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This document is an instruction manual for oil filled power transformers rated at 66kV and above produced by JSHP Transformer Co. It provides guidance on receiving, handling, installation, testing and maintenance of the transformers. The manual covers inspection for shipping damage upon receipt, safety procedures, contact information, internal inspection methods, and processing and testing recommendations.
This document is an instruction manual for oil filled power transformers rated at 66kV and above produced by JSHP Transformer Co. It provides guidance on receiving, handling, installation, testing and maintenance of the transformers. The manual covers inspection for shipping damage upon receipt, safety procedures, contact information, internal inspection methods, and processing and testing recommendations.
This document is an instruction manual for oil filled power transformers rated at 66kV and above produced by JSHP Transformer Co. It provides guidance on receiving, handling, installation, testing and maintenance of the transformers. The manual covers inspection for shipping damage upon receipt, safety procedures, contact information, internal inspection methods, and processing and testing recommendations.
Power Transformer Instruction Manual Version 1.0 Page 2 of 30
Table of Contents
1. General
2. Receiving
3. Moving and Handling
4. Storage
5. Assembly and Installation
6. Processing and Vacuuming
7. Field Testing
8. Energization
9. Maintenance
10. Attachments
Power Transformer Instruction Manual Version 1.0 Page 3 of 30 1. General
This manual applies to J iangSu HuaPengs (J SHP) modern liquid filled power transformers with high voltage rating of 69 kV and above. It is developed to assist in transformer receiving, installation, test and maintenance procedures.
1.1 Safety
The installation, operation and maintenance of power transformers present many potentially dangerous situations such as falling, asphyxiation, high pressure and high voltage. Always observe safety precautions and follow all applicable safety procedures such as OSHA requirements, local safety requirements and safe working practices. Good judgment must be used when installing, operating and maintaining power transformers.
1.2 Contact information
In the event of shipping damage, or any information that is not covered in this manual, contact J SHPs Service Department.
J SHP Transformer Co., Ltd. 68 Kunlun Development Zone Liyang City, J iangsu Province, P.R. China Phone: +86-519-87319099 Fax: +86-519-87319215 Email: rui_yin@jshp.com
Power Transformer Instruction Manual Version 1.0 Page 4 of 30 2. Receiving
It is important that shipping damage be detected before the transformer is off- loaded. A though inspection of the unit and its accessories should be made as soon as possible to identify any shipping damage. J SHPs transformers are covered by warranty against defective materials and workmanship. This warranty does not cover shipping damage and therefore does not relieve the user of the responsibility of accepting damaged transformer and/or it accessories from the carrier.
2.1 Inspection on receipt
Representatives from both J SHP and the carrier should be present during the inspection. Any evidence of damage should be noted on the Bill of Landing. Before removing the unit from rail car or truck, perform the following inspections to identify any damage that may have occurred during shipment.
2.1.1 Impact recorder
Impact recorders are provided on all rails and some truck shipment. The impact recorder used by J SHP is a three way device capable of measuring shocks in the longitudinal, vertical and transverse directions.
On shipments where impact recorders are provided, remove the tape in the presence of J SHP and carriers representative. If the tape recorder stopped or jammed before the transformer reached its destination, indicate this on the tape. Also write down the tape removal time and date on the tape. Have a representative sign the tape.
To analyze the tape, it is best to do it indoor or in an area sheltered form wind. Traces in longitudinal, vertical and transverse directions which are less than 3G, 2G and 2G are considered acceptable. Impact higher than those figures is considered rough handling and might cause shipping damage. In this case, authorization is needed from J SHP to inspect the unit further. If the traces indicate no probable shipping damage, the receiving inspection may proceed.
Replace tape in the recorders, seal and ship back to J SHP at the following address within one week:
J iangSu HuaPeng Transformer Co., Ltd. No. 68 Kunlun Development Zone LiYang City, J iangSu Province PR China 213300 Attn: Shipping Dept.
Power Transformer Instruction Manual Version 1.0 Page 5 of 30 2.1.2 External inspection
A damaged tank assembly may mean a faulty or damaged transformer. It is important that the transformer be inspected before it is off-loaded. A thorough inspection at this point saves time and cost of off-loading a damaged transformer. In addition, proper claims can be filed if damage is found or hidden damage is suspected.
i. Transformer tank
Visually inspect transformer tank, cover, drain valve, radiator valves and other external accessories mounted on the tank. Note any external damage.
All welds or bolted-on flanges and covers should be in place and secure, all valves and cabinet doors should be tightly sealed.
Check attached radiators for bent or dented fins.
Look for signs of oil leakage along weld seams on the exterior of small power transformers which are normally shipped oil filled.
Check gas pressure in the tank for dry air or N2 filled units. These units should have a positive or negative gas pressure in the tank if there is no leak. Zero gauge pressure is a good indication of a leak. Refer to section 2.4 for test for moisture entry if a leak is suspected.
ii. Bracing, blocking and tie down
Inspect bracing, blocking, etc. Note all damage, shifting and movement, etc. Take photos as well to substantiate possible claims.
Depressed steel platform cars usually have steels blocks welded to the deck and placed tightly against the transformer base at each end. Excessive impact could show up as dents in the base of the unit or results in block movement. Side blocks are normally placed tight against the base and tank movement will result in as scratched paint.
Flat car or truck loads normally use wood braces and blocking timbers. Some movement is expected, however, broken blocks or crashed timbers indicate rough handling.
