Doc. No. D-5-02-XX-02-00 Rev.

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ACCEPTABLE / PERMISSIBLE LIMITS FOR TRANSFORMERS & REACTORS

ACCEPTABLE / PERMISSIBLE LIMITS FOR TRANSFORMERS & REACTORS

A. Permissible Limits for parameters of tests to be carried out at Substation

SR EQUIPMENT / TEST DATA PERMISSIBLE LIMITS REFERENCE

NO
1. Capacitance for Bushings Within -5 % to +10 % Variation of previous test result POWERGRID Doc. No.: D-
Main capacitance (C1) 2-03-XX-01-01 Rev.01

2. Tan Delta for Bushing at 20ºC Less than 0.007 IEC – 60137 ed.2003
3. Contact Resistance of Bushing 10 Micro-Ohm /Connector POWERGRID Doc. No.: D-
2-01-03-01-01 Rev.01
4. Tan Delta for Windings at 20 ºC Less than 0.007 IEEE/C57.12.90.1999
5. Rate of Rise of Tan Delta (Bushing & 0.001 Per year (Max.) POWERGRID Doc. No.: D-
Winding) 2-03-XX-01-01 Rev.01
6. Magnetizing current Test (Excitation If the excitation current is less than 50 milli-amperes (mA), the POWERGRID Doc. No.: D-
Current Test) difference between the two higher currents should be less than 2-03-XX-01-01 Rev.01
10%. If the excitation current is more than 50 mA, the difference
should be less than 5%.
An agreement to within 25% of the measured exciting current with
the previous test is usually considered satisfactory. In general, if
there is an internal problem, these differences will be greater
(more than 50 times).

7. Magnetic Balance Test (Single Phase) Value of supply voltage (230 V AC) in one phase is equal to sum POWERGRID Doc. No.: D-
voltage induced in other two phases. When supply voltage 2-03-XX-01-01 Rev.01
applied in middle limb, voltage induced in outer limbs should
equal and roughly half of the supply voltage.
Zero voltage or very negligible voltage induced in the other two
windings should be investigated

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ACCEPTABLE / PERMISSIBLE LIMITS FOR TRANSFORMERS & REACTORS

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NO
Magnetic Balance Test (Continued) Normally, the voltage induced in the center phase shall be 50 to 90% of
the applied voltage. However, when the center phase is excited then
the voltage induced in the outer phases shall be 30 to 70% of the
applied voltage

8. DC Winding resistance (Resistance to be ± 5% variation between phases or from Factory test results POWERGRID Doc. No.: D-
converted to 75 ºC) 2-03-XX-01-01 Rev.01

9. Voltage Ratio of Transformer (All Taps) Within ± 0.5% variation from specified values or Factory test results POWERGRID Doc. No.: D-
2-03-XX-01-01 Rev.01
Trend of voltage ratio values with reference to the ratio values
measured during the commissioning tests may also be considered

10. INSULATION VALUE ( THUMB RULE/ Min insulation Values for one minute insulation resistance POWERGRID Doc. No.: D-
EMPIRICAL FORMULA) measurements for transformers may be determined by using the 2-03-XX-01-01 Rev.01
following empirical formula:
R = CE / √KVA Where
R = Insulation resistance, in MΩ
C = 1.5 for oil-filled transformers at 20°C, assuming that the
transformer’s insulating oil is dry, acid free, and sludge free = 30.0 for
un-tanked oil-impregnated transformers
E = Voltage rating, in V, of one of the single-phase windings( Ph-to-Ph
for delta connected and ph-to-neutral for wye connected transformers)
KVA = Rated capacity of the winding under test (If the winding under
test is three-phase and the three individual windings are being
tested as one, the rated capacity of three-phase winding is used

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ACCEPTABLE / PERMISSIBLE LIMITS FOR TRANSFORMERS & REACTORS

SR EQUIPMENT / TEST DATA PERMISSIBLE LIMITS REFERENCE

NO
IR Value of Winding Min Rated Voltage class Min desired IR value POWERGRID Doc. No.: D-
of winding at 1 minute at 30 °C 2-03-XX-01-01 Rev.01
(Mega ohm)
11kV 300

33kV 400

66kV & above 500

11. Polarization Index Polarization Index Insulation Condition POWERGRID Doc. No.: D-
Less than 1 Dangerous 2-03-XX-01-01 Rev.01
(Ratio of IR values at 10 min to 1 min)
1.0-1.1 Poor
1.1-1.25 Questionable
1.25-2.0 Fair
2.0 -4.0 Good
Above 4.0 Excellent
12. CORE INSULATION TEST Min 1000 K Ohms at 2.0 kV (Transformer) / 3.5 kV DC(Reactors) for 1 min POWERGRID Doc. No.: D-
2-03-XX-01-01 Rev.01
(Between CL and CC + G with tank
grounded)

13. Transformer/ Reactor Neutral Resistance Below 1 ohm POWERGRID SPECN.

Value C/ENGG/SPEC/SR Rev.
02
14. Turret/ Neutral CT Ratio Errors ± 3% IS – 2705 Part2- 2nd Ed.-
1992
15. Vibration Level for Reactors 200 Microns (Peak to Peak) POWERGRID SPECN.
C/ENGG/SPEC/SR Rev.
60 Microns (Average)
02

