Professional Documents
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PTRM : 0708
Page 1 of 205
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL
FOR
TRANSFORMERS
E-mail : customer-service.pti@areva-td.com
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 2 of 205
CONTENTS
Section
ISSUE/ REVISION
DATE
Description
Page
General
18
Storage
26
Installation
34
57
Commissioning
59
Erection Checklists
64
Commissioning Checklists
68
Operation
79
10
Maintenance
81
11
Trouble Shooting
89
12
Reference Standards
102
13
Transformer Accessories:
114
20/10/05
(a)
Temperature Indicator
115
(b)
124
(c)
140
(d)
152
(e)
156
(f)
161
(g)
Exhaust Fan
167
(h)
Flow Indicators
171
(i)
184
(j)
Flexible Separator
192
(k)
Thermosiphon Filter
197
(l)
200
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OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 3 of 205
MUST READ
THE FOLLOWING CLAUSES IN THIS MANUAL ARE OF
UTMOST IMPORTANCE AS REGARDS SAFETY AND HEALTH
OF THE PERSONNEL AND EQUIPMENT ARE CONCERNED.
HENCE, EVERY ONE INVOLVED IN THE ERECTION,
: (Erection Precuations)
: (Commissioning)
ISSUE/ REVISION
DATE
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28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
1.0
PTRM : 0708
Page 4 of 205
GENERAL
Transformer is a static equipment, which converts electrical energy
from one voltage to another. As the system voltage goes up, the
techniques to be used for the Design, Construction, Installation,
Operation and Maintenance also become more and more critical.
ISSUE/ REVISION
DATE
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28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
1.1
PTRM : 0708
Page 5 of 205
TRANSFORMER CONSTRUCTION
The techniques used in the design and construction of high voltage
transformers varies from manufacturer to manufacturer.
CORE
Core is manufactured from lamination of Cold Rolled Grain Oriented
Silicon Steel, which gives very low specific loss at operating flux
densities. Joints of the laminations are designed such that the
electromagnetic flux is always in the direction of grain orientation. The
core clamping structure is designed such that it takes care of all the
forces produced in the windings in the event of any short circuit.
1.1.2
WINDINGS
Windings are made from paper insulated copper conductors which are
transposed at regular intervals throughout the winding for ensuring
equal flux linkage and current distribution between strands.
1.1.3
COOLING
For ONAN/ONAF cooling, oil flows through the winding and external
cooler unit attached to the tank by thermo-syphonic effect.
1.1.4
ISSUE/ REVISION
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ERECTION, COMMISSIONING,
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PTRM : 0708
Page 6 of 205
Construction of the tank and cover are such that pockets for water
collection is avoided.
The tank and cover are designed such that these can be transported
by railways/road/water as per customer specification.
Note:
Transformer tank is provided with two earthing terminals. While
earthing the cable box, busduct etc., it should be ensured that no
closed loop is formed because of multiple earthing connections.
1.1.5
CONSERVATOR
Conservator is provided to take care of the expansion and contraction
of transformer oil, which takes place during normal operation of the
transformer.
Magnetic oil level gauge is fitted on the main conservator which can
give alarm / trip in the event of the oil level falling below the pre-set
levels due to any reason.
1.1.6
A bright colour coded mechanical indicator pin in the cover moves with
the valve disc during the operation of the pressure relief device and is
held in position by an 'O' ring in the pin bushing. This pin is clearly
visible from ground level, which gives an indication that the device has
operated.
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MANUAL FOR
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PTRM : 0708
Page 7 of 205
1.1.7
In the event of serious oil loss from the transformer, both alarm and trip
elements operate in turn in the manner previously described for gas
collection.
Two brass petcocks are fitted at the top of the relay body, the outlets of
which are threaded to take a bleed pipe if required for collection of gas
samples.
In the pipe connection between On Load Tap Changer and its oil
expansion vessel a single float Oil Surge Relay is fitted. This relay
operates on the principle of oil surge impinging on a flap causing
operation of the mercury switch connected to the trip circuit. Gas
actuated alarm switch is eliminated because the gas generated during
normal tap changing operation will give unnecessary alarm.
1.1.8
SILICAGEL BREATHER
Expansion and contraction of oil cause breathing action. The silicageldehydrating breather absorbs any humidity in the air breathed. An oil
seal in the air intake prevents external moisture being absorbed when
no breathing occurs.
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MANUAL FOR
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PTRM : 0708
Page 8 of 205
The size of the breather is chosen such that it can operate effectively
over a period of six months approximately. The factors, which influence
the selection of size of the silicagel breather required for a particular
transformer, depend on many factors like, the oil quantity in the
transformer, the adsorption capacity of silicagel, the loading pattern
and the atmospheric conditions prevailing at site. The loading pattern
and the site conditions are difficult for the transformer manufacturer to
assess. Hence, the selection of breather is based on certain
assumptions and it is difficult to fix up a time schedule for the
regeneration of silicagel. It is advisable to have a periodic inspection
(say monthly) of the indicator so that the gel can be regenerated or
replaced as soon it is saturated with moisture.
1.1.9
1.1.10
ISSUE/ REVISION
DATE
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28/01/07
01/08/07
ERECTION, COMMISSIONING,
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MANUAL FOR
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PTRM : 0708
Page 9 of 205
1.1.11
BUSHINGS
The high voltage connections pass from the windings to terminal
bushings. Terminal bushings upto 36 kV class, 3150 Amps, are
normally of plain porcelain and oil communicating type. Higher current
rated bushings and bushings of 52 kV class and above will be of oil
impregnated paper condenser type. The oil inside the condenser
bushings will not be communicating with the oil inside the transformer.
Oil level gauge is provided on the expansion chambers of the
condenser bushings.
Oil in the condenser bushing is hermetically sealed and it should not be
disturbed in normal operation. Oil level may be checked regularly and
any oil leakage should be reported to the bushing manufacturer for
immediate attention.
While connecting the overhead transmission line conductor to the
bushing terminal, ensure that the line pull is limited to the cantilever
strength of the bushing. The cantilever strength of bushings as per IS:
2099 for various types of bushings are as shown below.
Rated
Voltage
(kV)
52
72.5 & 123
145 & 245
420
1.1.12
800
(Amps)
102
102
127
254
3150
(Amps)
320
408
408
510
TAP CHANGER
Tap changers of power transformer are specifically of two types1.
2.
In the case of off circuit tap changer, the tap changing takes place only
when the transformer is de-energised, but in the case of on load tap
changers the tap changing takes place when the transformer is in
operation. The tap changer can be designed for changing the taps.
a.
Manually
b.
Automatically &
c.
From remote
ISSUE/ REVISION
DATE
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ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 10 of 205
1.1.13
1.1.14
ISSUE/ REVISION
DATE
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28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
1.2
PTRM : 0708
Page 11 of 205
ISSUE/ REVISION
DATE
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01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
1.2.1
PTRM : 0708
Page 12 of 205
ELECTRICAL SAFETY
The following hazards are commonly associated with the installation,
operation and maintenance of electrical equipment
Do not apply any voltage or even high voltage megger when the
equipment is under vacuum.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
1.2.2
HAZARDOUS SUBSTANCES
1.2.2.1
TRANSFORMER OIL
PTRM : 0708
Page 13 of 205
1.2.2.2
MERCURY
Mercury switches or thermometers containing mercury should
be handled carefully. Mercury vapour can be hazardous over a
period of time, especially in poorly ventilated room.
1.2.3
1.2.3.1
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
1.2.3.2
PTRM : 0708
Page 14 of 205
CONTROL OF FIRE
It is necessary to check the healthiness of the Transformer fire protection
system regularly so that the fire risk can be minimized
There shall not be any oil leakage.
During hot oil circulation in the Transformer keep fire extinguisher
ready near the Transformer, all the combustible materials shall be kept
at a safe distance.
Terminal connector, Fuses shall be checked against spark.
Condition of Transformer oil shall be checked regularly
Proper Housekeeping near Transformer may help to reduce the risk of
fire.
Proper fire fighting system as per CBIP recommendation shall be
installed near Transformer. Regular inspection & maintenance to be
done on the Fire fighting system.
1.2.3.3
ISSUE/ REVISION
DATE
Hot oil circulation shall be carried out only under the round the clock
supervision to prevent chances of fire on lagging materials etc.
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ERECTION, COMMISSIONING,
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MANUAL FOR
POWER TRANSFORMERS
1.3
PTRM : 0708
Page 15 of 205
1.3.1
DO'S
Insulating oil and insulation of windings and connections are
inflammable. Watch for fire hazards.
Before entering inside the Transformer, replace Nitrogen gas
completely with air if it was transported with nitrogen gas inside.
Make sure that nothing is kept inside the pockets before one
enters inside the main unit. Also take off the wristwatches and
shoes.
List up all the tools and materials to be taken inside and check it
after coming out to make sure that no tools are left inside.
There must be a protective guard for lamp to be taken inside.
Keep inspection covers open for supply of fresh air when some
one is working inside.
When one person is working inside, second person must be
available out side for emergency help.
Use rings spanners and tie them to the wrist of the person or
some where outside the tank.
Be careful during connections where bolted joints are involved
so that nut, washers etc. are not dropped inside the tank.
If it is required to weld some lugs or brackets etc., these should
be welded to tank stiffeners taking all precautions to avoid fire
hazards.
De-energise the unit by circuit breakers and line switches while
working on energised unit.
Check the diaphragm of explosion vent and replace it if cracked.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 16 of 205
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
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MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 17 of 205
Check the door seal of the Marshalling box. Change the rubber
lining if required.
Ensure proper tightness of top terminal of condenser bushings
to avoid entry of rainwater.
Check oil level in condenser bushing, any discrepancy should
be reported immediately to the manufacturer.
Do jacking only at jacking pad.
1.3.2
ISSUE/ REVISION
DATE
DON'TS
Do not weld any thing to the conservator vessel if Air cell bag is
inside.
Do not re-energise the transformer without conducting all precommissioning checks. The results must be compared with
factory test results.
Do not handle the off circuit tap switch when the transformer is
energised.
Do not energise the transformer unless the off circuit tap switch
handle is in locked position.
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ERECTION, COMMISSIONING,
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MANUAL FOR
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ISSUE/ REVISION
DATE
PTRM : 0708
Page 18 of 205
Do not change the setting of WTI and OTI alarm and trip
frequently. Setting should be done as per manufacturer's
instructions.
Do not close any valve in pump circuit for taking stand by pump
and motor into circuit.
Do not allow WTI / OTI temperature to exceed 70C during dry out
of transformer and filter machine temperature beyond 75C
Do not over load the transformers beyond limit specified in IS: 6600.
20/10/05
28/01/07
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ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
2.0
2.1
GENERAL
PTRM : 0708
Page 19 of 205
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ERECTION, COMMISSIONING,
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MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 20 of 205
Accessories and cooler are despatched separately. All oil pipes and
chambers are despatched in sealed condition to avoid entry of water
during transportation and storage.
2.2
PACKING
When any internal part like tap changer, CT's etc. are removed from
the main body for transportation, they shall be despatched in tanks
filled with oil or dry nitrogen gas or suitable measures are taken so
that they do not absorb moisture.
All fragile parts such as temperature indicators, oil level gauges etc.
shall be carefully packed to avoid breakage in transit.
Air cell type conservator shall be despatched with air cell mounted
inside the conservator and inflated with air at a slightly positive
pressure so that it remains fully tight inside the conservator. This is
to avoid relative movement of air cell inside the conservator during
transit and to avoid damages to air cell during handling.
All blanking plates, valves guards etc., which are used exclusively
for transportation are painted with a different colour shade than the
transformer (normally post office red) and shall be preserved for
future use.
2.3
RAIL TRANSPORT
Large capacity transformers are normally transported by rail due to
considerations of safety and economy. Depending on the weight and
dimension of the main body suitable wagons are selected for
transport. It should be ensured that the dimensions of the main body
when it is loaded on the particular wagon do not project beyond the
limiting dimensions specified by the Railways.
Detached parts are packed and normally despatched along with the
main body so that all parts are received at site along with the main
unit.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
2.3.1
PTRM : 0708
Page 21 of 205
Lifting Angle
Slinging Angle
MULTIPLYING
FACTOR FOR
DIFFERENT LIFTING
ANGLES
Lifting Multiplying
Angle
Factor
0
20
40
60
Fig. 2.2
Correct method of slinging
2.3.2
1.000
1.015
1.065
1.155
6
12
16
20
24
28
32
36
40
44
56
64
70
600
1,300
2,300
3,500
5,000
7,000
9,000
11,000
14,000
17,000
24,500
33,500
40,000
JACKING
For the purpose of jacking, only the jacking pads provided on the
tank are to be used. Capacity of Jacks should be at least 1.5 times
the weight of transformer. Put sufficient wooden/steel packing below
the jack to support the weight. Do not lift more than 30 mm at a time.
Use all jacks simultaneously. Jacks should not be left in the loaded
position for long time. Transformer should be handled only in the
normal upright position.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
2.3.3
PTRM : 0708
Page 22 of 205
LASHING
The transformer is lashed on all four sides by wire ropes or chain of
adequate size and is tightened using turnbuckles with locking facility.
After the movement of the consignment for a short distance the
tightness should be checked.
2.4
ROAD TRANSPORT
Generally road transport is resorted to in case of smaller units and of
2.5
site where rail link is not available or where well developed road
system exists.
Multi-axle tractors driven low-platform trailers are used for transport.
Prior to taking decision to transport the heavy consignment by road a
route survey has to be conducted to confirm strength of bridges and
the road worthiness and to identify constraints if any enroute.
Weak bridges if any should be strengthened with the help of,
Highways department.
A pilot vehicle with all-necessary tools and tackles and trained staff
should be run in front of the vehicle. Red flags and danger lamps
should be exhibited on the consignment.
Tightness of lashing should be verified at frequent intervals during
movement.
WATER TRANSPORT
Special cares to be taken during manufacture, packing and despatch
of transformers which are to be shipped through high seas. Even if it
is not specified by the purchaser the transformer should be applied
with anti corrosive coating and packaging should be strong enough
for possible rough handling enroute. Accessories should have
polythene covering and should contain silicagel or any other suitable
moisture absorbent.
2.6
SHIPMENT OF ACCESSORIES
Accessories are packed and despatched separately. Items, which
are detached from the main body for transportation, are listed on the
outline drawing. These will be transported in suitable crates.
Crates containing fragile items should be marked 'FRAGILE' and
handled carefully during loading on vehicle, shipment and unloading
at site.
Crates containing accessories, which should not be kept upside
down like condenser bushings, control panel etc. should marked
'THIS SIDE UP' and should be handled as per manufacturer's
instruction only.
ISSUE/ REVISION
DATE
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ERECTION, COMMISSIONING,
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MANUAL FOR
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PTRM : 0708
Page 23 of 205
FIG. 2.3
2.7
SHIPMENT OF OIL
Transformer oil is despatched to site in sealed steel drums or
tankers.
When oil is filled in drums, there should be sufficient air space to
allow for expansion and contraction of oil due to variations in
temperature.
Drums should be stacked only in horizontal position with the oil. This
will avoid collection of water on top of the drum, which may be
sucked in by the vacuum created inside the drum due to the
expansion and contraction of oil owing to changes in ambient
temperature.
Due to any reason, if the drums are kept in vertical position, drums
should be covered with polythene or tarpaulin sheet to avoid risk of
water getting collected on top and eventually leaking into the drums.
