Transmission & Distribution

INSTRUCTIONS FOR ASSEMBLING

AND MAINTENANCE
OF CURRENT TRANSFORMER
Type

IOSK 72,5…….550 kV

ISTR3-106
Trench Italia S.r.l

Strada Curagnata, 37 - 17014 Cairo Montenotte (SV) Italy tel (39) 019516111 fax (39) 0195161401
Codice Fiscale/Partita Iva 01458580097 - N° REA CCIAA di Savona 148062 - Capitale Sociale € 7.000.000 i.v. - Società
Unipersonale -

Unrestricted
 ISTR3-106
TRENCH CURRENT TRANSFORMER Ed. b - 18/04/16
IOSK 72 ÷ 550 kV Pag. 2/17

Index
1. Foreword
2. General safety warnings
3. General description
3.1 Nameplates
3.2 Ground connector
3.3 Secondary terminal
3.4 Primary terminal
3.5 Ratio change
3.6 Tightening torque of the screws
4. Shipping
5. Moving
6. Installation Commissioning
7. Installing
7.1 Primary ratio change
7.2 Three ratios
7.3 Double ratio
7.4 Connection to circuits
8. Maintenance
8.1 Visual inspection
9. Spare parts and devices
10. Diagnostic recommendations
11. Communications with TRENCH ITALIA
End of life treatment

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IOSK 72 ÷ 550 kV Pag. 3/17

1. FOREWORD

This manual has the following purposes:

1 to describe the transformer, to serve as a guide for assembling and putting it into
service
2 to analyse the transformer in service
3 to prescribe a number of ordinary maintenance operations
4 to enable the user to locate the individual components, facilitating requests for
information or spare parts

2. GENERAL SAFETY WARNINGS

In order to avoid potentially dangerous situations operate as follow:

þ ON ARRIVAL, CHECK THE TRANSFORMER AND ITS PAKAGE, ACCORDING TO THIS

PUBLICATION

þ ACT ACCORDING TO LAW PROVISIONS ABOUT ELECTRICAL DEVICES

þ FOLLOW SUBSTATION SAFETY INSTRUCTIONS, AND/OR PLANT PLACE SAFETY

INSTRUCTIONS AND/OR WAREHOUSE SAFETY INSTRUCTIONS

þ CAREFULLY FOLLOW OPERATIONS THAT ARE DESCRIBED IN THE PRESENT

PUBLICATION

þ SHORT CIRCUIT THE SECONDARY WINDINGS IF NOT USED

þ CONNECT TO EARTH ONE TERMINAL OF EACH SEPARATE SECONDARY WINDING

þ HANDLE WITH CARE, TO AVOID COLLISIONS, IN PARTICULAR AGAINST PORCELAIN

INSULATOR, FOLLOW CURRENT HANDLING INDICATIONS

þ IF THE RESULTS OF THE CHECK TESTS ACCORDING TO SITE QUALITY CONTROL

PLAN ARE NEGATIVE, CONTACT TRENCH ITALIA

þ UNUSED CAPACITIVE TAPS CT MUST ALWAYS BE GROUNDED INSIDE THE

TERMINAL BOX. OTHERWISE HIGH VOLTAGE WILL BE OPERATING INSIDE THE
TERMINAL BOX LEADING TO SPARKING AND DAMAGE OF THE TRANSFORMER.

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3. GENERAL DESCRIPTION
The IOSK 72,5……550kV is an OIL insulated CURRENT TRANSFORMER.
All transformers are hermetically sealed and employ oil-paper insulation. Changes in oil
volume due to temperature variations are accommodated by the stainless steel bellows or
expansion cell (alternative).
Two different kind of insulator body are available:
porcelain insulator
composite insulator, consisting of a tube made of fibre reinforced polymer (FRP) with cast
silicon sheds

3.1 NAMEPLATES

The nameplate with electrical data is placed near the secondary terminal box.
There are P1 (H1) and P2 (H2) plates, on the transformer’s head:
P1 (H1) indicates the conventional current input of primary terminal
P2 (H2) indicates the opposite primary terminal.
Two nameplates show, respectively, the ground tap described at par. 3. 2 and this one inside
the secondary terminal box. A diagram plate is attached inside the cover of the secondary
terminal box.
The primary ratio change diagram plate is applied inside the protective cover of the ratio
change.