Anchoring or spring loaded tie down rods should be straight and tight. All nuts should be tight as well. Any bent or looseness indicates movement of the unit.
Power Transformer Instruction Manual Version 1.0 Page 6 of 30 iii. Accessories inspection
Check the packing list against the materials received. Look for missing creates or containers.
Check radiators or coolers for dented or broken fins, loose or missing fans, etc.
Check bushings and lightning arresters for cracked or broken porcelains, oil leaks, porcelain shifts, etc.
Check conservator tanks for dents, cracks and leaks.
2.2 Internal inspection and tests
When required, follow the procedures listed below to conductor internal inspection.
2.2.1 Safety precautions
Do not allow anyone to enter the tank unless the oxygen content of gas at the tank bottom is measured and considered acceptable. The oxygen content should be at between 19.5% and 30%. For units shipped with nitrogen, purge air space with dry air first.
Always have a person stationed at the opening outside the tank whenever anyone is in the tank.
Before removing any covers and fittings, Make sure that there is no gauge pressure in the tank and the oil level is under that particular opening.
Fire extinguishers should be provided and smoking should not be allowed.
Ground transformer tank, all windings and all oil handling and processing equipment.
Do not perform electrical tests while the unit is under vacuum.
Do not walk on the cover while the unit is under vacuum.
2.2.2 Internal inspection preparation
Power Transformer Instruction Manual Version 1.0 Page 7 of 30 Extreme care must be taken to protect the transformer, especially its insulation system from damage. Care should also be taken to prevent foreign materials form entering the tank during inspection.
All personnel working on the top of the tank, while its open, should empty all pockets and remove all watches and jewelry. Wear protective clothing and shoe covers.
All tools, hardware and any other foreign objects that will be used during the inspection should be accounted for. If anything is dropped into to the tank and cannot be retrieved, notify J SHPs representive immediately.
Have provisions for closing the tank in case of rain or sudden weather change.
For transformers shipped dry, follow the steps below to perform internal inspection.
Adjust the internal pressure to zero PSI before opening the tank. Record the time tank is opened to determine total exposure time. Do not open the tank if the transformer temperature is below 0C. Circulate dry air. When transformer is opened and exposed to the environment, dry air (dew point of -40C) should be purged through the tank to prevent moisture entrance. Clear plastic sheets may be placed over the manhole openings to reduce the air volume required.
For transformers shipped oil filled, follow the steps below to perform internal inspection.
Adjust the internal pressure to zero PSI before opening the tank. Lower the oil level to allow for a limited internal inspection. Record the time tank is opened to determine total exposure time.
2.3 Perform internal inspections
For transformers shipped dry, the internal inspection should include, but not limited to, the following:
Access the overall condition of the active parts and all components. Check internal parts for tightness and damage. Inspect coils and insulation. Look for misaligned spacers or loose blocks. Look for loose insulation between the core and core clamps and any signs of lamination shifting. Make sure core ground lead is not loose. Power Transformer Instruction Manual Version 1.0 Page 8 of 30 Conduct core megger at 500 volts. A minimum of 200 volts megohms is acceptable. Check lead/cable for insulation abrasions, frayed strands at bushing connecting stud. Look for broken lead supports. Check contact alignment and tap leads of the off load tap changer. Make sure operating mechanism is free of damage. Check the support of current transformers. Verify that all leads from the CTs to the terminal blocks are secure and free of damage. Look for debris at the bottom of the tank. Look for signs of moisture such as rust or free water.
For transformers shipped oil filled, the internal inspection should include, but not limited to, the following:
Access the overall condition of the active parts and all components. Look for signs of moisture such as rust or free water. Make sure core ground lead is not loose. A visual inspection, through the oil, should be made to look for evidence of damage or loose parts.
The oil should be drained completely to allow a thorough inspection if there are any indications of damage or if the impact recorders indicate excessive impact.
2.4 Test for moisture
If moisture entrance is suspected, pressurize the tank to 6 PSI gauge pressure with dry air and look for leaks with soap and bubbles. Check welded and gasketed joints. If the leaks are found, repair leaks and re-pressurize the tank to 6 PSI. Let the unit sit for at least 24 hours and perform a dew point measurement.
The dew point inside a transformer can be related to the partial pressure of water vapour at the surface of the insulation material. This is called the vapour pressure and it is measured in micrometers of mercury.
Once known, the vapour pressure and the temperature of the insulation material determine the moisture content (percent by weight) at the surface of the insulation material assuming that all the partial pressure of gases in the gas space and in the insulation have come to equilibrium.
The attached chart, Figure 1, converts the measured dew point into the vapour pressure. The chart for determining moisture content from vapour pressure is called the moisture equilibrium chart, Figure 2. using the two charts, the moisture content can be determined.
Power Transformer Instruction Manual Version 1.0 Page 9 of 30 To make good judgment of moisture content, the actual temperature of the insulation materials must be known as accurate as possible. The best way to accomplish this is to make the dew point measurements in early morning hours when the insulation temperature, the tank pressure and the ambient temperature are all still relatively equal. In addition, the vapour pressure must be adjusted for any overpressure in the transformer tank.
Results which occur in the unacceptable range should be referred to J SHPs service department.
