Instruction Manual WHL Rupture Disk

ShenzhenHuadianElectricity FirePreventionLtd.
Ver:121010
0

FMD
(Rupture Disk Type)

Instruction Manual
for
Installation and Commissioning

LC Number/Date: IM2BDG0003712 / 120918 HS Code: 8419.5000

by
Shenzhen Huadian Electricity Fire Prevention Ltd.
Ver:121010
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Content
1 Introduction
1.1 FMD Principle: Explosion Prevention, Fire Prevention, and Fire Extinction
1.2 Characteristics & Functions
1.3 Application Scopes
1.4 Working Conditions
2 Structure and Major Components
2.1 Technical Data and Parameters
2.2 Major Components Characteristics
3 Ordering Information
3.1 Ordering Procedures & Requirements
3.2 Scope of Supply
3.3 Transformer Manufacturer
3.4 Substation or Power Plant Contractor
4 Installation
4.1 Ground Construction Preparation
4.2 Shutter
4.3 Oil Installation Valve
4.4 N
2
Installation Valve
4.5 Fire Detectors
4.6 Fire Cabinet
4.7 Pipes between Transformer and Fire Cabinet
4.8 Control Cabinet
4.9 Cable Layout and Connection
5 Commissioning
5.1 Testing Procedure
5.2 Mechanics
5.3 Electrics
6 Operation
6.1 Basic Requirements
6.2 Instruction before Normal Operation
6.3 Activation during Normal Operation
6.4 After Activation
7 Maintenance
7.1 Regular Inspection and Maintenance
7.2 Periodical Inspection and Maintenance
7.3 Device Reset
7.4 Replace the Loss Products
7.5 Common Fault and Eliminating Methods
7.6 Announcements
8 Statement
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T2 T2+0.2S T1 T0
0 1
T3
2
T4
3
T5
4 Time
0.55
A
B
C
Without PRV
1.0
1.5
D
Pressure
PRV ActivatingLevel
F
FMD ActivatingLevel
WithPRV andwithout FMD
E
Transformer Explosion Region
Transformer MaximumPressure
WithPRV and FMD
NitrogenInjection Begings
1 Introduction

Blast or fire of oil-immersed transformers generally results from a break down of insulation. It
may be caused by over-current, over-voltage, earthing, or short-circuit. If the insulator is decayed
and the oil is moistened or decomposed, the level of insulation drops. Once it exceeds a limit to
cause an electric arc, the oil in the transformer can be decomposed rapidly. Then, many different
kinds of ignitable gases are produced as well as the limit of the oil tank pressure is exceeded. As a
result, the body of the transformer or on load tap changer can be broken. Once the high
temperature oil or gas expel out of the transformer and ignite with nature gas, fire spreads onto the
transformer and the floor. The fire is even worse if the oil continuously delivers to the tank.

1.1 FMD Principle: Explosion Prevention, Fire Prevention, and Fire Extinction

Transformers are the most expensive and important equipment in power plants and substations,
and oil-immersed transformers are among the most popular type in the current power industry.
Because the body of this transformer contains many flammable substances, explosion and fire can
be easily caused. As a result, the adjacent equipment is damaged, electricity is shut down, and
economy is momentous loss. Therefore, special attention must be paid to protect the transformer.
It often focuses on the matter of transformer parameters, but the increasing level of oil pressure
due to break down of insulation is ignored.

Curve of Pressures under Different Condition during Transformer Failure

T0: Insulation breaks down and appears at time zero
T1: PRV activation time (under set value) (Point A)
T2: FMD activation time (Point B)
T2+0.2s: FMD start-up time. Oil drains and pressure releases (Point C)
T3: Time for transformer to explode if PRV inactivates (Point D)
T4: Time for transformer to explode due to insufficient pressure released by PRV (Point E)
T5: FMD Nitrogen injection activates (Point F)
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If the transformer is not working properly, an enormous of flammable gases is created in the
oil tank. Hence, the gas relay closes and the electric breaker switches off. At this moment, the
internal pressure of transformer increases due to the thermal inertia. Once the pressure exceeds
rupture disk activating level, FMD system is automatically and instantly operated. Consequently,
the drain oil valve opens to draw off oil in order to relieve the pressure inside the tank and prevent
any explosion and fire.

Meanwhile, the shutter under transformer conservator is activated. The oil supply from the
oil conservator to the transformer body is automatically cut off. The oil level is prevented to
continuously increase and to causes more serious fire. After draining oil for 3-20 seconds, injected
nitrogen through the bottom of transformer body stirs the oil, compulsively cools down failure
points and oil temperature, isolates oxygen with a protection layer. Fire prevention and extinction
is achieved when the oil temperature drops below a flash-point (135-150) and a burn-point
(165-190). It means fire can be prevented before it happens, and fire can be extinct if it is
happening. After the nitrogen gas is continuously injected for 45 minutes, the large amount
nitrogen gas sufficiently cools down the transformer, extinguishes fire, and prevents any
re-combustion.