Filter holes and air release holes shall be in one horizontal line. This
will avoid breathing in of moist air. If there is any leakage of oil it can
FIG. - 2.4
ISSUE/ REVISION
DATE
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28/01/07
01/08/07
ERECTION, COMMISSIONING,
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MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 24 of 205
easily be identified.
When oil is transported in tankers, there should be storage tanks of
sufficient capacity available at site. Such tanks should be fitted with
dehydrating breathers.
2.8
IMPACT RECORDERS
Impact recorders are attached to the main body of the transformer
during transportation to monitor the shock, which the transformer
may be subjected to, during transportation. Impact Recorders are of
two types, viz. Mechanical analogue type and electronic digital type.
Both types of shock recorders have ability to record shock and
impact from all directions.
2.8.1
Trucks trailer
Smooth road
2g
ii.
Truck trailers
Rough road
6g
iii.
Railway wagons -
6g
ISSUE/ REVISION
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ERECTION, COMMISSIONING,
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PTRM : 0708
Page 25 of 205
(ii)
For each stylus measure the length of the trace from centre line
in one direction to the end of the arc that extends farthest from
the centre line.
(iii)
Use the table below to find equivalent 'g' levels in the designated
column (X column for 'x' axis shocks etc.)
Direction
2.8.2
mm
space
2g
6g
6g
2g
6g
0.4
1.7
1.4
0.4
1.2
0.8
3.3
2.8
0.8
2.5
1.3
5.0
4.2
1.3
3.7
12
1.7
6.3
5.5
1.7
5.0
15
2.1
8.2
6.9
2.1
6.2
ISSUE/ REVISION
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ERECTION, COMMISSIONING,
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PTRM : 0708
Page 26 of 205
Shocks are recorded when the acceleration passes a predetermined threshold in each of the X, Y and Z-axes. Only the 128
shocks of greatest intensity are memorised, thus reducing the data
overload.
Before the mission, the threshold limits above which the shocks are
to be recorded are determined and the Minishock is activated.
During the mission, the acceleration is measured continuously and
recorded together with the date and time, whenever the threshold is
exceeded. After the mission, the data is downloaded via a RS 232
link and visualised using the Logishock software. The data can be
visualised graphically or in the form of tables.
The Sensor characteristics are as follows:
i. Range
: 10 g
ii. Resolution
: 0.1 g
: 0.2 g
iv. Threshold
: from 1.5g ~ 10 g
v. Band width
: 1 minute to 4 hours.
ISSUE/ REVISION
DATE
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01/08/07
ERECTION, COMMISSIONING,
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MANUAL FOR
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PTRM : 0708
Page 27 of 205
3.0
STORAGE
3.1
Check whether the transformer has arrived at site with a positive gas
pressure in case of despatch without oil. In case of despatch of main
body in oil filled condition, the oil level should be checked. One
transport oil level gauge is welded near the top of the tank for
indicating the level of oil in the tank.
Confirm that case numbers match with the packing list. Check their
contents tally with the packing list if the packing case is damaged.
IMPORTANT:
If any scratches or damage to the paint is noticed on receipt of Main
body or Accessories, touchup painting should be done immediately
over the damaged area. For procedures of touchup painting, refer to
Clause 4.22: Touchup Painting at site.
3.1.1
3.1.2
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
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MANUAL FOR
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3.1.3
PTRM : 0708
Page 28 of 205
3.2.1
Fig. 3.1
ISSUE/ REVISION
DATE
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ERECTION, COMMISSIONING,
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PTRM : 0708
Page 29 of 205
Lift the main body of the transformer with a mobile crane and wire
ropes. The crane capacity must be at least 10% higher than the
weight of consignment. Lifting angle of ropes should be limited to 30
deg. to vertical.
Unloading must be done with maximum care, avoiding any jerking
movements or dropping.
Use only the lifting bollards/hooks for slinging while lifting.
For lifting with hydraulic jacks, the transformers are provided with
jacking pads dimensioned for lifting the complete transformer filled
with oil.
If the foundation of the transformer is not ready and if the
transformers are to be unloaded temporarily, it should be done on
leveled hard surface. Under base of the transformer should not rest
on the ground as it will lead to rusting of the transformer.
Place at least 300 to 400 mm wooden sleepers to facilitate jacking.
3.2.2
PLACING IN POSITION
ISSUE/ REVISION
DATE
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ERECTION, COMMISSIONING,
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3.2.3
PTRM : 0708
Page 30 of 205
3.3
3.3.1
GENERAL
It is preferable to erect the transformer immediately on receipt at site
and fill with transformer oil. However, if it is not possible, the
following precautions should be taken for storing the main body and
accessories for longer duration:
Sufficient space is provided underneath for free flow of air and also
for lifting, jacking etc.
ISSUE/ REVISION
DATE
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01/08/07
ERECTION, COMMISSIONING,
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MANUAL FOR
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3.4
PTRM : 0708
Page 31 of 205
If the pressure of gas inside drops due to leakage, the leakage point
may be detected by using soap water. The matter shall be reported
to the manufacturer for immediate corrective action.
1. Cylinder Key.
2. Top sampling valve of
transformer.
3. Gauge for reading gas pressure
inside the transformer
4. Adapter.
5. Gauge to indicate gas pressure in
the cylinder
6. Gas pressure regulator.
7. Gauge to indicate gas pressure
from the regulator
8. Pneumatic pressure hose.
9. Hose clip.
10. Nitrogen cylinder.
FIG. 3.3
Should it not be possible to rectify the leak immediately, the
transformer must be covered by putting a tarpaulin sheet over the
whole tank until remedial measures can be carried out.
ISSUE/ REVISION
DATE
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28/01/07
01/08/07
ERECTION, COMMISSIONING,
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MANUAL FOR
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PTRM : 0708
Page 32 of 205
3.5
3.6
STORAGE OF OIL
If the oil is received at site in tankers, it is necessary to provide an oil
storage tank of enough capacity to hold the oil for one transformer.
The oil storage tank should be equipped with valves for oil filling,
draining, sampling and filtration, oil level gauge, silicagel breather
and a manhole on top cover. The inside of the tank should be
painted with oil resistant paint / varnish. Before filling oil, the inside of
the tank should be cleaned thoroughly.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 33 of 205
Fig. 3.4
3.7
STORAGE OF ACCESSORIES
The following points may be taken care of in order to keep
accessories in good condition without damage, rust and dust.
Check and confirm that all packing cases as per packing list are
received in good condition.
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 34 of 205
Accessories Storage
No.
Position
Position
Precautions
Location
Special
Inspection
Instructions
check
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
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 35 of 205
4.0
INSTALLATION
4.1
ISSUE/ REVISION
DATE
Tool/ Equipment
Qty.
Specifications
1 No.
Oil Purifier
1 No.
Vacuum Pump
1 Set
20/10/05
(of 3 m length)
5 Nos.
(of 10 m length)
2 Nos.
(of 10 m length)
2 Nos.
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 36 of 205
Sr. No.
Tool/ Equipment
Qty.
Specifications
Flexible Vacuum
Hoses of 10 m length
2 Nos.
1 Set
Vacuum Gauge
2 Nos.
Vacuum gauge of
Mc Leod type capable of
measuring vacuum less than
0.01 torr
Compound Gauge
1 No.
a)
Megger
1 No.
Megger of 5 kV with
motor operation is
preferable.
b)
1 No.
Megger of 2 kV.
c)
1 No.
10
Multi meter
1 No.
11
a)
3 Nos.
0 ~ 300 V AC range.
3 Nos.
0 ~ 75 V AC range.
2 Nos.
Voltmeter
b)
12
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
Sr. No.
13
Tool/ Equipment
Mobile Crane
Qty.
1 No.
PTRM : 0708
Page 37 of 205
Specifications
Mobile crane of 5 or
10 Tonnes capacity with a
maximum lift of 20 meters.
14
15
40 m2
For temporary
exposed parts
16
Vinyl Hose
30
meters
17
Hose Nipple
2 Nos.
12 mm hose nipples
covering of
ISSUE/ REVISION
DATE
18
19
20
10 m.
21
Knife
2 Nos.
22
Spanners
2 Sets
23
Screw Driver
2 Nos.
24
Painting Brushes
6 Nos.
each
15 mm, 25 mm & 75 mm
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
Sr. No.
Tool/ Equipment
25
Qty.
PTRM : 0708
Page 38 of 205
Specifications
a) 3 Phase, 440
Volts, 50 Hz.
Electric Power
Supply for
Operating the
vacuum pump
and filter machine
b) Water Supply if
Purifier is water
cooled.
ISSUE/ REVISION
DATE
26
Pulling winches/
Pulleys
2 Sets
each
27
Hydraulic/Mechanical
Screw Jacks with
Locking facility
4 Nos.
28
Measuring Tapes
2 Nos.
10 meter long.
29
1 No.
30
1 No.
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
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MANUAL FOR
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4.2
PTRM : 0708
Page 39 of 205
2 to 5
6 to 20
21 to 50
61 to 100
101 to 200
10
201 to 400
15
20
FIG. 4.2
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
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MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 40 of 205
Tan delta
Resistivity
If oil does not meet the specified criteria, oil should be filtered and
stored in the oil storage tank before filling in to the transformer.
While pumping oil from the barrels, the barrels may be tilted suitably
to ensure that complete oil is taken out from each barrel.
FIG. 4.3
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
4.5
PTRM : 0708
Page 41 of 205
ERECTION PRECAUTIONS
NOTE:
PRECAUTIONS MUST BE TAKEN TO ENSURE THAT ALL GAS
PRESSURE IN THE TRANSFORMER IS RELEASED BEFORE ANY
ATTEMPT IS MADE TO REMOVE A COVER AND DRYNESS (DEW
POINT) OF GAS IS CHECKED BEFORE A GAS CYLINDER IS
USED.
Dry air of dew point 40OC or better must be fed through the inside
of tank when covers are removed in case of 400 kV and higher class
of transformers to avoid direct contact of winding insulation with
moist air outside.
ISSUE/ REVISION
DATE
HV Earth (Tank)
LV/ IV Earth (Tank)
HV LV/ IV
Core Frame Earth (Tank)
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
4.6
PTRM : 0708
Page 42 of 205
ERECTION PROCEDURE
The following flow chart shows the installation procedure generally
followed at site.
PREPARATION FOR INSTALLATION .
INSTALLATION OF MAIN BODY ON FOUNDATION .
RECEIVING INSPECTION AND STORAGE .
OIL RECEIVING AND FILTERING .
REPLACING DRY GAS WITH OIL .
ASSEMBLE BUSHING TURRET .
ASSEMBLE LV BUSHING AND CABLE DUCT .
ASSEMBLE COOLERS .
ASSEMBLE CONSERVATOR .
ASSEMBLE PRESSURE RELIEF DEVICE .
ASSEMBLE HV BUSHINGS .
ASSEMBLE ACCESSORIES .
INTERNAL LEAD CONNECTIONS .
CONTROL WIRING
OIL LEAKAGE TEST .
OIL FILLING UNDER VACUUM .
PAINTING (Ref. Cl. 4.22) .
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
4.7
PTRM : 0708
Page 43 of 205
Make sure that the hose and pipe interiors are cleaned in advance.
Connect the oil pipes to the lower filter valve. Ref. fig. 4.4
Transformer
Oil Storage
Tank
Dry Gas
Filter Press
Transparent
Vinyl Hose
(For oil level
Indication)
FIG. 4.4
Attach a transparent vinyl hose to indicate the level of oil being filled
in the transformer.
Open the top filter valve or any other bolted covers on topmost point
on the transformer for releasing dry gas at the time of oil filling.
Open the bottom filter valve on the transformer and top air release
valve on the oil storage tank.
A small gas space (approx. 5~10%) should be left above oil for
expansion of oil.
During oil filling, if the filter press stops due to any reason, the top
filter valve and any other opening on the top of the transformer
should be closed immediately to prevent air getting into the
transformer.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 44 of 205
After filling oil, if the storage is expected to be for a long period, dry
gas should be filled above the oil at a pressure of 0.1 ~ 0.2 kg/cm2.
Assembling work should start from the bottom of the tank so that
after initial oil filling, oil need not be drained again for assembling
work.
4.8
Extreme care shall be taken against any foreign objects falling inside
the transformer tank during inside working.
Keep only one man hole open at a time and close it as soon as
possible.
Any tools taken inside should be tied by string or cotton tape to the
person who is using the same.
No. of tools shall be counted and recorded before and after each
days work in order to ensure that no tools are left inside.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 45 of 205
4.9
Joints must be fully tightened only when the transformer has been
fully erected; by that stage the pipes can be centralised.
Ensure that all accessories belong to the same unit. Indent No., Unit
No. and Serial numbers of each item are marked on each item. This
is to avoid mismatching at site.
E.g.:
Serial numbers of all items, which are dismantled from the main
body and sent separately, are shown in "PART MARKING AND
CABLE WIRING" drawing.
4.10
Since cooler headers are provided with butter fly type shut off valve,
oil from main body need not be drained for assembling cooler.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 46 of 205
Check and ensure that level of all the foundations for cooler support
are in same level as that of the top surface of rails. Level difference
should be compensated by putting shims if the level is lower and
chipping the concrete foundation if the level is higher.
While mounting the oil pump and oil flow indicators, care should be
taken to ensure the arrows indicating the oil flow direction are
towards the transformer tank.
Fix the fan mounting frames and fans as indicated in the general
arrangement drawing.
CONSERVATOR
Mount the conservator as shown in G.A. Drawing.
Very often the small conservator for on load tap changer is attached
to the main conservator.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 47 of 205
Magnetic oil level gauge shall be mounted after attaching the float to
the gauge. Check and confirm free movement of float arm and
proper locking of float to the float arm.
Mount connecting pipe with oil surge relay from OLTC to the
conservator.
Mount breather connecting pipes and silica gel breathers for the
main tank and OLTC conservators.
Set up the air cell in side the conservator. Care should be taken to
see that the hooks on air cell are properly engaged in the brackets
provided in side the conservator.
Inflate the air cell at a pressure as shown in the instruction plate (DO
NOT APPLY EXCESS PRESSURE AS IT MAY DAMAGE THE AIR
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 48 of 205
Open the air release valves and start oil filling from the bottom filter
valve of the transformer.
Observe the air release valves and as soon as oil starts overflowing,
close the air release valves one by one. Stop oil filling when all air
release valves are closed.
Stop the filling when the needle of MOLG shows the level
corresponding to the ambient temperature at the time of filling.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 49 of 205
Proceed as follows:
Create a vacuum in separator.
With the same source of vacuum, create a vacuum in the
conservator.
Open the oil filling valve of the transformer. Because of the vacuum
in the conservator, the oil level rises automatically.
Stop the oil filling once the required volume in the conservator is
attained.
Check on the vent-holes, and confirm that there is no more air in the
conservator or, if necessary, adjust the level.
CAUTION:
The above mentioned CAUTION regarding the opening of air release
valves after completion of oil filling is applicable for this case also.
4.12
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
4.13
PTRM : 0708
Page 50 of 205
FIG. 4.5
METHOD OF LIFTING CONDENSER BUSHINGS FROM PACKING
CASE AND MOUNTING ON THE TRANSFORMER AT AN ANGLE
If oil is drained from the tank a continuous supply of dry air should be
ensured while removing the blanking plates and fixing the bushing
turrets and bushings.
