Академический Документы
Профессиональный Документы
Культура Документы
(JIGCC) Project
SPTC Document No :
Revision : A00
NMR Code :
Revision History
CHEC-JIGCC6OOK-72-QC-QPL-0001
Installation, Operation and
Maintenance Manual
1
Installation, Operation and Maintenance Manual
General Index
2
Installation, Operation and Maintenance Manual
3
Installation, Operation and Maintenance Manual
4
Installation, Operation and Maintenance Manual
5
Installation, Operation and Maintenance Manual
6
Installation, Operation and Maintenance Manual
7
Installation, Operation and Maintenance Manual
Index of tables
Table 1 Minimum recommended (temporary) grounding cable size for copper cable ................... 16
Table 2 Temperature correction factors for megger (K 1 ) and power factor or tan tests (K 2 ). ...... 19
Table 3 Max. spanner values for bolt nut connections ................................................................ 19
Table 4 Recommended torque values for SEFCOR connectors.................................................... 20
Table 5 International System of units (SI) (Metric practice) ........................................................... 21
Table 6 Multiplication factors .......................................................................................................... 21
Table 7 United States System ........................................................................................................ 22
Table 8 SI conversion factors ......................................................................................................... 24
Table 9 Conversion table for pressure and stress .......................................................................... 25
Table 10 Dew point measurement .................................................................................................... 44
Table 11 Minimum number of rods required per set under the transformer ..................................... 51
Table 12 Required vacuum pump capacities ................................................................................... 53
Table 13 Oil treatment ...................................................................................................................... 70
Table 14 Required vacuum for flashing surface moisture ................................................................ 84
Table 15 Vacuum hold times for flashing surface moisture.............................................................. 84
Table 16 Maintenance inspection chart ............................................................................................ 99
Table 17 Electrical malfunction troubleshooting chart .................................................................... 100
Table 18 Mechanical malfunction troubleshooting chart ................................................................ 101
Table 19 Water in oil ....................................................................................................................... 104
Table 20 Particles in oil ................................................................................................................... 104
Table 21 Limits for normal values for Saudi Power Transformers Company ................................. 105
8
Installation, Operation and Maintenance Manual
Table of figures
Annexures
Annexure A Operation and Maintenance Manual for Oil to Oil Bushings
Annexure B Operation and Maintenance Manual for Pfisterer
9
Installation, Operation and Maintenance Manual
10
Installation, Operation and Maintenance Manual
1 General information
11
Installation, Operation and Maintenance Manual
In the Manufacturing Data Record Book (MDRB) a The most important drawings are the following:
separate binder the test reports of the transformer and The General Arrangement Drawing: shows a side, top
its accessories are included. and front view of the transformer. The dimensions and
weight of the fully assembled transformer are given, as
well as the weight of the oil. All important components
12
Installation, Operation and Maintenance Manual
are identified by "item numbers" which relate to the instructions are included in section [8]. The special
Materials List. instructions are specifically written for the transformer.
The Materials List: can be printed on the General
Arrangement Drawing or on a separate document. The NOTE
Materials List gives the type and brand of most Always consult the special instructions section [8] to
accessories. verify if special procedures have to be followed
during installation, operation or maintenance.
Schematic Drawings (of Control & Protection Circuits
and Motor Drive Unit): give information on the connection
between the different protective devices mounted on the
transformer.
1.1.7 For more information
Name Plate (or Rating Plate): gives the main electrical
characteristics.
1.1.7.1 Your Saudi Power Transformers
Company contact person
13
Installation, Operation and Maintenance Manual
For problems or questions after the warranty period has Use the padlock and key interlock system where
expired or for additional parts or materials (not included available to protect yourself and others.
in the scope of the order) you can contact SPTC directly.
Do not work under equipment that is raised and
insecurely blocked. Do not walk under equipment that is
suspended from a crane.
Saudi Power Transformers Company
St. # 111, Across St. # 144 Do not walk holding a ladder or any other long object
Second Industrial City near a transformer or overhead lines under voltage.
Dammam Before lifting any object by any means, ensure that its
Kingdom of Saudi Arabia weight can be handled correctly. Use the appropriate
lifting or handling tools.
Tel: +966 / (13) 814 4626
Fax: +966 / (13) 814 4627 Do not work on or adjust moving equipment. Do not work
on or adjust mechanical equipment unless its motive
source has been deactivated.
Every employee must have a safety program and he has Do not walk on a transformer under vacuum. Never
to know how to use it in the event of an accident. perform any electrical tests on a transformer under
vacuum. Do not apply vacuum when it is raining or when
Ensure that safety equipment and tools are always close the transformer is unsupervised.
at hand.
When pressure tests are being performed or when
Keep suitable fire extinguishing equipment and qualified vacuum is being applied, the pressure must be equalized
personnel available. Make sure that the equipment used between the main tank and the (On) Load Tap Changer
is suitable for fire involving oil filled electrical compartment if these compartments are separated by
installations.. Make sure that it is correctly charged and terminal panels which might not be able to withstand
that you know how to use it. pressure differences mechanically. Find out which parts
Always be alert to emergencies. If an accident should will not be able to withstand a complete vacuum.
occur, quickly utilize the safety equipment, emergency Before removing any cover plate or transformer fitting,
tools and equipment at hand. Before you begin a project, ensure that the overpressure inside the transformer is
ensure that at least two people know first aid procedures zero and that the oil level is lower than the opening in
and that they have the proper first aid kits at hand. question.
Ensure that all protective equipment required for the job In the event of a sudden change in the weather bringing
is available to all workers and ensure that it is used penetrating rain or snow, provisions must be made for
correctly. This equipment may include hard-hats, closing the tank quickly and pressurizing it with nitrogen
breathing apparatus, eye protection, gloves, foot in order to preserve the insulation.
protection,
To allow anyone entering a transformer the air has to
Ensure that all electrical circuits to be worked on have support life with a sufficient oxygen level (19.5 %).
been traced and de-energized. Ensure that all safety
grounds have been correctly applied to protect personnel Extreme precautions are to be taken to protect the
against the accidental application of power to these insulation of the transformer from any damage and to
circuits (refer to chapter 2 for more information on prevent the ingress of foreign objects and moisture
temporary grounding.) Do NOT assume that someone during the checking and erection of the transformer.
else has turned off the power, check for yourself.
14
Installation, Operation and Maintenance Manual
Whilst the transformer is open, no one may be allowed 1.2.3 Voltage hazards and temporary
on top of it, unless this person has emptied his/her grounding (earthing) systems for
pockets, has checked himself/herself for the presence of
objects such as watch, rings etc. and has removed them.
transformers
These precautions must be taken to prevent objects from
falling into the transformer. 1.2.3.1 Voltage hazards
Anyone going inside a transformer must wear clean The turns ratio between the windings of any power
clothes and clean synthetic-rubber boots. transformer makes them capable of transforming what
Never stand directly on any part of the insulation. are normally considered harmless voltages into
dangerous and even lethal levels.
Clean rags, sheets of paper, etc. are to be used under
the working surfaces in the transformer to prevent Electrical welders, continuity checking instruments and
objects from falling into the windings. insulation testing apparatus are examples of sources of
so-called harmless voltages. Even if these are direct
All tools must be listed. For safety first reasons they current (DC) devices, they are capable of producing
must be attached to the wrists or belt, so that they voltages high enough to be hazardous to human life,
cannot fall into the windings. when the circuits they are connected to are made or
Smoking is not allowed on the transformer, nor is it interrupted.
allowed in the vicinity of an oil-processing plant. Other situations which may present hazardous
Lamps used for lighting the inside of the transformer conditions include the high voltage produced by open
must be the shielded type with a maximum voltage of 36 circuited current transformers (including these which are
V. Debris from a broken lamp bulb may not be able to used for Winding-Temperature-Indicators, WTIs) which
drop out. have current flowing in the primary circuits and the
electrical charge which may by retained by condenser
If in spite of all preventive measures something style bushings after the transformer has been
does fall into the transformer tank and cannot be disconnected from the external circuits. The open circuit
retrieved, do not proceed with the energization and voltage that is developed depends on the design of the
do not perform any electrical tests that may cause CT, but is nearly always dangerously high. NEVER
damage to the transformer. Immediately contact disconnect a CT secondary while the primary circuit is
Saudi Power Transformers Company instead. energized. CTs must be connected to a suitable load or
must be shorted by a link that is suitable for carrying the
rated secondary current.
Correct operation of all protective circuits and protective
devices for the transformer should be checked on a Delta-connected windings that are not connected to any
regular basis. Neglection of these circuits or devices, or external circuit may also retain a charge after the
overriding of the functions of these circuits or devices transformer has been de-energized for a period of time.
could allow minor problems to develop into a major
problems. This may result in a total loss of the
transformer, damage to other equipment and injury of
personnel. DANGER
For personnel and equipment safety reasons:
A pressure relief device incorporates heavy spring in ground the transformer tank as soon as possible,
compression, DO NOT DISMANTLE such a device, ground all bushings whenever possible and connect
unless suitable safeguards have been implemented, CT secondary circuits to a suitable load or short-
otherwise personnel injury may occur. circuit them.
Recommended commissioning checks must be
performed before the first energization of the
transformer.
15
Installation, Operation and Maintenance Manual
1.2.3.2 Preventive measures For similar reasons, no slack or loops in the grounding
cables may be allowed.
When personnel is working on de-energized
If multiple grounding cables are used in parallel, they
transformers, winding terminals should be suitably short-
must be twisted or lashed together to prevent
circuited and grounded according to the correct safety
mechanical reaction between the cables during the flow
practice in order to avoid injury or even death (see
of fault current. The grounding clamps must be installed
section below).
touching each other to prevent them from pulling
Unused current transformers must always have their together and from possible loosening during a fault.
secondary windings short-circuited with suitably sized
Groundings are to be applied from each of the
wire to avoid high open circuit voltages.
transformer terminals to the station grounding bus.
Phase-to-phase jumpering after one phase has been
grounded is permissible. This short circuit limits the
a) Recommendations concerning temporary grounding
amount of fault current which circulates through the
(earthing) systems
grounding cable back to the phases. Jumpering is
usually not suitable in HV switchyards due to the large
Temporary groundings, used while personnel are inter-phase clearances.
working on de-energized transformers, must always be
applied in accordance with the approved safety and
operation practices issued by the employer. In addition, b) Minimum grounding (earthing) cable sizes
they must be in accordance with the instructions for the
specific grounding equipment used.
The following minimum grounding cable sizes are
Temporary grounding is required for a number of recommended, in association with suitably sized screw
reasons: type grounding clamps:
Induced voltage from adjacent energized lines.
Fault current feed-over from adjacent lines. Min. cable size per
Lightning strikes anywhere on the circuit. Max fault
Max
phase
Switching equipment malfunction or human error. current
duration of
2
Accident initiated contact with adjacent lines. fault current AWG mm
<22 kAmps 25 cycles 1x2/0 ~1x70
It is important to ground ALL terminals of the transformer 22-34 kAmps 25 cycles 1x4/0 ~1x110
(not just HV circuit) to protect against back-feed from the 34-60 kAmps 25 cycles 2x4/0 ~2x110
low voltage or tertiary voltage circuits. Table 1 Minimum recommended (temporary)
Only screw type grounding clamps may be used. Clip-on grounding cable size for copper cable
clamps are not acceptable. Clamps must always be
securely tightened. Clamps and cable size are to be
selected in accordance with the short circuit capability of
c) Establishing the grounding (earthing) system
the power system at the transformer terminals and for
the maximum duration of time that the fault current will
flow before the protection system de-energizes the
circuit. If the actual fault capacities are not known, DANGER
National Standards provide recommended levels that Ensure that at least one person is present who is
can be used. trained in the correct application of temporary
grounding systems.
Grounding cables are to be securely lashed to structural
members or other fixed objects to prevent violent
whipping of the cable due to electromagnetic forces In order to physically attach temporary groundings in a
developed by the flow of the fault current (violent correct manner, first ensure that the circuits are
whipping may loosen or disconnect the ground clamps). intentionally de-energized. Use an approved voltage
detector to assure yourself that the circuit is dead. Next,
16
Installation, Operation and Maintenance Manual
clean oxides and contaminants from the conductor to be 1.4 Warranty period and conditions
grounded, whether it is cable or busbar. When attaching
the screw type ground (earth) clamp, use the torque Although the equipment is under warranty for a certain
recommended in your safety procedures or by the clamp period, it is advisable to do whatever is necessary to
manufacturer. minimize the impact of abnormal conditions.
Minor problems may cause serious defects in
certain cases.
Never energize a transformer that is not fit for use.
1.3 Material Safety Data Sheets(MSDS) Always follow the instructions in this IOM-manual.
In case of doubt, contact Saudi Power Transformers
Material Safety Data Sheets for the potentially hazardous Company.
materials and products are included in the
documentation [part B]. The information in the MSDS
refers only to new materials and products as The applicable warranty period and conditions are
manufactured, before their use in/on a transformer or indicated in the contractual terms and conditions.
electrical product.