1.2 Characteristics & Functions

1.2.1 Functions
Prevent transformer explosion and fire
Extinguish transformer fire
Cool down transformer oil

1.2.2 Characteristics
State-of-the-art concept:
Rapidly drain oil to prevent explosion and inject nitrogen to prevent and extinct fire.
Excellent performance:
Utilize fast valve to drain oil within milliseconds with the technique from the national defense.
Fast response:
Once a fault signal is detected from the transformer, the oil is drained within milliseconds in order
to release pressure and to avoid explosion. The nitrogen gas is injected after 3s in order to mix and
cool down the oil, to reduce the concentration of flammable gases, to isolate oxygen gas, and to
extinct fire.
High reliability:
Utilize the principle of logic signal to prevent any improper or unnecessary activity to the system
and to provide a more flexible system.
High efficiency:
Able to inject nitrogen gas continuously for more than 31 min to completely cool down the
transformer oil as well as prevent and extinguish fire.
Reduce pollution:
No environmental pollution due to the characteristic of nitrogen gas in FMD. Extinguish fire
without water is an advantage to the lack of the water area.
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Feasibility:
Easy to install and maintain for either new or existing transformers.
Reasonable investment:
Minor price compare to other traditional transformer fire extinction systems, such as water
spraying systems and CO2 spraying systems.
Patent Right: National Patent Number 02225196.0.
FMD has been tested by National Fixed Fire Extinction System Fire-proof Quality Center.

1.3 Application Scopes

FMD is for both new or existing high power oil-immersed transformers and can be used in large
capacity power plants, such as hydroelectric plants; in electric grid substations, such as unmanned,
indoor, or underground; in the area where are cold or dry and where the space are limited.

1.4 Working Conditions

1.4.1 Working Environment:
Control Cabinet (indoor):
Max Temperature: 45
Min Temperature: 0
Relative Humidity:95% (20 )
Fire Cabinet:
Max Temperature: 60
Min Temperature: -40
Relative Humidity:95% (20 )

1.4.2 Operation Power Supply:
Control Cabinet: DC 110V 0.5A (Require 5A for Operation)
Fire Cabinet: AC 220V 2A (Dehumidify Heater Power Supply)

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2 Structure and Major Components

1. Shutter
2. Fire Detector
3. Rupture Disk
4. N
2
Injection Pipe
5. Oil Draining Pipe
6. N
2
Control Device
7. Fire Cabinet
8. Oil Draining Valve
9. N
2
Cylinder
10. N
2
installation valve

2.1 Technical Data and Parameters

Fire Extinction Medium: 99.99% Nitrogen
Purity;
N
2
Cylinder Volume: 2 X 40L;
N
2
Cylinder Pressure: 13~15MPa;
Depressurized N
2
Outlet Pressure: 0.6 MPa;
Oil Draining Activation Time: <0.2s;
Fire Extinction Time: <1min;
Total N
2
injection time: >45min;
Fire Detector Activation Temperature: 140
10;
Operation Power Supply: DC110V 5A;
Dehumidify Heater Power Supply: AC220
150W.

2.2 Major Components Characteristics

2.2.1 Shutter:
It is a valve, which can automatically cut off the oil delivered from the oil conservator to the oil
tank if the flux of oil suddenly increases. This shutter activates automatically while an enormous
amount of oil is leaking from a broken oil tank due to a transformer accident. Shutter is installed
between the oil conservator and the gas relay and connected by flanges. An electric signal will be
delivered to FMD Control Box if shutter activates. Shutter has to be reset manually after being
used.
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2
0
0
8
0
1
6
0
8hole
18
2
2
.
5
2
2
.
5

Send Signal: DC220V 0.25A;
Exterior Dimension: (diameter X length)
200X200 (mm);
Interior Diameter: 80;
Bolt Connection: 160, 8-hole18;
Weight: 6.3kg.

2.2.2 Fire (Temperature) Detector:
A high-strength or easy-melted alloy probe is equipped in the fire detector which activated at 130
10. This detector is installed on the top of a transformer where the fire is easily ignited,
such as beside bushings or an on load tap changer (OLTC). An electric signal will be sent when
fire is detected. The alloy probe has to be replaced after a fire incident.

Send Signal: DC 220V 0.5A
Dimension (lengthwidthheight): 18010040(mm)
Weight: 0.6kg

Fire Detector
2.2.3 Fire Cabinet:
It can rapidly evacuate oil and injects nitrogen gas after a signal is received from the control box.
This operation can be automatically or manually switched on. This cabinet should be installed
beside the transformer at a distance of 3 to 8 meters. If fire cabinet is located at outdoor, a
dehumidify heater should be used and installed inside the cabinet.
Exterior Dimension (lengthwidthheight): 10006002050mm
Weight: 420kg
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N
2
and Oil Pipes between Fire Cabinet & Transformer Control Box and Fire Cabinet