2.5 Damage claims
All shipping damage, both obvious and hidden, will be filed by J SHP. When obvious damage is observed, contact J SHP customer service immediately. A damage report must be completed by the carrier. Under no circumstance is a damaged shipment to be removed from the rail car or truck without written authorization from J SHP.
All hidden damage claims should be filed if:
The impact recorders indicate transit impact has exceed 3G, 2G and 2G in the longitudinal, vertical and lateral direction. Prolonged period of 2-3 hours or more of vertical ribbon effect is recorded. The impact recorders did not run full time. Excessively rough handling is evident.
Contact J SHP customer service immediately if hidden damage is suspected. The bill of landing should be signed with a statement Unit received with possible hidden damage.
Power Transformer Instruction Manual Version 1.0 Page 10 of 30 3. Moving and Handling
When no shipping damage is detected, the customer should remove the transformer from the rail car or truck and move it to the installation or storage site.
Extreme caution must be used in moving a transformer. Unsafe practices may result in serious injury or even death. Unsafe practices may also result in major damage to the transformer, substation equipment or moving equipment.
3.1 Before the move
The outline drawing of each transformer included with this manual has information on the weight of the unit, clearances required, and the locations of lifting eyes, jacking pads and mounting pads.
The new location should have been prepared and certified as ready, and the pathway along which the transformer will be moved should have been cleared of all obstacles.
Before positioning the transformer on a permanent or temporary pad, the foundation and surroundings should be checked carefully. Because of the weight of a power transformer is normally heavy and the weight is concentrated in a relatively small area, there is considerable stress on both the transformer and its foundation.
In addition to the strength required to support the unit, the mounting must provide for maintenance and service access to the transformer.
3.2 Move preparation
3.2.1 Newly received transformer should be inspected in accordance with the procedures described in the Receiving section of this manual.
3.2.2 For transformers that are to be moved from storage, pre-move inspection and processing should be performed.
Follow the steps below to prepare the move.
List all accessories and equipment that must be disconnected before moving. Relieve pressure in the tank. Match mark, disconnect and remove all accessories that must be removed. Clean and seal all tank openings created by the removal or disconnection immediately. Power Transformer Instruction Manual Version 1.0 Page 11 of 30 Wrap, identify and store all removed items in a dry location pending reinstallation. Inspect the tank exterior for damage or deterioration. Release and remove and bolts or nuts fastening the transformer to its foundation. Order, if necessary, damaged components during disassembly.
3.3 Actual move
The outline drawing of each transformer included with this manual has information on the various weights of the transformer and the precise location of the various lifting, pulling eyes, skid noses and jack bosses, etc.
When making a decision on the moving technique, take into consideration the size and weight of the transformer, the job site condition and the type and capacity of the lifting and moving equipment.
3.3.1 Lifting and moving transformer by crane
Whenever possible, the transformer should be lifted and positioned by crane. Moving by swing crane should not be attempted if working space is inadequate or overhead obstacles do not permit the crane boom to be raised or moved effectively.
When a crane is used to lift the unit, lift hooks or hitches should be attached only to the lifting eyes built into the tank and the cables must be held apart by a spreader to prevent bending the lifting lugs or putting too much strain on other parts of the tank. Safety ropes or guide lines should be attached only to the towing eyes at the tank base and the load should be carefully controlled during the lift operation. The load should never be permitted to swing freely.
Before the transformer can be lifted, the internal pressure should be less 3 PSI.
3.3.2 Moving transformer by rolling or skidding
When lifting a transformer by crane becomes impractical, the transformer can be moved along the ground by rolling or skidding.
Although the actual moving procedures will vary with the size and weight of the transformer, the condition of the ground over which it must be moved, and the travel distance. To ensure a successful move, the following precautions should be observed.
Power Transformer Instruction Manual Version 1.0 Page 12 of 30 i. The work surfaces including truck bed, railcar deck, skid way or rollway and foundations must be as level as possible and absolutely firm.
ii. Use jack bosses to raise the unit when necessary. Do not attempt to raise the unit by placing jacks under the base, drain valves, pipe connections or other attachments. Use the outline drawing for any special instructions. Generally there are four jack bosses, one at each corner. When lifting a transformer completely, use all the jacking pads provided. To avoid springing the base, all jacks should be loaded evenly. Interlocked hydraulic jacks are recommended for this purpose.
iii. When the transformer is to be moved on rollers, all rollers used must be of the same diameter and evenly and closely spaced. The use of sound hardwood rollers greater than 6 in diameter or steel rollers greater than 4 in diameter spaced on centers with less than 12 separation must be used. Rollers must extend at least 2 beyond the tank base.
iv. Movement of the transformer should be controlled at all times. A tow and drag winching system is recommended with one winch pulling in the direction of movement and a second acting as a brake.
v. Towing cables must be attached only to the jack pads or towing/pulling eyes provided. The tow cables should never be looped around the tank or attached to the radiators/coolers, pipes, etc. spreading yokes should be used if the hitch configuration will place undue strain on the towing/pulling eyes on the tank.
vi. When turning a transformer, it is a good practice to place the plywood or lubricated steel sheets under the base to minimize turning resistance. Use pulling eyes only to attach the cable. As for lateral movement, it should be accomplished by the use of the towing/pulling eyes provided for the purpose.
vii. Keep the transformer level at all times. The transformer must never be tilted more than 15 from the vertical in any direction.