The content of Material Safety Data Sheets may include:
Identification of the Substance/Preparation and the 1.4.1 Actions to be taken at installation
Company/Undertaking
and commissioning
Composition/Information of Ingredients
Hazards identification
The warranty becomes operational on the condition that
First aid Measures
following steps have been taken:
Fire-fighting Measures
Accidental Release Measures 1. Before energization: a complete (fax) copy of the
Handling and Storage Site commissioning report has been sent to your
Exposure Controls/Persona Protection Saudi Power Transformers Company contact
Physical and Chemical Properties person. Make sure that all tests and inspections
Stability and Reactivity have been satisfactory before energization.
Especially all securing and protective accessories
Toxicological Information
have to be checked. When not all parameters are
Ecological Information
according to the requirements, do not energize. We
Disposal Considerations will evaluate the report and advise you how to
Transport Information proceed.
Regulatory Information 2. After energization: a complete (fax)copy of the
Other Information Energization report has been received by Saudi
Power Transformers Company latest one week
after energization.
NOTE
The information provided in the Material Safety Data Only upon receiving these 2 reports the contractual
Sheets is correct to the best of our knowledge at the warranty conditions, concerning operational defects, will
date of its publication. The information given is be applied.
designed as a guidance for safe handling, use,
processing, storage, transportation, disposal, and During operation it is recommended to record all events
release and is not to be considered as a warranty or (readings, inspections, tests, network conditions, ) in a
quality specification. The information relates only to transformer log book. This log book should be available
the specific material in combination with any other at the time of an intervention.
materials or in any other process, unless specified in
the MSDS or in this IOM-manual.
17
Installation, Operation and Maintenance Manual
1.4.2 Actions to be taken in case of 1. Check for visible damage before unloading
severe abnormal conditions 2. Check the impact recorder for high readings
3. When assessing the damages sustained by packing
and/or contents: describe your findings in the
First of all, take all necessary preventive measures to
transport document intended for the carrier and be
minimize the risks of damage. If the transformer has not
sure to keep a copy. If need be, write down a joint
yet been switched off by own securing systems, make it
statement together with the driver.
manually! A quick response often prevents things from
4. You may subsequently unload.
getting worse. Once personnel are safe and equipment
conditions are stabilized, contact your Saudi Power
Transformers Company contact person and provide as Further procedure or assessment of damages after
much information on the event as possible. Never start receipt:
neither any corrective measures nor re-energizing
without the approval of Saudi Power Transformers a) If you received an insurance certificate and/or in
Company. case land carriage was preceded by MARIN
TRANSPORT
1. follow the instructions on the flip side of the
insurance certificate conscientiously
2. never sign any clean receipts but formulate your
1.5 Insurance reserve in these documents.
3. always inform our insurance department
1.5.1 Transfer of risks b) If you did not receive an insurance certificate and in
case land carriage was not preceded by MARIN
The transfer of risks is closely related to the delivery TRANSPORT
terms and conditions stipulated in the contract or order. 1. hold the carrier immediately liable by registered
We refer to the contractual terms and conditions for more letter
information about which delivery term applies. For more 2. inform our transport and insurance departments
information on delivery terms (FOB, CIF, DDU, ) and immediately
their implications, we refer to the international literature 3. always do what is necessary to limit the present
about this topic. damages and prevent subsequent damages.
c) In case of transport by rail: have the competent
authorities make a report at the arrival station.
18
Installation, Operation and Maintenance Manual
TC 65 70 75 80
K1 22.00 32.00 45.00 62.00 Remarks:
K2 1.46 1.56 1.75 2.00 This table applies to bolt nut connections that are not
Table 2 Temperature correction factors for greased ( = 0.14 steel and 0.20 for stainless steel):
megger (K 1 ) and power factor or tan the given values are in Nm and they are values at
tests (K 2 ). 80% of elasticity limit of the material.
values in lbs-ft can be found by multiplying the Nm
values by 0.737
0
Megger test: Resistance at 20 C = Resistance at mean the simple method of 1/4 turns past tight to tighten
oil temperature * K 1 bolts, can be used if an appropriate torque spanner
tool is not available. This however is not
Power factor (or tan ) test: Power factor at 20 C =
0
recommended.
Power factor at mean oil temperature / K 2
Also considered as joints without gasket are (see also
section [4]):
Gasket systems with gasket grooves or gasket
1.6.2 Torque values for bolt-nut
stops
connection High density fiber gaskets
1
This pressure range can be obtained by reducing
the gasket thickness to 2/3th of its original value.
19
Installation, Operation and Maintenance Manual
Hardware
Aluminium
Silicon Bronze Galv. Steel
Stainless Steel
Bolt
Dia in-lb ft-lb N-m in-lb ft-lb N-m
(J) 2
5/16 180 15 20.3 120 10 13.6
3/8 240 20 27.1 180 15 20.3
Figure 1 Example of SEFCOR connector
1/2 480 40 54.2 300 25 33.9
5/8 660 55 74.6 480 40 54.2
3/4 840 70 94.9 720 60 81.3
Table 4 Recommended torque values for
SEFCOR connectors.
Remarks
Connectors are not necessarily part of Saudi Power
Transformers Company scope of supply.
Recommended torque values do not necessarily
apply for other connector brands. Please consult
specific documentation.
2
See figure Example of SEFCOR connector
20
Installation, Operation and Maintenance Manual
21
Installation, Operation and Maintenance Manual
Linear measure
Inches Feet Yards Rods Furlongs Miles
1.0 .08333 .02778 .0050505 .00012626 .00001578
12.0 1.0 .33333 .0606061 .00151515 .00018939
36.0 3.0 1.0 .1818182 .00454545 .00056818
198.0 16.5 5.5 1.0 .025 .003125
7920.0 660.0 220.0 40.0 1.0 .125
63360.0 5280.0 1760.0 320.0 8.0 1.0
Square and land measure
Sq.
Sq. feet Sq. yards Sq. rods Acres Sq. miles
inches
1.0 .006944 .000772
144.0 1.0 .111111
1296.0 9.0 1.0 .03306 .000207
39204.0 272.25 30.25 1.0 .00625 .0000098
43560.0 4840.0 160.0 1.0 .0015625
3097600.0 102400.0 640.0 1.0
Avoirdupois weights
Grains Drams Ounces Pounds Tons
1.0 .03657 .002286 .000143 .0000000714
27.34375 1.0 .0625 .003906 .00000196
437.5 16.0 1.0 .0625 .00003125
7000.0 256.0 16.0 1.0 .0005
14000000.0 512000.0 32000.0 2000.0 1.0
Dry measure
Pints Quarts Pecks Cubic feet Bushels
1.0 .5 .0625 .01945 .01563
2.0 1.0 .125 .03891 .03125
16.0 8.0 1.0 .31112 .25
51.42627 25.71314 3.21414 1.0 .80354
64.0 32.0 4.0 1.2445 1.0
Liquid measure
Gills Pints Quarts U.S. Gallons Cubic feet
1.0 .25 .125 .03125 .00418
4.0 1.0 .5 .125 .01671
8.0 2.0 1.0 .250 .03342
32.0 8.0 4.0 1.0 .1337
7.48052 1.0
Table 7 United States System
22
Installation, Operation and Maintenance Manual
23
Installation, Operation and Maintenance Manual
24
Installation, Operation and Maintenance Manual
mm of
mm of
unity bar mbar Pa KPa MPa kgf/cm2 mercury psi
water
(torr)
1 bar 1 1000 100.000 100 0.1 1.01972 750.062 10197.16 14.5038
-3
1 mbar 0.001 1 100 0.1 0.0001 1.01972x10 0.7501 10.1972 0.0145
-5
1 Pa 0.00001 0.01 1 0.001 0.000001 1.01972x10 0.0075 0.10197 0.000145
1 kPa 0.01 10 1000 1 0.001 0.010197 7.5006 101.972 0.145
1Mpa 10 10.000 1.000.000 1000 1 10.1972 7500.62 101972 145.038
1 kgf/cm2 0.981 980.7 98066.5 98.0665 0.09807 1 735.56 10.000 14.2233
1mm of
-3
mercury 0.00133 1.333 133.3 0.13332 0.1333x10 0.001539 1 13.5951 0.01934
(1 Torr)
1 mm of 6
0.000098 0.098 9.807 0.009807 9.807x10- 0.0001 0.07356 1 0.00142
water
-3
1 psi 0.06895 68.95 6895.06 6.895 6.895x10 0.07031 52.717 703.012 1
25
Installation, Operation and Maintenance Manual
26
Installation, Operation and Maintenance Manual
27
Installation, Operation and Maintenance Manual
0
Oil in: main tank, radiators, conservator (at 20 C)
28
Installation, Operation and Maintenance Manual
2.3.1 General tank design Although the tank is designed to withstand certain
pressures, a pressure relief device (if requested) protects
The tank is a welded steel construction that is designed it against splitting under high internal pressures caused
to operate over a range of top oil temperatures as per by exceptional working conditions. The tank may be
specified standard or customer specifications. supplied with an optional switch. A gas detector type
Furthermore, the tank-cover-conservator combination Buchholz relay with alarm and trip contacts is a
can sustain the specified pressure and vacuum levels as commonly used accessory for this purpose.
per specifications.
For more specific details on the tank design, we refer to
the General Arrangement Drawing. CAUTION
Do not close a valve that may isolate a full oil-filled
The transformer tank, conservator and radiators are tank, because this can produce a very high internal
most likely designed for full vacuum, but to be sure over- or underpressure due to the thermal expansion
always check the transformer nameplate. of the oil. This can damage the transformer or parts
of it. Besides this, humidity or water can penetrate
and damage the insulation system.
CAUTION
Never apply full vacuum unless the nameplate states
that the tank / conservator has been designed for full DANGER
vacuum. Fault gases generated during operation are
combustible, keep away from fire if gases release.
29
Installation, Operation and Maintenance Manual
2.5.1 Introduction
30
Installation, Operation and Maintenance Manual
31
Installation, Operation and Maintenance Manual
1. Drycol breather
2. Conservator and parts
3. Tap changer
4. Bushing
5. Cable box
6. Current transformer
7. Lightning arrester
8. Current transformer
9. Marshalling kiosk
Motor drive unit
Drycol breather
10. Oil-air cooler
11. Radiator
12 Fan
13. Oil-water cooler
14. Pump
2
15. Equipotential bonding 25 mm
(M6)
16. Grounding (earthing)
2
connection 70 mm (M12)
17. Ground connection client (flat
30x10 / stainless steel)
32
Installation, Operation and Maintenance Manual
2.6 Transformer Painting Two components, polyamine adduct cured epoxy paint.
Contains zinc phosphate and mio.
The transformer painting is always in accordance with
the specifications of the customer. Composition:
Remark: Solvents: Xylen,
Preparation and painting of metal parts (conservator, Solids (62%):
pipes, radiators, ...) are equivalent to preparation and - resin: epoxy
painting for the main transformer (unless otherwise - pigments: zinc phosphate, colour pigments
specified). - micaceous iron oxide
- additives
33
Installation, Operation and Maintenance Manual
34
Installation, Operation and Maintenance Manual
35
Installation, Operation and Maintenance Manual
3.1 Packing
3.1.1 General
3.1.2.1 Seperately deliverd oil
The packing type, dimensions, weights and degree of
protection depend on: Separately delivered oil is usually packed in sealed
(metal)-drums of 200 liters. The drums are collected on
Allowed dimensions and/or weight for handling and standard pallets (4 drums per pallet).
transport
For bigger quantities also special oil-tanks or containers
Means of transportation (railway, road,
can be used.
seatransport, )
Legal obligations concerning transportation
Limitations given by roads, railways,
Limitations due to local handling equipment
Customer specifications 3.1.3 Condenser / oil-oil bushings
Condensor / oil-oil bushings are packed in the original
Each package is marked and contains a packing-list.
wooden box or crate. Each condenser bushing in an
These packing lists will be a usefull tool during
hermetic sealed plastic bag which contains a small
installation on site so make sure that they stay with the
quantity of silica gel (for humidity control).
packages.
Remarks:
a) Transformers which are partially filled with oil or
which are empty of oil during transportation, are 3.1.5 Radiators
equipped with an inert gas pressure system. This to
prevent humidity entering the transformer body Radiators are packed on pallets as a standard. Crates or
b) Smaller transformers can be transported completely boxes are provided if specified.
assembled and completely filled with oil. In these
cases there is no need for an inert gas pressure
system. Another advantage is that the installation
time is seriously reduced.
c) For details of dismounted parts for transport, see
3.1.6 Conservator, pipes and cable boxes
the General Arrangement Drawing and Materials
List [part C]. These parts are packed on pallets and protected with a
plastic cover. Crates or boxes are provided if specified.
36
Installation, Operation and Maintenance Manual
DANGER
Take all necessary safety measures during handling
and transportation to prevent personal harm.
3.1.7 Control cabinets Especially pay attention during the lifting or jacking
of a transformer: Never work under a non-secured
Control cabinets are provided with bags of an adequate lifted or jacked transformer.
quantity of silica gel for a storage of some weeks to Never attempt to move a transformer by pushing
prevent condensation water damage. The corners of the against the tank itself or any of the accessories.
cabinets are protected by special profiles. Do not weld other attachments to the tank, nor loop
Control cabinets are packed on pallets and protected cables around the tank or any of the accessories.
with a plastic cover. Crates or boxes are provided if
specified.