2.2.4 Control Cabinet and Control Box:
2.2.4.1 Control Cabinet:
Control Cabinet can be installed up to 3 Control Box and is located in the substation main control
room.
Exterior Dimension (lengthwidthheight): 8006002260mm
Weight: 180kg
2.2.4.2 Control Box:
The brain of the whole FMD system is Control Box, which is installed in Control Cabinet and
powered up by DC220V 5A.
Exterior Dimension (lengthwidthheight): 480480355(mm)
Weight: 10kg
2.2.5 Oil Draining Pipe and N
2
Injection Pipe:
Connecting the transformer tank and Fire Cabinet, the pipes should be zincified and are used as
channels to drain oil and inject nitrogen gas. Exhaust faucet should be installed on 90-degree
elbows closed to Fire Cabinet to release gas after oil filled during installation.
Oil Pipe: DN100
N
2
Pipe: DN25
2.2.6 Rupture Disk
Rupture Disk is installed in the terminal port
between Transformer, OLTC, and Bushing. An
electric signal will be delivered to FMD control box
after Rupture Disk Device activates. Rupture Disk
has to be replaced manually after being used.

Rupture Disk

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Once the pressure in transformer exceeds the blasting value of the rupture disk, it breaks
itself automatically and FMD system is automatically and instantly operated. Consequently, the
drain oil valve opens to draw off oil
in order to relieve the pressure inside
the tank and prevent any explosion
and fire. Note that the position of
exhaust faucet must be installed
vertically facing on the sky for the
purpose to evacuate the air.

Structure of Rupture Disk Set
1. DN100 Flange
2. Rupture Disk
3. Oil Resisted Rubber Washers
4. Elastic Pipe (Absorber)
5. Gate Valve
6. Exhaust Faucet

Structure of Rupture Disk Set
2.2.7 Cables:
2.2.7.1 Heat-resisted Cable:
It must be heat-resisted cable for delivering signals from Fire Detectors to the transformer terminal
box.
2.2.7.2 Control Cables:
They are used for the connections between control box, relay protection cabinet, control panel,
and fire prevention cabinet. The type and layout of these cables are listed in the project design
diagram.
2.2.7.3 AC Power Supply Cable:
It is used for the heater inside of Fire Cabinet to heating up and dehumidify inside of Fire Cabinet.
Its power (AC220V 150W) should be supplied directly from the transformer terminal box.
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3 Ordering Information

3.1 Ordering Procedures & Requirements

FMD explosion prevention, fire prevention, fire extinction equipment of transformer is highly
recommended based on project demonstrations and technical economic comparisons.
The construction investor may directly sign a contract with the FMD manufacturer or agent
and provides the following information of the transformer(s): the type, capacity, and quantity; the
manufacturer; the contract number; the location to install and the name of user; and the company
who designs the power plant or substation.

3.2 Scope of Supply

Please check the following table for the major and exterior component of each set of FMD. Note
that all components are depended on the real case of the transformer and the on-site location, and
the supply of FMD does not include any valve, pipe, or cables. Please consult with the FMD
manufacturer or agent for more information.

No. Name and Specification Qty Remark
1
Control Cabinet (Rupture Disk Type for Tank and OLTC
Protection)
1 set
2
Fire Cabinet (Rupture Disk Type for Tank and OLTC
Protection)
1 set
3 N2 Tee One Way Valve (DN25) (on Top of Fire Cabinet) 1 pc
4 Rupture Disk Set for Tank (Including Decompression Chamber) 1 pc
5 Bracket for Rupture Disk on Tank 1 set TX
6 Rupture Disk Set for OLTC 1 pc
7 Shutter (DN80) 1 pc
8 Nitrogen Cylinders 2 bottles
9 Fire Detector 6 pc
10 Rain Cover for Fire Detector 6 pc
11 Heat-resisted Control Cable for Fire Detectors21.5 30-40 m LOCAL
12 Steel Cable Sheath for Heat-resisted Control Cable 30-40 m LOCAL
13 Bracket for Fire Detector on Tank 6 pc TX
14 Power and Control Cable 1 set LOCAL
15 Oil Installation Valve (Stainless Knife Gate Valve DN100) 2 pc TX
16 Blind Plate for Oil Installation Valve 2 pc TX
17 Three-ways Tee Pipe (For lifting up PRV on OLTC) 1 pc TX
18 N2 Installation Valve (Ball Valve DN25) 3 to 5 pc TX
19 Blind Plate for N2 Installation Valve 3 to 5 pc TX
20 Bracket for Oil and N2 Pipes 1 set LOCAL
21 4" Elastic Pipe (DN100) with Flange 1 pc LOCAL
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22 4Zincified Steel Pipe (DN100) >13 m LOCAL
23
490Zincified Steel Elbow Pipe (DN100) with Flange and
Exhaust Faucet
1 set LOCAL
24 490 Zincified Steel Elbow Pipe (DN100) with Flange >2 pc LOCAL
25 4Zincified Steel Tee Pipe (DN100) with Flange 1 set LOCAL
26 4Flange >10 pc LOCAL
27 M1670 (Nickle Bolt and Nut with Flat and Elastic Nut) >40 pc LOCAL
28 4Gasket (Nitrile-butadiene Rubber) >10 pc LOCAL
29 1Zincified Steel Pipe (DN25) >25 m LOCAL
30
190Zincified Steel Elbow Pipe (DN25) with Flange and
Exhaust Faucet
1 set LOCAL
31 190 Zincified Steel Elbow Pipe (DN25) with Flange >8 pc LOCAL
32 1Zincified Steel Tee Pipe (DN25) with Flange >3 set LOCAL
33 1Flange >24 pc LOCAL
34 M1260 (Nickle Bolt and Nut with Flat and Elastic Nut) >96 pc LOCAL
35 1Gasket (Nitrile-butadiene Rubber) >24 pc LOCAL
36 Red Paint for Fire Prevention 1 set LOCAL
37
Three-ways Electric Ball Valve (DN25) (Optional if OLTC
with Filter)
1 set OPTIONAL
38 Oil Gases Separation Tank (Optional for Oil Storage) 1 set OPTIONAL
Note:
Items with LOCAL in the table are not supplied with FMD. Buyer should purchase and
install locally with the on-site contractor.
Items with TX in the table are not supplied with FMD. Buyer should purchase and install
with the transformer manufacturer.
Items with OPTIONAL in Appendix 2 are not standard component of FMD. Buyer should
purchase as optional order.
Number of items on this appendix might vary depending on the transformers. More
detailed should be found in the technical drawing.