3.2 GROUND CONNECTOR

There’s an earth screw M12 on one of the anterior support. This screw in made of stainless
steel and is used to ground the secondary terminal box too.
In accordance with customer’s request, Trench Italia can supply another kind of earth clamp.

Screw M12 stainless steel

Safety notice: Defective or inadequate grounding poses a danger to life in case

of contact with the transformer. In addition, the monitoring function of the
transformer is not guaranteed if grounding is defective or inadequate.

3.3 SECONDARY TERMINAL

The secondary terminals are located in the splash proof terminal box at the base of the
transformer.
The schematic drawing indicates the labelling of the terminals.

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3.4 PRIMARY TERMINALS

The primary terminals are made either of Al or tinned Cu.

The material as well as design (dimensions) of primary terminals should depend on
customer’s inquiry.

3.5 RATIO CHANGE

The IOSK 72,5……550kV allows both the primary ratio change and the one secondary.
For primary ratio change, the transformer is sent in parallel connection that can support the
maximum allowable current. See chapter 7.1.
For secondary ratio change, the connections must be made following the diagram plate
attached inside the cover of the secondary terminal box

3.6 TIGHTENING TORQUE OF THE SCREWS

TORQUE WRENCH SETTING[ Nm ]

Screw Use TORQUE WRENCH TORQUE
SETTING[ Nm ] WRENCH
SETTING[ Nm ]
M6 Secondary terminals 7
M8 Grounding (inside the 16
secondary terminal box)
M10 Primary ratio change 25
M12 Primary ratio change, 30
cupper line terminal
M12 Aluminium line terminal 50
M12 Gruonding (outside) 50 (A2 70) 85 (8.8)
M 16 Fixing to base 110 (A2 70) 200 (8.8)

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4. Packing material, Transportation, Storage,

Unpacking
Transformers are shipped in either the vertical or horizontal position.
Depending on distance and scope of delivery, ordinary means of transport (rail, ship,
truck, air freight) are employed. Packaging includes the required supports and cushioning to
prevent damage during the required shipment.
On arrival, the transformer and its package must be checked immediately to find possible
signs of damage or tampering.
If there are some damages, keep all the parts, including the package, notify the carrier and
warn Trench Italia.
Unpacking and inspection upon arrival
Inspect the packaging and contents immediately after receipt of the shipment at the
installation site. Possible damage includes
• Damage due to impact (porcelain/composite damage, broken glass)
• Oil leakage (cracked porcelain/ripped composite)
• Bent metal parts (terminals, connectors etc.)
If damage is found on inspection, the following actions should be taken:
a) Notify the insurance carrier immediately.
b) State on acknowledgement of receipt that the forwarder is liable.
c) In order to prevent expiration of deadline for claims against the forwarder, send a
registered letter notifying the forwarder of his liability.

5. MOVING
If no damage is found, use the same precautions in on-site transport as during shipment.
For long-distance transport, it is recommended that the transformer be left in its original
packaging or repackaged.
If the transformer must be stored for an extended time before being put in service, the
following actions should be taken:
a) Store the transformer, with or without packaging, in a protected, well-ventilated
place and in such a way that it cannot fall over.
b) Under no circumstances may the transformer be stored horizontally for an
extended period of time (max. 3 months).
c) Remove the shipping protection around the metal bellows as instructed in
section 6.3.
The temperature limits for storage are the same as for service. Avoid extreme pollution
and safeguard porcelain/composite sheds against possible damage. In addition protect
the packaging against rotting.

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IOSK 72 ÷ 550 kV Pag. 7/17

6. INSTALLATION, COMMISSIONING
6.1 Place of installation
The transformer must be installed on a horizontal, flat and level surface. If the surface
is not flat, insert shims at the hold-down positions as needed in order to eliminate
distortion stresses.

6.2 Erection
After releasing the fasteners, lift the transformer out of the packaging as shown in Fig.
2. The weight of the transformer is indicated on the rating plate. Hoisting gear should
be adequate for the weight of the transformer. Avoid jerky movement of the crane.
When moving the transformer horizontally, secure it against swinging.
Place of installation
The transformer must be installed on a horizontal, flat and level surface. If the surface
is not flat, insert shims at the hold-down positions as needed in order to eliminate
distortion stresses.