Always handle a transformer as gently as possible.
Heavy shocks or impacts can damage the transformer
internally without any external sign of damage. That is
why the prescribed receiving inspection must be followed
3.2 Transport and handling without any deviation. [see further in this section]
37
Installation, Operation and Maintenance Manual
3.2.2 Handling instructions during Ignoring this advice may result in deformation of the tank
loading and unloading and damage to the core and windings.
Saudi Power Transformers Company transformers are
3.2.2.1 Lifting a transformer by crane designed with lifting lugs No. 105 that can lift an
assembled and fully filled transformer.
Usually, the transformer body will be lifted by crane
during loading and unloading. The smaller packages can
be lifted by crane or forklift.
Lifting points are clearly marked by the red painted 3.2.2.2 Jacking a transformer
surfaces. In case of any doubt, consult the General
Arrangement Drawing (or other drawings concerning Also jacking can be a helpful method during loading or
transportation) before lifting. unloading, although handling by crane is preferred.
Jacking, however, becomes more useful for final
positioning of the transformer on its foundation as
described in section [4]
DANGER
Only use lifting points to lift the complete Saudi Power Transformers Company transformers are
transformer or assembly. Always use all lifting always equipped with jacking steps No. 102. These
points together. Consult the General Arrangement jacking steps are designed in such a way that each step
Drawing for the location of these lifting points. can support half the weight of the transformer (in addition
to the required mechanical design safety factors). This is
done to ensure the safety of the transformer when
Only an experienced crew should be allowed to move unbalanced movements are made.
and position a transformer by crane. Ensure that the
capacity of the lifting equipment is suited to the load
being lifted, including the angle from the vertical that the
DANGER
crane boom must provide.
Do not jack the transformer from any other point
Do not attempt to move a transformer by crane if there is than the jacking steps provided.
inadequate space in any direction. The crane boom must Never jack the transformer when it is under
be able to be swung, raised or lowered safely. Take vacuum.
great care concerning other electrical equipment that Always use all jacking points together. In
may be energized, including overhead lines. exceptional cases jacks can be used two by two
at one side of the transformer. In this case, pay
Take care to use spreader bars between the cables, or
attention to the angle of the transformer.
use a lifting beam appropriate in order to keep the lifting
Do not support the transformer for an extended
cable roughly vertical. THE LOADED CABLES
period of time using the jacks only.
SHOULD NEVER ANGLE MORE THAN 15 DEGREES
Add sufficient support blocking under the tank
FROM THE VERTICAL.
base (if a flat base) or under the skids (if a skid
An empty tank or a tank partially stripped of base) as soon as possible.
subassemblies may slope slightly when lifted by lifting Never work under the transformer when it is
lugs. Should the tank begin to tilt significantly, raised solely on jacks.
immediately put the transformer down and investigate
before continuing.
1. For maximum safety and stability, the jacks must be
Attach guide ropes to the skidding eyes at the base of
placed under the jacking steps as centrally as
the tank to guide the tank into position. Do not allow the
possible. A steel or wooden block must always be
transformer to swing freely from the crane. Do not lift the
placed under the jack that must be sitting flat and
load higher than necessary.
level on the ground.
Never attempt to lift the transformer unless the
transformer cover is securely fastened to the tank.
38
Installation, Operation and Maintenance Manual
39
Installation, Operation and Maintenance Manual
damage that occurs while the transformer is in transit. Thermometer for measuring the ambient
Damage that occurs during shipment may be the temperature
responsibility of the carrier. The carrier is relieved of Megger. (nominal voltage of 500 5000 V DC)
responsibility once the shipment has been accepted at Dielectric oil-test equipment
the destination. This is why careful inspection is required
before you accept the shipment.
In case of internal inspection:
Remarks:
Clean plastic boots (if there will be personnel entry)
A Receiving inspection report is included in section [7]. String or cord for securing tools, flashlight etc..
Complete this report and return it to your Saudi Power Clean rags or other clean wiping material
Transformers Company contact person within one week Material, covering manholes or handholes to keep
after the arrival inspection. out moisture laden ambient during inspection
In case of any damage, a claim procedure has to be Dry air installation for injecting dry air to chase away
started immediately. Follow the instructions in the the inert gas (nitrogen)
insurance guidelines available in section [1]
CAUTION
All tools or equipment that will be used over an open
manhole or handhole or that will be taken inside the
3.3.2 Transformer inspection procedure transformer, have to be secured by a cord or string
to a point outside the tank so that they can be pulled
The different steps are the following: out if dropped. Also be aware of the specific weight
1. Preparing for the inspection. of the oil, swimming is not possible.
2. Inspection of the external portion of the transformer
and attachments.
3. Inspection of the accessories and all other
components shipped with the main unit. 3.3.2.2 The external inspection
4. Receiving tests
a) Preliminary inspection
Internal inspection has to be avoided, except when there A preliminary inspection of the shipment must include
might be internal damage. looking for signs of damage to the blocking, guy rods or
cables, signs of impact on covers, control boxes, major
paint scrapes etc.. Note these observations on the form
"Receiving inspection report" in section [7]. Do not
attempt to repair any damage to the transformer main
3.3.2.1 Preparing for the inspection body or to any of the components.After the preliminary
inspection please proceed with the next steps in the
The inspection should take place with a representative of receiving procedure.
the carrier present. All the equipment necessary for the
complete inspection should be gathered before the
inspection process begins. The list of equipment should b) Inspection of the impact recorder and inert gas
include: pressure system
All necessary safety equipment, such as hardhats, If specified, an impact recorder (No. 145) has been
gloves, etc.. installed. This will be indicated on the General
Flashlight Arrangement Drawing
Tools (to open manholes, etc.) See further for more information.
Suitable grounds for grounding the transformer,
bushings and tank Inspect the nitrogen or dry air pressure system (if
Notebook and a camera with flash for recording applicable). If required, an inert gas pressure system has
purposes been installed. This will be indicated on the General
Arrangement Drawing.
40
Installation, Operation and Maintenance Manual
See further for more information. Electrical checks will be performed later during the
commissioning process.
Inspect radiators for dents, scrapped paint,
c) Detailed external inspection damaged or missing fans (if applicable).
Saudi Power Transformers Company has taken all Check all bushings for cracked or damaged
necessary precautions to limit damage during shipping. porcelain. Check for oil around gasketted joints.
However, even the most elaborate steps cannot totally Check the oil level on oil-filled bushings (the
eliminate the possibility of damage during transit. The bushing must be vertical or nearly vertical to check
largest component, and the one most seriously affected this).
by potential damage, is the main tank and the core and Check arresters (if any) for cracked or damaged
winding assembly it contains. That is why the external porcelain.
inspection should begin there. Report all observations on Check the conservator tank (if applicable) for dents
the form "Receiving inspection report". If damage is or scrapes or other signs of damage.
found, photograph the areas of concern to substantiate Check the shipment against the bill of loading and
any claims. Do not remove or open any part of the report any shortages.
shipment until the carrier's representatives have made
their inspection.
Examine the tank for signs of oil leakage, paint
scrapes, dents or other signs of damage. 3.3.2.3 Inspection of accessories
Examine timber bracing, steel blocking, boltdown
rods and cables for signs of shifting of the load. Locate the packing list, so that all accessories can be
checked off as they are inspected. Check for damage to
each crate or package. Open and inspect the contents of
INSPECTION HINTS each package while referring to the packing list. If any
Depressed steel rail cars will usually have steel packing or items are missing, immediately notify the
blocking welded to the car, sitting tightly against the carrier's representative and Saudi Power Transformers
base of the transformer. Shifting of the load can Company.
result in dents in the transformer at the location of
the blocks and/or of the steel blocking itself. Also
look for scratched paint. CAUTION
Flat rail cars and trailers will usually have wooden Hygroscopic materials are protected by packing in
blocking sitting tightly against the base or skid base hermetically sealed plastic bags, including silica gel
of the transformer, bolted to the bed of the car or as indicator for unacceptable moisture penetration.
trailer. Movement of the load may result in broken After inspection, store these materials according to
blocking, pulling out of the bolts or crushing and the instructions on the package (close bags and
splintering of the blocks. Tie down rods or cables store in dry room), or mount them immediately.
may stretch and become loose under high impacts.
Check that they are straight and tight all around.
If the transformer was shipped oil-filled, carefully
look for signs of leakage on welded joints, bolted
and welded flanges and covers. Inspect all valves 3.3.2.4 Standard receiving tests
(drain valves, sampling valves, radiator valves) for
damage or leaks. Check whether the oil level is a) Core grounding megger test
providing the right reading. The core grounding megger test is to be performed
All control cabinets (main control cabinet, LTC whenever possible. We refer to section [4] for detailed
motor drive etc..) should be tightly sealed and information. On a completely assembled and oil-filled
closed. Inspect for damage by water ingress and for unit one can also perform the winding insulation megger
signs of tampering. test. Please note however that the unit has to be oil filled
Check that the de-energized tap changer for safe measurement.
mechanically moves correctly (if applicable).
b) Dew point measurement
41
Installation, Operation and Maintenance Manual
42
Installation, Operation and Maintenance Manual
3.5.3 Procedure of an internal inspection Inform Saudi Power Transformers Company and the
carrier what was discovered. If damage was found, file a
Always read and follow the guidelines in the Danger & damage claim, but do not perform any further work until
Safety section [1] Saudi Power Transformers Company gives approval and
guidance.
A full internal inspection requires draining all the oil into
dry, clean tanks of suitable capacity, while filling the
transformer tank with dry air and having a dew point
0
equal to or less than -51 C.
3.6 Dew point measurement
43
Installation, Operation and Maintenance Manual
DANGER
For your personal safety and for the safety of the
equipment, always ground all terminals when
transformers are in temporary storage.
Liquid-filled transformers are meant to always have their If the correct maintenance activities in section [6] are
insulation covered by oil. Without oil they will survive performed, a completely filled transformer with
satisfactorily for some period of time, such as during conservator can be stored for unlimited time.
shipping. However, prolonged storage without the
Assemble and fill the transformer completely with oil as
insulation immersed may cause future problems, as the
soon as possible, at the latest within 30 days after arrival
insulation will pick up moisture and contaminant. Apart
on site (or maximum 90 days after shipment from the
from this, internal voids may form in the insulation as the
factory). In the intermediate storage period the inert gas
liquid gradually drains out of the insulation.
installation (if applicable) should be checked weekly.
When a transformer has to be stored, the procedures
Mount the silica gel air breather(s) by means of a
below have to be followed for safe storage.
temporary pipe connection to prevent unnecessary
Remarks: under- or overpressure because of ambient
temperature changes.
The higher the voltage and the larger the MVA of a
Activate and check all gas bleeders (if applicable).
transformer, the more important the storage
Connect and supply panel heaters to prevent
conditions. However, it is always better to store the
damage by condensation.
transformer correctly.
Ground all bushings and the tank to prevent
If a transformer is fully assembled, oil-filled and pre-
damage by unexpected lightning (see section [1]).
tested, the general maintenance instructions can be
followed (refer to section [6]). Store accessories in a safe place. (oil drums,
bushings, radiators, conservator, fans, etc..). For
instructions, see below.
Perform the recommended maintenance as
described in the maintenance chapter (section [6]) if
longer periods of storage are required.
44
Installation, Operation and Maintenance Manual
All accessories that are shipped separate from the Cover the drum with a plastic sheet, tied in place to avoid
transformer must also be stored correctly. All shipping water accumulation on the top.
crates or boxes that are opened for the receiving
inspection must be carefully resealed and stored in a dry
0 0
clean atmosphere between +5 C and +30 C. It is
recommended that all accessories, boxes or crates that 3.7.2.2 Bushings
are marked FRAGILE also be stored indoors in a dry,
0
clean room and above +5 C. All accessories stored Bushings are packed in wooden boxes or crates. All
outdoors must be covered and protected from severe condenser / oil- oil bushings (or other bushings with
weather. hygroscopic parts) are packed separately in a
hermetically sealed plastic bag to keep moisture out and
45
Installation, Operation and Maintenance Manual
do contain a bag of desiccant. Prior to storage, check For storage periods exceeding 30 days, it is
that the bushing upper end terminal and wrap is tight and recommended that bags of fresh, dry silica gel be
undamaged. Replace the desiccant if necessary. Ensure attached to the inside of the blanking plate (attachment
that oil-filled bushings are stored with the top of the cap to the blanking plate means it is unlikely the bag will be
0
elevated at a minimum of a 20 angle. accidentally left inside during final assembly).
Remark:
Bushings packed in their original boxes are always
elevated at the right angle
3.7.2.6 Control cabinets
Bushings thus protected from the environment may be
stored outdoors, although if indoor facilities are available, Control cabinets shipped separately from the transformer
it is highly recommended that they be used instead. are usually packed in wooden crates or boxes. Venting
Regularly verify that the desiccant is dry. openings or breathers may be closed to prevent water
ingress. A bag of sufficient silica gel is placed inside the
control box to pick up the moisture of the inside air
during the normal shipping time.
