the deviation in the
properties of the oil takes place, cause for this can be found out and necessary measures
can be taken accordingly. Dissolved gas analysis is very useful tool to achieve this. The
DGA has following advantages:

It assesses the internal condition of the transformer.

The knowledge of solubility of Hydro-carbons and fixed gases at different

temperatures in the oil helps to dissolved gas analysis.

The absolute concentration of fault gas indicates status of insulation whereas

relative concentration provides a clue to the type of the fault.
Formation of gases takes place in oil filled transformer due to following reasons.

Oxidation

Vaporisation

Insulation decomposition

Oil Breakdown

Electrolytic action

For DGA generally Rogers Method is used which analyses proportion of one gas
with respect to other gas. The gases involved are
i) Methane (CH4) and
Ethane (C2H6)
ii) Ethylene (C2H4)
iii) Acetylene (C2H2)
iv) Hydrogen (H2)
v) Carbon di-oxide (CO2)
vi) Carbon Mono oxide (CO)

- at 1200 C
- at 1500 C
- at very high temp

Guide lines for condition monitoring of transformer by DGA technique are

indicated in table 2.04 of ACTM Vol.II (Part I)
10.3

Mhth, ds ifj.kkeksa dk foys"k.k@

k.k@Analysis of DGA Results

If methane/hydrogen ratio is 1, slight over heating below 1500 C.

If methane/hydrogen ratio is 1 and ethane to methane is 1, overheating between 1500

- 2000 C.

If ethane to methane ratio is 1, overheating is between 2000C 300 0C.

If ethylene to ethane ratio is 1, normal conductor over heating.

August 2010

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

27

If methane to hydrogen and ethylene to ethane ratio are 1, circulating currents and
overheated of joints.

If acetylene to ethylene is 1, flash over without power flow current.

If ethane to methane and acetylene to ethylene are 1, Tap changer selector breaking
current.

If Ethylene to Ethane and Acetylene to Ethylene are 1, Arc with power flow through
or persistent arcing.
Note:
i) Ratios < 1.0 are designated as 0.
ii) Ratios > 1.0 are designated as 1.

10.4

LoLFk VkalQkeZj esa foyhu xSlksa dh vuqKs; lkUnzrk@Permissible Concentration

of Dissolved Gases in the Oil of a Healthy Transformer

10.5

Gas

Less than 4 years in

service (ppm)

4 - 10 years
(ppm)

More than 10 years

(ppm)

H2

100 - 150

200 - 300

200 - 300

CO2

3000 - 3500

4000 - 5000

9000 - 12000

CO

200 - 300

400 - 500

600 - 700

CH4

50 - 70

100 - 150

200 - 300

C2H6

100 - 150

150 - 200

200 - 400

C2H4

30 - 50

100 - 150

800 - 1000

C2H2

20 - 30

30 - 50

200 - 150

fofHkUu nks"k voLFkk esa xSl dk Lrj lHkh lkUn

lkUnzrk ihih,e esa@

Gas Level for

Different Fault Conditions (All Concentration are in PPM)

Hydrogen
(H2)

Methane
CH4

Ethane
C2H6

Arcing

500 - 1000

20-130

10-30

10-30

40-100

3000-4000

Partial
Discharge

500 - 1000

20-130

10-30

10-30

10-15

3000-4000

Hot spot

20-150

10-30

10-30

150-200

10-15

3000-4000

Gradual
Overheating

20-150

10-30

150-200

10-30

10-30

3000-4000

Gases
Fault

Training Package on Auxiliary Transformer

Ethylene Acetylen
C2H4
C2H2

Carbon dioxide
CO2

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

28

11.0

D;k djsa vkSj D;k u djsa@

11.1

D;k djsa@Dos

11.2

DOS AND DONTS

1.

Replace DO fuse periodically.

2.

Always use transformer oil procured from RDSO approved suppliers.

3.

Check silica gel regularly.

4.

Examine the bushings for dirt deposit, coating and clean them periodically.

5.

Attend any type of oil leakage at the earliest possible.

6.