If weather is bad (rain, snow or fog) the tank should not be opened
unless adequate shelter is provided.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 51 of 205
While lowering draw lead type condenser bushing the cable shall be
held tightly by using strong steel/plastic rope. Remember that
dropping of cable can cause injury to the personnel and damage to
the transformer.
Check and ensure that secondary leads of C.T's. mounted inside the
transformer are connected to the proper terminals in the terminal
board.
If holes are not provided in the CT terminal box for fixing cable
glands, suitable holes shall be drilled and cable glands assembled.
Fix all air release pipes between bushing turrets and Buchholz relay
connecting pipe. Please refer to the part marking drawing for
respective part numbers of air release pipes.
4.14
TEMPERATURE INDICATORS
Sensing elements of oil and winding temperature indicators are to be
fitted on to the thermometer pockets welded on the top cover of the
transformer.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 52 of 205
4.15
Operate the DM manually from rated tap to tap no. 1 and then to the
other extreme tap position and bring back to rated tap.
Verify the ratios on all taps using ratio meter or digital voltmeter.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
4.16
PTRM : 0708
Page 53 of 205
Cable sealing ends shall be fitted on to the end of the cable before it
is inserted and bolted on to the cable box.
4.17
Synthetic rubber bonded cork sheets once used should not be used
again.
4.18
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 54 of 205
4.19
4.20
Remove the breathers and connect dry gas cylinder with pressure
gauge to the connecting pipes if conservator is not provided with air
cell. If conservator is fitted with air cell, pressure shall be applied
after connecting an equaliser pipe between the air release valve and
breather connection pipe. Otherwise the air cell may get damaged.
Remove PRD and explosion vent if provided and blank the opening.
Open all valves between conservator, main tank and OLTC.
Fill oil in the transformer upto 1/3 rd of the conservator through oil
filter.
Apply a gas pressure above the oil such that the pressure at the
base of the tank is between 0.7 kg/cm to 1.0 kg/cm.
Check for oil leakage at all bolted and welded joints by keeping the
pressure for 12 Hrs.
If any leakage is noticed, rectify the leak and continue the test.
Break pressure and reassemble breathers, PRD, explosion vent etc.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
4.21
PTRM : 0708
Page 55 of 205
Initial oil filling shall be done at a slow rate. Rise in oil level per hour
inside the transformer shall be limited to 300 mm.
Natural rubber hose shall not be used as sulphur in the rubber may
react with oil.
Oil inlet valve shall be closed and after one hour the vacuum shall be
broken.
Oil level indicating vinyl hose can be removed by closing the bottom
sampling valve.
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
4.22
PTRM : 0708
Page 56 of 205
If a welding has been done on the transformer at site, the paint film
burnt by the welding shall be removed by wire brush or metal
spatula.
Remove the rust by wire brush and emery paper #80 / #100.
Wash away the oil, grease, dirt and dust by using suitable solvent
and dry it up.
After cleaning, stir the ready mixed rust resistant primer paint 'Yellow
Zinchromate' or 'Red Oxide' primer paint. Before applying the paint,
confirm the correct viscosity.
Apply the paint uniformly by using a brush. drying time for the paint
is normally 4 hours.
After the first coat of paint is dried up, mix and stir the finish coat
paint to the desired viscosity and apply by brush uniformly. Drying
time of finish coat paint is normally 6 hours.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
4.23
PTRM : 0708
Page 57 of 205
New oil can be mixed with each other irrespective of the source or
degree of refinement if both the oils meet the same standard
specification.
Inhibited oils can be mixed only if the inhibitor used is same in either
oils or the other one is uninhibited.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
5.0
5.1
PTRM : 0708
Page 58 of 205
Coolers also shall be included in the hot oil circulation towards the
end of the process.
Drain the oil by simultaneously admitting dry air or nitrogen gas from
the top. This is to avoid winding insulation coming in contact with
moisture.
Start hot oil circulation again as explained earlier and continue for 4
cycles. Maintain temperature of 60 ~ 700 C.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 59 of 205
FIG. 5.1
Variation of Insulation Resistance with Temperature
Dryness of insulation is determined by measuring insulation
resistance of transformer winding.
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 60 of 205
6.0
COMMISSIONING
6.1
6.1.1
The log should include dates and details of all inspections and
maintenance carried out.
6.1.2
PHYSICAL CHECKS
Check oil levels in the level gauges of all condenser bushings.
All air release plugs shall be loosened and closed after releasing
trapped air if any.
Check all bolted gasket joints and confirm that there is no oil leak.
All blanking plates and spares including spare gasket should be
stored carefully for future use.
Check all cable terminations and ensure that cables are properly
connected and cable numbering ferrules are provided.
Check and ensure that all protective covers like valve guards, LV
bushing protection covers etc. are removed.
Check and confirm that all bushing porcelain are cleaned thoroughly
and are without damage.
Check & confirm that the test tap caps of all Condenser type
Bushings are tightened.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 61 of 205
Remove the cap provided at the bottom of silicagel breather for the
transportation purpose.
6.2
Do not apply any voltage or even high voltage megger when the
equipment is under vacuum.
6.3
RATIO TESTS
Connect 3-phase 415 volts supply between HV terminals and
measure the voltage ratios at all taps and record.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
6.4
PTRM : 0708
Page 62 of 205
6.5
6.6
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 63 of 205
R (75)
6.11
OPERATION CHECKS
Check signalling circuits for pump fail/fans fail etc., and reset.
Open the petcock slowly and allow air to enter into the Buchholz
relay.
Close the air supply and release all the air by opening the other
petcock on the Buchholz relay.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 64 of 205
Open the petcock quickly and allow air full flow with surge. Record
the minimum pressure required to operate the surge contacts.
Rotate the pointer slowly and confirm that the trip signal is received
at the set temperature.
For set values of alarm and trip contacts, please refer to the
instruction manual.
Repeat the test for all winding temperature indicators if more than
one indicator is provided.
Remove the thermal sensing bulb from the transformer cover and
insert in hot oil bath.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 65 of 205
APPENDIX A
EQUIPMENT DETAILS:
SITE
SL. No.
1
CHECK POINT
O.K.
NOT
O.K.
REMARKS
AVAILABILITY OF DOCUMENTATION
Erection drawings including OGA
Erection / Maintenance Manual
Transport packing list
RECEIPT OF TRANSFORMER
Externally inspected damage (if any)
Gas pressure on receipt (Where
applicable)
Oil level (in case of oil filled transformer)
Unit correctly positioned
RECEIPT OF ACCESSORIES
All materials stored correctly
Packing Cases inspected, damage if any
Marshalling box inspected, damage if any
Control panels (RTCC)inspected damage
if any
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
SL. No.
CHECK NPOINT
O.K
PTRM : 0708
Page 66 of 205
NOT O.K.
REMARKS
ERECTION
Transport rollers mounted
Conservator mounted
Buchholz relay and oil surge relay mounted
(arrow marked should be towards conservator)
Breather mounted and duly charged
HV Bushings mounted
LV Bushing mounted
Tertiary Bushing mounted (if applicable)
HV neutral Bushing mounted
LV Neutral Bushing mounted
Bushing installed at correct angles
Diaphragm checked
MOLG mounted
Radiator mounted
Fans mounted
Pressure Relief valves mounted
Alignment of all pipe work
OLTC Conservator mounted
Heat Exchangers assembled with pipe work
Topping up of transformer oil
Leakage observed after 24 hrs.(if any)
Rating Diagram and identification plate fitted
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 67 of 205
OIL FILLING
All bushing oil level
Tap changer selector oil level
Diverter switch oil level
Auxiliary unit oil level
Radiator, Headers oil filled
Transformer / OLTC Conservator oil tight
Complete transformer oil tight
All air release plug vented
Valves in service position
All drain / filter valves blanked
MULTICORE CABLE
All tray work adequately secured
All cables adequately tied/clipped back to tray
Cables glanded correctly
WTIs and OTIs satisfactorily installed
BREATHERS
Transformer silica gel breather satisfactory
Tap changer silica gel breather satisfactory
Drycol breather correctly installed
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
8
PTRM : 0708
Page 68 of 205
FANS
Fans rotate freely & quickly
Pumps installed for correct flow
Flow indication visible
CONTROL PANELS
Cable termination
Cable glanding
Control cabinet clean & tidy
Heater supplied
Locking arrangement
10
Date:
Signature: ----------------------------------
----------------------------------
Name:
----------------------------------
----------------------------------
(FOR AREVA)
ISSUE/ REVISION
DATE
(FOR CUSTOMER)
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 69 of 205
APPENDIX -B
PRE-COMMISSIONING CHECKS & TEST RESULTS
Customer: ______________________
Site:______________________________
EQUIPMENT DETAILS:
(Rating, Ratio, Maker's Ref., Sl. No., Year etc.)
___________________________________________________________________
Vector Group: -------------------------- Amps. (H/I/L) ---------------------------------------------Tapping Range: --------------------%
Wdg. ---------------------------
GENERAL CHECKS:
STATUS
CHECK POINTS
OK
1
10
11
Overall clearances.
12
13
14
15
ISSUE/ REVISION
DATE
20/10/05
28/01/07
REMARKS
NOT OK
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 70 of 205
REMARKS
NOT
OK
Timer settings.
ISSUE/ REVISION
DATE
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28/01/07
01/08/07
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PTRM : 0708
Page 71 of 205
b. Manual Remote
c. Auto & Stand by operation
4
Overload setting
Starting current
Running current
Megger values
OK
Manual operation.
10
11
12
13
14
15
Earthing.
16
17
ISSUE/ REVISION
DATE
20/10/05
28/01/07
REMARKS
NOT OK
01/08/07
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PTRM : 0708
Page 72 of 205
Setting of Timers.
W.T.I. Repeater.
O.T.I. Repeater.
10
O.L.T.C. Operations :
a. Individual :
b. As Master :
c. As Follower :
11
Emergency Trip.
12
13
Manual operation.
Auto operation.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
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MANUAL FOR
POWER TRANSFORMERS
Stand-by changeover.
Overload setting
Starting current
Running current
10
11
ISSUE/ REVISION
DATE
20/10/05
28/01/07
PTRM : 0708
Page 73 of 205
01/08/07
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PTRM : 0708
Page 74 of 205
PART 2
S I T E T E S T R E S U L T S:
NOTE: Instruments provided by Customer will normally he used for the tests after
ascertaining their operation in the applicable ranges.
A. Insulation Resistance:
Range, Make, kV rating & Type of tester: _________________________________
1
Megger Values:
60
Sec.
H.V. to L.V.:
600
Sec.
60 Sec.
H.V. to T.V.:
H.V. To
Earth
T.V. To Earth
L.V. to T.V.:
L.V. To Earth
600
Sec.
CHECK POINT
Continuity
Approx. Ratio
Polarity (Only for REF
/ DIFFL. C.T)
Saturation check only
for PS class C.T's
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
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Page 75 of 205
Make
Rating A / V
Tan delta
NOTE: Please ensure that the bushings are absolutely clean. Atmosphere should be
dry & bushing should be in vertical or mounted on transformer during testing. Test
O
tap should be cleaned with CTC & dried out using a hot air dryer (60 C) if need be.
Short the terminals of other bushings & connect to earth. Arcing horns & line
terminals to be removed.
D. SHORT CIRCUIT TEST ON TRANSFORMER:
Method of testing:
Tap Position
Current in Amps
HV
LV
IV
NEUTRAL
FIRST
NORMAL
LAST
REMARKS: Value of short circuit current should be observed on other taps for any
abnormality & abnormalities if any may be recorded.
E. PHASING CHECK ON MULTI-RUN OF CABLES (HV & LV):
Ensure absence of cross connections by physical inspection, and continuity check.
PHASING CHECK BEFORE PARALLELING:
ISSUE/ REVISION
DATE
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01/08/07
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F.
Tap
No.
HV Volts (applied)
1U-1V
1U1N
1V1W
LV1 Volts
1W-1U 2U-2V
1V-1N 1W-1N
2U2N
2V2W
LV2 / Tertiary
2W-2U
3U-3V
3V-3W
3W-3U
2V-2N 2W-2N
3W-3N
3V-3N
3W-3N
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
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
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1U-1N
1V-1N
1W-1N
2U-2N
2V-2N
2W-2N
TAP No.
1V-1W
1W-1U
1U
1V
1W
1V -2V :
1V -2W :
1W -2W :
1W -2V :
1V -2V :
1V -2W :
1W -2W :
1W -2V :
1U -1V :
1V -1W :
1W -1U :
(Signature & Name): _____________ (Signature & Name): _______________
AREVA ENGINEER
ISSUE/ REVISION
DATE
20/10/05
28/01/07
CUSTOMER'S ENGINEER
01/08/07
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PTRM : 0708
Page 78 of 205
PART 3
PRE-COMMISSIONING CHECKS
To be carried out after transformer is connected to lines & before energisation
CHECK POINTS
1
2
3
4
6.
STATUS
O.K. NOT OK
REMARK
S
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
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PTRM : 0708
Page 79 of 205
H.V.BUSHINGS:
Make:
Rating:
Sl. No.:
L.V.BUSHINGS:
Make:
Rating:
Sl. No.:
O.L.T.C. DETAILS:
Make:
Type:
Sl. No.:
FACIA DETAILS:
Make:
Sl. No.:
Model:
No. of windows :
Voltage:
ISSUE/ REVISION
DATE
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28/01/07
01/08/07
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7.0
PTRM : 0708
Page 80 of 205
OPERATION
After the inspection and pre-commissioning tests are successfully
completed the transformer can be energised at no load.
Check and confirm that tap position indicators is same in local and
remote indicators.
While temperature is falling, observe that the pumps and fans are
switched off at preset temperature.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
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7.1
PTRM : 0708
Page 81 of 205
S. No.
Items to be inspected
Frequency
Load current
Hourly
Terminal Voltage
Hourly
Ambient Temperature
Hourly
Winding Temperature
Hourly
Oil Temperature
Hourly
Tap position
Daily
Daily
Daily
Daily
10
Daily
11
Daily
12
Connections
Monthly
13
Monthly
14
Quarterly
15
Quarterly
16
Half yearly
17
Half yearly
18
Half yearly
19
Half yearly
20
Yearly
21
Yearly
22
Yearly
23
Surface paint
2 ~ 3 Years**
Note:
** Duration of surface repainting depends on the level of pollution prevailing at site.
If pollution level is high, a frequent repainting schedule may have to be worked
out.
Core and coils are to be inspected only if such an inspection is warranted by test
results of dissolved gas analysis, any abnormality in performance or for
suspected internal damages due to external short circuit.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
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8.0
PTRM : 0708
Page 82 of 205
MAINTENANCE
Maintenance Schedule
Periodicity
Preventive Maintenance
Procedures
3
Replacement / Regeneration of
Silica gel Breather
8.1
Months
6
12
Scheduled
outage
Oil Sampling
Oil Filtration
Surface Painting
Oil Sampling
Oil sample should be tested for the following and results recorded: -
8.1.1
Electric Strength
If the dielectric strength of oil in transformer is less than 55 kV at 2.5
mm gap, the oil must be filtered to improve the characteristics.
For line end OLTC diverter chamber, oil filtration is recommended
when the BDV is 40 kV at 2.5 mm gap.