3.7.2.3 Radiators Unpack all control cabinets immediately after arrival.
Verify that the silica gel is dry and that there is no
All radiators and radiator assemblies that are shipped
corrosion damage.
separately have their openings sealed with a shipping
gasket covered by a temporary attached cover plate. Check for loose or broken parts (plug-in relays,
Ensure that all seals are tight before storage. Storage wiring channels etc..).
conditions must ensure that water will not collect and Verify that all venting openings are open and mount
stand around sealed openings. Radiators and radiator breathers.
assemblies should not sit directly on the ground, but Connect heaters to the appropriate power supply. If
should be on timber supports above the ground. heaters cannot be connected to the supply, check
the silica gel weekly and replace it if necessary.
Store the cabinet indoors in a dry, clean room and
0 0
between +5 C and +30 C.
3.7.2.4 Fans
Fans have weatherproof motors and can be stored 3.7.3 End of storage
outside. However, since their shipping positions are not
necessarily the normal working positions it is required
Check the transformer and all stored components again
that they be stored inside in a dry, clean atmosphere and
0 just before final assembling and testing in accordance
above +5 C.
with the standard receiving procedures in section [3].
46
Installation, Operation and Maintenance Manual
47
Installation, Operation and Maintenance Manual
48
Installation, Operation and Maintenance Manual
49
Installation, Operation and Maintenance Manual
Seal the openings carefully, using blanking plates Traffic: sometimes transportation routes will cross
and gaskets. NEVER re-use shipping gaskets other routes such as roads, loading docks, railway
for the final assembly tracks etc. Make arrangements to block, keep clear
Tighten all blanking plates and covers carefully or divert other traffic if required.
50
Installation, Operation and Maintenance Manual
Gently lower the transformer until it is resting on the If rods are to be used with timbers, the timbers must
rollers. be steel faced. Each set of rods must have its own
The transformer may be now rolled into position. set of timbers.
0
Unbolt each roller and turn 90 . Bolt each roller into 180 - 210 39 33 30
the new position using all available bolts. 210 - 240 45 36 33
Raise the transformer slightly, and remove the 240 - 270 51 42 36
blocking. 270 - 300 57 48 39
Lower the transformer gently until it is resting on the
Table 11 Minimum number of rods required per
rollers.
set under the transformer
The transformer may now be moved in the new
direction.
Remarks:
To remove the wheels: The table above assumes the use of 3 300 mm (3
- 12 inch) wide steel faced timbers
Follow the guidelines to assemble the wheels in The table above gives the number of rods per set
opposite order. under the transformer.
b) Moving a transformer on steel rods Different steps in moving a transformer on steel rods:
A transformer is moved by "skidding" whenever lifting
and moving by crane is impossible or unpractical. The first step is to prepare the route for moving the
Transformers with a skid base are made to be skidded in transformer:
directions at right angles to the tank base using steel The truck bed, the railcar deck or the transfer car
rods. Transformers with a flat base can be moved in any bed must be jacked up and blocked so that it is
direction. level and firm
Ensure that the supporting surfaces are firm
Remark: The estimated force to start horizontal enough to support the weight of the
movement is 15-20% of the weight to be moved. transformer
Steel rods must all be the same diameter, evenly and Assemble the necessary tools (such as jacks, "tow
closely spaced. Refer to the table below for the minimum and drag" winches etc..), support blocks, rods,
required number of rods in relation to the weight being greased turning plates or greased skids etc,
moved. required for all events of the movement.
Connect appropriately sized cables to the haulage
Use at least three sets of rods side by side. The eyes located near the transformer base. Only pull a
rods must be of sufficient width to suit the transformer by the correct attachment points.
transformer being moved. Do not use a single row Haulage eyes are mentioned on the general
or two rows of rods. arrangement drawing. Utilize a spreader bar if
Rods are preferably iron-pipe profiles, double extra required to limit the strain on the haulage eyes.
strong IPS pipe. Raise the transformer using four hydraulic jacks.
Place the rods on the steel faced timber (or on the
rails in the event of using a transfer cart with
51
Installation, Operation and Maintenance Manual
embedded rails) and roll them under the 4.2.1 Planning of the installation
transformer. The longitudinal skid members serve
as stops for positioning the rollers. When all of the As some equipment or resources are not always readily
rollers are in place, carefully lower the transformer available it is advised to start some weeks or even
onto them. months in advance depending on the available
Move the transformer into the next position. experience. A graphical planning tool (e.g. MS-Project)
Once the transformer is situated on its foundation: can be useful in accomplishing a good installation
Remove the haulage cables program including all necessary steps and resources.
Jack the transformer to remove timbers and/or
rollers from under the transformer
Set the transformer onto its foundation.
52
Installation, Operation and Maintenance Manual
All necessary safety equipment, such as hardhats, Oil quantity Recommended vacuum pump
flashlights, fire extinghuisers, plastic overboots (for capacity
internal inspection), etc,... < 25 m
3 3
250 m /h
A set of large socket wrenches and optional < 50 m
3 3
500 m /h
compressed air tool for the use of the sockets. < 100 m
3 3
1000 m /h
These will be needed for opening and closing
manhole and handhole covers, for removing Table 12 Required vacuum pump capacities
blanking plates etc..
Crowbar and claw hammer for opening accessory Vacuum gauge
crates etc.. Pipes and valves of suitable size depending on the
A set of large open end wrenches. capacity
Cable cutter(s) The right quantities of transformer oil
Strong nylon ropes and slings for bushing A Megger (500 5000 V DC)
installations. Transformer Turns Ratio meter (or use voltmeter
Strong strings for installation of draw leads (to pull system).
leads through bushings) and for tying tools taken Oil dielectric tester.
inside of the transformer tank. Dewpoint tester.
A crane for installation of heavy components and or
correctly sized blocks and tackle assemblies.
Normal tools for an electrician (for external A dielectric test set especially if benchmark tests are to
wiring and connection). be taken prior to in service
CLEAN tarpaulins, plastic sheeting etc..
Clean rags for cleaning.
Methyl Hydrate (or equivalent) for cleaning
bushings. 4.3 Installation of the transformer body
Powdered talc and/or gasket-glue for use on
gaskets.
4.3.1 Grounding the tank
Dry air cylinders, with pressure regulators and inlet
hose if internal work is to perform.
Once the transformer has been placed on its foundation,
it is important to ground the tank before any more work is
done. For positioning of the grounding pads, refer to the
General Arrangement Drawing No. 115. The grounding
4.2.3.2 Oil filling and processing tools and
leads must be of suitable dimension to be effective.
equipment
Refer to section [1]: Danger and safety notes and section
[2] for general information on transformer grounding.
Once the transformer accessories are installed, it must
be filled. In addition, the following filling and oil treatment
equipment will be required:
CAUTION
Oil processing and pumping equipment, with filters
Correctly ground the transformer tank before doing
etc. This equipment may include:
any assembly or commissioning work.
vacuum degassing and drying function
filtering function
pumping function
Vacuum pump (can be a part of the oil treatment
equipment) 4.3.2 Preparation of the transformer
Capable to obtain the required vacuum before assembling accessories
(recommended 0,2 mbar or lower)
Required capacity depends on transformer oil
While working on an inert gas-filled transformer, pay
quantity
attention to the internal overpressure. It could be up to
0.3 bar at any time. This is especially so while opening
53
Installation, Operation and Maintenance Manual
valves or removing blind flanges. Also bushing turrets In case of any doubt, contact Saudi Power Transformers
are under pressure. Company before energization.
To install certain accessories, the transformer tank will
have to be opened. Depending on the specific shipping
or storage conditions:
Oil has to be (partially) drained and the removed oil 4.4 Installation of accessories
has to be stored in dry and clean containers
Inert gas has to be replaced with breathable dry gas There are a lot of different accessories that can be used
on power transformers. Some guidelines always apply,
whatever the type of accessory to install. Other
guidelines are more specific. We will start by providing
DANGER
general recommendations concerning installation. Next,
Do not attempt to enter a transformer or do not put
we will provide an overview of the most frequently used
your head inside, until:
accessories and their mounting instructions.
The tank has to be evacuated using a vacuum pump
to 50 mm of mercury (absolute); and then to be filled Although not all provided information will apply to the
with dry air; scope of delivery of the transformer, it might be useful to
The tank has finally been checked for sufficient have it at hand for other transformers or for future
oxygen to support life. The check should be extensions.
performed with an approved gas detector. A
Always have a look at the drawings in section [part C]
minimum of 19.5% of oxygen is required. Failure to
and documentation in section [part B] to learn about the
comply with this warning can be fatal.
specific accessories used and to apply the correct
instructions.
When opening a transformer:
Try to open only one manhole or handhole at a time
to prevent cross breathing of the tank (which lets in
moisture). 4.4.1 Unpacking accessories
Do not open a transformer if bad weather threatens,
and try not to open the tank during periods of high Unpack the shipping boxes or crates (except for oil-filled
humidity. Temporary weather shields may be / oil-oil bushings), identify and inspect the parts. It is
necessary as a last resort. important to handle all accessories with care.
Besides following the above measures, always limit
the exposure time of core and windings to 24 hours.
This is the total allowable time the active part may NOTES ON OIL-FILLED (CONDENSER) BUSHINGS:
be exposed to atmospheric conditions. If exposure Oil-filled bushings may not be immediately
time exceeds 24 hours, the vacuum pulling process unpacked. The reason for this is that the top must
has to be extended. remain higher than the bottom so that the air space
does not travel into the insulation. At this point, only
In case of any doubt about humidity of the insulation: identify each bushing. During assembly, unpack only
one bushing at a time: unpack the bushing when it is
Fill the transformer with dry nitrogen or air (dew needed for assembly.
point < -51 C) and wait for 48 hours.
Take a sample and perform a dew point
measurement. If requirements are not met, perform
an extended vacuum processing. [see further in this
section]
Decide whether the insulation is dry or not.
54
Installation, Operation and Maintenance Manual
55
Installation, Operation and Maintenance Manual
9 7 1 5 11
3 4
12 6 2 8 10
1
7 6
3 4
5 8
2
56
Installation, Operation and Maintenance Manual
The gasket material is usually high quality nitrile. For Sometimes, gaskets are made from two or more pieces
some specific components, other base material can be in order to cover the whole gasket surface. If this is the
used. The gasket is powdered (with talc) or treated with case, the following instructions have to be taken into
acid-free Vaseline. The surface of the flanges is treated consideration.
to prevent corrosion. The gaskets might be considered
Replacement or spare gaskets for systems A and D may
re-usable after accurate inspection of the used gasket.
need to be cut and/or adjusted on site as follows:
System D: This system is used where metal gasket stops
must be present (for ANSI and CSA standards). The
gasket material is nitrile or impregnated cork. The gasket
stops prevent overstressing of the gasket material.
Sealing compound may not be used. The gaskets may
be considered re-usable after accurate inspection of the
used gasket. Depending on the expected lifetime of the
gasket system, special gasket material can be provided.
c) Lifetime of gaskets
The re-usability of the re-usable gaskets is influenced by
time and temperature. However, within a period of 4.5 Installation of Conservator and Pipes
approximately 10 years, normal re-use of gaskets is
allowed. Therefore, we recommend renewing the
gaskets when a gasket is removed after 10 years from
date of manufacture.
57
Installation, Operation and Maintenance Manual
58
Installation, Operation and Maintenance Manual
1. Unpack all components, check them and clean all Remarks: As small amounts of oil may leak out of
gasket surfaces. closed throttle valves, make sure that an oil can is
2. Mount the conservator support(s). placed underneath the throttle valves. Connect the
3. Mount the conservator on its supports (bolts are not radiators as soon as possible.
to be tightened at this time). with an inert gas and without any oil: the radiators
4. Mount the oil pipes on the cover, including new should be filled during the vacuum-filling process of
gaskets (bolts are not to be tightened at this time): the main tank.
The oil connection between tank and conservator.
The oil connection between bushing turrets and the
oil pipe (if any).
The oil connection between the tap changer head
and its conservator.
5. Mount the vertical oil pipes and their components
including new gaskets (bolts are not to be tightened
at this time):
The oil drain valve(s) (LTC and main conservator).
The pipe to the silica gel breather and the breather
itself.
If all components are in place, tighten the bolts on
the pipe connections in the same sequence as you
have mounted them. Then tighten the bolts on the
conservator support(s).
CAUTION
Before final tightening of oil connections, check the
position of the valves: full oil filled chambers may
not be entirely closed by any valve, because thermal
oil expansion may produce high internal pressures
possibly damaging the transformer or its Figure 9 Example of radiator No. 92
components.
59
Installation, Operation and Maintenance Manual
The same instructions apply for mounting radiators on a During this process, the oil level in the transformer tank
cooler bank. For connecting the cooler bank to the must be checked regularly; the oil level may never sink
transformer we refer to the General Arrangement under the radiator inlet / highest point of the windings to
drawing. avoid moisture, air, or gas ingress. For this reason, it
could be necessary to fill-up oil immediately (refer to oil
filling instructions).
This gasket type does not use gasket-stops (see also 1. Close valve No. 123 between the conservator and
section [3] for different gasket types) the main tank and close both throttle valves No. 93
of the radiator No. 92.