Power Transformer Instruction Manual Version 1.0 Page 13 of 30 4. Storage
Generally a transformer should be set up in a permanent location, assembled and processed for operation as quickly as possible after receiving inspection is complete. However, if the transformer needs to be stored before installation, the following rules should be followed.
4.1 Storage location
The foundation should be firm and relatively level. If a transformer is to be stored on a timber platform, support timbers should be closely and evenly spaced. Transformers should never be stored on rollers, blocks or jacks. When transformers are to be partially or fully activated during storage, the conditions of access and ventilation appropriate to permanent location should apply.
All transformers stored in temporary locations should be grounded as though the installation was permanent. Ground connections to both the tank and installed accessories should be checked carefully. Heaters should be connected and energized to prevent condensation in closed compartments.
4.2 Storage duration
It is important to know the duration of the storage so proper procedures can be followed. Generally speaking, the storage duration can be classified as less than 3 months, between 3 and 18 months and over 18 months.
The storage period should be considered as beginning on the date of shipment from the factory. All in-transit time and all time consumed in the receiving process should be included in determining which storage classification is applicable. An internal inspection is recommended if a transformer is shipped without oil and will be stored for more than 3 months.
4.2.1 For units to be stored for less than 3 months, the storage procedures are intended to preserve the as-delivered condition of the transformer. Where practical, transformers not immediately energized should be positioned in a permanent location and placed in a semi-active storage condition. Where storage in a temporary location is necessary, inactive storage is acceptable, however, the control cabinet and LTC control cabinet heaters should be energized to prevent condensation.
i. When the transformer is stored in a semi-active mode on a permanent pad, the transformer should be assembled, fitted with all the accessories, processed for installation, filled with oil and have all control cabinets and heaters energized.
Power Transformer Instruction Manual Version 1.0 Page 14 of 30 ii. When the transformer is stored in an inactive mode on a temporary pad, the transformer should be kept either in dry air (or nitrogen) or oil filled.
When transformers are received filled with factory oil, they can be stored for up to 3 months in the as received condition without further attention.
To store the transformers in dry air, a positive pressure of 2-3 PSI should be maintained at all times. A reserve air supply controlled by a pressure regulator should be connected to the tank. The air supply should be coupled to the tank via the pressure vacuum regulator. Both the reserve air supply and tank pressure should be monitored daily during the first 7 days of the storage period. Gauge readings should be taken approximately the same time each day and recorded carefully. If supply and tank pressure remain stable during this period, the interval between readings may be extended.
To store the transformers in nitrogen, a positive pressure of 0.5-5 PSI should be maintained at all times. For normal pressurization, 2 PSI is recommended. If the tank is pressurized during warm weather (above 25C), a 3 PSI reading is recommended. Connections to the tank, installation of gauges or regulators and monitoring procedures should be the same as described above for dry air.
4.2.2 For units to be stored between 3 and 18 months, the transformers should be filled with oil to the proper level. Transformers with conservators should be filled to about 20 below the cover. The space above the oil should be pressurized by dry air or nitrogen to 3 PSI. Control cabinet and LTC control cabinet heaters must be energized to prevent condensation.
4.2.3 For units to be stored more than 18 months, the transformer should be completely assembled and fully functional. All accessories should be installed and connected. All heaters, fans and pumps, etc. should be connected and operational. Stored equipment should be tested and maintained as though operational.
4.2.4 Accessories storage. Accessories not mounted on the transformer tank at the factory or not installed immediately after receiving must be protected from damage or deterioration during storage. Carefully reseal shipping boxes opened for inspection and store inside to prevent damage. All items stored outdoors should be covered and protected from the weather.
Power Transformer Instruction Manual Version 1.0 Page 15 of 30 Accessories stored outdoors and are not protected properly from the weather are susceptible to rust and other moisture related damage.
4.2.5 Removal from storage. During long storage, moisture may accumulate in transformer insulation if the transformer is not properly stored. Excessive moisture in the insulation lowers its dielectric strength and may cause failure
For transformer stored dry, a dew point measurement should be made before relieving the storage pressure in the tank. When making a dew point measurement, follow the instructions provided with the dew point tester. The dew point of the gas sampled should be below the acceptable limits shown on the moisture equilibrium chart, Figure 1. 1% moisture in the insulation system is considered acceptable.
For transformers stored oil filled, an oil sample should be measured for moisture content. An acceptable limit is 15 ppm.
5. Assembly and Installation
Assembly and installation methods vary with the size and type of the transformer, and facilities for handling transformers and their components. J SHPs Parts List and Shipping Instructions should be used for items that are detached for shipment. These items should be reassembled on the transformer as instructed below.
5.1 Ground the tank
Before assembling the transformer, the tank should be permanently grounded by means of the grounding connection provided at the bottom of the tank. The ground cable must be of correct size and must be 4/O or larger.
5.2 Contamination prevention
Carefully plan for control of all tools, hardware and other objects that are going to be used in the assembly process.
5.3 Bushing installation
Remove bushings from their crates with care using rope or nylon slings. Make sure not to damage or chip any of the porcelain skirts on the bushings. If the porcelain is chipped or cracked, or if there is any other damage to the bushing, contact J SHP for further instructions. Always make sure that the top end of the bushing is higher than the lower end when handling bushings.
Power Transformer Instruction Manual Version 1.0 Page 16 of 30 Place the bushing on a suitable surface for cleaning. The cover removed from the crate can be used as a base with rugs to cushion the bottom threads. Never rest the porcelain section on the bushing on anything. Use bushing flange for support as necessary.