3.3 Transformer Manufacturer

3.3.1 The transformer manufacturer should contact the FMD manufacturer or agent (the seller)
immediately if the transformer is going to be equipped with FMD.
3.3.2 Submit the pressure values in both normal and designed explosion condition for the
transformer tank; the type and activation pressure value of the pressure relieve valve.
3.3.3 Submit detailed diagrams (from top, side, and front) of the transformer and its layout of
oil pipes.
3.3.4 Before connecting the oil pipe from the transformer to the FMD fire cabinet, drill a
110mm hole on an approved location at the side and close to the top of the transformer and weld
a pipe (DN100) with a flange and a (butterfly valve) oil installation valve sealed by a blind flange.
3.3.5 Before connecting the N
2
pipe from the transformer to the FMD fire cabinet, drill 2 to 6
hole on approved locations at the side and close to the bottom of the transformer and weld a pipe
(DN25) with a flange and a (ball valve) N
2
installation valve sealed by a blind flange.
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3.3.6 Reserved DC220V power supply with 6A breaker from the transformer terminal box for
the FMD heater that is in the FMD fire cabinet.
3.3.7 Install the FMD shutter between the oil conservator and gas relay and its related parts
with provided installation diagrams from the FMD manufacturer or agent.
3.3.8 Install the brackets for the FMD fire detectors on the top of the transformer.

3.4 Substation or Power Plant Contractor

3.4.1 Design a location and direction of the FMD cabinet. The distance must be in between 3
to 8m from the transformer tank.
3.4.2 Design a fundamental diagram for the pipes of FMD with the FMD manufacturer or
agent.
3.4.3 Provide the required signals for FMD including: breaker tripping, over gas concentration
protection, and pressure relief valve (PRV) activation.
3.4.4 Provide DC110V 5A power supply from the main control room where the FMD control
cabinet will be located.
3.4.5 (Optional) Reserve space on the control panel in the main control room to display the
conditional signals of FMD system from the FMD control cabinet
3.4.6 Design all cables for the connections and distributions of FMD including: quantities,
lengths, and types with the FMD manufacturer or agent. The following is general cable connection
layout.
3.4.7 Provide AC 220V 2A 150W power supply for the FMD heater located in the FMD fire
cabinet.
3.4.8 Reserved the required signals for Control Cabinet including: Public, Control Box
Power Supply Loss, Fire Detector Activation, FMD System ActivationTransformer Over
Pressure, the Signal of Shutter Activation, N2 Low Pressure and Oil Leakage.
3.4.9 FMD manufacturer shall provide following diagrams:
Fire Cabinet and its ground base drawing; FMD Cable layout installation drawing; Cable
connection drawing; Terminal connection drawing; Cable specification table.
.

Cable Connection Layout
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4 Installation

This manual comes with the shipment of FMD and should be kept in a specific area. Each
component should be checked one by one right after the package of the shipment is opened. This
manual should be read carefully before the installation. Supervisors from FMD manufacturer or
agent with local technical engineers should be appointed to instruct the installation.

4.1 Ground Construction Preparation

4.1.1 Oil Storage Container for FMD:
An underground oil storage container made by steel is highly recommended for the purpose to
collect the drained oil from the FMD fire cabinet during a transformer accident. The capacity of
container should be able to store 30% of the transformer oil. And this steel container should
pre-bury a DN150 steel pipe to connect through the base to the FMD fire cabinet.
If the storage container is on the ground, please to inform us in advance. The connections of
oil-drained pipe (on fire cabinet) and storage container should be done by the user.