Always mount two new gaskets together (2x2mm) and 2. Unscrew the protection cover of the drain plug No.
position them on the valves between the stud-bolts. 95
Using a small amount of a correct sealing compound will 3. Make sure that the air vent No. 94 is fully closed.
help to keep the gaskets in place during installation and 4. Unscrew entirely and make sure that outcoming oil
will limit the risk for leaks. does not drip on the ground.
5. After a while, the oil flow stops due to a vacuum
created in the radiator.
6. Connect a flexible hose or another device to the
4.6.2.2 Impregnated cork gaskets or O-rings: drain plug so that oil spillage is avoided.
7. Open the air vent No. 94
These types of gaskets need a gasket stop (usually by 8. Remove the protection cover.
9. Open the air vent by turning the screw in a
positioning the gasket in groves at the valve-side, see
counterclockwise direction.
also earlier in this section for different gasket types).
10. Incoming air in radiator results in a rapid oil draining
Inspect the O-ring for any damage prior to reusing it via the drain plug.
in the final installation. 11. After draining :
Use fresh cork-gaskets to the radiator valve. A close vent plug No. 94
small amount of petroleum jelly will help to keep the remount protection cover of vent plug
gaskets in place during installation. close drain plug No. 95
remount protection cover of drain plug
60
Installation, Operation and Maintenance Manual
61
Installation, Operation and Maintenance Manual
62
Installation, Operation and Maintenance Manual
4.8.1.2 Mounting
Reverse procedure.
4.8.2.2 Mounting
Reverse procedure.
63
Installation, Operation and Maintenance Manual
4.9.1 Type
64
Installation, Operation and Maintenance Manual
4.9.2 Mounting instructions incorporate a capacitive tap, where the final capacitive
foil (the ground layer) is brought out through a special
1. Dismantle the pre-assembled bushing and clean it. test tap. This test tap may be used for monitoring
2. Remove the blind flange on the transformer tank purposes as well as for testing the bushing. The test tap
(cover), remove the shipping gasket and clean up must be directly grounded or fixed to the ground over the
the gasket surface. Cover the opening for foreign monitoring device.
parts, dust and moisture.
3. Screw the copper stem in the threaded hole (see
detail A), in the internal connection, tighten them
with the correct torque (see documentation for the
4.10.1 Different types of condenser
specific bushing), so that the contact surface is
correctly tightened, using nut and conter-nut on the bushings
top side of the stem.Mount the porcelain (together
with the fixation ring) over the stem, using a new Remarks:
gasket. Make sure that the porcelain is correctly Check the General Arrangement drawing to find out
seated on the base, look for the correct positioning which bushing type is used.
of the porcelain over the upper part (turn the
porcelain so that the locking ring on the upper part Some of the bushings may come with a corona shield
of the stem does not damage the porcelain) of the that is usually manufactured from spun aluminum and is
stem. Draw the draw lead in the porcelain (in case quite delicate. The shield must not be bended. The
of a draw lead conductor). coronal shields are usually shipped separate from the
4. Mount the upper gaskets, the press rings and the bushings, in well-padded packaging. Ensure that the
lock nut, without tightening them. shield is properly attached to the bushing and all
5. Tighten the fixation ring carefully, first by hand and mounting bolts are tightened prior to installing the
then progressively tighten the bolts with the correct bushing.
torque (see documentation for the specific bushing).
6. Tighten the lock nut with the correct torque (see
documentation for the specific bushing).
7. Mount the upper connector (and arcing horns if
applicable).
NOTE
For draw lead bushings (for current ratings of 630
Amps and below), the lower part of the copper stem
is replaced by a flexible copper conductor. There are
no internal connections to be made in that case.
65
Installation, Operation and Maintenance Manual
4.10.1.1 Draw lead condenser bushings 4.10.1.2 Bottom connected condenser bushings
66
Installation, Operation and Maintenance Manual
67
Installation, Operation and Maintenance Manual
11. Tighten the top terminal arrangement and the flange 11 Ground the bushing for personnel safety as well as
bolts with the correct torque according to the to ensure that the transformer will not be damaged
specific documentation. due to lightning.
12. Ground the bushing for personnel safety as well as
to ensure that the transformer will not be damaged
due to lightning.
4.10.2.3 Oil to Oil Bushings
68
Installation, Operation and Maintenance Manual
4. Wire or plug the fans into the appropriate junction 1. Remove the protection on the cable-end and check
box and check for the right air flow. Correct the wire marking with the wiring diagram.
direction of fan rotation is given with an arrow on 2. Clean wire ends (and contact-pins of cable-plugs, if
the fan housing. any).
5. Remove drain plugs from the holes in the fan 3. Fix the cable in the cable channel.
motors to allow condensation to escape. 4. Introduce the cable into the cable gland.
5. Check with the wiring diagram.
6. Connect the wires to the right terminal.
7. Tighten the cable gland.
4.12 Wiring on the transformer
Once again, make sure that the right connection has
The wiring on the transformer is always completed and been established.
checked during assembly in the factory. However, the
connection between transformer and remote control
cabinets is only made as a temporary base for testing.
During disassembly for shipment of the transformer,
4.13 Oil quality requirements
some parts with an electrical connection must be
disconnected. This will result in free cable-ends (or free
The oil quality is very important for the reliability of the
plug-ends) that can be situated on the dismantled part or
transformer. Oil filling and oil treatment procedures have
on the transformer. Free cable-ends will be coiled and
an enormous impact on the oil quality. This is why the
protected by plastic bags or another protection and tied
procedures below should be followed strictly.
to the transformer tank or assemblies. The wires of free
cable-ends are marked with the same terminal number The specific filling and treatment procedure to follow
as the terminal to which they have to be connected depends on:
during the final wiring on site.
The transformer design
Current transformer circuits have been short-circuited The oil supply method
before and during transportation for safety purposes. The voltage class (Un < 70 kV Un > 70 kV)
This short circuit wire has to be removed at the time of The method of shipment of the transformer
final wiring and/or testing.
The following wiring types are used: In the explanation below we assume that:
Cabling with a certain cable type. The cables are The transformer has been assembled according to
mounted into stainless steel cable channels the previous guidelines.
(possibly with covers) that are fixed to the The transformer is filled with an inert gas and does
transformer tank or assembly. This is the normal not contain any oil.
standard for IEC transformers.
Wiring into conduits (galvanized or in aluminum)
that are fixed on the transformer tank or assembly. Remarks:
This is the normal standard for ANSI and CSA Starting from an empty, inert gas filled transformer,
transformers. vacuum filling can be performed in one step (commonly
Plug-in cable connections, used for some typical used for small transformers and for sealed transformers
accessories (Qualitrol apparatus, fans, etc.). or for transformers with a positive pressure system) or in
two steps (commonly used for large transformers): first
filling the tank and then filling up the conservator.
4.12.1 Mounting instructions All necessary oil filling and oil treatment equipment
is available.
After mechanical installation of the parts that are to be New transformer oil of the right quality is available
electrically connected: (see below).
69
Installation, Operation and Maintenance Manual
3
Minimum Pressure
NOTE
T (C) Pa Mbar Torr
Oil quality and care in handling are extremely
40 5 0.05 0.04
important for the proper functioning of the
50 10 0.1 0.075
transformer.
60 20 0.2 0.15
70 40 0.4 0.3
80 100 1.0 0.75
90 400 4.0 3.0
4.13.1 New transformer oil 100 1000 10.0 7.5
Table 13 Oil treatment
New transformer oil can be available in drums or in
containers. Normally, new transformer oil is not
degassed and has to be treated (streamlined) according
to the processing parameters below. Before using any See section [5].
transformer oil to fill (or top up) a transformer, the oil
Required oil quality after oil treatment:
quality should be in accordance with the applicable
standards: Dielectric strength: 75 kV (IEC 60156)
IEC 60296 Water content: see section 5
ASTM D 3487-88
Tangent (90 C): 0.5 %
If temporary storage of the oil is required, prevent air and
water from entering the container. Test the oil again just
4.13.2 Oil treatment (degassing, before filling.
streamlining) Remarks:
Some filling installations are equipped with integrated
Oil treatment is used to improve the oil quality by filtering
degassing features and do not require separate
and degassing the oil.
degassing. In this case, oil samples should be taken at a
Transfer the oil from the barrels into a dry and clean regular basis before the oil enters the transformer.
container of suitable size (preferably the same size as
the amount of oil to be treated). Connect the treatment
installation in a closed loop to the container and circulate
the oil volume 3 times. The vacuum should be 1 mbar or
less. 4.13.3 New treated transformer oil in new
equipment
Non-inhibited transformer oils: treatment should be
2
performed at a temperature of 60 C (maximum 65 C).
Oil quality should be in accordance with the applicable
Inhibited transformer oils: due to the volatile character of standards and Saudi Power Transformers Company
the inhibitor one should limit the temperature in order to specifications:
prevent loss of inhibitor. Conditions that have been found
satisfactory for most inhibited mineral oil processing can IEC 60422
be found in the table below. In general, one should limit ASTM
the treatment temperature for inhibited transformer oils to Saudi Power Transformers Company specifications:
50 C. see further in this section and section [5].
2
Temperature at the outlet of the degassing installation 3
Reference: ASTM D 3787
70
Installation, Operation and Maintenance Manual
4.13.4 Transformer oil for transformers in case a connection with valve is used, the valve should
service be open while pulling vacuum and closed when the
transformer is energised.
Same as above (4.13.3) applies. If the conservator is of a membrane type, the membrane
is NOT capable of withstanding a vacuum or
overpressure. Install the necessary pressure equalizing
pipe (B) between the expansion membrane, the
conservator compartment of the transformer and the
4.14 Pulling vacuum conservator compartment of the (O)LTC.
The purpose of pulling vacuum is to lower the pressure
inside the transformer tank below the partial pressure of
water vapor at the temperature of the insulation. The CAUTION
more the vacuum is lowered below the partial pressure, Mount the necessary equalizing pipes between all
the better the removal of the surface moisture will be. hydraulic chambers that cannot resist full vacuum
by itself before drawing a vacuum or before starting
any filling process. Check the General Arrangement
drawing, the documentation and nameplate for more
details on vacuum resistance. Especially have a look
4.14.1 Before pulling vacuum at the tap changer and its conservator, membrane
type conservators etc.
Test if there are any leaks. This can easily be done by
applying a pressure of 0.15 up to 0.2 bar with dry air or
nitrogen. If leaks are detected, close them. B Transformercompartment
OLTC-compartment
Ensure that all radiator valves are opened.
Expansion tank
If the transformer is equipped with non-vacuum/pressure
tight accessories (such as a gas detection apparatus,
vacuuminstallation
drycol breathers, pressure relief devices, etc.) block A
CAUTION
In case a Drycol dehydrating breather is installed on
the conservator, or if a gas analyzer and electronic Figure 21 Equalizing pipe connections
devices such as a Hydran is installed on the tank,
do NOT allow either a vacuum to be drawn on, or oil
to be injected into the apparatus. Ensure that either
the valves on this apparatus are closed off on both
DANGER
inlet and outlet sides or that the devices are removed
Never perform an electrical test on a transformer
for the period of pulling vacuum and filling.
under vacuum. Internal flashovers may occur at
voltages as low as 200 V, causing severe damage.
Do not attempt to climb on a transformer, or walk
If the transformer is equipped with a(n) (on) load tap around on any part of the cover, while the
changer, refer to the appropriate (O)LTC documentation transformer is under vacuum. This is unsafe for
included in this IOM. Prior to pulling vacuum or personnel and equipment.
performing a leak test using overpressureing be aware
that, an equalizing pipe (A) is installed between the
(O)LTC compartment and the tank during transportation.
Maintain this connection untill starting to pull vacuum. In
71
Installation, Operation and Maintenance Manual
4.14.2 Establishing connections The vacuum pump requires servicing and/or new
sealing oil.
Connect the vacuum connecting point on the conservator The vacuum connections or the transformer itself
No. 125 with the internal part of the atmoseal bag (via are leaking.
dehydrating breather connection flange, on top of There is significant moisture in the tank and the
conservator). The vacuum connection should be made vapor pressure of the moisture is limiting the
as short as possible. Ensure that a shut off valve is vacuum to drop to the specified level.
installed. Please refer to the Figure in "Filling
Procedures" included in this IOM.
Try the following procedure to determine the cause of the
Connect a vacuum proof transparent hose (L3) problem. While the vacuum pump is running, close the
between the oil sampling device on the bottom filter valves (for a minimum of 30 min.) between the vacuum
valve No. 112 and the connecting line of the pump and the transformer tank.
vacuum pump (L2) on top of the conservator (or
Compare the level of vacuum on the tank and on
tank if no conservator is present) to visualize the oil
the pump side of the valves that are closed. If the
level during filling. This transparent hose should be
tank pressure increases quite fast, the transformer
at least 50 cm (20) longer than necessary.
is leaking.
Connect the oil pump installation (VP, F) to the
If the vacuum pump side of the valves does not
bottom filter valve (No. 112 - L1). A filter and
drop down quickly, the pump capacity is too small
degassing installation (if non-degassed oil is used)
or probably requires servicing.
should be part of the installation procedure in order
If the vacuum pump side of the valves drops down
to filter out all the water particles and impurities.
quickly and the transformer tank pressure increases
Open all the cooling systems isolation valves No.
slowly, then there is excess moisture in the tank.
93 if this has not been done already.
