Look at the fans anytime you are around transformers in the switchyard or in the power plant. If it is a hot day and transformers are loaded, all the fans should be running. If a fan is stopped and the rest of the group is running, the inactive fan should be repaired. During an inspection, the temperature controller should be adjusted to start all the fans. Listen for unusual noises from fan bearings and loose blades and repair or replace faulty fans. Bad bearings can also be detected with an IR scan if the fans are running.
After 1 month of service and yearly, inspect and test the oil pumps
Inspect piping and connections for leaks. Override the temperature controller so that the pump starts. Check the oil pump motor current on all three phases with an accurate ammeter; this will give an indication if oil flow is correct and if unusual wear is causing additional motor loading. Record this information for later comparison, especially if there is no oil flow indicator.
If the motor load current is low, something is causing low oil flow
Carefully inspect all valves to make sure they are fully open. A valve stem may break and leave the valve partially or fully closed, even though the valve handle indicates the valve is fully open. Pump impellers have been found loose on the shaft, reducing oil flow. Sludge buildup or debris in lines can also cause low oil flow.
If motor load current is high, this may indicate impeded pump rotation.
Listen for unusual noises. Thrust bearing wear results in the impeller advancing on the housing. An impeller touching the housing makes a rubbing sound which is different from the sound of a failing motor bearing. If this is heard, remove the pump motor from the housing and check impeller clearance. Replace the thrust bearing if needed, and replace the motor bearings if the shaft has too much play or if noise is unusual.
Three phase pumps will run and pump some oil even when they are running backwards. Vane type oil-flow meters will indicate flow on this low amount. The best indication of this is that sometimes the pump will be very noisy. The motor load current may also be lower than for full load. If this is suspected due to the extra noise and higher transformer temperature, the pump should be checked for proper rotation. Reverse two phase leads if this is encountered.
After 1 month of service and yearly, check the oil flow indicator
It has a small paddle which extends into the oil stream and may be either on the suction or discharge side of the pump. A low flow of only about 5 feet per second velocity causes the flag to rotate. Flow can be too low, and the indicator will still show flow. If there is no flow, a spring returns the flag to the off position and a switch provides an alarm. With control power on the switch, open the pump circuit at the motor starter and make sure the correct alarm point activates when the pump stops. Check that the pointer is in the right position when the pump is off and when it is running. Pointers can stick and fail to provide an alarm when needed. Oil flow may also be checked with an ultrasonic flow meter. Ultrasonic listening devices can detect worn bearings, rubbing impellers, and other unusual noises from oil pumps.
Pumps can pull air in through gaskets on the suction side of the pumps
The suction (vacuum) on the intake side of the pump can pull air through gaskets that are not tight. Pump suction has also been known to pull air through packing around valve stems, in the suction side piping. This can result in dangerous bubbles in the transformer oil and may cause the gas detector or Buchholz relay to operate. Dissolved gas analysis will show a big increase in oxygen and nitrogen content. High oxygen and nitrogen content can also be caused by gasket leaks elsewhere.
After 1 month of service and yearly, inspect water-oil heat exchangers
Test and inspect the pumps as mentioned above. Look for and repair leaks in piping and heat exchanger body. Examine the latest dissolved gas analysis results for dissolved moisture and free water. If free water is present and there are no gasket leaks, the water portion of the water-oil heat exchanger must be pressure tested. A leak may have developed, allowing water to migrate into the transformer oil, which can destroy the transformer. If the heat exchanges piping is double-walled, check the drain for water or oil; check manufacturer’s instruction manual.