For neutral end OLTC diverter chamber, oil filtration is recommended
when the BDV is less than 30 kV at 2.5 mm gap.
8.1.2
Moisture Content
For transformers of 400 kV and above class, if the moisture content is
found to have increased beyond 20 ppm oil should be filtered.
For transformers of voltage class up to 245 kV, if the moisture content
is found to have increased beyond 25 ppm oil should be filtered.
ISSUE/ REVISION
DATE
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01/08/07
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8.1.3
PTRM : 0708
Page 83 of 205
Acidity
It the acidity is increased beyond 0.5 mg KOH/g, than the oil needs
filtration.
After draining the oil completely from the transformer, core, winding,
insulation and interior of tank should be washed by hot oil jet. The oil
being used for washing of internal body also must be drained
completely.
Refilling of oil in transformer should be done under vacuum.
8.2
Sampling procedure
Special care in oil sampling is required for Delta connected transformer
and autotransformers.
8.2.1
Tools required
8.2.2
Spanner set
Thermometer
Steel sampling bottles with polyethylene cone caps.
Silicon rubber tubing 10 mm bore - 1 m long.
Clean synthetic sponge.
Polyethylene sheet - 1 m square
Clean cloths
Self adhesive labels
Procedure
The sampling bottles shall be labelled and marked with information like
20/10/05
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8.3.1
8.3.2
Procedures
The purpose of this check is to confirm that the winding temperatures
Indicators are functioning accurately.
The transformer shall be isolated and earthed.
Rotate the indicator pointers slowly to the alarm set value and confirm
from the control room that the alarm signal has been received.
Rotate the pointer still further and confirm from the control room that
trip signal is received.
8.3.3
Calibration
Remove the thermal sensing bulbs from the transformer and insert it
into the hot oil bath.
Check the winding temperature readings up and down the scale at
intervals of 5 C.
Confirm from control room that remote temperature readings are
tallying with the local readings.
Replace the sensing element into the transformer pocket.
For any adjustment, see the manufacturer's catalogue.
8.3.4
8.3.5
ONAN Rating
Set the cooler supply isolator of OFF position.
Connect the secondary injection test set across the heater coil
terminals.
Inject current and check the resultant gradient for ONAN rating.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
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8.3.6
OFAF Rating
8.4
PTRM : 0708
Page 85 of 205
8.4.1
Procedure
The purpose of this test is to ensure correct operation of Buchholz
ISSUE/ REVISION
DATE
relay.
Transformer shall be isolated and earthed.
Connect nitrogen cylinder to the top petcock of Buchholz relay.
Open the other petcock.
Allow gas to enter the relay.
Check and confirm from control room that alarm signal is received.
Check continuity of alarm contact by using multimeter.
Close petcock on gas supply side and release all gases trapped in
relay casing.
Increase the gas pressure to approx. 2 kg/cm (30 psi)
Open the test petcock and allow full surge of gas to enter the relay
casing.
Check and confirm from control room that trip signal has been
received.
Check continuity of trip contacts by using multimeter.
Close Buchholz relay test cocks.
If relay has not operated, increase gas pressure and repeat the test.
20/10/05
28/01/07
01/08/07
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TAPCHANGER OPERATION
Regular inspection of tap changing equipment is not required because
8.6
OIL FILTRATION
Purpose of this maintenance is to improve the unsatisfactory condition
of oil found during sampling.
Transformer shall be isolated and earthed.
8.6.1
8.6.2
Procedure
Remove the blanking plate from filter valves and connect the oil inlet
hose to top filter valve and oil outlet hose to the bottom filter valve.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
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Open the filter valves and start circulation of hot oil. Oil temperature
shall be 55C to 70C.
Circulate the oil for 4 full passes.
Re sample and arrange to test.
Continue until oil condition is acceptable.
8.7
CORRECTIVE MAINTENANCE
All flange gaskets must be renewed wherever joints are dismantled.
Cleanliness of gasket surfaces and correct compression (40 % ~ 50%
approx.) of gasket must be ensured during reassembling.
8.8
8.8.1
8.8.2
Procedure
8.9
8.9.1
ISSUE/ REVISION
DATE
28/01/07
01/08/07
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Procedure
Transformer shall be isolated and earthed.
Set the cooler supply isolator of OFF.
Close the inlet and outlet valves if radiator is mounted on a separate
cooler tank.
Close the top and bottom isolating valves of radiator.
Open the top air release plug.
Remove the bottom drain plug and drain the oil to oil container under
gravity.
Sling the radiator with jib crane.
Remove the radiator clamping bolts.
Remove radiator.
Blank off the radiator and header openings.
Close the air release and drain plugs.
For Re fitting the Radiator.
Remove the blanking plates.
Fix new gaskets.
Assemble the radiator and tighten the clamping bolts.
Open the top header air release plug.
Open the bottom radiator isolating valve.
If the radiator is on a separate cooler bank, oil shall be filled into the
radiator bank through the bottom header valve by using the filter
machine. If the radiator is tank mounted, the oil from the oil tank should
be pumped into the tank by using the filter machine.
Close the air release plug on top as soon as oil starts flowing through
the air release plug.
Shut down the oil filter machine
Open top header isolating valve.
In case of separate cooler banks, air should be released through the
top common header air release plugs.
8.10
8.10.1
ISSUE/ REVISION
DATE
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28/01/07
01/08/07
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8.10.2
Procedure
8.10.3
PTRM : 0708
Page 89 of 205
ISSUE/ REVISION
DATE
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9.0
PTRM : 0708
Page 90 of 205
TROUBLE SHOOTING
Following table shows some of the symptoms, possible causes and
remedies in case of abnormal situations:
If the abnormality is of a major nature, the manufacturer should be
contacted at the address given else where in this Manual. When the
matter is referred to the manufacturer it shall contain the following: Transformer Rating.
Voltage Rating.
Manufacturers Indent No. / Serial No.
Year of Manufacture.
Date / Time of failure.
Brief description of the problem.
Checks done and their results.
9.1
TROUBLE
High Winding/ Oil
Temperature
Electrical
Troubles/ Winding
Failure
ISSUE/ REVISION
DATE
20/10/05
CAUSE
REMEDY
Over voltage
Over current
High ambient
temperature
Insufficient cooling
Deterioration/
sludge formation
of oil.
Short circuited
core
Lightning, short
circuit, Overload
Oil of low dielectric
strength.
28/01/07
01/08/07
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When the operation of a protective device does not clearly indicate an internal
fault, it is desirable to conduct the preliminary measurements and analysis
before dismantling the transformer.
Conditions before and after the development of fault should be taken into
consideration in arriving at a conclusion.
No
CHECK POINT
DESCRIPTION
CRIETERIA
Measurement
of Insulation
Resistance of
Windings
Measurement
of winding
resistance
Measurement
of Transformer
Ratio.
Measurement
of No Load
Current
If values obtained
are higher
compared to
factory test results,
it indicates faulty
condition.
Testing of oil
Judgment to be
made with
reference to tables
9.1, 9.2, 9.3, 9.4 &
9.5
Measurement
of Tan delta of
Windings
Comparison with
factory test result
Analysis of gas
collected in
Buchholtz
Relay
Manufacturer may
be contacted for
advice
Dissolved Gas
Analysis
ISSUE/ REVISION
DATE
20/10/05
28/01/07
Comparison with
factory test results.
01/08/07
ERECTION, COMMISSIONING,
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9.3
PROTECTIVE DEVICES
No.
1
9.4
PTRM : 0708
Page 92 of 205
DETECTIVE
DEVICE
DESCRIPTION
Pressure Relief
Device
Valve cant
be opened
ISSUE/ REVISION
DATE
20/10/05
POSSIBLE CAUSE
Loose joint
Welding joint
Gland packing not
fitted correctly.
Valve spindle bent.
Seating for valve plug
corroded
28/01/07
REMEDY
Tighten the joint evenly. If the leak does not
stop, renew the gasket.
Take the help from manufacturer.
Renew the gland packing and adjust gland
packing nuts evenly.
Fit new valve spindle. Dismantle valve, free
valve plug or fit new valve.
01/08/07
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9.5
PUMPS
SYMPTOM
Pump Motor
over heats
POSSIBLE CAUSE
Impeller binding
Pump motor
vibrating
Pump running;
but output low.
Insulation failure of
Motor Winding
Two phase operation
Motor bearings worn
Impeller damaged
Pump bearing
bushes or rings worn.
Valve not fully open
Impeller damaged or
worn
Speed too low
9.6
REMEDY
Remove the pump and investigate the
problem.
Remove the pump and investigate the
problem.
Check power supply.
Remove pump and investigate the reason
Remove pump and investigate the reason
Remove pump and investigate the reason
Open the valve fully.
Remove pump and investigate the reason
Check electric supply.
FANS
SYMPTOM
9.7
PTRM : 0708
Page 93 of 205
POSSIBLE CAUSE
REMEDY
Fan motor
overheats
Fan vibrating
BUCHHOLZ RELAY
SYMPTOM
POSSIBLE
CAUSE
Rate of gas
evolution
Electrical
response
of relay
NONE
None
Trip
mechanism
operated
by oil
surge
ISSUE/ REVISION
DATE
20/10/05
28/01/07
REMEDY
Inference
Oil surge
Sudden
vaporisation of
oil at
260~400OC
Boiling of water
in exceptional
cases
Simultaneous occurrence of
a heat producing fault and
entry of water into the tank.
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RAPID
MEDIUM
Alarm
operates
and
repeats
after
releasing
gas
Air or
inert gas
Trip and
alarm
mechanism
operates
Hydrogen
Thermal
decomposition
of oil above
400OC
Hydrogen
and
carbon
monoxide
Thermal
decomposition
of oil and
insulation
Air or
inert
gas
Air leaks or
leakage due to
mechanical
fault.
Thermal
decomposition
of oil above
400OC
Alarm
operates
and
repeats
within
minutes or
hours after
each
release
of gas
Hydrogen
Hydrogen
and
carbon
monoxide
Alarm
operates
SLOW
ISSUE/ REVISION
DATE
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Page 94 of 205
28/01/07
Air or
inert
gas
Thermal
decomposition
of oil and solid
insulation.
Presence of
air due to
mechanical
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Hydrogen
Hydrogen
and
carbon
monoxide
No gas
pressure in
Buchholtz
relay
ISSUE/ REVISION
DATE
20/10/05
Alarm
operated
28/01/07
N. A.
PTRM : 0708
Page 95 of 205
fault or
physical
absorption
Decomposition
of oil only
transformer, crack in
tank, pipe or relay
casing, faulty oil pump.
Low current arcing not
involving solid
insulation,
gassing caused by high
electrical stress, corona
discharge
Decomposition Low energy arcing
of oil and solid involving
insulation
decomposition
of solid insulation,
creepage through solid
insulation, oxidation of
insulation
Low oil level
Oil level falling below
the level of Buchholtz
relay due to oil leakage
01/08/07
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More than 50
More than 40
More than 30
Judgment
Good
Replace or do filtration
0.3 ~ 0.5
Replace immediately
Above 0.5
Judgment
Good
Fair
1x1011 to 0.1x1012
Poor
At 90OC, 40 ~ 60 Hz
0.2 Max.
1.0 Max
ISSUE/ REVISION
DATE
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01/08/07
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9.8
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Page 97 of 205
(Oxygen)
N2
(Nitrogen)
CO2
(Carbon dioxide)
CO
(Carbon monoxide)
H2
(Hydrogen)
CH4
(Methane)
C2H2
(Acetylene)
C2H4
(Ethylene)
C2H6
(Ethane)
C3H6
(Propylene)
C3H8
(Propane)
Table 9.6
"Normal" Values of Dissolved Key Gas Concentration Limits in oil of
Power Transformers in Service [Parts per Million ppm].
(Ref. FIST 3-30 : October 2000)
CH4
C2H2 C2H4 C2H6
CO
CO2*
TDCG**
Status
H2
Condition 1
100
120
35
50
65
350
2500
720
Condition 2
101~
121~
36~
51~
66~
351~
2500~
721~
700
400
50
100
100
570
4000
1920
Condition 3
701~
401~
51~
101~ 101~ 571~
4001~
1921~
1800
1000
80
200
150
1400
10000
4630
Condition 4
>1800 >1000 >80
>200 >150 >1400 >10000
>4630
**
ISSUE/ REVISION
DATE
20/10/05
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01/08/07
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Condition - 1
Total Dissolved Combustible Gas (TDCG) and any individual combustible gas
below this level indicate normal operation of the transformer. If any gas
exceeds the specified level, it needs investigation.
Condition - 2
TDCG and any individual combustible gas in this range indicate greater than
normal combustible gas level. A fault may be present. Further monitoring is
required.
Refer Table 9.7 for recommended sampling frequency and actions.
Condition - 3
TDCG and any individual combustible gas in this range indicate a high level of
decomposition of cellulose insulation and / or oil.
Refer Table 9.7 for recommended sampling frequency and actions.
Condition - 4
TDCG and any individual combustible gas in this range indicate excessive
decomposition of cellulose insulation and / or oil. Continued operation could
result in failure of the transformer.
Refer Table 9.7 for recommended sampling frequency and actions.
Note:
A sudden increase in key gases and the rate of gas generation are more
important in evaluating a transformer than the amount of gas.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
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Table 9.7
Action based on Dissolved Combustible Gas concentration.
Conditions
Condition 1
TDCG Level or
Highest
Individual Gas
(Ref. Table 9.5)
TDCG
Generation
Rates
(ppm / day)
720 ppm of
TDCG or
highest
condition based
on individual
gas from Table
9.5
Condition 2
Condition 3
Condition 4
ISSUE/ REVISION
DATE
20/10/05
28/01/07
< 10
Annually/ 6
Monthly for
EHV Trf.
10 ~ 30
Quarterly
> 30
Monthly
< 10
Quarterly
10 ~ 30
Monthly
> 30
Monthly
< 10
Monthly
10 ~ 30
Weekly
> 30
Weekly
< 10
Weekly
10 ~ 30
Daily
> 30
Daily
Operating Procedures
Continue normal operation
01/08/07
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Table 9.8
Transformer Fault Types and the gases they produce.
Key Gases
H2, possible trace of CH4
and C2H6, possible CO
Possible Faults
Partial discharge (Corona)
Possible Findings
Weakened insulation from
ageing and electrical
stress.
H2, CO.
Discoloration of paper
insulation. Overloading or
cooling problem. Bad
connections. Stray current
path and/or stray magnetic
flux.
Paper insulation
destroyed. Oil heavily
carbonised.
Note: Transformers are so complex that it is impossible to put all causes into a chart.
Several other reasons like high current surges due to faults down stream,
static electric discharges, multiple core earthing, sustained operation under
over load, over/under voltage etc. may also be seen.