DANGER
Never leave a transformer under vacuum 4.15 Oil filling standard
unattended.
4.15.1 Oil filling
A vacuum of minimum 13 mbar must be maintained
4.14.4 Troubleshooting during the entire filling process. This means the valve of
the oil supply pipe has to be throttled to maintain this
If the specified vacuum cannot be reached or vacuum. This is necessary because, while entering the
maintained, one or more of the following may be the tank, the oil will give off dissolved gasses that must be
case: evacuated by the vacuum pump. The oil-filling valve
must be adjusted to maintain a positive pressure up to
The vacuum pump is too small for the size of the the throttled valve.
transformer.
72
Installation, Operation and Maintenance Manual
If degassed oil is used to fill the transformer, the quantity minutes later, bleed all bleeder points on the transformer.
of oil flowing into the tank should not exceed 12 mm (0.5 Restart the pumps and proceed with a number of cycles.
inch) per minute, even if the required vacuum can be
Ensure that the (O)LTC compartment (and its
held at a higher filling rate. This rule should be followed
conservator) is correctly filled.
to ensure all voids are correctly filled with oil.
In the case of a conservator design transformer, bleed
The use of oil treatment equipment (streamliner) with an
air from manholes, bushing turrets, cooling component
integrated vacuum degassing chamber is preferable. In
systems etc., using the bleeder screws or valves on the
this way residual dissolved gasses are removed while
equipment. Mount the air breather(s).
the oil enters the transformer tank. The risk for a process
interruption will be limited as well. Recheck the transformer oil level and top up if necessary
(see further).
Remarks:
Certain transformers with a maximum voltage class of 34
kV may be filled with non-degassed oil. The oil should be
entered on the top of the tank using a special spray-
nozzle. The rate of oil admitted to the tank should not
exceed 33 liters or 12 mm per minute, even if the
required vacuum can be held at a higher rate. This rule
should be followed to ensure degassing of the oil during
filling and to ensure all voids are correctly filled with oil.
Check the dielectric strength of the oil during filling in
samples taken from the transformer side of the oil
treatment equipment. If a test indicates a lowering of
strength, the filters must be replaced before continuing. Figure 22 Transformer filling (without conservator)
73
Installation, Operation and Maintenance Manual
CAUTION
The purpose of vacuum filling is to remove all gas
from the insulation structure. The presence of gas in
the insulation may cause failures and/or may
develop partial discharges that can develop into an
internal failure. In addition, the
interpretation/analysis of dissolved gasses will be
not correct. Therefore, it is very important that the
vacuum filling is performed strictly in accordance
with these instructions.
Figure 23 Transformer filling with conservator 4.16 Topping up oil after initial vacuum
filling
This procedure can be used after the initial vacuum filling
of the main tank (leave filling line L1 connected to the
4.15.2 Filling procedure in the event of bottom filter valve No. 112) or for transformers that are
process interruption shipped (partially) oil-filled (connect the filling line L1 to
the top oil filter valve No. 111). Please note that initial
The procedure of pulling vacuum and oil filling is meant filling of an empty transformer should always be done
to be a smooth and uninterrupted process. Should the following the vacuum filling procedure described above
process be interrupted for any reason, then: or by using the oil-spray-system. In certain
circumstances only topping up the oil might be done
Stop the flow of oil into the transformer tank. Attempt to without following the vacuum filling procedure. However
return power to the process equipment as soon as if vacuum filling equipment is available, vacuum filling is
possible. Upon the resumption of power, inspect the to be prefered in any case as this method prevents air
vacuum gauge.
bubles to be trapped in the transformer.
If the internal tank pressure is below 13 mbar: proceed
Conservator design type transformers and Un < 70
with the filling process.
kV may be topped up with degassed oil, directly
If the tank pressure is between 13 and 32 mbar: first pull pumped through a suitable filter (1 to 5 m) into the
vacuum below 6.7 mbar, then continue with the filling conservator without drawing vacuum.
process. Conservator design type transformers and Un > 70
kV must be topped up under vacuum; the same
If the tank pressure is above 32 mbar: drain the oil from
procedure applies as for initial vacuum filling.
the tank and begin the vacuum filling process all over
However, the vacuum hold time before filling may
again (from the start).
be reduced to 4 hours.
Non-conservator design type transformers only
need correction of the oil level using degassed oil.
If radiators are not mounted before the initial
vacuum filling, mount and fill them according to the
mounting and filling instructions for radiators (see
earlier in this section).
Remarks:
If no degassed oil is available, use streamlining
equipment and apply the correct processing parameters
(depending on the oil type used).
74
Installation, Operation and Maintenance Manual
75
Installation, Operation and Maintenance Manual
Special tests:
Insulation power factor test
4.18.3 Electrical tests Bushing power factor test
Winding resistance test
If the oil quality meets the specifications, you can Continuity / impedance check
proceed with the electrical tests. Before starting any
voltage tests, make sure that the current transformers
are correctly short-circuited.
Required tests have to be performed in all cases. 4.19 Pre-operational tests and checks of
Although the optional test, the vector group test, is an accessories
often performed field test, it is not necessary. In the Site
commissioning report section [9] test sheets are General items
available for the required and optional tests.
Check for remaining equipment or tools on the
Special tests are only to be performed if there are transformer cover or other parts
indications of potential problems or defects. Check for leaks or other damages
If Saudi Power Transformers Company is doing the Check for damaged painting
erection and commissioning, contractual specifications Check the presence of the Nameplate (or Rating
concerning site testing have precedence over the plate)
sequence below. Check grounding connections
Remarks:
The transformer tank, all external metal parts and
Tests and checks related to the specific network or to
accessories should be permanently grounded according
remote controls, as well as cable tests are not included
to the correct safety and operation practice and in
in this section.
accordance with instructions for the specific equipment
being used.
76
Installation, Operation and Maintenance Manual
77
Installation, Operation and Maintenance Manual
CAUTION
4.21 Megger test (Required)
For transformers with OFAF cooling (Oil Forced Air
Forced), oil pumps always have to be in operation if The purpose of the megger test is to detect internal
the transformer is energized, even at no load: pumps movement of parts that may have shorted out some of
always have to run. the insulation on the core and on the windings and leads,
as well as to check for excessive moisture
contamination.
Remarks:
For all megger tests a good estimate of the inner
4.20 Oil sampling and testing transformer temperature is required. For oil-filled
transformers the oil temperature gauge can give a
4.20.1 Sampling good estimation. Be aware of the atmospherical
influences.
For the sampling procedure we refer to the maintenance Multiply the measured insulation resistance by the
section [5] further on in this IOM Manual. correction factors, given by the table in section [0],
0
to bring the measured value back to a 20 C
reference temperature.
Insulation resistances measured without oil filling on
a nitrogen-filled transformer are not comparable
4.20.2 Required oil quality tests with the measured values in the factory. Below
values are given for an oil-filled transformer.
After oil filling and before performing electrical tests two
oil tests are required. Write the test results on a copy of
the Site commissioning report.
Dielectric strength 4.21.1 Winding insulation megger test
Moisture or water content
A megger test on a transformer winding is a single-
phase test. When testing the HV winding, ground all LV
More information on these oil tests and additional oil
and TV bushings, connect all HV bushings together, and
tests is provided in the maintenance section [5]. The
megger the HV bushings to ground. Wait for one minute
additional tests may be necessary if there are indications
and repeat the test. Do this for 10 subsequent
of potential problems or if specific maintenance
measurements. Follow the same way for all megger tests
procedures require reference values (e.g. DGA analysis).
of all windings. The polarization index is the
measurement after 10 minutes divided by the one after
one minute.
Use a megger voltage of 5000 V DC (1000 V DC for a
4.20.3 Oil quality requirement nitrogen-filled transformer). The bushings must be
cleaned and dry. Do not use pieces of strings etc.., to
Minimum dielectric strength of transformer oil must be hold leads apart, as they may damp and introduce a
met: see section [5]. leakage path sufficient to greatly distort the true
Maximum moisture content as a function of the readings. High atmospheric humidity will also influence
temperature must be met: see section [5]. the test results.
More detailed oil specifications are given in the In the case of a two-winding transformer, the following
applicable standards IEC 60422 and ASTM. winding megger tests should be performed:
HV windings to ground, with LV windings grounded.
LV windings to ground, with HV windings grounded.
Connect all HV and LV windings together and
megger to ground.
78
Installation, Operation and Maintenance Manual
The core grounding megger test is used to determine the 4.21.3 Accessories insulation megger test
state of the core clamping structure, core to ground
and/or clamp to ground insulation. The core is tested by The insulation of accessories should be meggered with a
accessing the core ground bushing located on the cover megger voltage of 500 V DC.
of the tank No. 137.
The test is conducted by using a megger voltage of 1000
V DC. All windings must be shorted and grounded before
starting this test.
Both core grounding and clamp grounding megger
values should exceed 100 Mohms corrected to 20C
according to the correction table in the table section [0].
1. Open the access hole towards the terminals No.
137 by unbolting the access cover. The atmosphere
in this box is air.
2. Disconnect the core grounding link by unscrewing
the bolts on the core bushing and grounding point.
The core is now disconnected from ground
potential.
3. Perform a megger test between bushing and
grounding point.
79
Installation, Operation and Maintenance Manual
80
Installation, Operation and Maintenance Manual
Figure 25 Vector group test 4.25 Bushing power factor test (Special
test)
81
Installation, Operation and Maintenance Manual
CAUTION
The bushing test terminal grounding cap MUST be
Grounding put into place at the end of the test. Operation of the
spring bushing without grounding the tap electrode will
very likely cause flashover due to the high open
Tap
electrode
circuit voltage produced at the tap.
Insulating
bushing
82
Installation, Operation and Maintenance Manual
adversely affect the operation of the transformer Supply voltage = 10 % or less of the impedance
protection system. voltage. (expressed in % of the rated voltage on the
Nameplate or Ratingplate).
DANGER Current supply = 10 % or less of the rated current
Read the following points concerning the energy (refer to the Nameplate or Ratingplate).
stored in the winding during this test.
The power may be supplied to the HV windings or to the
LV windings, depending on the available power supply.
Although a power supply of only 12 volts is used, the The not supplied windings are to be shorted with
amount of energy stored in the inductive reactance of the adequately sized shorting leads. Refer to the transformer
windings is quite large. Switching the circuit on is safe, Nameplate (or Ratingplate).
but interrupting the current at the completion of each test
can be dangerous. Please pay attention to the Once all connections are made, switch the power on and
following: read the supply voltages and currents. Switch off the
supply and repeat the test for each position of the de-
Use a resistance bridge that is specifically suitable energized or load tap changer. Do not operate the load
for measuring highly inductive loads. tap changer while the supply is switched on.
Break the circuit slowly dissipated in an arc, or
shunt the winding through a resistance before In the case of unbalanced currents, voltages or
opening the circuit. discontinuity, something is wrong with the internal
Before disconnecting the leads from the connections or there is a malfunction on the load tap
transformer, ensure that all stored energy has been changer.
dissipated.
83
Installation, Operation and Maintenance Manual
The vacuum to be drawn depends on the temperature of After the required hold time has been achived, break the
the insulation (removal of moisture by vacuum of vacuum with dry air or nitrogen that has a dew point
moisture in freezing weather is unpractical without the lower than desired for the transformer. Repeat the dew
application of heat). The drying process will be point test after a period of at least 24 hours this period
accelerated by providing a lower vacuum than listed. is needed for the moisture content of the gas and
insulation to stabilize. If the dew point is satisfactory,
proceed with the final vacuum for filling. If the dew point
Insulation Partial Required is still not satisfactory, contact Saudi Power
Temperature Pressure of vacuum Transformers Company for further instructions.
C water vapor Microns
Microns
25 105 100 or lower
20 85 80 or lower
15 50 45 or lower
4.28.2 Removal of surface moisture by dry
10 36 32 or lower air recycling
5 26 23 or lower
2 22 20 or lower A simple method for removal of surface moisture can be
useful in some cases: i.e. when vacuum equipment is not
Table 14 Required vacuum for flashing surface directly at hand.
moisture
Recycle transformer with dry air and maintain at all
The hold time, or the duration that the vacuum must be times a positive pressure on the tank (minimum
held, depends on the relative humidity of the ambient air 0.05 bar and maximum 0.2 bar)
that entered the transformer during the exposure period, Inflation point and bleeding point of dry air is
the time of the exposure, the amount of air infiltration and preferably diagonally located.
the temperature at the time the vacuum is applied. Total quantity of dry air required is about three
Unfortunately, the relative humidity and the amount of times the tank volume of transformer.
infiltration is a very difficult thing to monitor. Extending The total tank volume can be taken from oil content
the vacuum hold time for longer than the table below as shown on the nameplate.
suggests is recommendable. After passingthrough a volume of dry air, equal to
3 times the tank volume, the bleeding point has to
be closed and a positive pressure as mentioned
Relative Hold time Hours above, has to be maintained for at least 3 days.
humidity Expo- Insula- Insula- Insula-
of ambient sure tion tion tion
air time temp temp temp Re-measure dew point as described above.