Ground Base of Fire Cabinet
4.1.2 Fire Cabinet Ground Base:
The engineers who design power plant or substation should first confirm the location of the fire
prevention cabinet and then design a construction diagram for the base of the fire prevention
cabinet with its detail drawing and scheme provided by the FMD manufacturer or agent.
The base should pre-bury a DN150 steel pipe for draining oil and two DN50 pipes for
connecting cables into the FMD fire cabinet.
The buried oil pipe should be connected directly or through an isolated channel to the oil
storage container. The scatter pipe should not be connected to the oil container at the bottom of the
transformer. The following diagrams are the structure of ground base and bottom of the FMD fire
cabinet.

4.2 Shutter

Shutter should be installed horizontally between the oil conservator (on the top of transformer)
70
7
0
0
4
7
5
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and the gas relay. An elastic pipe can be added if it is necessary. All connections between flanges
must be fixed with oil resisting rubber washers. PLEASE PAY ATTENTION ON THE DIRECTION
OF THE SHUTTER THAT THE ARROW ON THE SHUTTER SHOULD BE POINTING TO THE
TRANSFORMER TANK (NOT THE OIL CONSERVATOR). And also note that the condition of
shutter (open or close) is depended on the flux of the oil. Therefore, the handle on the shutter must
be held and fixed to the Always Open position manually during filling oil to avoid automatically
turning the shutter to the close position. Once the valve of the shutter closes, a signal will be sent
to the FMD control box as a result the shutter indicator and alarm on.

Shutter in between Oil Conservator and Gas Relay

4.3 Oil Installation Valve

The transformer manufacturer should drill a hole with a diameter of 108mm that is located at a
side of transformer tank and 200-250mm from the top. J oint the hole with a DN100 steel pipe
(with a flange at the other end). This oil installation valve is a stainless knife gate valve installed
between the flange and a blind flange in the transformer factory.

i

Oil Installation Valve on Transformer Tank and OLTC
Left: Before Rupture Disk and Oil Pipe Connection
Right: After Rupture Disk and Oil Pipe Connection

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4.4 N
2
Installation Valve

The transformer manufacturer should drill holes close to the bottom of the transformer. The holes
should be connected with the N2 installation valves (ball valves).

N
2
Installation Valve with N
2
Pipe
4.5 Fire Detectors

Fire detectors should be mounted on the top of transformer evenly or the key area where fire can
be easily detected. The easy-melted alloy probe of the detector should face downward. The
transformer manufacturer should weld the brackets for the detectors in advance. Welding for the
brackets should be done and designed with the transformer manufacturer. All Brackets welded on
the top of transformer and should be covered with anticorrosive paint twice and red paint once.
Fire Detectors should be installed horizontally and fixed with M4 bolts with the brackets. Cables
for Fire Detectors must be heat-resisted. These Cables should be separated into 2 pairs. Each pair
should be paralleled to half of Fire Detectors (as seen in the following diagrams) and connected to
the transformer terminal box. The joint area for cables should be sealed completely.

Fire Detector with Heat-resisted Cable

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4.6 Fire Cabinet

1. DN100 Flange (Optional)
2. High Pressure Pipe
3. N2 Cylinder Pressure Meter
4. N2 Cylinder Valve
5. Massive Regulator
6. N2 Control Device
7. Oil-Gas Separator
8. DN25 Tee.One Way Valve
9. DN100 Flange
10. Temperature and Humidity Controller
11. Oil Leak Tester
12. Oil Draining Valve
13. Screen for Checking
14. Heater
15. Base of Fire Cabinet (Optional)

Structure of Fire Cabinet

4.6.1 Fire Cabinet Body:
This cabinet that is the core of the whole FMD system is necessary to have a steady installation
and should fix with M10 bolts and a gasket nut on the pre-designed ground base.
Stick oil-drained pipe (DN100) into a steel oil pipe (DN150) which is pre-buried into the ground

4.6.2 N
2
Cylinder
The cylinder is an outsourcing with its manufacturer product certificate and injected with 13 to
15MPa 99.99% pure nitrogen. For installation, two cylinders should be first fixed with metal
hoops inside of the fire cabinet. Then connect each high pressure pie between the N
2
cylinder
valves and N
2
pipe system respectively. All connections must be sealed to avoid any gas leakage.
Do not adjust the N
2
control device because it must be pre-adjusted in FMD manufacturer. Before
FMD commissioning, the N
2
cylinder valves must be closed.

4.6.3 N
2
Control Device:
The N
2
Control Device is first installed in FMD manufacturer in a Safety Condition . Once
FMD is activated, the N
2
Control Device must be replaced.

4.6.4 Oil-Gas Separator:
This oil-gas separator is already adjusted and installed in FMD manufacturer. Users are not
required to work anything if FMD is newly installed.
If FMD is activated or during maintenance, close all N2 installation valve and the oil-gas separator
must be replaced with a new one.

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4.6.5 Oil Draining Valve Installation (No Work Done Required):
It is connected to oil pipes with flanges with preset close condition. This valve is opened
automatically with a signal from the control box only if FMD is activated or during simulation test.
Signal indicator on the control box represents the conditions of
the valve. The valve can only be closed manually. The isolation
or position of the valve can be inspected through the screen.

