OLTC OVERHAUL

Apart from overhauling of OLTC due the poor or bad condition of OLTC based on OQA,
DGA and electrical tests, overhaul is still performed based on the condition of the OLTC
counter reading. OLTC overhaul will be carried out when EITHER the counter reading shows
no. of tap changer switching operation has reached the minimum number for overhauling as
recommended by the manufacturer (Table 4-43) OR when the age of the OLTC in-service has
reached the minimum recommended age for overhauling, which ever comes first.

Minimum Requirement for Overhaul

No. of Switching
Transformer
OLTC Type Operations
Rated Age in Service
(MR) (without filter
Current
unit)
V III 200 D, Up to 100 A 100,000 2 years after
V III 250 D Up to 250 A 70,000 commissioning or
V III 350 D, Up to 200 A 100,000 4 years after last
V III 400 D Up to 400 A 70,000 overhaul

The following procedures on OLTC overhaul is specific for MR Oil Type VIII OLTC since
more than 95% of the type is used in the power transformers of TNB distribution system.

GENERAL

Prior to OLTC overhaul, a shutdown of the power transformer must be performed in

accordance with Seksyen 3, Aturan Keselamatan Elektrik, Bahagian Pembahagian TNB,
where the transformer shall amongst others be made dead, isolated, proven dead and earthed
at all points of isolation of supply to the transformers including points of isolation from the
neutral earthing equipment. In addition, all preparation to avoid possible oil spill to the
ground shall also be conducted accordingly.

TOOLS

1.0 Spanners & Wrenches

 Double-ended socket wrench, 8 x 10 mm
 Double-ended socket wrench, 13 x 17 mm
 Double-ended open jaw wrench, 17 x 19 mm
 Double-ended open jaw wrench, 22 x 27 mm
 Ring & open jaw wrench, 10 mm
 Off-set screw driver, 2.5 mm
 Off-set screw driver, 4.0 mm
 Off-set screw driver, Torx TX40

2.0 Operating key for diverter switch insert

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3.0 Cleaning Brushes
 Brush for oil compartment, 400 mm diameter
 Brush for switching tube, 140 mm diameter
 Brush for suction tube, 40 mm diameter

4.0 Mountings & Rods

 Jig pole and Chain block
 Mounting device for OLTC Insert
 Brush mounting rod with ring
 Brush extension rod

5.0 Hexagon Socket Screws (for inner screening ring)

 6 nos M6x30.
 2 nos M6x10
 6 nos M5x8
 3 nos M8x20
 1 no M8x28

6.0 Measuring Equipment

 Insulation resistance test set
 Turns ratio meter
 Dynamic winding resistance meter
 Digital multimeter
 Digital Vernier Caliper
 BDV Test set

7.0 Personal & Environmental Protective Equipment

 Safety helmet
 Oil resistant nitrile gloves
 Oil waste vessel/container for cleaning OLTC insert
 Effective Microorganisms (EM) liquid for cleaning oil spill area

8.0 Wipes
 Lint free wipes for general use
 Calico cloth for cleaning external parts
 Chemsearch oil absorbent/cloth for cleaning internal parts/surfaces
 Kimberly clerk paper tissue for drying internal parts
 Scotch brighter polisher for cleaning roller contact surface

POCEDURES

Testing

Testing the Transformer with Turns Ratio, Dynamic Winding Resistance and Insulation
Resistance Tests
1. Before commencement of tap changer overhaul, proceed with Turns Ratio, Dynamic
Winding Resistance and Insulation Resistance Tests to compare results after overhaul
completed

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Preparation

Setting Up Jig Pole and the Chain Block

1. To setup the jig pole, screw the base of the jig pole to the transformer.
2. Hook slings to the jig pole and tighten them.
3. Put the ring at the horizontal arm of the jig pole.
4. Hook the chain block to the ring.
5. Put the ring at the horizontal arm of the jig pole.
6. Hook the chain block to the ring.

Disassembly

Setting the Withdrawal Position

1. The Tap Changer must be in the mid/adjustment position for withdrawal. eg. tap 9b.
2. Switch OFF the main switch and change mode to LOCAL.

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 3. To bring into adjustment position, move the tap changer to tap 11 or 13 and then back
to tap 9b.
4. The operating position is marked by red arrow on the indication dial of the motor
drive and by turning the hand crank clockwise.

Draining the Tap Changer Oil

1. Close the stop valve between oil conservator and tap changer head.
2. Open the drain valve of the changer and bleeder valve on the tap changer (remove the
screw cap M30/w.s.36 and lift the valve tappet with the help of a screwdriver).
3. Drain the oil from the oil compartment.