Erection and transport

The transformer may be shipped in either the vertical or horizontal position.
When lifting or erecting, always support by two lifting eyes (two on vertical or horizontal
either head or one each on head and base). If the transformer must be returned to the
horizontal position, note the shipping position with the terminal box facing up. Provide
appropriate support for transformer in horizontal position.
Fig. 2

Horizontal transport Setting up Vertical transport

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Transformer is top-heavy

6.3 Transport protection of metal bellows / metal expansion cell

After shipping and on-site transport, remove the cap (1) to expose the cardboard tube
used to protect the bellows during transport. Remove the cardboard tube (2).
Alternative: The metal expansion cell is supported by foam plastic blocks (4) which
must be removed. After removing the transport protection replace the cap, securing
with the two pre-positioned slot-head screws (3).

Commissioning

Observe all in-house regulations applicable for placing the transformers in service.
Check that the insulators free external pollution and defects.
Inspect the transformer for damage, and in particular for oil leaks.
Make sure that the bellows in the head are correctly positioned for the given
temperature.
Inspect the primary and secondary connections to make certain that no wiring errors
have been made. Verify that the contacts are good. The grounding connection must be
made to the base of the transformer.
Check the transformer secondary leads for continuity.

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7. INSTALLING
The fixing to the transformer on its support is achieved using base slots or holes.
The base is 10 mm thick in the points of fixing.
Verify the sizes on the drawing of the transformer’s overall dimensions.

7.1 PRIMARY RATIO CHANGE

The IOSK 72,5……550kV transformer allows the primary ratio change with various
connections, depending on the number of ratios prescribed and on the value of the current:
∂ THREE RATIOS (ex. 1600-800-400/1)
∂ TWO RATIOS (ex. 1200-600/1)
The transformers are always shipped in the connection that can support the maximum
allowable current.
If it necessary the ratio change, act as follows:
∂ unscrew the nuts of pos. 2, remove the cover showed in pos. 1, without damaging the
washer of pos. 3
∂ make the connections as primary ratio change diagram plate shows.
It is convenient to clean the plates with an abrasive sponge when executing a ratio change.
Grease the plates immediately afterwards with Electat Grease 453 or vaseline.

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7.2 THREE RATIOS

The three ratio permits the use of the apparatus with three levels of primary current, arranging
the ratio change plate in three different ways:
P1 side
- four copper plates
- M10 stainless steel nuts
P2 side
- four copper plates
- one copper potential connection
- M10 stainless steel nuts

The tightening torque for all nuts is 30 Nm.

The possible connections with three ratios are:
“PARALLEL” connection
“SERIES-PARALLEL” connection 9
“SERIES” connection
7
“Parallel” connection (higher ratio) - Ex. 1600-800-400 8 7 8
P1 side 5 6 5 6
- put a plate between points 1, 3 and 5 3 4 3 4
- put a plate between point 3, 5 and 7 1 2 1 2
- place a plate between points 2, 4 and 6
- put a plate between points 4, 6 and 8
P2 side
- repeat the above directions
- attach the potential connection between points 8 and 9 P1 P2
“Series-parallel” connection (intermediate ratio) - Ex. 1600-800-400 9 9
P1 side
- put a plate between points 1, 3 and 5
7 8 7 8
- put a plate between points 3, 5 and 7 6 6
- place a plate between points 8 and 9 5 5
- put a plate between points 6 and 8 3 3
2
P2 side 1 1

- repeat the above directions

- attach the potential connection to point 2,
folding back on itself P1 P2
“Series” connection (lower ratio) - Ex. 1600-800-400 9 9
P1 side
- put a plate between points 11 and 7
- put a plate between points 6 and 10 11
7 8
10
7 8
10
6 11 6
- put a plate between points 1, 3 and 5 5 5
- put a plate between points 8 and 9 3 3
P2 side 1 1
2

- repeat the above directions

- attach the potential connection to point 2,
folding back on itself
P1 P2
The pictures are shown on the diagram plate inside the protective cover of the ratio change.

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IOSK 72 ÷ 550 kV Pag. 11/17

7.3 DOUBLE RATIO

“Series” and “series-parallel” or “parallel” and “series-parallel” connections can be used in

presence of ratio change. The directions written at the preceding paragraph must be carefully
followed.