Cad Drawing of Oil Draining Valve Picture of Oil Draining Valve

4.6.7 Heater (No Work Done Required):
Consisting of a control device and a heater, it is installed at the lower right corner of the fire
cabinet. This heater requires an external power supply AC220 (not from the FMD control box)
connected to the terminal port of the cabinet. The power supply could be obtained directly from
the transformer terminal box if available. In order to operate the components in the fire cabinet
normally in a suitable temperature, this heater is on automatically if the temperature drops below 5
and off if the temperature exceeds 15. The heater is also on automatically if the humidity
exceeds 85%RH5%RH.

4.7 Pipes Between Transformer and Fire Cabinet

4.7.1 Oil Pipe:
4.7.1.1 The size of oil pipe should be DN100 or DN150. The structure of this pipe includes the
oil installation valve from the transformer tank, a elastic pipe (optional) for more flexible
connection purpose, a horizontal oil pipe, a 90 elbow welded with a exhaust faucet, and a vertical
oil pipe to the top of fire cabinet.
4.7.1.2 The welding process should be done by a technician who has experience of welding
To R 1/2 Low
Pressure Pipe

FMD Oil-Gas Separator
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pressure vessel. The welding must ensure no leakage and neatly.
4.7.1.3 Before the oil pipe is installed, all dust and rust must be removed and the pipe should be
rinsed two times by the transformer oil. After welding, the whole oil pipe should be painted with a
primary layer of anti-rust material and the surface layer of red color.
4.7.1.4 All flanges must connect with oil-resisted rubber gaskets or type-O washer. They should
be evenly tightened with bolts in order to ensure no leakage.
4.7.1.5. The horizontal pipe should be ascended (2% higher on the fire cabinet side than the
transformer side) in order to release air from the exhaust faucet. The horizontal pipe should be
supported its weight with adequate brackets.
4.7.2 N
2
Pipe:
4.7.2.1 The pipe should be DN25. Depending on the condition of location, its connection can be
used with flange or direct welding, and the pipe should be supported and fixed with some angle
iron and pipe nipper.
4.7.2.2 The welding process should be done by a technician who has experience of welding
pressure vessel. The welding must ensure no leakage and neatly.
4.7.2.3 Before the oil pipe is installed, all dust and rust must be removed and the pipe should be
rinsed two times by the transformer oil. Pressure within the pipe should be up to 0.15 MPa for 2
hours to ensure no leakage. After welding, the whole oil pipe should be painted with a primary
layer of anti-rust material and the surface layer of red color.
4.7.2.4 Flanges are connected to oil-resisted rubber gaskets or type-O washer. They should be
evenly tightened with bolts in order to ensure no leakage.
4.7.2.5 The horizontal pipe should be ascended 2% lower on the fire cabinet side than the
transformer side.
4.7.2.6 Oil pipe can be connected to the oil gases separator; DN25 valve should be added at the
bottom of the connection pipes for the purpose to evacuate oil in the tank and pipes.

4.8 Control Cabinet

It is a high-quality standard control cabinet installed in a reserved area (must be indoor) in the
main control room by M10 bolts. Each standard cabinet can be installed with three FMD control
boxes and one FMD UPS.

4.9 Cable Layout and Connection

The transformer manufacturer should reserve terminals in the transformer terminal box that
connect signals from the fire detectors, shutter, pressure relief valve, gas relay and AC power
supply for the heater. Cables should precisely follow the designed circuit diagram and layout to be
connected. The cables in the terminal should be clearly labeled for the purpose of testing and
inspecting. Fire detectors should connect with the heat-resisted cables.

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5 Commissioning

Supervisor from FMD manufacturer or agent with local technical engineers should be appointed
for the on-site commissioning with FMD Testing Report. After approving and signing by
corresponding department, FMD can be operated in a normal condition.

5.1 Testing Procedure

The oil installation valve and N2 installation valve on the transformer should be closed
before any testing. Then follow 5.2 and 5.3.

5.2 Mechanics

1. Inspect all connections flanges. They should be installed with tightened bolts and airproof
gaskets (washers).
2. Close and open all valves respectively with . Inspect each valve including its open-close
conditions and output signals.
3. All on and off conditions should be corresponding to their actions.
4. N
2
cylinder should be mounted tightly. High pressure pipe should be twisted tightly. Open the
N
2
cylinder valve to inspect the pressure and density of the gas on the gauge. Inspect the
isolation on the N
2
control device. DO NOT CONNECT ANY ELECTRICAL SIGNAL TO
ANY TERMINAL AT THIS MOMENT.
5. Dehumidify heater, Depressurized N2 valve and Oil-gases separator have pre-adjusted in
FMD manufacturer.
6. Please also refer to FIG 5.1 to 5.4.

5.3 Electrics

1. Make sure all cable or wires are connected correctly. Check with the schematic diagrams and
terminal layouts.
2. Make sure the fire detectors and their heat-resisted cable and the other control cables are laid
and connected correctly.
3. Make sure the voltage of power supplies DC110V in the control box and AC220V in the fire
cabinet are in corresponding voltage levels. Make sure the breaker protection of power
supplies works promptly
4. Use 500V Meg Ohm Meter to make sure the resistance of insulator is more than 20Mohm for
each terminal of the control box.
5. Make sure all operation signals are functioned properly with FMD Test Report. They should
all be tested at their respective terminals.
6. Please also refer to FIG 5.1 to 5.4.