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ACCEPTABLE / PERMISSIBLE LIMITS FOR TRANSFORMERS & REACTORS

B. Permissible limits for parameters of tests to be carried out at RTL/STL/ Oil Laboratories (CIOTL/IOTL)

SR EQUIPMENT / TEST DATA PERMISSIBLE LIMITS REFERENCE

NO
1. Specification for uninhibited mineral insulating oil-new/ unused before filling in transformer
(a) Appearance Clear & transparent and free from suspended IS 335 – 1993
matter or sediments
(b) Density at 29.5 ° C, 0.89 g / cm3 (Max.) IS 335 – 1993
(c) Kinematic Viscosity at 27 ° C 27 cSt (Max.) IS 335 – 1993
at 40 ° C, Max under consideration
(d) Interfacial Tension (IFT) at 27° C 0.04 N/m (Min.) IS 335 – 1993
(e) Flash point, Pensky Marten (Closed) 140 ° C (Min.) IS 335 – 1993
(f) Pour point - 6 ° C (Max.) IS 335 – 1993
(g) Acidity (Neutralisation Value)
(i) Total Acidity 0.03 mg KOH / g (Max.) IS 335 – 1993
(ii) Inorganic acidity/ Alkalinity Nil IS 335 – 1993
(h) Corrosive Sulphur Non – Corrosive IS 335 – 1993
(i) Di-Electric Strength (Breakdown Voltage)
(i) New unfiltered oil 30 KV , rms (Min.) IS 335 – 1993
(ii) After filtration 60 KV , rms (Min.) IS 335 – 1993
(j) Dielectric Dissipation Factor (Tan δ) DDF at 90°C 0.002 (Max.) IS 335 – 1993
(k) Specific Resistance (Resistivity)
(i) at 90 ° C 35*1012 Ω-cm (Min.) IS 335 – 1993
(ii) at 27 ° C 1500*1012 Ω-cm (Min.) IS 335 – 1993
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ACCEPTABLE / PERMISSIBLE LIMITS FOR TRANSFORMERS & REACTORS

SR EQUIPMENT / TEST DATA PERMISSIBLE LIMITS REFERENCE

NO
(l) Oxidation Stability
(i) Neutralization Value after Oxidation 0.40 mg KOH / g (Max.) IS 335 – 1993
(ii) Total sludge after Oxidation 0.1 % by weight (Max.) IS 335 – 1993
(m) Ageing characteristics after accelerated ageing
(Open Breaker method with copper catalyst)
(i) Specific Resistance (Resistivity)
at 27 ° C 2.5*1012 Ω-cm (Min.) IS 335 – 1993
at 90 ° C 0.2*1012 Ω-cm (Min.) IS 335 – 1993
(ii) Dielectric Dissipation Factor (Tan δ) at 90 °C 0.2 (Max.) IS 335 – 1993
(iii) Total Acidity 0.05 mg KOH/ g (Max.) IS 335 – 1993
(iv) Total Sludge 0.05 % by weight (Max.) IS 335 – 1993
(n) Water content of New unfiltered oil 50 ppm (Max.) IS 335 – 1993
(o) PCA Content (Polycyclic Aromatics) 3 % by mass (Max.) IEC- 60296, 2003
(p) Presence of Oxidation Inhibitor Oil shall not contain antioxidant additives. Value of IS 335 – 1993
0.05 % by mass (Max.) shall be treated as absence
of DBPC- Phenolic type inhibitor
(q) PCB Content (Polychlorinated Biphenyls) Not detectable IEC- 60296, 2003
0.1 mg/ kg (Max.)
(r) Dissolved Gas Analysis (DGA) Not applicable IS 335 – 1993
(s) 2 – Furfural (Furan Analysis, Test Method – IEC 0.1 mg/ kg (Max.) IEC- 60296, 2003
61198:1993)

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ACCEPTABLE / PERMISSIBLE LIMITS FOR TRANSFORMERS & REACTORS

SR EQUIPMENT / TEST DATA PERMISSIBLE LIMITS REFERENCE

NO
(t)Furfural (Aging criteria for oil-immersed Warning Trouble CIGRE DOC. No. 227.
1.5 ppm 15 ppm Life Management
Power Transformer)
Technique for Power
Transformer

(u) Total furan content 250 parts per billion (ppb) Transformer Diagnostic
USBR, June 2003, Page-
15
Additional requirement for inhibited oil
Inhibitor content (Antioxidant additive content)

DBPC ( Ditertiary Butyl Paracresol) Minimum 0.08 % by mass and Maximum 0.4% by mass
IEC- 60296, 2003