“Series-parallel” and “parallel”

9
“Series-parallel” connection – Ex. 1200-600 9

P1 side
- put a plate between points 1, 3 and 5 7 8 7 8
- place a plate between points 3, 5 and 7 6 6
5 5
- put a plate between points 8 and 9 3 3
- place a plate between pins 6 and 8 1
2
1
P2 side
- repeat the above directions
- attach the potential connection to point 2, folding back on itself
P1 P2
“Parallel” connection – Ex. 1200-600
P1 side 9
- put a plate between points 1, 3 and 5
- put a plate between point 3, 5 and 7
- place a plate between points 2, 4 and 6 7 8 7 8
- put a plate between points 4, 6 and 8 5 6 5 6
3 4 3 4
P2 side 1 2 1 2
- repeat the above directions
- attach the potential connection between points 8 and 9
“Series-parallel” and “series”
P1 P2

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9 9
“Series-parallel” connection – Ex. 400-200
P1 side
- put a plate between points 1, 3 and 5 7 8 7 8
- place a plate between points 3, 5 and 7 6 6
5 5
- put a plate between points 8 and 9
3 3
- place a plate between pins 6 and 8
1 1

P2 side
- repeat the above directions
P1 P2
“Series” connection - Ex. 400-200
P1 side 9 9
- put a plate between points 11 and 7
- put a plate between points 6 and 10
7 7 8
- put a plate between points 1, 3 and 5 11
8
6
10
11 6
10

- put a plate between points 8 and 9 5 5

3 3

P2 side 1 1

- repeat the above directions

7.4 CONNECTION TO CIRCUITS P1 P2

To implement connection to circuits, act as follows:
- connect ground terminal, that is on the support of the transformer, with a copper cable
- connect secondary windings, following diagrams of the station and using cables right
suitable to the current, accuracy class and circuits length
- CONNECT TO EARTH ONE TERMINAL OF EACH SECONDARY WINDING
SEPARATELY, using appropriate earth clamp, located into secondary terminal box.
This prevents the secondary winding from assuming a dangerous electrostatic
potential
- SHORT CIRCUIT THE UNUSED SECONDARY WINDINGS to avoid endangering the
staff and causing the apparatus to ill-function
- carefully clean the primary terminals;
- connect to the network.
- if it necessary to change the primary circuits configuration, follow the directions written
in the par. 7.1 and what is marked on the primary ratio change diagram plate applied inside
the protective cover. All primary contacts are greased. It is convenient to clean the plates
with an abrasive sponge and grease them immediately afterwards with Electat Grease 453
or vaseline, when executing a ratio change.
Make the same treatment to the secondary clamps

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IOSK 72 ÷ 550 kV Pag. 13/17

8. MAINTENANCE
8.1 VISUAL INSPECTION

IOSK 72,5……550kV needs only ordinary external cleaning, depending on environmental

conditions and in accordance with the established cleaning cycle for other near equipment
(circuit breaker, disconnectors, etc.). In general, external inspection is enough to ascertain the
condition of device.
While operating, a deposit (dust, soot, salt, etc.) is formed on the surface of tongues of the
insulators and it can reduce their surface tightness. To clean these tongues special tools are
not necessary, but you can wash them like other similar instruments. Washing system that
spray water upwards, are good, so that the insulators are cleaned while working.
For composite insulator:
∂ in service cleaning is not necessary to remove pollution
∂ if insulator has been contaminated before putting into service (during manufacturing,
transport or handling ), clear it with soapy water, by a cotton cloth. After the cleaning,
dry the insulator, always by cotton cloth.

The visual inspection shall also concern a visual checking of all metal parts (corrosion) and
any other mechanical damages (cleaning, greasing and / or painting if necessary).
Every 6 months visually inspect component.

9. SPARE PARTS AND DEVICES

As the apparatus are static and sealed, it is not necessary to store spare parts.