Uncoupling Drive Shaft

1. Loosen the lose clamp at the guard plate for the horizontal drive shaft.
2. Remove the guard plate.
3. Unlock and loosen the six screws size 6mm on the coupling piece to the upper gear
unit.

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Removing Tap Changer Cover
1. Unscrew 20 bolts size 17mm. Remove Tap Changer Cover and take care not to
damage the o-ring gasket.

Removing the Gearing Unit

1. Make sure the 3 pairs of red triangle marking meet each other.
2. Using screw M5x20, withdraw the fixing bolt from the spring energy accumulator.
3. Loosen the screw connection at the suction pipe R ¾”.
4. Loosen 5 screws size 13mm. Do not loose the spring washer.
5. Remove the gearing by lifting it out.
6. Take note of the position of the support bars and the marking for later reinstallation.

Removing the Suction Pipe

1. Lift the suction pipe with the help of the lifting device until the upper slot.
2. Grasp the second slot and remove the suction pipe completely by hand.
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Removing Tap Changer Insert
1. Fix lifting device by using 3 bolts M10x20.
2. Bring change over selector into withdrawal position by turning operating key
clockwise until the movable change over contact are in the position between the
stationary contact of different phases (free position).

Lifting Tap Changer Insert

1. Lift out Tap Changer insert slowly and carefully.
2. Make sure sufficient clearance between screening rings, parts of the switching
elements, tap changer insert and oil compartment.

Cleaning the Oil Compartment

1. Open the stop valve between tap changer head and oil conservator.

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 2. Drain the oil, from the oil conservator until only clean oil is flowing. If necessary
flush the oil conservator with new transformer oil.
3. Flush inside oil compartment with new transformer oil.
4. Carbon deposits to the inner surface of oil compartment can be removed with the help
of a brush of 400mm diameter.
5. Check the contacts for any burn sign with mirror.

OPEN

CLOSE

Cleaning the Suction Pipe

1. Wipe the outer surface of the suction pipe with a rag.
2. Clean inside with a brush of 40mm diameter.
3. Finally flush with new transformer oil.

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Cleaning the Tap Changer Insert Externally
1. Check visually inside and outside Tap Changer Insert.
2. Clean outside of the Tap Changer Insert by using a brush.
3. Finally flush all parts with new unused transformer oil.

Cleaning the Tap Changer Insert Internally

1. To clean inside of the changer insert must remove bottom bearing, switching element,
screening rings and inner screening rings.
2. Unlock 4 bolts at bottom bearing, three M8x20 bolts and one M8x25 bolt.
3. Remove bottom bearing.
4. To remove the Switching Element, unlock and unscrew the 6 fixing bolts M5x8/w.s 8
of the upper screening ring and unlock and loosen the 6 fixing screws M5x8/w.s 10 of
each switching element as follow :
a. one screw each in the center on top and bottom
b. one screw each, on the left and on the right, on top and bottom.
5. To remove the Inner Screening Rings, take out the washer from the groove provided
for switching element.
6. Proceed with each inner screening ring by removing the 3 hexagon socket head screw
M6 x 10/ w.s.4 with dished washer. Note: The screws are self locking and must be
replaced by new ones during reassembly.
7. Remove all inner screening rings carefully. Note: Any damage to the inside of the
switching tube can reduce the insulation properties.
8. To cleane the Switching Tube, flush the inside of the switching tube thoroughly with
new unused transformer oil.
9. Clean the switching tube. Carbon deposit sticking on the surface can be removed using
a 140mm diameter brush.
10. Flush again with new unused transformer oil.

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Assembly

Reinstalling the Inner Screening Rings

1. Fix the inner screening ring to the switching tube by 6 screws M6x30.
2. Attach each of the inner screening rings with 3 hexagon socket head screws M6x10
max torque 9Nm (secured by lock tabs).
3. Fix 1 screening ring 6 screws M5x8 with lock tabs max torque 5Nm.
4. Fix bottom bearing 3 screws M8x20 and 1 screw M8x25 with lock tabs max torque
15Nm. Note: Replace new washer.

Measuring the Transition Resistors

1. Use a Multimeter to measure the transition resistors.
2. Transition resistors when connected should be between 0.5 and 20 ohms between
switching contact rollers and transition contact rollers. Note: Plus minus 10% is
permissible.