DBP (Ditertiary Butyl Phenol) Minimum 0.15 % by mass and Maximum 0.3 % by mass

2. TRANSFORMER OIL for in-service transformer

Oil Parameters At the time of first charging During O&M
(a) Appearance Clear, free from sediment Clear without visible IS-1866 -2000
and suspended matter contamination
(b) Break Down Voltage (BDV) (GAP – 2.5 40 kV for <72.5 kV 30 kV for <72.5 kV IS-1866 -2000
mm) – Min 50 kV for 72.5 to 170 kV 40 kV for 72.5 to 170 kV
60 kV for > 170 kV 50 kV for > 170 kV
(d) Acidity (Neutralization value) (Max) 0.03 mg KOH/ g 0.3 mg KOH/ g IS-1866 -2000
(e) Sediment & Sludge (Max) 0.01 % by mass 0.02 % by mass IS-1866 -2000

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ACCEPTABLE / PERMISSIBLE LIMITS FOR TRANSFORMERS & REACTORS

SR EQUIPMENT / TEST DATA PERMISSIBLE LIMITS REFERENCE

NO
Oil Parameters At the time of first charging During O&M
(f) Resistivity
(i) Resistivity at 20 ºC (Min) 1* 1012 Ohm–cm IS-1866 -2000
12 12
(ii) Resistivity at 90 ºC (Min) 6* 10 Ohm –cm 0.1* 10 Ohm–cm IS-1866 -2000
(g) Dielectric Dissipation Factor at 90 ºC 0.015 for < 170 kV 1.0 for < 170 kV IS-1866 -2000
and 40-60 Hz (Tan Delta/ Power Factor) 0.01 for 170 kV 0.2 for 170 kV
(Max)
(h) Inter Facial Tension (IFT) AT 27 ºC (Min) 35 mN/ m 15 mN/ m IS-1866 -2000

(i) Flash Point (Min) 140 ºC Max decrease of 15 ºC from IS-1866 -2000
initial value
(j) Density at 29.5 ° C (Max.) 0.89 g / cm3 Not Applicable IS-1866 -2000
(k) Kinematic Viscosity at 27 ° C (Max.) 27 cSt Not Applicable IS-1866 -2000
(l) Pour point (Max.) -6°C Not Applicable IS-1866 -2000
(m) Oxidation Stability of uninhibited oil
(i) Neutralization Value (Max.) 0.4 mg KOH / g Not Applicable IS-1866 -2000
(ii) Sludge (Max.) 0.1 % by mass Not Applicable IS-1866 -2000
Additional requirement for inhibited oil
(n) Oxidation Stability of inhibited oil Minimum 0.08 % by mass and Maximum 0.4% by mass IEC- 60296, 2003
{Antioxidant additive content}

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ACCEPTABLE / PERMISSIBLE LIMITS FOR TRANSFORMERS & REACTORS

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NO
3. Dissolved Gas Analysis (DGA)
Typical rates of gas increase for Power Values in milliliters per day
transformers
Hydrogen (H2) <5
Methane (CH4) <2
Ethane(C2H6) <2
IEC: 60599-1999
Ethylene (C2H4) <2
Acetylene (C2H2) <0.1
Carbon Monoxide (CO) <50 Given only for guidelines
Carbon Dioxide (CO2) <200 and for information
Interpretation of DGA
Equation to calculate the rate of gas increase as per IEC: 60599-1999 results need to be
Rate = (Y2 - Y1)m / { (d2 - d1) } ml/ day reviewed by CC/OS or
Where DGA Committee
Y1 = is the reference analysis
Y2 = is the last analysis
(Y2 - Y1) = is the increase in micro-litre per litre
m = is the mass of oil , in kilograms
= is the mass density, in kilograms per cubic metre
d2 = is the date for Y1
d1 = is the date for Y2

4. Moisture measurement of Winding (RVM IEEE Std. 62-1995 CIGRE DOC. No. 227.
Measurement) Life Management
Insulation condition % Moisture by dry % Water saturation Technique for Power
weight in paper (Wp) of oil ( RS ) Transformer
Dry (at commissioning) 0.5-1.0 % <5%
Normal in operation <2%
Wet 2-4 % 6-20 %
Extremely wet > 4.5 % > 30 %
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ACCEPTABLE / PERMISSIBLE LIMITS FOR TRANSFORMERS & REACTORS

SR EQUIPMENT / TEST DATA PERMISSIBLE LIMITS REFERENCE

NO
5. Sweep Frequency Response Analysis Tests In general, changes of +/- 3 dB (or more) in following
(20 Hz to 2 MHz) frequency range may indicate following faults:

Frequency Range Probable Fault

5 Hz to 2 KHz Shorted turns, open circuit, residual Euro-Doble Client

magnetism or core movement Committee/
50 Hz to 20 KHz Bulk movement of windings relative to Transformer Diagnostic-
each other USBR, June 2003

500 Hz to 2 MHz Deformation within a winding

25 Hz to 10 MHz Problems with winding leads and/or

test lead placement
Given only for guidelines
6. Degree of Polymerization (DP) EPRI’s Guidelines for the Life Extension of Substations and information
2002 Interpretation of test
New insulation 1,000 DP to 1,400 DP results need to be
reviewed by CC/OS or
60% to 66% life remaining 500 DP Committee meant for them
30% life remaining 300 DP
0 life remaining 200 DP