Clean the bushing well using a rag dampened with a fast drying solution such as denatured alcohol. Check MADS prior to using any solvent. All bushing surfaces which will be inside the tank should be wiped clean and tried to prevent contamination of the oil in the tank.
Bushings with draw lead leave the factory with the conductor ends loosely sealed. Dirt and moisture may accumulate in the conductor tube. To clean this, draw a cloth saturated with cleaning solvent through the hollow conductor. Make several passes until the cloth comes out clean. If the bushing comes with a corona shield, make sure not to make any dent on the shield.
To install bushings, first relieve tank pressure to 0 PSI by loosening a manhole cover, a shipping cover or a plug, whichever is most convenient to vent the transformer.
If the transformer is shipped without oil, start flowing dry air through the transformer. Record the time to determine how long to hold vacuum on the unit before filling.
For draw lead bushing installation, follow the steps listed below.
i. Remove the bushing shipping plate. Inspect the gasket and make sure there is no damage. Clean the bushing mounting boss and install the gasket.
ii. Pass a pull wire down through the center tube of the bushing and attach it to the small hole in the top of the cable terminal stud. Lower the bushing into the transformer opening. Do not allow slack in the pull wire as it may allow the lead to become kinked below the end of the bushing.
iii. Install the locking pin at the top of the bushing and remove the pull wire. Thread the terminal cap in to position. Make sure the gasket is in place. Tighten the terminal cap to seal against the gasket. Torque the stud nut and cap as directed by the bushing manufacturers installation instructions.
iv. Install and tighten the bushing flange hardware to apply even pressure to the flange. Hardware should be tightened alternating across the flange.
Power Transformer Instruction Manual Version 1.0 Page 17 of 30 v. Check all leads to maximize clearance to ground or to other electrical parts.
For bottom connected bushings, follow the steps listed below.
i. Lower the oil level when the transformer is shipped oil filled. Do not drain oil below the top clamping ring.
ii. If the transformer is shipped dry, start flowing dry air through the transformer and record the time.
iii. Remove the bushing cover plate. Inspect the gasket to make sure there is no damage. Clean the bushing mounting boss with a solvent.
iv. Place the bushing into the right position on top of the transformer. Install the internal transformer connectors to the bottom of the bushing studs and tighten the bolts alternately and evenly with a wrench. Secure the bushing on the transformer cover by tightening all the bolts evenly in several steps. Do not attempt to pull the bolts down to the final setting on the first tightening. Allow time between each tightening to allow the gasket to seat properly.
v. Connect the internal bushing cables to the internal bushing spades.
vi. Check all leads to maximize clearances to ground or to other electrical parts.
5.4 Radiator installation
Do not remove the shipping cover until ready to install radiators. Verify that all radiator valves on the tank are closed before removing the shipping covers on the radiator flanges. Use care to prevent gasket and paint damage. It is recommended that the radiators be lifted from the crate with manila rope with sling spreaders and be placed across suitable supports while preparing for mounting to the tank.
Inspect for moisture or contamination inside the radiators headers. Contact J SHP is contamination is found. Make sure the flange face is free of paint or other material. Clean gasket groove and flange face and install gaskets.
Lift the radiator by lifting eye in the top header and swing it into position over the valves. Bolt the radiator header to the valves with the bolts provided and pull down evenly all the way around. Attach radiators with mounted fans first and then attach the remaining radiators. Leave the radiator valves closed. Touch up the paint when necessary.
Power Transformer Instruction Manual Version 1.0 Page 18 of 30 For transformer shipped or stored with oil, do not allow oil level to fall below the top of the top coil clamping ring. If there is insufficient oil in the tank, stop the radiator filling process and add oil before completing radiator filling. If the unit was shipped or stored over-filled with oil, the radiator valves should be opened at this time to lower the oil level. Loosen the top radiator header plug and slowly open the bottom radiator valves one at a time. This will allow the radiators to be filled from the bottom, avoiding trapping of gases or air pockets in the radiator. As the oil becomes visible around the header plug or when all of the gas is purged from the radiators, tighten the header plug and open the top valve. After all radiators have been filled with oil and the oil adjusted to the 25C level, remove the top header plug, then reinstall using Teflon pipe thread tape on the plug to prevent future leaks.
For transformer shipped or stored dry, leave the radiator valves closed until the unit is ready for oil filling.
5.5 Cooler installation
Coolers should be placed plat on suitable support with fans on the top side. Remove the shipping covers and make sure there is no internal contamination. The gasket groove and flange faces should be clean.
5.6 Conservator installation
Install the conservator per outline drawing. Make sure flow pipe is correctly aligned before tightening the tank down.
Following the mounting of all accessories, a final internal inspection should be performed if any work has taken place inside the tank. Electrical connections should be checked for tightness. Bushing gasket sealing and the draw lead connections should be checked as well. Also check all leads for maximum clearances. In addition, check the liquid float and operation of the indicator for free movement.
Finally, verify all tools and foreign materials that have been used inside the tank have been removed.
Reinstall all manhole and hand hole covers and other covers where a device has not been installed.
Ground bushings to protect personnel and the transformer.
Record the time that the transformer is closed to determine total exposure time.