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TRANSFORMER
TRIPPED OR
MALFUNCTIONED
ROUTINE TESTS
SHOW DEVIATION
FROM PAST
ANALYSIS OF DATA
DATA GATHERING
TABLES 2 AND 3
MONITOR
YES
NO
PROBLEM
YES
CANDIDATE
FOR REPAIR
YES
NO
DAMAGE
IS
OBVIOUS
RETURN TO SERVICE
TESTING
TABLE 4 AND TABLE 5
FOCUSED TESTS
SELECTED FROM
TABLE 4 AND TAB LE 5
SELECTED
TESTS
NO
ANALYZE TEST
RESULTS
APPENDIX A
SCRAP
INTERNAL INSPECTION
TABLE 8
ANALYZE-SECTION 6
YES
PROBLEM
FOUND
TESTING
TABLE 4 AND TABLE 5
NO
NO
PERFORM
CORRECTIVE
ACTION
FURTHER
TESTING
YES
YES
FIELD
REPAIR
NO
NO
FACTORY
REPAIR
DECISION
YES
TEARDOWN-TABLE 10
ANALYZE-SECTION 6
FIG. 9
NOTE: For further details please refer to IEEE Std. C. 57. 125 - 1991
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10.1
10.1.1
POWER TRANSFORMERS:
IS 1866
IS 2026 ( Part5)
IS 6600
: 1972 Guide
for
loading
of
oil
immersed
transformers.
IS 10561
IS 11171
IS 10028(Part1)
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Installation
"
Maintenance
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: 1972 Nitrogen.
IS 1576
IS 2312
IS 3024
IS 3070 (Part3)
IS 3151
(M5 to M64)
IS 1363 (Part 2)
IS 1363 (Part 3)
(M5 to M64)
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IS 8603 (Part 1)
: 1977 Dimensions
bushings
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for
for
porcelain
use
in
transformer
heavily
polluted
: 1977 Dimensions
bushings
for
for
porcelain
use
in
transformer
heavily
polluted
atmosphere 24 kV Bushings.
IS 8603 (Part 3)
: 1977 Dimensions
bushings
for
for
porcelain
use
in
transformer
heavily
polluted
atmosphere 36 kV Bushings.
IS 8603 (Part 4)
: 2003
IS 12676
: 1989 Dimensions
52 kV Bushing.
for
oil
impregnated
paper
IS 13312
IS 15137
IS 1573
: 1986
IS 2629
: 1985 Recommended
practice
for
hot
dip
IS 4759
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IS 3401
IS 3588
IS 3637
IS 3639
IS 4253 (Part1)
IS 4253(Part2)
IS 5561
IS 6088
: 1988 Oil
to
water
heat
exchanger
for
transformers.
IS 1666
: 1961 Paper
Covered
Rectangular
Copper
IS 8478
IS 104
: 1979
IS 2074
: 1992 Ready mixed paint, air drying, red oxide zinc chrome, priming.
IS 2932
undercoating,
(b)
finishing.
IS 13213
IS 13238
IS 1554 (Part 1)
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IS 1554 (Part 2)
IS 9147
1S 9700
IS 12943
IS 4257 (Part 1)
: 1981 Dimensions
for
clamping
arrangements
10.1.3
INSTRUMENT TRANSFORMERS
IS 1885 (Part28) : 1993 Electro Technical Vocabulary Instrument
Transformers.
IS 2705 (Part1)
IS 2705 (Part2)
IS 2705 (Part3)
IS 2705 (Part4)
IS 3156 (Part1)
IS 3156 (Part2)
IS 3156 (Part3)
IS 3156 (Part4)
IS 4146
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IS 4201
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IS: 5547
10.1.4
TRANSFORMER BUSHING
IS 1885 (Part54) : 1993 Electro Technical Vocabulary - Insulators.
IS 2099
IS 3347(Part 1to8)
Dimension
for
porcelain
transformer
bushings.
IS 4257 (Part 1)
IS 5621
IS 8263
Dimension
for
porcelain
transformer
: 2003
52 kV Bushing
IS 8704
IS 12676
: 1989 Dimensions
for
oil
impregnated
paper
: 1992 Guide
for
Selection
of
insulators
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in
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IS 13305
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for
: 1992 Dimensions
of
porcelain
oil
filled
10.1.5
REACTORS
IS 5553 (Part 1)
IS 5553 (Part 2)
IS 5553 (Part 3)
: 1990 Current
limiting
reactors
and
neutral
earthing reactors.
IS 5553( Part 6) : 1990 Earthing transformers (Neutral Couplers)
IS 5553( Par 8)
10.1.6
: 1993
IS 1448 (Part 10) : 1970 Method for test for petroleum and its
products cloud point and pour point.
IS 1448 (Part 16) : 1990 Density of crude petroleum and liquid
petroleum products by Hydrometer method.
IS 1448 (Part 21) : 1992 Petroleum and its Products - Flash point by
Pensky Martens Apparatus.
IS 1448(Part 25) : 1976 Determination of Kinematic and Dynamic
Viscosity.
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IS 1866
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Page 110 of 205
supervision
of
insulating
oils
in
equipment.
IS 2362
IS 6103
IS 6104
of
insulating
liquids.
IS 6792
IS 6855
IS 9434
IS 10593
IS 12177
IS 13567
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Coulometric
Karl
Fisher
IS 12463
10.1.7
: 1961 Method
for
voltage
means
IS 2071 (Part1)
measurement
by
of sphere gaps.
General
: 1974
Test procedures.
IS 2071 (Part3)
: 1976
Measuring devices.
IS 2165 (Part1)
IS 2165 (Part2)
IS 3716
: 1978 Application
guide
for
insulation
for
partial
co-
ordination.
IS 6209
: 1982 Methods
discharge
measurements.
IS 8690
ISSUE/ REVISION
DATE
IS 2551
IS 8923
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IS 12776
: 2002 Galvanised
strand
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for
earthing
Specification.
10.2
IEC STANDARDS
IEC 60071-1 (2006)
Power
transformers;
Insulation
levels,
Power
transformers;
Determination
of
Power
transformers;
Determination
of
sound levels.
IEC 6007611 (2004)
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Current Transformers.
High
Voltage
Test
techniques:
Partial
discharge measurements.
IEC 60289 (1988)
Reactors.
mineral
insulating
oils
for
Railway
applications
Traction
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gases
in
mineral
oil-impregnated
Loading
guide
for
dry
type
Power
Transformer.
IEC 60947 (Part 1 to 7)
Direct
Connection
transformer
and
gas
between
insulated
power
metal
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TRANSFORMER
ACCESSORIES
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TEMPERATURE INDICATOR
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APPLICATION
The Temperature indicator is used as an Oil Temperature Indicator (OTI) or
as Winding Temperature Indicator (WTI) for the protection of liquid immersed
power transformer. In the case of dry type transformers it is used as
Temperature Indicator (T.I.) to monitor the temperature of the windings.
2.
SCOPE OF SUPPLY
OTI & TI: Instrument with specified Range, Number of control switches, length
of capillary and sensing bulb.
WTI: Same as 2.1 but fitted with specified thermal image device.
TRANSMITTER (OPTIONAL): A precision potentiometer is mounted inside
the case of OTI or WTI (2.1 or 2.2) to transmit the measured temperature to
remote point(s).
REPEATER (OPTIONAL): Analogue indicator supplied separately for remote
indication of the temperature measured by OTI or WTI (2.1 or 2.2)
3.
OPERATION
The instrument operates as OTI when its sensing bulb is mounted in an oil
filled pocket located in the hottest oil of an oil immersed transformer.
The instrument operates as TI when its sensing bulb is exposed to the
medium adjacent to the windings of a dry type transformer.
When a proportionate load current of the transformer is passed through the
thermal image device, the instrument operates as a WTI integrating the
simulated temperature rise of the thermal image device and the top oil
temperature measured by the sensing bulb.
Remote indication of the temperature measured by the OTI or WTI is provided
by connecting the transmitter to the repeater either directly or through a
resistance transducer (resistance to current converter).
4.
CONSTRUCTION
LIQUID-FILLED SYSTEM (Refer Fig. 1): A sensing bulb (25), a measuring
bellows (2) and a small bore capillary tube (24) connecting the two, form the
measuring system. A second bellows (16-compensating bellows)
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connected with a second capillary (24) running parallel to the first capillary
and terminated at the head of the bulb from the temperature compensating
system. Both the systems are completely filled with the same liquid (other
than mercury). The two bellows are linked to a compensating lever (15) in
such a manner that the effect of ambient temperature changes on the
capillary line and measuring bellows is compensated. The movement of the
measuring bellows is related only to the temperature being measured by the
sensing bulb. This movement is amplified by the link and lever mechanism
(6), which directly drives the rotating disc (21) carrying the control switches.
The same mechanism moves, through rack and pinion a separately mounted
indicating pointer (Fig. 2, 11) over a calibrated dial. Head compensation is
provided by sealing both the systems under initial pressure, which is greater
than the possible head pressure due to differences in the elevation between
the bulb and indicator.
MAXIMUM POINTER (RED COLOURED) located on the indicator lid, is
resettable from outside the case by a screw driver blade. Unscrew and
remove black cap to reach the screw driver-slot.
CAUTION: Never use the switch testing knob for setting the maximum
pointer. If used, the switch contacts will close and initiate the external control
circuits when the instrument is in operation.
SWITCH TESTING KNOB: It is fitted on the indicator lid to check mercury
switches setting and potentiometer operation. This knob when rotated moves
the indicating pointer, switch mechanism and potentiometer wiper together
and facilitates testing these circuits without opening the lid. Rotate the knob
slowly and steadily for an accurate check. Never allow the knob to spring back
suddenly or quickly, as this will cause damage.
THERMAL IMAGE DEVICE (Refer Fig. 1): A heater coil (3-Bellows Heater) is
fitted around the measuring bellow (2) and supplied from a current
transformer in the load circuit of transformer. The heater coil simulates hotspot temperature of the winding over top oil temperature for a given load. The
measuring bellows reacts to this simulated temperature rise in addition to the
top oil temperature measured by the sensing bulb and the instrument
functions as a WTI displaying the hottest spot temperature of the winding. An
adjustable shunt resistor (17-calibrating shunt) is provided for shunting portion
of the current through the heater coil to obtain precise thermal image.
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FIG. 1
INDICATOR
(LID & DIAL REMOVED)
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TERMINAL Nos.
WIRED TO
1,2 Switch
3,4
5,6
7,8
9,10,11
12,13,14
5.
S1 Alarm
S2 Trip
S3 Cooler Control 1
S4 Cooler Control 2
Bellows, Heater & Shunt
Potentiometer-Min., Wiper, Max
PRE-INSTALLATION TESTING
EQUIPMENT:
1. Controlled constant temperature bath with continuously stirred liquid.
2. Certified Standard Thermometer.
3. A continuity test circuit.
4. High voltage breakdown tester.
5. A constant current source.
Note: Calibration baths are generally suitable for use only in workshop. If
required for use in the field, they should be used under cover and in a non
hazardous environment.
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PRE-CONDITIONING: Before commencing any tests check the following: 1. The instrument is as per purchaser specification.
2. The instrument is not damaged in any way and any such damage is
rectified before testing.
3. The instrument is mounted correctly. (Refer 6.1)
3. The shipping stop (22 - Fig. 1) is removed.
SPAN ADJUSTMENT: Use this adjustment for correcting reading near the
maximum scale value. Referring to Fig. 1, slacken the shoulder screw (7) half
a turn but do not remove the same. Turn the range adjuster screw (8)
anticlockwise or clockwise to increase or decrease respectively the sweep of
the pointer. Make the adjustment in small increments and carefully. Half a turn
in either direction may correspond to approximately 0.5 reading. After
adjustment, retighten the shoulder screw.
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Ensure that the lock nut (4) and shoulder screw (7) are properly tightened after
the above adjustments. Repeat the tests in cold and hot bath until the
accuracy limit of 1.5% f. s. d. is achieved.
40 C and 120 C
6 C and 80 C
20 - 120 C
50 C and 120 C
6 C and 90 C
30 - 120 C
50 C and 120 C
6 C and 100 C
0 - 150 C
45 C and 150 C
0 - 240 C
80 C and 240 C
12 C and 160 C
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INSTALLATION
MOUNTING: Mount the instrument in a vertical position. Otherwise errors,
particularly in the horizontal plane, will upset the zero setting of the mercury
switches. Place a sprit level on the top of the indicator case to ensure correct
positioning and operation of the mercury switches.
If vibration exists at the mounting position, mount the indicator on a nonvibrating structure. Suitable anti-vibration mountings are supplied. Do not use
these mountings during transport.
CAPILLARY LINE: Do not stretch hard twist or bend the capillary to a radius
less than 75 mm. Continuously support the capillary by suitable clips at
intervals of 300 to 450 mm. Allow necessary slack at the bulb and for
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mounting and removing the bulb without sharp bend at the joint. Wind in spiral
(minimum dia. 150 mm) the possible excess length of capillary close to the
indicator or the bulb.
7.
8.
MAINTENANCE
Normally no maintenance is required for the temperature indicator. However,
adjustment or replacement of switches and resetting of the maximum pointer
may become necessary.
9.
REPAIRS
If a mercury switch is damaged in anyway, it may be unclipped from the
switch carrier and the leads removed with a hot soldering iron. After resoldering the leads to a new switch and locating back the switch in the clip,
the switch should be re-balanced. This is done by making the switch to topple
in its carrier at the instant when the mercury flows toward or away from the
electrodes. By sliding the switch a little in the appropriate direction in the clip,
correct topping is achieved. After correctly balancing the switch, check the
operation at preset temperature. If necessary re-zero the switch scale by
slackening the switch zeroing screw (12-Fig. 1) at the top of the switch scale
and rotating the scale to required position. Retighten the screw after
adjustment. If the bellows, bulb or capillary are damaged, repairs can be done
only at the manufacturer's factory.
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CONTENTS
I.
General
2.
Applications
3.
Advantages
4.
Construction
5.
Functional Test
6.
Electrical Connection
7.
8.
Basic Characteristics
9.
Function
10.
Operating Characteristics
11.
12.
Specifications of Relays
13.
14.
PREFACE
The ever increasing demand for electrical energy goes together with the demand for
more and more efficient and reliable "protection devices'' for power, distribution and
supply facilities. In the field of power supply, transformers represent key installations
that demand effective protection to ensure the constant availability of electrical
energy.
One of the most essential devices to protect a transformer is a Buchholz relay. For
more than 20 years, Buchholz relays have been manufactured in India. They are
made by an experienced staff of skilled workers, highly qualified technicians and
engineers ensuring a high degree of precision and quality.
A wide range of type corresponding to the BIS & International Standards are
available to meet the many requirements of manufacturers and users of
transformers.
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GENERAL
Power Transformers are considered to be a highly reliable type of equipment,
yet, in order to ensure the continuity of service that modern conditions
demand, protective devices are required. The purpose of such devices is to
disconnect faulty apparatus before large-scale damage is caused by a fault
to the apparatus or to other connected apparatus. Such devices generally
respond to a change in the current or pressure arising from the faults and are
used for either signalling or tripping the circuits.
Protective devices in the ideal case must be sensitive to all faults, simple in
operation, robust for service and economically feasible. Considering liquid
immersed transformers, a near-ideal 'protective device' is available in the form
of Gas and Oil relay described here. The relay operates on the well-known
fact that almost every type of electric fault in a `liquid immersed transformer'
gives rise to gas. This gas is collected in the body of the relay and is used in
some way or other to close the alarm or the tripping circuit
The principle of the Gas and Oil relay was first successfully demonstrated and
utilised by 'Buchholz' many years back. In a series of experiments carried out
extensively in Germany it was proved that the Relay is capable of bringing to
light incipient fault thereby preventing further spreading of the fault and
extensive damage and thus saving expensive and protracted repairs. So
successful is the principle of this Relay that despite the continued search for
better protective devices in other electrical fields the Gas-and-Oil Relay is still
on its own in providing protection against a variety of faults.
