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Periodic testing and analysis supported by proper diagnostic techniques is must for better understanding and assessment of health and serviceability of the transformers. Further, effectiveness of the diagnosis is based on proper choice of diagnostic techniques. Design review is a powerful diagnostic tool. Now-a-days, with the advances in technology of sensors and software integration, on-line non-invasive diagnostic techniques are gaining wider acceptance. Case studies on condition monitoring of transformer by proper design review supported by analysis of DGA case history and further confirming the problem through proper on-line and off-line tests have been illustrated.