(hours) 21C or 10C to under
higher 21C 10C
10 6 9 12
20 12 18 24
10 to 25% 30 18 27 36
40 24 36 48
50 30 45 60
10 15 23 30
20 25 38 50
25 to 50%
30 40 60 80
40 55 83 110
10 20 30 40
50 to 70%
20 40 60 80
Table 15 Vacuum hold times for flashing surface
moisture
84
Installation, Operation and Maintenance Manual
5 Commissioning
85
Installation, Operation and Maintenance Manual
86
Installation, Operation and Maintenance Manual
If applicable, check also if all connections of the 5.2.1 Alarm circuits and contacts
ELASTIMOLD or PFISTERER type have been sealed
voltage proof. Otherwise the transformer may not be Alarms are mentioned as a warning for an abnormal
energized. situation on the transformer or its accessories that needs
observation, action and follow up. There is no need to
place the transformer out of service.
The most commonly used alarms are:
5.1.2 Energization follows 4 weeks to 6 Slow gas production (Buchholz or gas relay).
months after installation and testing Temperature alarms (first stage oil and/or winding
temperature).
Repeat: Oil level alarms (low and/or high level).
Internal pressure alarms.
Air venting procedure according to section [3]
Alarms on the cooling circuits (supply failures, oil
All pre-operational tests and checks of accessories flow failures, etc.).
according to section [3]
LTC alarms (supply failures, etc.).
87
Installation, Operation and Maintenance Manual
5.2.2 Trip circuits and contacts Carefully check the settings of:
The thermostat(s)
Trip contacts on the transformer or on accessories Oil thermometer(s)
immediately place the transformer out of service in any Winding Temperature Indicators (WTIs) for the
abnormal situation that can damage the equipment or its different windings
environment.
The most commonly used trip contacts are:
Quick gas production (Buchholz or gas relay). 5.2.5 Verification of overpressure relief
Quick internal pressure rises.
devices
Network protection relays (fed by current and/or
voltage transformers on the transformer).
The same remarks apply as for the temperature settings.
(O)LTC failure. etc.
DANGER
5.2.4 Temperature settings If the ambient temperature is very low or can be
expected (below -20C), special precautions should
Make sure all temperature settings are correct and equal be taken before energanization. Contact Saudi Power
to or lower than the values on Saudi Power Transformers
Transformers Company for further instructions.
Company drawings (Nameplate and/or Schematic
drawings). Never use higher settings than the ones
indicated on these drawings, as this can cause too slow
reaction (or no reaction at all) of the protective devices. It is useful to start here with a log-book, recording all
Needless to say that serious damage may occur. important readings and observations for each
88
Installation, Operation and Maintenance Manual
transformer, will be helpfull for the maintenance and for 5.3.2 First energizing at no load
identifying problems during the life time of the conditions.
transformer. It is highly recommended to take an oil
sample for DGA prior to energisation. This analysis
Set the (O)LTC/DTC for the right voltage ratio. Lock the
forms a benchmark for all future DGAs.
DTC drive against mal-operation while the transformer is
under voltage.
To reduce the inrush-current during the first energizing, it
is advisable to set the (O)LTC two or three steps out of
5.3.1 Minimum oil stabilising period after the voltage ratio, so that more turns are in service (refer
final oil filling to the Nameplate). This can only be done if the
transformer is of a variable flux design.
The transformer oil should be stabilised after final oil
1. Switch on the voltage:
filling. This condition will be normally fulfilled if the
2. Check the secondary voltage (and eventually the
transformer has been filled some days or weeks before
tertiary voltage).
energisation.
3. Check the no load current.
NOTE
5.3.1.1 Transformer with forced oil circulation During the first energizing, a noise-peak can be
using pumps detected. This peak will be dissapear after a few
minutes upto an hour.
Have the pumps run for at least 2 hours and wait for :
minimum 8 hours if high voltage 245 kV
A general observation of and around the equipment is
minimum 24 hours if high voltage > 245 kV
suggested and should include a general awareness of
what is happening to all the equipment located in the
electrical substation. Unusual noises and disturbances
CAUTION should be investigated. such as :
The pumps may not be switched on if oil
temperature is below 10 C. In this case follow the Fans, pumps, etc.. operating when they should not
required waiting times for transformers without Circuit breakers or other equipment operating at
pumps, energise at no load conditions and wait until odd moments.
oil temperature raised above -10C. Proceed with LTC taps changes too frequent or no changes at all.
pumps running. Oil leaks. Small quantities of oil can spread over
large areas and can collect a lot of dust very
quickly.
89
Installation, Operation and Maintenance Manual
90
Installation, Operation and Maintenance Manual
6 Maintenance
91
Installation, Operation and Maintenance Manual
92
Installation, Operation and Maintenance Manual
Transformers are very reliable electrical equipment if well The bushing porcelains must be kept free from dust and
maintained and working under normal operation dirt and have to be inspected at least once a year.
conditions. Nevertheless, failures due to improper Abnormal conditions such as sandstorms, salt deposits,
maintenance or abnormal operation conditions may dust, or chemical fumes require regular cleaning to avoid
cause the transformer to be out of service for a long accumulations to the external surface. Accepted
time. This will especially be the case when custom made methods of hot line washing or cleaning with solvents
parts have to be ordered and installed. As power supply may be used.
may often be critical, it is absolutely worth spending the Keep the heat radiating surfaces of the transformer
necessary time on a good maintenance program. clean. External surfaces of forced oil heat exchangers
Remarks: should be periodically cleaned as a particular dusty
location may dictate. Transformers near the seacoast or
1. Transformer logbook: It is recommended to record in corrosive atmosphere areas should be painted
readings and observations for every transformer in regularly to prevent corroding or rusting of metal parts.
a logbook. This should not only be done during the
warranty period but during the complete lifetime of If it becomes necessary to remove a radiator or air-
the transformer. cooled oil cooler, first close the valves, top and bottom,
2. Special service conditions: Special attention must and bolt them in the closed position. Next, drain the oil
be paid when the transformer operates under from the radiator by removing the drain plug from the
abnormal conditions. bottom header and the vent plug from the top. After
a) Bushings exposed to dust or chemically laden draining the oil, remove the radiator. If the radiator/cooler
air must be kept clean to prevent flashovers from is removed for any length of time, the transformer valves
occurring due to the formation of conducting should be sealed with gaskets and covered with suitable
deposits on the porcelain. plates. This also applies to the radiator-cooler openings.
b) Transformers installed near a seacoast must be All breathers and small openings in pressure relief valves
kept well painted to avoid corrosion by salt air. (and pressure vacuum bleeders on sealed tank system
and inert gas system units) must be kept clean and in
operating condition.
93
Installation, Operation and Maintenance Manual
All ground buses and wiring leads to ground must be Venting is also required when components are replaced
kept in good condition. Proper relay operation depends which are situated in places where oil is involved.
on low ground resistance. Ground resistance must be
measured annually
94
Installation, Operation and Maintenance Manual
6.2.7 Cooling system condensation) and check also that the fan blades can
rotate without any obstruction of foreign objects (like
Regarding naturally cooled transformers and birds nests etc.).
transformers equipped with air-cooled oil coolers, there
is, in general, no need for taking special steps to keep
the inner side (oil circuit) of the cooling surfaces clean,
as long as the oil is in good condition. If, however,
6.2.9 Temperature
formation of sludge in the oil has set in, the sludge may
deposit in horizontal surfaces in radiators and coolers. In
The life of a transformer is highly dependent on the
such a case, the radiators and the coolers should be
temperature prevailing in the windings and the core of
rinsed in connection with the changing of oil and
the transformer under operation. It is therefore important
overhauling of the transformer. If the sludge does not
loosen by flushing with oil, use benzine, trichlorethylene, that the temperature is continually kept under
etc., and afterwards flush with oil. observation (e.g. via a remote sensing system towards a
dispatch center).
The other side that is exposed to the elements by dust,
Even with a low temperature of the cooling medium
sand, etc., has to be cleaned as mentioned before.
(ambient air), the transformer can be overloaded. Hence
the permissible overload must not be judged only from
the temperature rise of the oil above the cooling medium,
because the temperature drop winding-oil increases with
6.2.8 Fans the 1.6th power of the increase of load. The ANSI/IEC
Loading Guide may be used on condition that the
6.2.8.1 Bearings assumed characteristics at rated load as mentioned in
the applicable standard, will be replaced by actual
Fan motors are executed with sealed ball bearings characteristics after testing. This means that the actual
lubricated with heavy-duty grease that do not require any ratio for no load and load losses including the actual top
maintenance as experienced by our fan suppliers and oil and average winding rise has to be used for good
also by Saudi Power Transformers Companys after judgment on allowable overload situations.
service engineers during many decades. The bearings In case of doubt, Saudi Power Transformers Company
are from the so-called maintenance free type; it is has to be consulted.
advisable to know the general maintenance instructions
on bearings as mentioned by bearing, motor and fan Normally, it is not possible to place a temperature
manufacturers. measuring device directly on the windings of a
transformer, except in a few special cases where fiber
optics are mounted in the windings to measure direct
temperatures. Saudi Power Transformers Company uses
a method by means of which an artificially obtained
6.2.8.2 Periodical fan operation temperature is measured, which follows the temperature
in one or more of the windings of the transformers.
During extended periods of reduced transformer capacity
not requiring fan operation, it is required that the fans be This device is installed if the design specifications called
activated on a periodical base (bi weekly for 1 hour), to for a Winding Temperature Indicator or WTI. In case a
assure satisfactory operation when required. This is valid WTI is not installed, the top oil temperature indicator
for all electrical motors of fans, pumps etc. related to the ambient temperature will give a reasonable
indication about the load conditions.
If, without an increase in load or change in environmental
conditions, there is a tendency for the temperature of a
6.2.8.3 Other transformer to rise, the reason may be that in some way
the cooling is reduced (e.g.: fans out of service).
Make sure that the drain holes (closed with a plastic plug Another reason for abnormal temperature may be that
upon delivery) are open (to allow draining of the oil has started to form sludge deposits in the
95
Installation, Operation and Maintenance Manual
96
Installation, Operation and Maintenance Manual
97
Installation, Operation and Maintenance Manual
COMPONENT 1 2 3 4 5 6 7 8 9 10
98
Installation, Operation and Maintenance Manual
COMPONENT 1 2 3 4 5 6 7 8 9 10
99
Installation, Operation and Maintenance Manual
6.5 Troubleshooting
100
Installation, Operation and Maintenance Manual
Observations made
Oil level is not correct.
Alarm on Buchholz, gas relay.
Alarm on temperature devices.
Fans or oil pumps do not work.
Insulation resistance is too low.
Power factor is too low.
Visual oil leaks.
Possible cause of malfunction Rectification measures
X Level indicator is defective. Repair or replace level indicator.
Low oil level due to oil leak(s). Locate oil leak(s); repair leak(s).
Replace leaking device or gasket(s).
X Insufficient air venting during erection. Gas analysis is recommended.
Fault gas production. Consult manufacturer for further actions.
X The ambient temperature is too high. Reduce load.
Overloading.
Malfunction of the temperature devices. Check / replace temperature device.
Malfunction of the cooling system.
X Defect on temperature detecting system. Check detecting system.
Devices are defective. Replace defective devices.
X Contamination on bushings, etc. Clean-up external bushings, terminals,
Penetration of humidity in the insulation Consult the manufacturer.
system.
X Degradation of the insulation system. Clean-up external bushings, terminals,
Consult the manufacturer.
X Defective gaskets. Tighten bolts.
Replace gaskets.
Table 18 Mechanical malfunction troubleshooting chart
101
Installation, Operation and Maintenance Manual
102
Installation, Operation and Maintenance Manual
or in the valve. Therefore, drain off three or four clean and filled with oil, completely free of gas
liters of oil into a clean bucket before taking the bubbles. Close the 3-way valve to the syringe.
oil sample. Rinse the clean container several Close the sampling valve and remove the
times with oil prior to taking the actual sample. syringe. Place the syringe in the syringe box.
The oil can contain a large amount of dissolved
water, invisible to the eyes but easily detected
Take the spare sample following the same
by test. If the sample bottle contains liquid
procedure.
water, contact Saudi Power Transformers
Company immediately. It is preferred that the
temperature of the oil be equal or warmer than
the ambient air to prevent contamination by
condensation. 6.8 Dielectric strength
A period of 12 hours should be observed
between taking the sample and performing Oil sampling has to be in line with ASTM D 923 or
tests, to allow the oil to stabilize and become IEC 60475. The test should be performed in a well-
homogeneous. equipped laboratory according to the applicable
standards.
Required values for transformers in service:
6.7.2 Taking samples for DGA tests > 60 kV/2.5 mm (as tested per IEC 60156)
> 30 kV/2.54 mm (as tested per ASTM D 877)
For DGA tests it is always recommended to take a
spare sample. This spare sample can be used if
something happens to the first sample, or if the If values are lower, the oil should be filtered or
analysis is very odd. Testing has to be in line with streamlined. Test the oil annually or even more
ASTM D 3613 or IEC 60567. frequently if the operation condition of the
transformer questions the continuity of the oil quality
Use dry clean syringes, equipped with a 3-way in general.
syringe valve. Record the transformer serial
number, the ambient temperature, the oil Low insulating oil strength may also be an indication
temperature and the date of sampling. that the transformer insulation contains excess
moisture. Further evaluation should be made such
The sample is to be taken from the oil sampling
as power factor tests and taking oil samples to
valve. The location of this valve is indicated on
determine moisture content in oil.
the General Arrangement drawing.