2.
APPLICATIONS
Double element relays can be used in detecting minor faults in a transformer.
The alarm element will operate, after a specified volume of gas has collected
to give an alarm indication. Examples of incipient faults are a)
b) Shorted laminations
c) Bad contacts
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Earth faults
b)
c)
Puncture of bushings
d)
The trip element will also be operated if a rapid loss of oil occurs. Single
element relays can be used to detect either incipient or major faults in oil filled
potential transformers, reactors, capacitors etc. A special single element relay
is available for the protection of on load tap-change equipment.
3.
ADVANTAGES
a)
b)
Unique internal design of 'housing' prevents false air traps on top of the
relay.
c)
d)
e)
Built in test facility for checking continuity of both Alarm and Trip
circuits.
f)
g)
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4.
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CONSTRUCTION
The Buchholz relay essentially consists of enclosure 1 i.e. an oil tight
container and an inserted assembly 2 comprising of two pivoted elements
fitted with switches (Refer fig. above). The enclosure is provided with inlet 1.1
and outlet 1.2 for the liquid. To allow connection of pipes, the enclosure
openings can be designed with pipe thread or flange.
The front inspection glass is provided with a graduation (100 to 300 cm) to
allow readings the accumulated volume of gas and observe colour of gas for
fault analysis.
For checking the function of the inserted assembly a Test Key (1.3) is
provided. There is also a visual indication on the scale (1.4) of service and
Test/Locking position, in the form of movement of red indicator on the reading
scale. This allows the testing of the alarm and Trip circuits before installation
and even when the transformer is in service.
Just above the inspection glass an arrow shows the specified direction of flow
of the insulation liquid to the conservator. Enclosure 1 and its inserted
Assembly cover are made out of Cast Iron.
5.
FUNCTIONAL TEST
5.1
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'key' clockwise the Alarm and Trip circuits will not show continuity. The circuits
will be actuated to 'ON' position only when there will be a fault in the
transformer.
Repeat the functional test each time a relay is started or maintenance
completed.
5.2
Testing the relay Function with the Test Pump. Screw the test pump/Air bottle
to the test cock. Open the test cock and pump air gently into the Buchholz
relay until the upper switching system operates.
For operating the lower switching system air has to be pumped suddenly with
a jerk which will in turn operated the lower switching system.
6.
ELECTRICAL CONNECTION
To allow installation of the 'signal wire' open the terminal box cover
comprising of the nameplate and the instruction sticker on the backside. Then
pass the wire through one of the two-conduit screwings (1.6) into the terminal
box. By using either one or the other openings, facility is given for the cable
to enter the terminal box from the left or right. The upper two studs are
terminals for the Alarm switching circuit and are denoted by A. Likewise
the lower two studs are terminals or the Trip switching circuit and are
denoted by T.
7.
INSTALLATION
7.1
Installation in to pipeline.
For installing the relay into pipeline proceed as follows:
-
See that the Buchholz relay is positioned with the arrow pointing towards
the conservator, the connection box is in the Y plane (vertical) and to Test
cock. (1.7) and air vent cock (1.8) are at the top.
Mount the Buchholz relay as close as possible to the tank in the pipeline
between transformer and conservator.
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Make sure pipe ascends to the conservator at angle between three degree
to seven degrees.
See that the relay enclosure is not subjected to stress. If necessary, use
expansion compensators.
Ensure that he slot on the Test Key remains in the T/L (Test/Locking)
position during storage or loose transportation of the relay.
- Ensure that the slot on the Test Key remains in the 'S' (Service) position
and the Test Key Bolt is Tightened just before commissioning of the relay.
7.2
7.3
Remove the protective acorn nut (1.9) from the air vent cock.
Open the air vent cock to let air escape until insulation liquid emerges.
Maintenance
The Buchholz relays are not sensitive to external influences. No servicing is
needed during operation. On routine inspections of the protection equipment,
test the function of the Buchholz relay as described earlier and check the
alarm and trip devices connected to them.
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Basic Characteristics
The Gas and Oil relay provide protection against a number of internal faults
but it also is able to indicate in several cases the type of fault. This is possible
because the gas collected in relay can, from its colour, odour and
composition, indicate where the fault may be and what its nature is. By
examining the gases collected it is possible to infer the nature of fault.
Thus :
a. If the gas is colourless and odourless or with only a faint odour of oil, the
gas is air trapped in the oil or the insulation.
b.
If the gas is Greyish White with sharp and penetrating odour and noninflammable it is due to overheated or faulty insulation (fuller board etc.)
c.
d. lf the gas is dark Grey and inflammable it may be due to a flashover in oil
or due to excessive overheating of the oil caused by a fault in the winding
or the core.
On the operation of the alarm if investigation of the collected gas does not
indicate a serious fault it is possible to leave the transformer in service till it is
convenient to carry out a through inspection. This occurrence is possible on a
newly commissioned transformer due to air trapped in the oil or the insulation.
On repeated and frequent alarm signals the transformer should be taken out
of service for thorough check up.
9.
FUNCTION
The function of a double element relay will be described here.
During normal operation of a transformer the Buchholz relay is completely
filled with oil. Buoyancy and the moment due to counter weights keep the
floats in their original top positions.
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In the event some fault in the interior of the transformer tank gas bubbles are
produced and accumulate in the Buchholz relay on the way to the
conservator. In consequence, the oil level in the relay enclosure drops which
in turn lowers the upper bucket.
This causes the mercury switch/Reed switch to operate an alarm signal.
The lower bucket does not change its position, because when the gas
reaches the upper inside wall of the pipe it can escape into the conservator.
Hence, minor fault in the transformer tank will not trigger the lower switching
assembly and will not trip the transformer.
In case the liquid continues to drop due to loss of oil, the lower also goes
down. In consequence lower switching system operates if the level of oil goes
below the bottom level of the pipe connected to the relay.
The lower bucket, does not change its position, because when the gas
reaches the upper inside wall of the pipe it can escape into the conservator.
Hence, minor fault in the transformer tank will not trigger the lower switching
assembly and will not trip the transformer.
In case the liquid continues to drop due to loss of oil, the lower also goes
down. In consequence lower switching system operates if the level of oil goes
below the bottom level of the pipe connected to the relay.
Alternately in the event the liquid flow exceeds a specific value (which is
continuously adjustable, by means of a flap) the lower bucket is forced down,
thus triggering the lower switching system to operate.
As the liquid flow rate decreases or the level of the liquid rises the bucket
returns to its original position. The single element relay has only one operating
element and it responds to either gas collection or oil surges. The method of
operation is similar to that described for double element relay. Single element
relays are suitable for the protection of oil filled reactors, capacitors and
potential transformers. The single element oil Surge relay has been
specifically designed for use with on load tap change equipment and it will
bypass normal amounts of gas which are generated by tap change operations
and will only respond to oil surges and loss of oil.
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OPERATING CHARACTERISTICS
Relays of the double element type are made in three sizes. The sizes are
distinguished by the numerical prefix 1, 2 or 3. This refers to the diameter of
the bore of the oil pipe connecting the transformer to the conservator tank.
They are referred to as Type GOR 1, GOR 2 and GOR 3, where the
Alphabets indicate 'Gas and Oil Operated Relay' and the number refers to the
pipe bore diameter as 25, 50 and 80 mm. respectively.
The implications of the various Type Nos. and their operating conditions can
be listed as follows: TYPE NO.
GOR 1
GOR 2
GOR 3
SR 1
SR 1/V
GOR 1E
GOR 2E
The symbol /VO following their type markings indicate that the relays contain
Reed switches and normally open type
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The symbol /S following their type markings of all relays mentioned indicate
that the relays are suitable for Silicon Oil normally used in Electro static
precipitator transformers.
All relays mentioned above are normally open types. Normally closed type
relays can also be supplied on request.
11.
The outward appearance of these relays are exactly the same as those with
mercury switches but they are distinguished from them by the symbol /VO
following their type marking. The latter V (for vibration) indicates that the relay
contains reed switches and the latter O that the contacts are normally open.
Thus a Type GOR 2/VO signifies a 50 mm. (pipe size). Double float relay with
normally open Reed Switches.
OPERATION
In the double element relay, collection of gas causes the oil level within the
relay to fall. This in turn causes the upper element to rotate on its pivots,
bringing the magnet it carries into a position where it operates the Alarm
Switch.
An oil surge through the relay will cause the lower element to rotate about its
pivots and its magnet into a position so as to operate the tripping switch.
CONNECTIONS
The terminal box and the terminals are the same as that of mercury switch
type relays. In the reed switch relays, each reed switch is protected by, an
inductor in series. These inductors are intended to protect the reed switch
contacts from the effects of capacitive loads, such as are imposed by long
leads or pilot cables, and must not be removed from relays in service.
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Protection of reed switch contacts against the effects of inductive loads, such
as those imposed by contactors and Electro-Magnetic relays, is achieved by
means of a diode wired across each load. This diode must be rated with
forward current at least as high as the steady load current and connected
observing polarity so as to absorb the back e.m.f.. These diodes are not
provided with the relay.
The Mounting position and Testing on site procedure are same as that of
'Mercury Switch type' Buchholz relay.
OPERATING CHARACTERISTICS
All double element relays are adjusted so that their performances lie within
the limits given in table 14. In addition the Reed Switch Relay is capable of
withstanding shocks of up to 4g. Such shocks will not of themselves cause the
relay to operate.
SWITCH DATA:
TYPE ---------------------------------------------------------- Normally Open
CONTACT RATlNG ------------------------ 250VA A.C. (r.m.s.) or D.C. max.
SWITCHING CURRENT --------------------------------- 5A A C or D.C. max.
SWITCHING VOLTAGE --------------------------------------- 300 V D.C. max.
----------------------------- 240 Volts A.C. (r.m.s.) max.
BREAKDOWN VOLTAGE --------------------------------- 650 Volts D.C. min.
INITIAL CONTACT RESISTANCE ------------------------- 70 milli-ohms max.
RESONANT FREQUENCY ------------------------------- greater then 700 Hz.
ACTUATING TIME (Including Bounce) -------------- 2 milli-seconds (Typical)
THESE SWITCHES HAVE RHODIUM CONTACT, LOCATED MIDWAY
ALONG THE LENGTH OF THEIR GLASS TUBES, THE TUBES CONTAIN
AN ATMOSPHERE OF NITROGEN.
PROTECTION OF REED SWITCH CONTACTS:
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SPECIFICATION OF RELAYS
Parameter
Rating
Tolerance
Contact System
Mercury switch
Type of contact
Make Contact
Switching voltage
220V AC/DC
12 V to 250V AC/DC
Switching Current
0.05 to 5 Amp
Switching Capacity
1000 W/VA
Frequency
50 HZ
0 to 60 HZ
Limiting temp of
insulation liquid
+ 120 C
100 cm to 300 cm
65 cm/sec to 160
cm./sec. (depending
on size)
400 cm/sec.
Vibration sensitivity
Continuously adjustable
Assembled relays are pressure tested with transformer oil at 3kg/cm for 60 minutes.
Electrical circuits are tested at 2000 volts R.M.S. for one minute.
Insulation resistance measured at 500 volts is not less than 10 Megaohms in air.
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IMPORTANT
The various part of a relay including the body, form one complete calibrated unit and
must not be inter changed with those of other relays.
We strongly recommend that relay should not be taken apart, and under no
circumstances should any alteration be made to the angle of the flap on the trip
element. This has been correctly adjusted during manufacturing.
RELAY
TYPE
GOR 1
RELAY
TYPE
SR1
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CONTENTS
1.
2.
3.
4.
5.
Installation
6.
7.
8.
9.
Safety
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3.
HANDLING AND
UNPACKING:
Please refer to Fig. 5, 6 & 7
The unpacking should be done at
the time of installation. During
unpacking, mechanical stresses or
jerks are to be avoided on the
bushings. On receipt, carefully
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open the top cover of the wooden case and inspect the bushings thoroughly
for any transit damage. Ensure all the accessories are received in good
condition and report, in case found to be missing.
Note: Any damage or shortages should be reported immediately.
Bushing should be handled only with mechanical lifting arrangements, such
as the illustrated in Fig. 5.
When bushings are taken out of the packing case, they must not be allowed
to rest on the lower part of the bushing. The operation is best carried out two
lifting gears and two ropes as shown in Fig. 6. One rope is slung around the
lower end of the metallic flange and let directly to the hook of the first crane
and the other passed around the shell, between two sheds and then led to the
hook of the second crane. The bushing is raised sufficiently in the same
inclination angle as in the packing case with hoists and then lowered at the
flange end. When positioning the bushing upright (Fig. 7), care should be
taken to avoid any shocks, jerks or scratch to the oil end porcelain and bottom
stress shield. On no account the bushing should be balanced on rope, passed
around the porcelain at its centre of gravity.
4.
Mount the bushing vertically on a suitable stand and clean the surface
thoroughly with a dry cloth, particularly the oil end. Inspect the bushing
physically for any leakage or damage on the porcelains. The oil end and
inner portion of the central tube should be further cleaned with transformer
oil. Care should be taken to prevent scratching of the painted surface of
the bottom stress shield / base plate.
ii)
Check oil level of the bushing in vertical position. The oil level should be
such that the oil level is clearly visible through the oil sight glass provided
on the bushing. The oil level is filled in the factory upto the mid point of the
sight glass, which is considered to be the normal oil level. The oil in the
prismatic type sight glass can be identified by the
highlighting of the red colour reflector at any position mounted from vertical
upto a maximum of 30 degrees.
iii)
Ensure the top terminal is tightened firmly with its gasket provided to avoid
water / moisture entry into the transformer.
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Measure and record the IR values of the bushing with a 2.5 kV meggar.
The recommended values are:
4000 Meg ohms (Min) between oil end terminal or top and test tap.
1500 Meg ohms (Min) between test tap and flange with 1 kV meggar.
The IR values may vary due to the atmospheric condition (humidity), surface
cleanliness of the porcelains, dryness of test tap etc. In such cases,
preheating of porcelains, terminals test tap etc., with hot air is recommended.
This is only an indicative test, however, the healthiness of the bushings can
be known only after measurement of Tan delta & capacitance values.
v) Capacitance and Tan delta values of the bushing should be measured
between the top terminal and test tap at 2 kV to 10 kV (Maximum). The
measurement should be preferably carried out indoors with RH not exceeding
60% and at ambient temperature, with the facilities and procedure as
described as described below:
Schering Bridge
The voltage applied on the bushing should be limited to 10 kV, when the
bottom end is not immersed in oil. Utmost care should be taken to avoid
any contact with the bushing during testing as this may result in fatal
injury to the personnel.
The test tap should be dry, free from any moisture condensation and dirt
deposition. The threaded test tap cover should be fixed back to the test
tap, immediately after the test.
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Factory test values of tan delta and capacitance are indicated in the test
report of individual bushing at working voltages. However, site values may
vary, as they do not resemble factory test conditions. The site values recorded
at the time of commissioning should be taken as the reference values for
comparison with future measurements. The bushing can be commissioned, if
tan delta value measured is less than or equal to 0.007, and capacitance
value as per the factory test value with maximum variation of 10%. If higher
values are obtained, please contact ALSTOM, Customer Service Department
giving full details of testing arrangement, for further advice.
Note:
The bushing should be kept vertical or mounted on transformer for a minimum
period of 24 hours before application of voltage.