10. Diagnostic recommendations

We recommend that the following checklist be employed when inspecting the current
transformer.
Natural ageing of the material , electrical overload or mechanical forces can lead to a
situation were the instrument transformer has to be taken out of service. This manual
recommends methods for analysing the instrument transformer to decide if the unit is still
in healthy conditions, risk conditions or has to be taken out of service.
If the results of some inspections are between normal conditions and the limits for
units to be taken out of service the time intervals for the inspections has to be
decreased.
If there is a significant difference in the results in only one instrument transformer in a
three phase system, this unit should be considered as a risk unit.
For better investigations of old instrument transformer the time intervals for the tests can
be de-creased. (e.g. when the results of DGA are still OK but there is a remarkable
increase of the gases compared to the previous analysis).
Trench should be informed when the measured values of an instrument transformer
exceed the normal values or concentrations.

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Inspection intervals A B C D E F G H I J K L
Before energizing, after any movement of o o o o o o o o
transformer

Routine inspection (approx. 1-year interval) o o o

After every 10 years in service (approx.) o o o o o o o o

After electrical overloads (primary or o o o

secondary)
Before re-energizing, after change of burden o o o o o
or connections

After excessive mechanical loads on o o

transformer (due to being dropped, storm or
earthquake)

When secondary current readings are o o o o

doubtful
Inspection checklist

Possible inspections
A Verify correct grounding
Check the tightness of screws holding the ground connection to the base.

B Verify that all connections are sound

Connections, including screw-type connections, must be mechanically tight and exhibit a low contact
resistance. They must also be kept free of corrosion.

C Verify that unused secondary windings of the current transformer are shorted
The burdens (including line impedance) connected to the secondary windings of the current
transformer must not exceed the rated value (see rating plate). Unused secondary windings must be
shorted in the terminal box of the transformer. Failure to follow this instruction may lead to
destruction of the secondary insulation. The voltage across open secondary terminals can exceed
10 kV.
D Measure secondary currents against specified values
The step-down ratio can be measured by injecting a current of 5% of rated current, at rated
frequency, through the primary connections. Disconnect the primary connection from the highvoltage
line before performing this test.
Connect a low-resistance ammeter to the respective secondary terminals of a core.
Short the other windings of the current transformer.
The measured step-down ratio should not differ greatly from the nominal value. If there is a large
discrepancy, damage must be suspected and the transformer shall not be returned to service without
further tests.
E Check bellows position
The bellows position indicator must be between the "Min." and "Max." marks at all ambient and
service temperatures. In a three phase system all bellows indicators must be in about the same
position between min and max. (a difference should be clear detectable from the ground - about 3
cm or more). If the position of a bellows indicator is above max. or below min. the unit is to be taken
out of service.

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F Examine for traces of oil

The following parts of the transformer must be checked for oil traces:
∂ Head
∂ Primary terminals
∂ Terminal box (at multi-terminal bushing)
∂ Oil drain valve
∂ Insulator at points of contact with head and base sections
is an oil leakage detected, the unit is to be taken out of service.
G Inspect that the terminal box is clean and well sealed
The terminal box must be kept clean, dry and free from insects. The vent hole in the bottom of the
terminal box should be sealed with a piece of metal screen. If rainwater has entered the terminal
box, inspect the rubber weather stripping of the door and if necessary tighten the stainless steel
screw which holds the terminal-box door shut.
H Inspect porcelain/composite insulator and clean if necessary
Minor damage to the porcelain sheds can lead to hairline cracks, which are initially too small to see,
and later to oil loss. In case of damage, a thorough examination is recommended.
Heavy pollution of the porcelain insulator surface combined with moisture can lead to phenomena
ranging from surface corona discharge to flash-over. No in-service, keep insulators clean in
accordance with local (plant) experience and clean as far as necessary.
No in-service, cleaning may be necessary for composite insulators. Composite insulator surface
which has been contaminated during transport or handling can be cleaned by wiping with a moist
cotton cloth. The cloth can be soaked by 5% watery solution of liquid dishwashing detergent.
Follow applicable safety rules when cleaning (also see IEC/TS 60815).
I Perform overall corrosion check on metal parts
Inspect connections for corrosion, especially if unlike metals are in direct contact with one another.
If necessary, improve corrosion protection by painting.
J Check temperature
Internal damage can cause the external housing to heat up by more than 60°C above the ambient
temperature. After energization it may take as long as 20 hours for the final temperature to be
reached. Measure the temperature on the head of the current transformer. This measurement should
be performed within approx. 5 minutes after disconnection. Excessive temperatures (over 100°C)
can also be detected by the vaporization of water droplets sprinkled on the housing. A non-contact
thermovision temperature measurement is recommended.
K Check oil
Ageing of the oil is largely prevented by the complete sealing of the transformer. If necessary, it is possible to
analyse the oil by sampling it. Sampling should take place only in dry weather; the method set forth in the
separate instruction manual E 8291 should be used. The sample should be taken only by a trained specialist
and analyzed by a qualified laboratory. Trench has such a laboratory and trained experts.
Whenever a sample is removed, the volume of oil withdrawn should be made up with new oil
of the same quality and type.
A measurement of the tan d at 90 °C (IEC 60250), the breakdown voltage UD (IEC 60156) and the
water content in the oil (IEC 60814) is recommended.
Depending on the results of the oil test and other inspection procedures, Trench may recommend an
oil change.
normal conditions or limits
concentrations units to be taken out of service