Power Transformer Instruction Manual Version 1.0 Page 19 of 30
6. Processing and Vacuuming
Tests to be performed after final processing (24 hours):
Leak test. Apply 6 PSI of dry air on the unit. Log readings until pressure levels off indicating no leak. Core ground test. Hold a steady voltage for 3 minutes with a megger. The minimum reading should be 200 volts megohms. Ratio test. Complete readings on all taps and compare with test report from factory. Check all current transformers including hot spot heating coil circuit for open circuit using an ohmmeter.
Oil quality check
Oil samples from the transformer should be taken from the oil sampling valve at the bottom of the tank. Oil samples from tankers or drums should be taken from the bottom as well.
Before the oil can be pumped into the transformer, it should have the following characteristics:
Moisture content <15 ppm Gas content <0.5% Dielectric strength: >35 kV (ASTM 877), >60 kV (ASTM 1816, 0.08 gap) Oil power factor. The maximum allowed is 0.5% at 90C
Processing for transformers shipped or stored oil filled
If any oil must be removed or added for any reason, the oil may be replaced by one of the following methods.
i. If oil must be removed below the top of the core or below the top of a 350 kV BIL or above terminal board, the oil must be complete removed and vacuum processed per section 6.4 below.
iii. If limited amount of oil, such as make up oil, is removed, it may be allowed to add the oil through the manhole by laying the hose on top of the core and directing the oil along the top of the core. Adding additional amount of oil entails a greater risk of aeration of the oil and the possibility of entrapping air bubbles in the windings. This method is therefore not preferred and should only b used when there is no other alternative. Power Transformer Instruction Manual Version 1.0 Page 20 of 30
If this method is used, a minimum of 24 hour sit time must be observed.
Vacuum filling procedure
Equipment needed for vacuum filling:
Vacuum pump, approximately 150 CFM capable of 200 microns in the blank-off condition. Filter press, approximately 30 gallons per minute. Extra set of filters. Vacuum gauge. Vacuum pipes or flexible hoses (2 diameter minimum). Oil supply lines and connections. Vacuum valve. Dry air supply.
The principal function of vacuum treatment is to remove trapped air and moisture from the insulation. Small gas bubbles have much lower dielectric strength than the solid and liquid insulation and may cause dielectric failure if located in high stressed areas.
The transformer should be oil filled on relatively clear days when the humidity is less the 70%. The oil temperature must be 0C or higher.
Before setting up the vacuum filling procedure the conservator and the air bag should be checked carefully for any defects and contamination.
Follow the procedures below for vacuum filling:
i. Pressurize the air bag with 0.5 PSIG so that the air bag will be flat and straight prior to oil filling. This work can be done on the ground before the conservator is installed on the mounting bracket.
ii. Connect the vacuum line and vacuum gauges in preparation for pulling a vacuum. An oil sight gauge (or tube) should be installed as well.
iii. Check all radiators or coolers to make sure that all the valves are open and bolted to the open position.
iv. All transformers should be filled through bottom filling valve. v. Make sure equalization is achieved between main tank and LTC and between conservator tank and its bladder.
vi. Pull a vacuum to 1 torr.
Power Transformer Instruction Manual Version 1.0 Page 21 of 30 vii. Hold a vacuum of at least 1 mm for a minimum of 4 hours, plus an additional hour for each hour the transformer was open for inspection and assembly. The vacuum must be held for a minimum of 8 hours at 1 torr. or lower for transformers rated up to 350 kV BIL, 12 hours for 450-550 kV BIL, 24 hours for 650-750 kV BIL and 48 hours ??for 825-1050 kV BIL. During this period, the vacuum level should be recorded at least once every hour.
viii. At the end of vacuum hold cycle, the oil filling process can then be started. An oil temperature of 50-75C is recommended as higher temperature oil will speed up the impregnation of solid insulation.
ix. During oil filling, the vacuum level should be maintained at 5 torr. or less. The operator should observe the oil sight gauge. When oil level reaches approximately 10-12 inches form the top of the cover, the oil filling process should be stopped by closing the top filling valve.
x. Break the vacuum with dry air or nitrogen. The main transformer should then be pressurized to approximately 0.5 to 1 PSIG. The vacuum fittings should also be removed at this time and the vent sealed.
xi. Open the top filling valve. Fill the conservator tank until the oil level gauge on the conservator register 25C or higher depending on oil temperature. As the oil is being pumped into the conservator the pressure in the bag should be observed and air bled off as the oil level rises. The pressure in the bag should not exceed 2 PSIG during filling. The vent valves on the conservator tank should be open to relieve the air pressure in the conservator that will build as the oil is pumped into the conservator.
xii. Inject 1 PSIG into the bladder. Oil should discharge from the conservator tank filling valve. Install the male plug on the valve right after. Adjust oil level so the gauge corresponds to the oil temperature. Level correction with temperature should be considered.
xiii. Close top filling valve and remove fill line.
xiv. Air that is entrapped in various locations should be bled off as follows:
Normally the air entrapped in the top of the main transformer can be bled off through the gas monitor. Some transformers are designed with bushing wells or turrets. There will be vent valves through which the air must be bled off. Power Transformer Instruction Manual Version 1.0 Page 22 of 30 There are some designs in which the top cover will be crowned. These will have piping with vent valves through which this air must be bled off. In other cases there are vent valves on the conservator from which the air must be bled off.
xv. Check thoroughly that all vent valves are closed so that oil will not be forced out of them.
xvi. Check the gas monitor to make sure that all air has been purged from the piping leading to the gas monitor. If this is not done, the gas monitor will trip and show gas in the transformer.
xvii. It is recommended that the gas monitor be checked one week after the transformer has been oil filled to confirm that it is reading in the normal range. If it is not, more than likely there is air entrapped wither in the gas monitor or the line that must be bled off.