Ver:121010
18

FIG 5.1 FIG 5.2

FIG 5.3 FIG 5.4

Ver:121010
19
6 Operation

6.1 Basic Requirements

Before operating, please read and understand this manual. If there is any question, please contact
and consult with the FMD manufacturer or its authorized agent.

6.2 Instruction before Normal Operation

First, follow 5.2 to inspect the FMD system. Then, follow the procedure below:
6.2.1 In the control box, turn the operation condition switch to Stop and the activation condition
switch to Automatic. Then, unplug the keys and keep them by a specified person.
6.2.2 Open the exhaust faucet halfway to release gas from the N
2
pipe. THE FAUCET MUST BE
OPENED VERY SLOWLY IN ORDER TO AVOID CLOSING THE VALVE OF THE SHUTTER.
There will be some oil and gas mixture at the beginning. Until there is only ejecting oil with no
gas, tighten the faucet.
6.2.3 Oil draining valve should be closed.
6.2.4 The shutter should always be in a normal condition if FMD is working normally. If the
shutter is close, turn the shutter handle counter clockwise to the normal position.
6.2.5 Connect modified wires to the terminal box of the fire cabinet (make sure there is no voltage
on the terminal.)

6.2.6 Open two N
2
cylinder valves.
6.2.7 If it is necessary, connect the power supply for the heater in the fire cabinet (AC220 150W).
6.2.8 Connect power supply (DC110V) to the control box. Turn the operation condition switch to
Normal and the activation condition switch to Automatic.
6.2.9 Operating procedures finish without any alarms on.
6.2.10 Please also refer to FIG 5.1 to 5.4.

6.3 Activation during Normal Operation

6.3.1 If the activation condition is at Automatic position and the transformer has an accident,
I-type signal (High Gas +Transformer Overpressure +Breaker Tripping) should be received and
FMD will automatically start-up to prevent explosion and fire. If the transformer is on fire, II-type
signal (High Gas + Fire Detector + Breaker Tripping) should be received and FMD will
Ver:121010
20
automatically start up to extinguish fire.
6.3.2 When a fire is obviously around or on the transformer and the breaker tripping signal is
received, the user can turn the activation switch to Manual position and press Manual Start Up
Confirm Button on the control box to manually activate FMD. FMD can be started-up from a
certain distance to extinguish fire.
FMD will continuously inject N
2
for more than 45 min to cool down the oil and the fault
portion inside the transformer in order to avoid re-ignition. Please also refer to FIG 5.1 to 5.4.

6.4 After Activation

Once FMD injects N
2
and drains oil to and from the transformer, the following must be replaced
Oil-gas separator
Fire detectors and its damaged control cables if the transformer was on fire.
N
2
control device
Rupture Disk
Recharge N
2
cylinder to FMD required pressure with 99.9% purity nitrogen gas, and follow the
procedures from 5.1 to 5.3 and 6.2 to re-operate the FMD system. Please also refer to FIG 5.1 to
5.4. For more information about the replacement, please contact the FMD manufacturer.

Ver:121010
21
7 Maintenance

In order to ensure the reliability of FMD system to protect the transformer, FMD system have to
be inspected for maintenance in a certain periodWhen maintenance, user must rigorously follow
the instruction below. If improper operation or misoperation, the user responsible for the
consequences. The whole FMD system must be inspected at least every 3 years. And all
maintenance records should be saved. The procedures and details for FMD maintenance are listed
in FMD Periodic Maintenance and Inspection. Please contact the FMD manufacturer or agent
for any maintenance service and spare component. Please also refer to FIG 5.1 to 5.4.

7.1 Regular Inspection and Maintenance

7.1.1 Inspect the pressure of the N
2
Cylinder every week. When the pressure of N
2
cylinder is
below 11.7MPa, a signal will be sent to the FMD control box, as a result, the N
2
low pressure
indicator and alarm on.
Record the interior temperature of the FMD Fire Cabinet, date, and time in the
specified data sheet by a specified supervisor.
The pressure of N
2
cylinder must be above 8 MPa (20).
When the pressure of N
2
cylinder drops below 8 MPa, recharge N
2
cylinder to
FMD required pressure with 13 to 15MPa 99.99% purity nitrogen gas (20)
7.1.2 Inspect the oil pipe, N
2
pipe, flange, exhaust faucet and fast oil draining every week.
7.1.3Inspect N
2
cylinder, massive regulator, N
2
injection pipe, maintenance valve, fast oil draining
valve, operating mechanism, N
2
control device and oil-gas separator every month. Make sure that
all of them work properly.
7.1.4 Inspect the power supply of control cabinet, indicator and alarm every month.