Clean conservator thoroughly before refilling.

7.

Ensure periodic testing of transformer oil.

8.

Maintain record of transformer and oil, transformer wise for future reference.

9.

Check DO assembly barrel spring tension.

10.

Always use proper size lugs in cable for connections.

11.

Use proper rating of fuses on primary and secondary side.

12.

Use silica gel breather minimum capacity of 250 grams at least.

13.

Use motorised megger to measure IR values.

D;k u djsa@Donts
1.

Dont use under capacity pulley and tirfor for unloading

2.

Dont leave any loose connection.

3.

Dont meddle with protection system.

4.

Dont allow conservator oil level to fall below (minimum oil level) 1/3 level.

5.

Dont over tight the nuts & bolts to stop any leakage.

6.

Dont use fuses higher than the prescribed ratings.

7.

Dont tamper with earthing connections.

8.

Dont keep the breather pipe open or exposed.

9.

Dont re-energize the faulty transformer unless the oil test report including DGA is
satisfactory.

10.

Dont impinge hot oil jet on the transformer windings for cleaning.

11.

Dont use reclaimed oil in transformer.

12.

Dont mix old & new transformer oils.

13.

Dont energise the transformer without conducting commissioning checks.

14.

Dont over load the transformer.

15.

Dont use cotton waste for cleaning any inside part of transformer the bushing.

August 2010

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

12.0

ekWMy u@
u@MODEL QUESTIONS

12.1

fo"k;ijd dkj@
dkj@Objective Type
1.

29

Before starting work on faulty circuit it should be ensured that

a.
The faulty circuit has been isolated from power supply and earthed.
b.
The worker is capable to do the work.
c.
The connections are not approachable.
d.
None of the above.

2.

One can protect himself from electric shock by wearing hand gloves of good.
a. Conducting material
b. Insulating material
c. Semiconductor material
d. Any of the above.

3.

Which of the following are safety precautions?

a. Dont touch live wire or equipment with bare hands.
b. Before switching on DO fuse, see no one is working on Auxiliary
Transformer.
c. Use insulated material hand gloves.
d. All of the above.

4.

Which material is recommended as fire extinguisher in electrical cases?

a. Carbon tetra chloride
b. Carbon di- oxide
c. Sulphur hexafluoride
d. Any of the above.

5.

The BDV of Auxiliary Transformer oil minimum should be.

a. 20kV
b. 30kV
c. 40kV
d. 50kV

6.

The colour of moisturized silica gel is

a. Pink
b. Blue
c. Yellow
d. Green

7.

The material filled in breather of transformer is

a. Silica gel
b. Sulphuric acid
c. SF6
d. Mineral oil

Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

30

8.

The protective device to internal fault in a Auxiliary Transformer is

a. Thermal relay
b. Bucholz
c .Lead
d. None of the above

9.

Which of the following is not the function of Auxiliary Transformer oil

a. Cooling of winding and core.
b. Providing additional insulation
c. Media for arc quenching
d. Provides inducting coupling

10.

Transformer oil should be free from

a. Odor
b. Gases
c. Temperature
d. Moisture

11.

The short circuit test of a transformer gives

a. Copper loss at full load
b. Copper loss at half load
c. Iron loss at any load.
d. Sum of iron loss and copper loss.

12.

The type of oil, which is suitable as transformer oil is

a. Crude oil
b. Organic oil
c. Mineral oil
d. Animal oil

13.

Auxiliary Transformer is an example of

a. Current transformer
b. Potential transformer
c. Auto transformer
d. Distribution transformer

14.

The colour of fresh transformer oil is

a. Pale yellow
b. Dark brown
c. Blue
d. Colourless

15.

The purpose of conservator tank in a transformer is to

a. Monitor oil level
b. Top up the oil
c. Both a & b above
d. None of the above

August 2010

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

12.2

31

fjDr LFkku Hkjsa@Fill in the Blanks

1.

Transformer is a .device

2.

Auxiliary transformer has.windings

3.

An emf induced in a coil due to variation of flux in another coil is called

4.

The coils of a transformer are wound on a core of .material

5.