Oil Filling When Core and Coil Assembly Are Below 0C
i. Pull a vacuum of 5 torr. for 4 hours.
ii. Following this, spray hot oil through the cover of the transformer. The oil should be sprayed so that the stream is broken up into droplets for more efficient heating of the core and coils. Maintain a vacuum of 10mm or better on the transformer during the oil spraying operation in order to prevent oxidation of the oil and to aid in the removal of gas from the insulation.
It will probably be necessary to maintain some oil in the bottom of the unit to feed the output pump. Usually 12 to 24 inches of oil level in the bottom will be sufficient. Do not allow the oil level in the bottom to exceed 36 inches. A clear plastic hose can be used as an oil level indicator. Pump the oil from the bottom of the transformer through filters, through degasification and dehumidification equipment, through the heat exchanger, and finally back to the cover of the transformer.
The oil temperature entering the tip of the transformer should be as high as possible but should not exceed 90C. Continue spraying the hot oil under vacuum until the temperature of the core and coils is well above 0C. The temperature of the core and the coils will be at equilibrium conditions when the output oil temperature becomes constant, and will be within 5C of the temperature of the input oil.
Power Transformer Instruction Manual Version 1.0 Page 23 of 30 The heating rate can be increased by closing the bottom valves to the coolers or radiators and by blanketing the outside of the tank to restrict heat loss.
iii. After the temperature of the core and coils has been elevated above 0C, drain all oil from the tank and coolers or radiators. It will be necessary to break the vacuum in order to drain the oil. The vacuum must be broken with dry air (-60C dew point) to prevent condensation in the tank.
iv. As soon as the oil is drained from the tank, immediately start the vacuum treatment.
Open all valves to all radiators, pumps, coolers, or other cooling equipment. Pull vacuum to 1 torr. and hold for 8 hours prior to filling. Then admit oil (60C) into the top filter press valve while holding the vacuum level at 5 torr. until oil reaches the normal level as shown by the liquid-level gauge. Then proceed as explained on Section 6.4.
Safety precautions
Never leave a transformer that is under vacuum unattended. Never walk or stand on a transformer cover when the unit is under vacuum. Never apply any voltage to a transformer that is under vacuum.
7. Field Testing
The following tests must be performed before the transformer can be energized.
Oil dielectric strength. The minimum value should be over 40 kV (ASTM D-877) or 35 kV (ASTM D-1816, 0.04 gap)
Oil power factor. The maximum allowed is 0.05% at 25C or 0.3% at 100C
Oil water content. The maximum 15 ppm
Ratio test. The maximum allowed is within 0.5% of calculated value. The tested value should also be very close to the factory test results.
Insulation power factor and capacitance including bushings. The maximum allowed power factor is 0.5% corrected to 20C. Capacitance should not vary for more than 5% compared with factory test results.
Power Transformer Instruction Manual Version 1.0 Page 24 of 30 Core ground test. The core ground should have been tested during the internal inspection. If the internal inspection is not done, the core ground should be tested at this time.
Winding resistance. The resistance of transformer windings can be measured using either the resistance bridge method or the Drop in Potential method. The values reported on the factory test report are corrected to either 75 or 85C. Correct the measured value to the same temperature base for comparison.
Current transformers. All current transformers must either have their secondary windings short circuited or connected to a load before a voltage is applied. Never open the secondary circuit of a current transformer while the primary is carrying current. A high voltage might develop which can be harmful to personnel or equipment.
Accessories test. For transformers furnished with thermometers for measuring oil and winding temperatures, the settings for the signaling should be made per customer standard. In addition, all indicators such as fault pressure relays, pressure relief devices, etc. should be tested. Follow instructions provided and check that all signals, trappings, etc., are going through.
Fan motors. The direction of fan motors rotation should be checked to ensure correct fan cooling.
8. Energization
8.1 Check the following before energization.
Transformer tank and neutral bushing(s) are properly grounded. The connections to lines, bus bars and ground are secure. No bushings and arresters are strained. All bolts and gaskets are sufficiently tightened. All relays are adjusted to specifications. No tools or equipment are left on the transformer. The off load tap changer is in the desired position and is locked in place with a padlock. All insulating oil is at its proper position. Valves from the conservator to the main tank should be in open position. All radiator/cooler valves should be open and bolted. All paint damage is repaired. Silica gel in conservator tank breather should be blue. Terminal connections in control cabinet are tight. Power Transformer Instruction Manual Version 1.0 Page 25 of 30 Place shorting straps across the full CT winding for all CT are not connected to load. All CT secondary circuit must be grounded, whether the CT is in use or not, either in the transformer control cabinet or at the load. Shorting straps on winding temperature indicator CT terminal block and line drop compensator CT terminal block should be removed. Similarly, shorting straps on all other CTs that connected to loads should be removed. Make sure heaters in control cabinet are in working condition. Bleed gas detect relay. Remove all temporary shipping plugs. Reset all drag hands on alarm gauges and the LTC position indicator.