If oil circulating pumps are installed on the Remarks:
transformer, they should be operated for a
If some work has been carried out on a transformer
minimum period of one hour before taking any
and the oil has, during that time, been exposed to
oil samples.
the humidity of the air, the breakdown value of the
Allow 3 to 4 liters of oil to run into a clean
oil should be checked.
bucket to ensure a true sampling of the tank oil.
Attach the 3-way syringe valve and the
sampling syringe to the sampling valve (using
an adaptor).
Open the sampling valve very slowly and allow 6.9 Moisture content
the oil to flow through the 3-way valve into the
clean bucket without injecting air bubbles into Transformer oil is hygroscopic and therefore it
the stream. Avoid bubbles in the sample by absorbs moisture from the air. The absorption of
using the 3-way syringe. moisture is minimized by the oil preservation
Flush the syringe by using the 3-way valve. Let system. The oil conservator system with a silica gel
the oil in the syringe and push the oil to the breather also minimizes the entry of moisture as
bucket, using the syringe plunger. Repeat this long as the silica gel is properly renewed or
procedure several times until the syringe is regenerated as soon as its ability to absorb moisture
103
Installation, Operation and Maintenance Manual
begins to diminish. Check also whether the oil lock If severe formation of particles has set in, the oil
in the silica gel breather is properly filled with oil changes its color and gets darker. The appearance
(check maximum and minimum oil level indications of the oil is usually muddy. By filtering, it is possible
in lock). to remove the sludge but, having once started, the
formation of sludge will increase with time. Such oil
Moisture content in ppm is related to the operation
should be completely changed as soon as the
conditions of the transformer. Moisture in oil can
service conditions permit it.
lead to reduction of the dielectric strength in oil and
windings. The table below gives the maximum For the reasons mentioned above, Saudi Power
allowable ppm of water in oil. Transformers Compnay has produced its own
criteria for particles in new transformer oil. We take
these criteria into account before testing a
Maximum water transformer. The same values can be used for
Temperature ( C) transformers in service.
content (ppm)
- 20 5
- 10 9 Maximum amount of
0 16 Particle size particles in 10 ml
10 20 sample (0.338 fl.oz)
Table 19 Water in oil all Particles 1.5 m
2500
of which :
Particles 5 m 1500
Particles 20 m 30
Example: Particles 30 m 10
In case 50 ppm moisture is detected in oil that is Table 20 Particles in oil
sampled at 10 C oil temperature, free water has
been created already and this water might have
Since each measurement will produce different
been absorbed inside the windings and other critical
results, it is a practical matter to provide 5 or 6
parts of the transformer. This is a dangerous
measurements. The average of measurements is
situation for the transformer.
then the base for the determination whether the
particles are within the required limits.
Remarks:
104
Installation, Operation and Maintenance Manual
$
5000 ppm for transformers with sealed conservations system
(atmoseal), 10000 ppm for transformers with open breather
conservation system
6.11 Dissolved Gas Analysis on ** If a communicating OLTC-conservator is in use, this value will
be 270ppm
transformer oils from the main if a communicating OLTC-conservator is in use, this value will
tank of a transformer be 1 ml/day
105
Installation, Operation and Maintenance Manual
6.13.1 Actions
NO
First DGA-sample of Evaluate with respect to
a transformer historical data
YES
NO
NORMAL-status
Level gas > table
Concentration gas1?
> Resample 1 year
table 1?
YES
YES
ALARM-status
Contact Saudi Power
Transformers Company
Check rate immediately
106
Installation, Operation and Maintenance Manual
YES
NO
Concentration gas > table 1? NORMAL-status
Resample 1 year
YES
YES
NO ALERT-status
Rate C2H2 > table 1? Contact SPTC ASAP
Resample 3 months
YES
ALARM-status
Contact SPTC immediately NO
Resample immediately
NO
ALARM-status Rate new sample > table 1?
Consider to shut down
Contact SPTC YES
Immediately
Shut down!
Resample within 2-4
Inform SPTC
weeks
immediately
NO
ALERT-status
Rate gas > table 1?
Resample 6 months
YES
NO NORMAL Condition
Concentration gas > table 1?
Resample 1 year
YES
NO ALERT-status
Rate gas > table 1?
Resample 6 months
YES
ALERT-status
Contact SPTC ASAP
for evaluation and
further actions
107
Installation, Operation and Maintenance Manual
108
Installation, Operation and Maintenance Manual
7 Forms, checklists
109
Installation, Operation and Maintenance Manual
110
Receiving inspection report
Date of report:
Transformer Serial No:
1 Customer and Equipment information
A Customer information
Customer Name:
Contractor Name:
User name:
Purchase Order No:
Additional information:
B Equipment information
Rating: MVA KV
Arrival location:
Date of arrival:
Transport by: VESSEL TRAIN TRUCK PLANE
Additional Information:
3 Appendices
Remarks: Complete this report and send it to your Saudi Power Transformers Co. contact person.
If there is any damage or missing material, follow the procedures mentioned in the IOM manual.
111
Energization Report
Date of report:
Transformer Serial No:
1 Customer and Equipment information
A Customer information
Customer Name:
Contractor Name:
User name:
Purchase Order No:
Additional information:
B Equipment information
Rating: MVA KV
Site location:
Delivery date:
Additional Information
2 Energization information
Energization date:
Energization hour:
Atmospheric condition:
Ambient temperature:
Additional information
concerning energization
conditions:
Have all the tests and inspections listed in the Site commissioning report
YES NO
been performed?
Has a copy of the Site commissioning report been sent to Saudi Power
Transformers Company (in case erection and commissioning has not YES NO
been done or supervised by Saudi Power Transformers Company)?
Has energization been successful and without any problems?
YES NO
Remarks on energization:
3 Appendices
Remark: Saudi Power Transformers Company (SPTC) will confirm receipt of this report.
112
Parts ordering form (1)
1 Customer information
A Customer information
Customer:
(1)
Customer P/O No :
Contact Person:
Tel:
Fax:
Additional information:
B Transformer information
Transformer serial No:
Rating: MVA KV
Date of energization:
Tel:
Fax:
3 Parts
(2)
Item No Description Type/Specifications # Unit Price Total Price
(1) When ordering parts: an official Purchase Order with reference to our quotation is required.
(2) Item Nos are provided on the General Arrangement drawing and materials list (in IOM manual).
113
Site commissioning report
Cover sheet
Project
Customer
customer reference
Order number
Site
Country
CG Power Solution
Saudi Arabia reference
Serial number
MVA
HV
MV
LV
Vector group
Date
114
Mechanical inspection Tx.Nr.
Remarks :
If applicable, measurement of core-to-tank insulation (CG Power Solutions Saudi Arabia IR or IR3))
After erection
General check
OK NOK NA
ground connections of all accessories mm mm
distance between lightning rods & ground
check position of all valves
Position of flap valves (radiators)
oil level transformer
oil level tap changer
desaeration of relevant parts
absence of oil leaks
absence of tools on transformer
markings, terminal plate, rating plate
air breather(s) : oil lock, silica gel condition
painting
115
Mechanical & electrical checks Tx.Nr.
OK NOK NA
Synchronisation of drive / tap changer
Functional test
Funtioning of mechanical interlocks
OK NOK NA Voltage
Check position of links --> operating voltage
CONTROL CABINET
OK NOK NA
External wiring completed
Current transformers connected or short circuited
All wiring insulation tested with 500V (except remote)
position ind / AKM Trafoguard / DIGEM
Tightmess of connections
Phase rotation of incoming supply
Rotation of each fan
Rotation of each pump
OK NOK NA
Manual control of fan operation
Thermal device control of fan operation
Manual coantrol of pump operation
Thermal device control of pump operation
Breaker contact operation of pump control
Oil flow indicator(s)
Automatic change over of supply voltage
Heating : functioning and control
Indication of Fans working and contact (if applicable)
Indication of Pumps wordking + contact (if applicable)
Indication of Tap changer running + contact (if applicable)
116
ALARM CONTACTS Tx.Nr.
C.C. CLIENT NA
Buchholz transformer
Buchholz cable boxes
Oil level transformer minimum
Oil level tap changer maximum
Oil level tap changer minimum
Oil temperature alarms
Winding temperature alarms (primary)
Winding temperature alarms (secondary)
Winding temperature alarms (tertiary)
MCB cooling supply
C.C. supply-control relay(s)
MCB tap changer supply
Tap changer suppy-control relay
Aux.contacts of fan MCBs
Aux. contacts of pump MCBs
TRIP CONTACTS
C.C. CLIENT NA
Buchholz transformer
Tap changer protective relay
Buchholz cable boxes
Overpressure relief device 1
Overpressure relief device 2
Overpressure relief device on cable boxes
Oil temperature trip
Winding temperature trip (primary)
Winding temperature trip (secondary)
Winding temperature trip (tertiary)
Non return flap valve (Sergi)
INDICATION CONTACTS
C.C.. CLIENT NA
Check all applicable signalisation contacts
117
Tx.Nr.
Temperature settings values on Saudi Power Transformers Company
drawings
Thermostat degrees C NA
start fans (pumps)
alarm
trip
Oil thermometer degrees C NA
st
stop fans (pumps) or alarm 1 stage
nd
start fans (pumps) or alarm 2 stage
alarm
trip
118
Insulation resistance measurement Tx.Nr.
Date :
Atmospheric condition
Ambient temperature
Oil Temperature
Tap changer position
Megger
Make
Type :
HV LV + Tank LV HV + Tank
Applied voltage kV Applied voltage kV
1 min 1 min
2 min 2 min
3 min 3 min
4 min 4 min
5 min 5 min
6 min 6 min
7 min 7 min
8 min 8 min
9 min 9 min
10 min 10 min
Measured value M
119
Insulation resistance measurement Tx.Nr.
Date :
Atmospheric condition
Ambient temperature
Oil Temperature
Tap changer position
Megger
Make
Type :
Measured valur M
120
Oil test results Tx.Nr.
Sampling date
Atmosperic condition
Ambient temperature
Oil temperature
Testing date
Ambient temperature
Oil temperature
Dielectrical strength
Instrument used
Make
Type :
1 kV 1 kV 1 kV
2 kV 2 kV 2 kV
3 kV 3 kV 3 kV
4 kV 4 kV 4 kV
5 kV 5 kV 5 kV
6 kV 6 kV 6 kV
121
Voltage ratio test Tx. Nr.
Instrument make :
Instrument type :
tap.pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
122
Vector group test Tx.Nr.
Applied voltage
AB V
BC V
CA V
Measured voltage V
V
V
V
V
V
Equations
Vector group =
A
A a
a
b
c
b
c c
C B C B
A
A
C B
C B
123
Winding resistance measurement Tx.Nr.
Secondary winding ;
_
_ Oil Temperature
_
Winding temperature
Tertiary winding :
_
_
_
124
Tg delta measurement Tx.Nr.
Date
Atmospheric condition
Ambient temperature
Oil temperature
Tap changer position
Test device
Make
Type
MV HV + LV + Tank %
LV HV + MV + Tank %
HV + MV - LV + Tank %
HV + LV - MV + Tank %
MT + LV - HV + Tank %
125
Current transformer checks Tx.Nr.
Location : Name
Specs. Ratio
Insulation resistance with 2500V P1=
Kneepoint voltage determination NA P2=
Voltage S1=
Current S2=
Connections tightened or shorted
Location Name
Specs. Ratio
Insulation resistance with 2500V P1 =
Kneepoint voltage determination NA P2 =
Voltage S1 =
Current S2 =
Connections tightened or shorted
Location Name
Specs. Ratio
Insulation resistance with 2500 V P1 =
Kneepoint voltage determination NA P2 =
Voltage S1 =
Current S2 =
Connections tightened or shorted
Location Name
Specs. Ratio
Insulation resistance with 2500V P1 =
Kneepoint voltage determination NA P2 =
Voltage S1 =
Current S2 =
Connections tightened or shorted
Location Nom
Specs. Rapport
Insulation resistance with 2500 V P1 =
Kneepoint voltage determination NA P2 =
Voltage S1 =
Current S2 =
Connections tightened or shorted
126
Zero phase sequence impedance determination Tx.Nr.
3) Apply single phase voltage between Hv winding and HV neutral (220 240 V)
lowest
nominal
highest
127
Automatic voltage regulation check Tx.Nr.
Device(Type)
Make
Serial Number
Simulate the P.T. voltage and balance the relay on this voltage (no presignal). While the bandwidth is set at 1%,
increase the voltage by approximately 1.2 %. After the set time delay the tap should move to a lower position (more
winding turns in primary).
Lower the simulated P.T. voltage to approximately 1.2 % below the desired P.T. voltage.
The tap should move to a higher position (less winding turns in primary).
Y N
Did the relay pass this function test ?
OK NOK NA
128
CONCLUSION Tx.Nr.
Corrections to be made.
Other remarks.
Name : Name :
Signature Signature
Date : Date :
129
Installation, Operation and Maintenance Instructions
8 Special Instructions
130