tan χ at 90°C < 0.1 >0.2

U D in kV > 60 < 50

H 2O in PPM at 20 °C < 10 >20

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L Perform gas in oil analysis

The sample should be taken only by a trained specialist, in accordance with instructions E 8291, and
analyzed by a qualified laboratory. Trench has such a laboratory and trained experts, who are also
competent to interpret the results of oil in gas analyses.
For additional information see IEC 60567.
The contents of the following gases should be analysed:
Hydrogen (H2), Carbonmonoxide (CO), Carbondioxide (CO 2), Methane (CH4), Ethan (C 2H 6), Ethylen
(C2H4) and Acetylene (C2H2). The dissolved gases can show partial discharges (PD), discharges of
low and high energy, thermal faults in oil and thermal faults in paper. Additional measurement of
Oxygen (O2) and Nitrogen (N2) can be important for indication of leakage and information of the
quality of oil sampling. For additional information see IEC 60599.
Values of the following normal conditions or limits
gases in vpm, concentrations units to be taken out of service
μl/l

H2 < 300 > 1000

CO < 330 > 1000
CO 2 < 900 > 2000
CH 4 < 30 > 75
C2H6 < 25 > 70
C2H4 <4 > 25
C2H2 <1 > 10
Partial discharge measurement
The PD Measurement as diagnostic tool can only be used if there are suitable equipment to
measure on-site (see IEC 60270).
For tests in the laboratory the limits of IEC 60044-1 are recommended.
Because of the high noise on-site the partial discharge is not recommended for routine check of the
instrument transformers, but only as additional information method.

11. COMMUNICATIONS WITH TRENCH ITALIA

If it necessary to require reports or further information or to order spare parts for this device,
correspondence or a rapid answer are facilitated if you:
o refer to the instructions, using the same terms and indicating paragraph, picture and
position
o indicate the nameplate data of the device, particularly the serial number

To contact Trench Italia please call:

Cairo Montenotte Factory

Strada Curagnata, 37
17014 Bragno - Cairo M.tte (SV)
Tel.: +39 019 516111
Fax: +39 019 5161401

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End of life treatment

High voltage transformer type IOSK
Legal requirements: European waste catalogue and hazardous waste list
Commission Decision 2008/98/CE

To transformer and/or its components disposal and recycling, follow table below.
It is recommended to recycle, when it is possible.

Kind of waste Kind of material EWC Code

Transformer assembled, - 16 02 14
without insulating oil
Transformer assembled , - 16 02 13*
with insulating oil
Liquid Mineral oil 13 03 07*
Aluminium and aluminium alloy 17 04 02
Copper 17 04 01
Solid – metallic Iron and iron alloy 17 04 05
Ferromagnetic coil(1) 16 02 15*
Copper cable 17 04 10*
Porcelain hollow insulator (without 17 01 07
aluminium alloy flanges)

Porcelain hollow insulator with 16 02 16

aluminium alloy flanges
Composite hollow insulator (with
Solid non metallic and/or without aluminium alloy flanges) – made
16 02 16
of glassfiber reinforced polymer tube with silicon
rubber sheds

Plastics(2) impregnated in oil 16 02 15*

Paper impregnated in oil 16 02 15*
Wood package 15 01 03

(1): made of Fe-Si alloy or Fe-Ni alloy

(2): e.g.: ABS, EPDM, PTFE, polypropylene terephthalate, hostaphan, bakelite…

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