8.2 Sitting time
To guarantee complete oil penetration and dissolving of any gas bubbles in the insulation, the transformer should not be energized until sufficient time has passed to allow oil to dissolve any gas bubbles which were formed in the vacuum filling process. The following table sows the recommended sit time based on units BIL rating.
BIL (kV) Sit time (hours) 350 or less 12 450 to 550 16 650 to 750 24 825 to 1050 48
8.3 Energizing the transformer
Applying full voltage and allow the transformer to operate for at least 2 hours without load. Listen for abnormal noises. Check for excessive vibrations.
After applying full voltage, the transformer can be loaded. The transformer should be closely observed during the first few hours of operation under load. Check gauges to see if specified limits are exceeded.
After several days of operation, check the oil moisture content and dissolved gas level.
Power Transformer Instruction Manual Version 1.0 Page 26 of 30
9. Maintenance
Proper maintenance is essential in ensuring trouble free transformer operation. Power transformers in service are often subjected to various electrical, mechanical and thermal stresses. In order to avoid faults, it is important to carefully inspect and maintain the transformers.
Certain items on a transformer must be inspected regularly to ensure proper operation and long service life. The frequency of these inspections is determined by the size and type of the transformer, the operating environment and the importance of the unit.
Internal inspections should be only conducted when there is a suspicion of trouble, when oil is removed from the tank. In the event a transformer is opened for inspection, follow the same procedures and precautions as for an initial installation.
Spare transformer should be inspected and maintained in the same manner as transformers in operation.
9.1 External maintenance
i. Regular annual inspection is required on transformer tank, tank cover, gaskets and valves.
ii. Cleaning is another part of external maintenance. Use solvent to thoroughly remove any oil that is on the tank or the gasket.
The bushing porcelain must be kept clean and inspected yearly. Abnormal conditions such as sand and dust, salt deposits, chemical fumes, etc. require more frequent cleaning to avoid accumulations on the surface. Acceptable methods are hot line washing and washing with solvent.
Keep the heat radiating surface of the transformer clean. External surfaces of coolers should be periodically cleaned. Transformers near the sea coast or in highly corrosive environment should be painted regularly to prevent corroding or rusting of metal parts.
All breathers and small openings in pressure relief valves and pressure- vacuum bleeders must be kept clean and in good operating condition.
All ground buses and wiring leads to ground must be kept in good condition.
9.2 Cooling systems Power Transformer Instruction Manual Version 1.0 Page 27 of 30
Cooling fan motors use pre-lubricated sealed ball bearings that do not require lubrication maintenance. During extended periods of reduced capacity not requiring fan operation, it is suggested that fans be run periodically to ensure proper operation.
External cooling surfaces should be cleaned annually to remove any accumulation of dirt or debris that may block external air passages of radiators or coolers so that free air flow can be maintained.
9.3 Temperature
Transformer temperature, oil and/or winding, is one of the major factors that determine the life of a transformer. Therefore it is important to monitor the transformer temperature on a regular basis.
If the temperature of a transformer rises without load increase, it is possible that some of the cooling is impaired. This situation should be carefully investigated.
9.4 Oil
Transformer oil is hygroscopic thus easily absorbs moisture from the air. The absorption of moisture is minimized by the conservator system with a silica gel breather. The gel should be properly renewed or regenerated as soon as its ability to absorb moisture begins to diminish. A change of gel colour from blue to pink indicates saturation with moisture.
If the transformer oil has been exposed to air while work has been carried out on the transformer, the oil should be checked for moisture content and dielectric strength. A similar check of the oil should be made on all transformers at regular intervals. IEC standards provide guidance for the acceptance, maintenance, continued use and reclamation of insulating oil.
In addition to oil quality checks, oil levels in the tank and LTC mechanism compartment should be checked weekly during the first month of operation and annually afterwards.
In addition, dissolved gas analysis should be performed to provide early warning of evolving problems within the transformer and to allow preventive actions to be taken before serious damage occurs.
9.5 External circuit and control equipment
The following should be inspected 30 days after installation and once per year afterwards. Power Transformer Instruction Manual Version 1.0 Page 28 of 30
Control circuit voltage. Excessive heating of parts as evidenced by discoloration of metal parts, charred insulation or odor. Freedom of moving parts. Excessive noise in relay coils. Excessive arcing in opening circuit. Evidence of water or oil in the control cabinet. Proper functioning of timing devices, sequencing of devices, relief device alarm contacts and thermometer contacts.
9.6 Accessories
All accessories should be tested once a year. Inspect all apparatus, electrical cables and conductors, signaling and operating devices to the control room or control board.
9.7 Paint
The paint of the transformer should be free of damage when the unit is put into service or storage. In order to ensure maximum corrosion protection, all damage, such as chipped paint or scratches through to the bare metal, should be fixed and the paint thickness should be restored to its minimum value as soon as possible.
If bare metal is exposed, the area must be sanded down to blend the damaged area into the undamaged paint surface. Wipe the sanded area clean with denatured alcohol or a solvent to remove dust or oil. The area must then be brush or spray painted with primer, intermediate coat and finish coat. If the primer is not damaged, lightly sand the damaged paint surface to smooth rough edges. Brush or spray on the intermediate coat and then the finish coat to restore or exceed the original finish thickness.
Power Transformer Instruction Manual Version 1.0 Page 29 of 30
10. Attachments
Figure 1. Dew Point to vapour Pressure Conversion Chart
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