5.
INSTALLATION:
Please refer to Fig. 8
The bushing is suitable for
installation for a maximum angle of
30 degrees from vertical. During the
lowering of the bushing into the
transformer, extreme care should
be taken to prevent the lower
porcelain hitting the wall of the tank.
The bushing should be so mounted
on the transformer that the oil sight
glass is visible from the ground
level. Ensure the visibility of the oil
level to the naked eye.
Maximum stress experienced by the
bushing is at the bottom stress
shield
during
testing.
Hence
sufficient care should be taken to
avoid any flashover from the stress
shield to the wall of the
turret. The flashover voltage depends on the clearance maintained in oil
between the stress shield and turret, oil
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The threaded test tap cover should be fixed back to the test tap
immediately after the test.
CAUTION:
THE TEST TAP WILL ALWAYS BE EARTHED AS LONG AS THE
THREADED CAP IS FIXED (Fig. 2a). HENCE THE CAP SHOULD NEVER
BE KEPT OPEN.
7.
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9.
SAFETY:
Understanding the procedures and instructions are a must while handling
bushings. Also, all applicable safety procedures such as regional or local
safety rules and regulations must be followed. Safe working practices and
good judgement are essential by the personnel while installing, testing,
maintaining or disposing the bushings.
CAUTION:
FAILURE TO FOLLOW THE INSTRUCTIONS MIGHT RESULT IN FATAL
INJURY TO PERSONNEL OR DAMAGES TO PROPERTY INCLUDING
TRANSFORMER AND ITS ALLIED EQUIPMENT.
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SILICAGEL BREATHER
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MAINTENANCE
Inspect the breather on monthly basis; more frequently, if found necessary by
experience (eg. highly humid atmosphere).
When the breather is first installed, the crystals have a blue tint, and after a
period of operation, the colour of the tinted crystals gradually changes to pink;
this is an indication that the silicagel is becoming saturated and losing its
absorbent properties. When there is a preponderance of pink crystals the geI
should be changed or reactivated.
Silicagel may be reactivated by heating in a shallow pan at a temperature of
150 C to 200 C for two to three hours when the crystals should have
regained their original blue tint.
Before filling the container with silicagel, clean and dry all parts of the
breather. Verify that the oil Level in the oil cup is correct when reassembling.
Ensure that the breather is not choked and is free for passage of air.
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TYPE 1
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SILICAGEL BREATHER
TYPE 2
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SIDE VIEW
FRONT VIEW
MATL.
Float 50 p x 100
Terminal Box
Cover for T. B.
Dial Body with switch housing
Mercury switch
Nut for Switch Adj.
Brass
Cast Al.
Cast Al.
Cast Al.
Glass
Brass
Sr. No.
7.
8.
9.
10.
11.
12.
DESCRIPTION
MATL.
M.S.
Cast. Al.
Brass
Brass
Brass
Brass
Fig. 1
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CALIBRATION
The standard calibration of dial is Empty, 1/4, 1/2, 3/4, Full. Calibration of
marks Empty & Full is done after leaving 65 mm from bottom and top of
conservator to avoid striking of float to conservator wall. Different calibrations
are done to suit customer's needs.
MOUNTING
In fig. 2, indicator is shown mounted by keeping dial and mounting pad in
vertical position. However, indicator can be mounted in titled position towards
ground (max 30) for easy viewing by fixing mounting pad at desired angle.
The position of indicator on the conservator can be selected to suit site
condition. Float mechanism passes through the hole in pad (see Fig. 2).
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SPECIFICATIONS
1.
Operating Liquid
2.
Working Temperature
0 to 100 C of Oil
3.
Working Pressure
0 to 4 kg/cm
4.
Environment
5.
Size
6.
Weight
7.
Mounting Specifications
8.
Float Travel
9.
Electrical witch
10.
Contact Rating
11.
Switch Setting
12.
Dial Size
250 mm dia.
13.
Dial Position
Vertical or Inclined
14.
Conservator dia
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GLOSSARY OF TERMS
PRV
: Pressure Relief Valve
Tank
: Tank in which transformer winding & oil etc. are housed.
Figures : Figures in brackets in write-up refer to part list of Drg. CD-601-R-3
1.
APPLICATION:
This PRV is designed to be used on Power Transformer. When pressure in
the tank rises above predetermined safe limit this valve operates and
performs following functions.
Allows the pressure to drop by instantaneously opening a port of about
150 mm diameter.
Gives visual indication of valve operation by rising a flag.
Operates a micro switch.
This switch has 1 NO and 1 NC contacts (Four terminals). Hence switch can
be effectively used in control circuit.
2.
SPECIFlCATIONS:
See Drg. No. CS-601-R-3.
3.
TESTS:
Tests are carried out as per test certificate attached to this leaflet.
4.
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The diaphragm restores its position as soon as pressure in the tank drops
below set limit. The lift of the diaphragm is utilised to operate flag ( 10) and
micro switch ( 11) with the help of rod (8). The flag and switch remain
operated until they are reset manually.
5.
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6.
PTRM : 0708
Page 166 of 205
7.
INSTALLATION
Each valve should be cleaned from inside (tank side) with compressed air jet.
All particles should be removed from tank side. While cleaning, care should
be taken that the jet does not attack the switch and the flag mechanism. The
PRV should be installed considering the following aspects.
The indicating flag (10) is easily seen from distance, The valve is accessible
for manual resetting and for routine manual checking. While installing remove
dirt and clean the mounting surface, remove all traces of oil, grease.
The rubber gasket supplied with the valve should be properly cleaned & be
located properly in the recess carefully.
All the bolts should be tightened evenly so that equal pressure is exerted on
gasket and base.
Connect control circuits to terminal plate provided in the switch box through
cable gland (14).
As per wiring diagram (ref. fig. 1 drg. CS-601-R-3), check the operation of flag
and switch by lifting operating rod (8) and confirm that both controls operate
as required.
The PRV can be put to service.
ISSUE/ REVISION
DATE
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28/01/07
01/08/07
ERECTION, COMMISSIONING,
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8.
PTRM : 0708
Page 167 of 205
9.
GENERAL NOTES:
Store the valve on its base duly packed in polythene bag to ensure that dirt
or other solid particles do not enter the valve port from tank side.
Do not remove the protection cover on flag box and switch box when it is
stored.
Keep the flat gasket (2) duly tied to the valve. Remove it only when it is to be
installed. This gasket should be kept dry.
After installation of valve on transformer, test periodically the functioning of
switch operation and flag operation by lifting the operating rod manually.
This will ensure the switch operation and flag operation when valve opens
due to rise in pressure inside the tank.
It is not possible to change the operating pressure at site.
The valve gaskets are of entirely different nature for synthetic liquid and
transformer oil. Hence use proper valve for liquid as described on product
label.
ISSUE/ REVISION
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Page 168 of 205
EXHAUST FAN
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Page 169 of 205
COOLING FANS
GENERAL
Exhaust type cooling fans used on transformers are designed to operate
outdoors in all weather conditions. Generally the following sizes of fans are
used.
SIZE
(mm)
450
610
610
915
915
SPEED
(r.p.m.)
1400
700
900
550
700
INPUT
(watts)
410
240
500
700
1200
PHASE
VOLTAGE (volts)
FREQUENCY (Hz)
415
50
415
50
415
50
415
50
415
50
CURRENT
0.9
0.5
0.9
1.5
2.5
(amps.)
MOTORS
The fans are powered by totally enclosed, squirrel cage induction motors. The
motors are adequately rated to give reliable service for many years.
IMPELLER
The impeller is designed to give maximum volume at minimum noise level
with minimum power consumption.
For reducing vibrations, special shoes made of rubber are provided at fixing
points of fan lugs.
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MOUNTING
1.
The arm is secured by the resilient mounting caps, which are placed
over the rubber sockets and secured to the diaphragm with 8 screws,
nuts and washers provided. The lock washers should be fitted under
the heads of the screws.
2.
Rubber sockets fitted to arms. To be fitted so that flat side will come in
contact with the diaphragm.
3.
4.
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DATE
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Page 171 of 205
CONSTRUCTIONAL DETAILS
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
ISSUE/ REVISION
DATE
PART NAME
TERMINAL BLOCK
BALL BEARING
STATOR WINDING
EARTH SCREW
ROTOR STAMPING
STATOR STAMPING
RESILIENT CAP
RUBBER SLEEVE
BACK COVER FIXING SCREW
BACK COVER
FAN FIXING BOLT
WING
CH. HD. SCREW
20/10/05
28/01/07
No.
14
15
16
17
18
19
20
21
22
23
24
25
PART NAME
WING FIXING BOLT
SPLIT PIN
SHAFT
HUB FIXING BOLT
HUB
BALL BEARING
LUBRICATOR SCREW
MOUNTING ARM
MOTOR FIXING BOLT
DIE CAST AL. ROTOR
CH. HD. SCREW
DIAPHRAGM
01/08/07
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Page 172 of 205
FLOW INDICATORS
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Page 173 of 205
FLOW INDICATORS
FUNCTION
Flow indicators included in this catalogue are mainly designed as a safety device
looking to the need of an electrical signal on failure of forced circulation of liquid in
pipeline. They perform following functions:
1.
2.
Operate one or two mercury switches when rate of flow drops near to 70% of
specified full flow.
These switches can be used to initiate precautionary systems or safety
devices.
APPLICATION
Consider the case of furnace transformer in which one Flow Indicator can be
mounted on suitable member of oil circulating pipe and one on water circulating pipe
of heat exchanger. The pointer of respective Flow Indictor will indicate whether
desired rate of flow is maintained or not and switch will operate if the flow drops near
to 70% to initiate precautionary system. For similar purpose it can be used on liquid
circulating pipes in chemical processes, heavy-duty bearings, compressors, etc.
MOUNTING
To introduce these Flow Indicators in a pipe line a `T-Mounting is necessary. In this
catalogue we have tabulated dimensions of 'T-Mounting' for range of size from 40
mm (1.5") to 250 mm (10") N.B. Pipes. But customer can always specify if his
requirement is different than the tables on page 8.
ISSUE/ REVISION
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PTRM : 0708
Page 174 of 205
pointer and a cam. The pointer is set to read the specified rate of full flow and the
cam is set to operate one or two mercury switches when flow drops near to 70%.
A return spring is used which acts in the opposite direction of flow. Hence any steady
position of pointer is the result of equilibrium of force due to impinging liquid on vane,
spring tension & weight of vane. The pointer does not remain steady for unsteady
flows. The size and shape of vane and tension on return spring is adjusted to suit
specified full flow. The vane occupies very small area out of full cross section of pipe
at NO-FLOW position. At full flow it becomes almost parallel to flow. Hence there is
practically no head-loss across Flow Indicator.
DIAL MARKING
The spread of flow indicating portion of dial is only about 70. Hence it is not possible
to print more markings. Usually PUMP ON-PUMP OFF or FULL FLOW-NO FLOW
type of limit markings is printed. Intermediate markings such as ALARM. TRIP is also
printed if required. Besides, specifications such as value of full flow, liquid, pipe size
and direction of flow are also printed. The background of dial is white. Direction
indicating arrow is in red colour and all other markings in black colour.
SWITCHES
One or two mercury switches of SPST type are provided. The contact position can
be set to No or NC at full flow. If required, switch can be changed from NO to NC or
vice versa at site.
In case of single switch, it is set to operate near 70% when flow is falling. In case of
two switches, both are mounted on same plate. Hence both operate at same rate of
flow. But in order to satisfy design requirements, one switch can be set to operate
near 80% and the other near 70% or one near 70% and the other near 60%. It is not
possible to set a switch to operate at lower value than 60%. Even when both
switches are set to operate at lower value than 60%. Even when both switches are
set to operate at same rate of flow, some switching differentiate is observed due to
use of mercury as switching element, We can modify setting suitably if switching
requirements are clearly specified.
WIRING
Leads from mercury switch/switches are brought into a terminal box positioned at
the bottom of indicator. A two-way or four-way terminal strip is provided. Terminals
are accessible for wiring after removing cover. A hole with conduit threads is
ISSUE/ REVISION
DATE
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PTRM : 0708
Page 175 of 205
provided for fixing cable gland to box. Terminals are marked. Wiring should be done
as per respective wiring diagrams.
SETTING
Full Flow- Each indicator is set in water-flowing condition. Pipe size, pipe position,
direction of flow is maintained. By adjusting a valve in pipeline, the specified rate of
full flow is established, then the pointer is set to read the full flow mark. This method
of setting gives very accurate results as it is based on equilibrium of vane at full flow.
In case of liquids other than water, proportional rate of flow of water is maintained for
setting.
Switch - After setting of pointer at full flow, switches are set in the sequence ordered
by customer. Flow is reduced to check operation of switch & increased to check
automatic resetting. The rate of flow at which switching occurs is approximate. The
switch position is kept adjustable to compensate difference in pipe gradient at site.
TESTING
Static Pressure: At 7 kg/cm.
Flow: Indicator is mounted on pipe. Water is allowed to flow in specified direction.
Rate of flow is checked when pointer reads full flow. For Liquids other than water
proportional rate of flow of water is checked.
Switch: Switch operation is checked by reducing and increasing flow in pipeline.
Contact rating: Switches are tested in laboratory at 5A.24OV.AC
Dielectric strength: Live terminals are checked at 2 kV with body.
A test Certificate is provided with each instrument.
DESIGN FEATURES
1.
2.
3.
4.
5.
6.
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DATE
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ERECTION, COMMISSIONING,
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Fig. 1
PTRM : 0708
Page 176 of 205
SCHEMATIC
Item Description
1 2 3 4 5 6 7 8 9 10 -
Fig. 2
WORKING POSITIONS
Item Description
1
2
3
4
5
Main Pipe
T - Mounting
Connecting Flanges
Flow Indicator
Flange of indicator
Horizontal Pipe
Vertical Pipe
NOTES:
I.
Flow indicators are not interchangeable for different liquids, pipe dia.,
direction of flow or rate of full flow. Hence they should be ordered
separately.
2.
3.
ISSUE/ REVISION
DATE
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PTRM : 0708
Page 177 of 205
Fig. 4
Accessories
(Supplied at extra cost if agreed)
T-Mounting, Weldable connection,
Flanges, hardware.
Part List
No. Description
1
2
3
4
5
6
7
8
9
10
ISSUE/ REVISION
DATE
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Page 178 of 205
Environment
Working temperature
Working pressure
Water, oils
37 to 250 NB (1.5" to 10)
One or two SPST mercury switches
depending on series.
Indoor or Outdoor
0 to 100 C of liquid in pipe
0 to 4 Kg/cm
Material of Construction
Wetted Parts
Vane shaft, return spring
St. Steel
Vane, spring housing, screws
Brass
Base
Aluminium (G. M. on Order)
Magnet
Alnico.
Note: All Brass Parts chrome plated and Aluminium Parts anodised.
Other Parts
Dial Body, switch housing, terminal box, covers Aluminium
Dial shield
Tough glass
Terminals
Brass
Mercury switch
Hg in hard glass
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Page 179 of 205
Fig. 5
Details of vane orientation common to Series 4021 & 4022
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PTRM : 0708
Page 180 of 205
Accessories
(Supplied at extra cost if agreed)
T-Mounting, Weldable connection,
flanges, hardware.