Ingress of moisture is prevented by means of .

6.

The breather is attached to and contains

7.

Pink colour of silica gel indicates..

8.

The colour of transformer oil become dark brown, it indicates presence of

9.

Operating vacuum of transformer oil purification plant should be .

10.

DGA stands for ..

11.

DO fuse element rating of 10 kVA auxiliary transformer is

12.

DO fuse element rating of 100 kVA auxiliary transformer is

Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

32

13.0

lakks/ku@
ku@MODIFICATION
Arrangement of additional arching horn fixed to 9 tonne insulator as per RDSOs
Drg No. TI/SK/PSI/ARCHON/RDSO/00001/08/0 has been issued.

5
50
200mm

165mm

10mm

20mm Bolt with flat washer

18mm Single Clevis

Double strap with

20mm GSM pin

August 2010

20

MS flat 50 x 6 mm

10
20mm bolt with flat
washer on both side

SCHEMATIC ARRANGEMENT OF ADDITION ARCING HORN

FIXED TO 9 - TONNE INSULATOR

A schematic arrangement of additional arching horn fixed to 9 tonne insulator

shown in below.

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

33

lanZHk
1- ,lh VSDku vuqj{k.k ,oa ifjpkyu eSuqvy okWY;we

II

ikVZ I 1994 A

2- vkWDthyjh VkalQkeZj ij vkjMh,lvks }kjk tkjh LislhQhdsku la- bZVhvkbZ@ih,lvkbZ@15 08@2003

,oa bZVhvkbZ@ih,lvkbZ@15, 07@82 A
3- fofHkUu dk;Z{ks=ksa dk v/;;u ,oa ogk ls ,d= lkexzh A
4- bjdSeVsd Xokfy;j esa fnukad 06 vxLr 2010 dks vk;ksftr lsehukj esa fofHkUu jsyksa ls vk;s gq;s
izfrfuf/k;ksa }kjk fn;s x;s lq{kkoA

REFERENCES
1. Manual of AC Traction Maintenance and Operation Volume II (Part I).1994
2. RDSO specification No. ETI/PSI/15 (08/2003) & ETI/PSI/15A (7/82) on Auxiliary Transformer.
3. Study and collection of literature from field.
4. Suggestions recieved during the seminar held at CAMTECH on date 06th august 2010 on
Training Package on Auxiliary Transformer.

Training Package on Auxiliary Transformer

August 2010

CAMTECH/E/10-11/Trg.-AT/1.0

34

gekjk mn~ns;
;
vuqj{k.k izkS|ksfxdh vkSj dk;Ziz.kkyh dk mUu;u
djuk rFkk mRikndrk vkSj jsyos dh ifjlEifRr
,oa tukfDr ds fu"iknu esa lq/kkj djuk ftlls
vUrfoZ"k;ksa esa fooluh;rk] miyC/krk] mi;ksfxrk
vkSj n{krk izkIr dh tk ldsA
;fn vki bl lanHkZ esa dksbZ fopkj vkSj foks"k lq>ko nsuk pkgrs
gksa rks d`Ik;k gesa bl irs ij fy[ksaA
lEidZ lw=

funskd ( fo|qr )

Ik=kpkj dk irk

Hkkjrh; jsy
mPp vuqj{k.k izkS|ksfxdh dsUnz]
egkjktiqj] Xokfy;j e- izfiudksM 474 005

Qksu

0751&2470803
0751&2470740

QSDl

0751&2470841

bZ&esy

[email protected]

August 2010

Training Package on Auxiliary Transformer

CAMTECH/E/10-11/Trg.-AT/1.0

35

OUR OBJECTIVE

To upgrade maintenance technologies

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

If you have any suggestions and any specific Comments

please write to us.
Contact person

Director (Elect.)

Postal Address

Indian railways
Centre for Advanced
Maintenance technology,
Maharajpur, Gwalior.
Pin code 474 005

Phone

0751 2470740
0751 2470803

Fax

0751 2470841

E- mail

[email protected]

Training Package on Auxiliary Transformer

August 2010