Detecting Internal Breakdown of the Tap Changer Insert

1. Use a 5kV Insulation Resistance Tester to check whether there is any internal break
down.
2. Insulation level can also be measured using Phase to Earth method.

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Determining Contact Wear of the Contact Rollers
1. Contact wear of the contact rollers can be measured with a slide gauge or a Vernier
Calipers.
2. Normal diameter for contact roller is 22mm. If the diameter decreased to 17mm or
less, it needs to be replaced.

Checking the Spring Movement of the Contact Rollers

1. Check smooth spring operation of the contact rollers for switching contacts and
transition contacts.

Reinstalling the Tap Changer Insert

1. After reassembling Tap Changer Insert, clean and flush it with new transformer oil.
2. Fit lifting device. Lower Tap Changer Insert slowly and carefully into oil
compartment and make sure screening rings and parts of switching element are not in
contact with stationary parts in oil compartment.
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 3. Push down the Tap Changer Insert to lock it in place.

Setting and Checking the Adjustment Position of the Tap Changer Insert
1. Turn operating key and set to adjustment position by closing the change over contact
in the anti clockwise direction.
2. Remove operating key and check adjustment position with the help of the triangle
marks.

Installing the Suction Tube

1. Insert the suction tube into the hole at the center of the Tap Changer Insert.
2. Press the upper end of the suction tube to lock it into the oil compartment at the
bottom.

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Installing the Gearing Unit
1. When inserting the gear unit make sure the roller of the drive lever for the change over
selector engages into the corresponding groove of the change over selector.

Fixing the Gear Base Plate

1. Use 5 screws 13mm maximum torque 14Nm, secure by spring washers.
2. Connect the connector to the suction pipe.
3. Insert the fixing bolt for the energy accumulator springs. The correct installation
position is shown by the red arrow.

Fixing the Top Cover

1. Fix the top cover with 20 bolts size 17mm.

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Coupling the Horizontal Drive Shaft
1. Couple the horizontal drive shaft to the upper gear unit and the bevel gear using 6
screws M6/w.s 10, maximum torque 9Nm, lock tabs.
2. Check the horizontal and vertical drive shaft, especially at their coupling point. If
necessary grease the coupling bolts and ‘O’ rings.
3. Check the upper gear unit on the changer cover and the bevel gear. Add grease if
necessary.

Testing the RS Relay

1. Remove terminal box cover by removing 3 nos. M6 screws.
2. Operate the ‘TRIP’ push button.
3. Check that the flap valve is inclined and red circular mark on flap has come to the
middle of inspection window.
4. Operate the ‘RESET’ push button.
5. Check that the flap valve is in vertical position.
6. Check contact operation at terminals.
7. Install the relay in horizontal position with test push buttons on the top of housing.
8. Connect leads through cable gland.
9. Connect earthing lead to the earthing connection M6 in the terminal box with
maximum torque of 5Nm.
10. Fix the terminal box cover by 3 nos. M6 screws with maximum torque of 5Nm.

Oil Filling & Filtration

1. Change all filter cartridges of the filtration machine with new ones witnessed by TNB
personnel.
2. Before start of oil filling and oil filtration, ensure that OLTC breather is removed, and
heater of the filtration machine is off. Oil filling and oil filtration will be conducted
without any applied heat at ambient temperature.
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 3. Connect the inlet of the oil filtration machine to the oil drum, and outlet of the
filtration machine to the suction pipe.
4. Open the suction valve and fill the OLTC compartment with oil up to 1/3 of the OLTC
conservator.
5. Remove hose from oil drum and connect the outlet of the oil filtration machine to the
OLTC conservator drain valve, and oulet of the suction pipe (S) to the inlet of the
filtration machine.
6. Ensure shut off valve on the piping from the conservator and suction valve are at open
position before commencement of oil filtration.
7. Filter oil inside OLTC and conservator OLTC with minimum 3 passes and continue
filtration until the oil achieve minimum 60kV BDV result. After result achieved, stop
filtration process.
8. Record all measurement in oil filtration running sheet.
Note: BDV test must be performed only when oil sample is at 25⁰C. Therefore, it is
recommended to conduct BDV test in the control room so to achieve temperature of
oil of 25⁰C.

Testing

Testing the Transformer with Turns Ratio, Dynamic Winding Resistance and Insulation
Resistance Tests
1. After completion of the tap changer overhaul, proceed with Turns Ratio, Dynamic
Winding Resistance and Insulation Resistance Tests.

Cleaning

Wipe and clean all area from oil spill and spray oil spill area with EM liquid.

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