7.2 Periodical Inspection and Maintenance

7.2.1 During transformer maintenance:
7.2.2 Close the gate valve and close N
2
installation valve.
7.2.3 Inspect the power supply of fire Cabinet and control cabinet, signal lights and alarm every
moth.
7.2.4 Unscrew the fire detectors, its switch is activated. A signal will be sent to the FMD control
box as a result the fire detectors activation indicator is on. When the fire detectors return the
normal position, the fire detectors activation indicator is off.
7.2.5 Inspect the electric performance of breaker tripping, transformer over pressure, transformer
over pressure, shutter and gas over concentration in control cabinet. Short the terminal, the
corresponding indicator is on. Make sure their wire connections are not loosened.
7.2.6 Open Pressure Relief Valve on Rupture Disk Device to avoid the changes of pressure and
temperature, close the gate valve and N
2
installation valve during with transformer maintenance or
the inspection of transformer oil. After maintenance and inspection, close Pressure Relief Valve
and open the gate valve and N
2
installation valve. And follow the procedures from 5.1 to 5.3 and
6.2 to re-operate the FMD system.
Ver:121010
22
7.2.9 During the annual power cut off of the transformer maintenance, inspect all airproof washers
and Type-O ring for the connection of flanges to avoid any oil leakage. If there is any damage,
replace a new one immediately.
7.2.10 Inspect the brackets and the pipes annually. Make sure they are fastened tightly.

7.3 Device Reset

Electric reset: Remove the wires of simulation signals.
Remove the short wires.
Mechanical reset: Follow the operation procedures.

7.4 Replace the Loss Products

7.4.1Replace the loss product in normal
1. High Pressure Pipes should be replaced with new pipes at least every 3 years or during
with transformer maintenance.
2. Oil-gas separator should be replaced with new one at least every 3 years or during with
transformer maintenance.
3. N
2
control device should be replaced with new one at least every 3 years or during with
4. Rupture Disk device should be replaced with new one at least every 3 years or during with
5. Prepare N
2
cylinder with FMD required pressure with 99.99% purity nitrogen gas, when
the pressure of recharge N
2
cylinder drops below11.7Mpa. Recharge the N
2
cylinder or
replace, when N
2
cylinder drops below 8 MPa.
Close the valve of N
2
cylinder, and remove the high pressure pipe. Recharge N
2

cylinder to FMD required pressure with 99.9% purity nitrogen gas.
After N
2
is recharged, fix the N
2
cylinder like before. Then open the valve of the N
2

cylinder, the pressure should be back to normal. And inspect any leakage.
7.4.2 Replace the loss products after activation
Oil-gas separator
N
2
control device
Fire detectors and its damaged control cables if the transformer was on fire.
Recharge N
2
cylinder to FMD required pressure with 99.9% purity nitrogen gas.
Rupture disk device

7.5 Common Fault and Eliminating Methods

Common fault Reason Eliminating Methods
Leakage of pipe
The flanges are not tighten, or gaskets are
aging
Tighten every flanges or change the
broken gasket.
The connectors from N
2
cylinder to N
2

control device are not tightened.
Tighten every connector. N
2
Cylinder Low
Pressure
The high pressure pipe is aging. Replace the high pressure pipe.
The connector is not tighten. Tighten the connectors Leakage of
Oil-gas separator
Leakage on the oil-gas separator. Replace the oil-gas separator
Ver:121010
23
Short ciruit inside of detectot box caused
by aging or not fastened tightly.
Fire Detector
alarms on
Detector is broken or aging.
Tighten the connectors or replace the
detector.
The flow rate is so fast when extraction
the transformer oil
Shutter activation
The flow rate is so fast when oil
conservator replenish the oil to the tank
Turn the shutter handle counter
clockwise to the normal position.
Follow the operation procedures in
4.2.

7.6 Announcements
1. The maintenance procedures must strictly accord to the maintenance instructions;
2. Before FMD commissioning, the N
2
cylinder valves must be closed;
3. Before FMD commissioning, do not connect lead wires of electric actuator;
4. Once the alarm on when commissioning, first to make sure the fault category. Then press the
alarm off buttoneliminate alarm. After eliminating fault, to re-operate the FMD system
according to the steps.
5. When maintenance the transformer, the FMD system must be run out. After maintenance
FMD is back into normal working condition.
6. If there any liquid in Oil Leak Tester, check the liquid is oil or water to judge the rupture disk
is or isn't leakage.
7. If encounter problems do not operate without authorization, lest damage the device. Please
consultation technical personnel of our company.

Ver:121010
24
8 Statement
The registered patents and the interpretation rights of FMD are belong to Shenzhen Huadian
Electricity Fire Prevention Ltd. All copyrights are reserved. If there is any new modification in this
manual, the information will not be individually notified. For more updated information about
FMD, please contact Shenzhen Huadian Electricity Fire Prevention Ltd frequently.

Shenzhen Huadian Electricity Fire Prevention Ltd.
Address: 7/F Block C Donjiaotou Industrial Zone, Shekou, Shenzhen, China 518067
Tel: +86 755 26868025
Fax: +86 755 26815766
Email: hk@whl.com.cn
Web site: http://www.whl.com.cn

Instruction Manual WHL Rupture Disk

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