Part List
No. Description
1
2
3
4
5
6
7
8
9
10
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DATE
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ERECTION, COMMISSIONING,
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PTRM : 0708
Page 181 of 205
Fig. 8
Wiring Diagram
For Series 4031
Fig. 9
Accessories
(Supplied at extra cost if agreed)
T-Mounting, Weldable connection,
flanges, hardware.
Part List
No. Description
1
2
3
4
5
6
7
8
9
10
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
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MANUAL FOR
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PTRM : 0708
Page 182 of 205
It may noted that mounting specifications, flow sensing mechanism, vane orientation
and size of dial is same in both series. Basic difference between two series is that in
Series 4021 only one mercury switch is provided. Whereas in Series 4022 two
mercury switches are provided. Proportionately, number of terminals, size of switchbox and size of terminal box differ,
After suitable series is selected, requirement should be specified as per 'How to
Order' column on Page 3 of this catalogue. Because each indicator is set to suit
requirement specified by customer.
Common specifications of Series 4031 & 4032 working:
Principal of working, switch operation and other details as explained on page 2 & 3
of this catalogue.
Environment
Working temperature
Working pressure
Water, oils
37 to 250 NB ( 6" to 10" )
One or two SPST mercury switches
depending on series.
Indoor or Outdoor
0 to 100 C of liquid in pipe
0 to 4 kg/cm
Material of Construction
Wetted Parts
Vane shaft, return spring
St. Steel
Vane, spring housing, screws
Brass
Base
Aluminium (G. M. on Order)
Magnet
Alnico.
Note : All Brass Parts chrome plated and Aluminium Parts anodised.
Other Parts
Dial Body, switch housing, terminal box, covers Aluminium
Dial shield
Tough glass
Terminals
Brass
Mercury switch
Hg in hard glass
ISSUE/ REVISION
DATE
20/10/05
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PTRM : 0708
Page 183 of 205
Fig. 10
Details of vane orientation common to Series 4031 & 4032
Fig. 10 above shows vane positions at no-flow as seen from dial side of indictor.
Indicators are set for any one direction out of four illustrated in Fig. 5. T figure also
shows direction of forces acting on vane due to impinging liquid and return spring
(gravitational force not shown).
ISSUE/ REVISION
DATE
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ERECTION, COMMISSIONING,
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PTRM : 0708
Page 184 of 205
Fig. 11
Wiring Diagram
For Series 4032
Accessories
(Supplied at extra cost if agreed)
T-Mounting, Weldable connection,
flanges, hardware.
Part List
No. Description
1
2
3
4
5
6
7
8
9
10
ISSUE/ REVISION
DATE
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ERECTION, COMMISSIONING,
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PTRM : 0708
Page 185 of 205
ISSUE/ REVISION
DATE
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ERECTION, COMMISSIONING,
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PTRM : 0708
Page 186 of 205
2.
Do not remove the M. S. end covers till the pump set is to be installed in pipe
circuit. These are meant to protect the internal components against dirt and
dust during transit and storage.
3.
4.
The bearings are lubricated by the transformer oil and hence the pump should
not run dry, to avoid damage to bearings.
5.
Keep the entire pipe circuit perfectly clean and free from moisture and foreign
material.
ISSUE/ REVISION
DATE
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ERECTION, COMMISSIONING,
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Page 187 of 205
6.
Ensure that the electrical supply available is suitable for data given on the
pump rating plate.
7.
Care should be taken that the valves are in the 'open' position, when the
pump set is operated, because the pump works correctly only when all valves
are fully opened. The oil filled pump will produce Pressure even with the
valves closed, but there is no circulation, there will be oil churning inside the
pump set and the pump motor might also get overheated.
INSTALLATION
Before mounting on pipeline check the following:
1.
Remove the terminal box cover (8), and check the insulation resistance of the
set with a meggar to ensure minimum resistance of 10 meg-ohms.
2.
Remove end covers and check for free rotation of the rotor. Ensure that
Impeller (5) and locking screw (19) with washer are in their proper position.
3.
Connect the supply terminals and ensure rotation of impeller as per 'Arrow
Mark' on the Impeller Housing i.e. anti-clockwise rotation when looking
through the impeller housing opening.
Checks
1) Reduced or No delivery
ISSUE/ REVISION
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2) Low Pressure
PTRM : 0708
Page 188 of 205
a) Shaft bent.
b) No free movement of rotating element.
4) Pump is noisy
a) Hydraulic Noise:
Cavitation, wrong direction of rotation
b) Mechanical Noise : Bearing worn-out.
a) Supply failure.
b) Defective Phase.
c) Loose Contacts.
d) Rotor Mechanically locked.
a) Winding burnt.
b) Interphase shorts.
ISSUE/ REVISION
DATE
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PTRM : 0708
Page 189 of 205
No.
DESCRIPTION
QTY. No.
DESCRIPTION
QTY. No.
DESCRIPTION
QTY.
12
IMPELLER WASHER
23
LOCK WASHER
16
ENDSHIELD (ODE)
13
24
16
ENDSHIELD (DE)
14
25
15
26
I MPELLER
16
27
TERMINAL BOX
17
28
PLAIN WASHER
18
29
TERMINAL COVER
19
30
LOCK WASHER
TERMINAL BOARD
20
31
PLAIN WASHER
12
10
SQUARE RING
21
16
11
22
PLAIN WASHER
32
ISSUE/ REVISION
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Page 190 of 205
CONSTRUCTIONAL FEATURES
TYPE OF PUMP
Wt. kg.
IL - 5A
345 200
25
502
380
240
270
295
23
65.0
IL - 3A
285
20
425
305
210
240
240
23
41.0
ISSUE/ REVISION
DATE
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150
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Page 191 of 205
SPECIFICATIONS
MOTOR
STATOR
ROTOR
BEARING
COOLING
PERFORMANCE
PUMPS
CASING
: Cast Iron
IMPELLER
SEALING RINGS
: Neoprene rubber
FRAME
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Page 192 of 205
7.5 HP
DISCHARGE
(l.p.m.)
1190
1880
TOTAL HEAD
(m)
11.00
11.00
(mm)
100/100
150/150
Pump Ref.
Dis. Flange
P1 d1
M1
S1
Suc. Flange
LA1 N
P2
d2
M2
S2
Overall
LA2 L
HB
Wt.(kg.)
HC HD Net Gross
EL4.3R
18
18
111
EL7.5R
20
20
131
Fig.
ISSUE/ REVISION
DATE
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Page 193 of 205
FLEXIBLE SEPARATOR
(AIR CELL)
ISSUE/ REVISION
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Page 194 of 205
FLEXIBLE SEPARATOR
1.
INTRODUCTION
Flexible separator (Air Cell) is provided inside the conservator of power
transformers for avoiding direct contact of air with the transformer oil. Air Cell
provides a permanent, flexible and non porous barrier between the
atmosphere and the transformer oil without affecting the operational function
of the system.
The basic construction of the separator is a highly resistant fabric coated
externally to resist transformer oil and internally to Ozone and weather
resistant. Flexible separators offer the following advantages :-
DESCRIPTION
Flexible separator is fitted inside a cylindrical conservator. Oil being outside,
the separator is in direct contact with atmosphere. This type of mounting
makes it possible to compensate for the oil volume displacements due to
temperature variations.
3.
CHARACTERISTICS OF MATERIAL
Flexible separators are made from coated fabric consisting of :
Coating
Textile reinforcement
Polyamide
Breaking Strength
before immersion in oil
ISSUE/ REVISION
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4.
PTRM : 0708
Page 195 of 205
INSTALLATION PROCEDURE
1 Connection to the
inside of Air Cell
2 Connection to the
inside of
Conservator
3 Magnetic Oil
Level Gauge
Fig. 1
Details Of Hook On
On Conservator
On Conservator And
Handle On Air Cell
Fig. 2
ISSUE/ REVISION
DATE
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Fig. 3
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5.
PTRM : 0708
Page 196 of 205
Keep air release valves open. Fix air filling adapter on breather pipe and
inflate the air cell at an air pressure indicated on the INSTRUCTION
PLATE affixed on the transformer and hold air pressure.
Observe the air release valves and as soon as oil starts overflowing, close
the air release valves one by one. Stop oil filling when all air release
valves are closed.
ISSUE/ REVISION
DATE
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Page 197 of 205
CAUTION:
Do not open any of the air release valves after completion of oil
filling. If air release valve is opened, air will enter and oil level will
drop.
The plain oil level gauge on the end cover of the conservator
should indicate full oil level always. If air enters the conservator, it
can be seen by a fall in the oil level in plain oil level gauge.
The plain oil level gauge should be monitored on regular basis.
Proceed as follows:
Stop the oil filling once the required volume in the conservator is
attained.
Check on the vent-holes, and confirm that there is no more air in the
conservator or, if necessary, adjust the level.
20/10/05
28/01/07
01/08/07
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Page 198 of 205
THERMOSIPHON
FILTER
ISSUE/ REVISION
DATE
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Page 199 of 205
POWER TRANSFORMERS
1.
INTRODUCTION
Thermosiphon filter is provided on large capacity, oil filled Power
Transformers for keeping the moisture level of insulating oil at a very low
level. At the time of initial erection and commissioning of transformer, most of
the moisture present in the oil is removed by hot oil circulation. The moisture
absorption of oil is eliminated by directing the air breathed in by the
transformer during its operation through silica gel desiccant. Air cell in
conservator avoids direct contact of oil with air and thereby eliminating the
chance of moisture absorption.
However, it is a well known fact that water is released to the oil from the paper
insulation due to ageing process. Thermosiphon filter helps in removing this
moisture from oil. When the transformer is on load, the thermosiphonic action
of liquid causes circulation of oil through the filter. The adsorbent filled in the
Thermosiphon filter adsorbs moisture and keeps the oil dry.
2.
CONSTRUCTION
ISSUE/ REVISION
DATE
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01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 200 of 205
3.
MAINTENANCE
Thermosiphon filters do not require any routine maintenance. Oil samples
shall be tested periodically and the values of resistivity and tan delta shall be
compared with the values given in the Operation & Maintenance Manual. If
the results are within the limits, reactivation of the adsorbent needs to be done
only as part of the annual maintenance.
If there is a rapid deterioration in the values, reactivation of the adsorbent
should be done immediately.
4.
MONITORING
The periodicity of oil testing and acceptance criteria is explained in the
Instruction Manual of the Transformer. However, the same is reproduced here
for your ready reference.
a)
b)
c)
5.
REGENERATION OF ADSORBANT
Regeneration of adsorbent can be done by circulation of hot gas at a
temperature of 180 to 250O C.
To confirm proper regeneration, the dew point of the purged gas may be
measured and it should be less than 70O C.
For regeneration of adsorbent, dry nitrogen gas is preferred. A continuous
stream of gas is to be maintained during heating and gas pressure is not
important.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 201 of 205
OIL TO WATER
HEAT EXCHANGER
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 202 of 205
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
PTRM : 0708
Page 203 of 205
INTRODUCTION:
In transformer oil cooler, the hot oil from the transformer is passed through the
shell, which comes in contact with the external surface of the tubes, which is
constantly cooled by the incoming cooling water flowing inside the tubes. Heat
transfer takes place due to temperature difference between the oil and cooling
water flowing through tubes resulting in cooling of the oil.
2.
DESCRIPTION:
The transformer oil cooler is a shell and tube type oil cooler. It is also known
as lantern ring type oil cooler. The hot oil passes through the shell, and cooling
water passes through tubes, tubes are secured to the tube sheet by
expansion. Baffle plates have been provided to support the tube. The baffles
are held in position by tie rod and spacers. Baffles have thermal significance in
that the shell side fluid is made to flow to and fro across the bundle from one
end of the exchanger to the other end. The flow induced vibration is avoided
by proper spacing of the baffles. Separation of shell and tube side fluids at the
floating head is obtained by means of packing rings (o rings) installed
between outside of the floating tube sheet and recesses in the rear head
flanges. The shell and tube fluids have their own packing rings (o rings),
which are separated, by a lantern ring provided with weep holes for leak
detection. Leakage at the packing will not cause mixing of the shell side and
tube side fluids within the exchanger itself.
Channel side has been provided with pass partition arrangement so as to have
the flow of cooling water inside the tubes in each section. The inside surface of
channel except tube sheet have been coated with epoxy paint to prevent
corrosion of carbon steel material. Zinc anodes are provided to reduce the
galvanic corrosion.
3.
HYDRO TESTING:
The equipment shall be subjected to hot oil test on shell side and hydro test on
tube side to a pressure of 1 times of the design pressure to check for leaks.
Before conducting hydraulic test for new unit or one that has been out of
service for sometime or for unit that has been opened, carry out a thorough
internal and external inspection to ensure:
ISSUE/ REVISION
DATE
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
4.
PTRM : 0708
Page 204 of 205
OPERATING INSTRUCTIONS:
Inspect the transformer oil cooler and ensure that the external surfaces and
channels are free of dirt and ensure the readiness of cooling water supply on
the tube side.
5.
START UP PROCEDURE:
The start up of the oil cooler in a system consists of putting into service
various equipment in a definite logical operating sequence. Open the vent
and drain valve on the channel side of the oil cooler. Establish cooling water
flow through channel and tubes When water flows through the vent and drain
close the same. Open the oil side vent & drain and adopt the same
procedure as that of tube side Temperature of oil shall be raised gradually
with specified flow rate.
6.
7.
8.
CLEANING METHODS:
The bundle assembly is taken out and the internal and external surface
of the tubes are cleaned by smooth wire mesh or cleaning agent.
After cleaning, the bundle is inserted and the gasket and o ring are
replaced with new ones and the equipment is tested hydraulically
before setting the unit under operation.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
9.
PTRM : 0708
Page 205 of 205
PRESERVATION
9.1
In case of longer shut down, the shell side of the oil cooler is to be
drained and rinsed with oil. Dry all internal surfaces of oil cooler by
using hot air. Blank all open nozzles to avoid ingress of dust. Clean the
tube side to remove dirt, impurities etc., and fill with suitable clean
water and retain in that condition.
The dry preservation is used in case of long term shut downs. In case
dry preservation, it is important that the plants/systems or components
are completely dried before passing nitrogen or dry air.
The preservative air, which is to be blown through plants/systems or
components to be maintained dry, shall be dust free, oil free and free
from aggressive ingredients. The relative humidity of the out coming
O
P.S.: The above instructions are applicable for single tube Heat Exchangers.
ISSUE/ REVISION
DATE
20/10/05
28/01/07
01/08/07
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EMR
India
Phone : 91 44 26390863 (lluntmg) , l'ax : 91 44 26390881 , e-mail : helpdesk @easunmr.com
1. General
1.1 Operational principal of the on-load
changer (fig.1)
A tap-change operation begins with the tap selector
preselecting the desired tap on the transformer
winding.
501 -
123 /
B-
10 19 1W
Type
Number of
Poles
Example in Fig.2:
On-load tap changer type M
single-pole, max rated throughcurrent 500A, insulation to ground
according to Um = 123 kV, tap
selector size B, basic circuit
diagram code 10 19 1 W
meaning: 10 contacts, 19
operating positions, with one midposition, change-over selector
used as reversing switch
Pitch of
tap selector
contact circle
19
Max. number of
service positions
oil
without
10
12
14
16
18
10
12
14
16
18
with
09
11
13
15
17
Mid-positions
1
0
1
3
Change-over
selector
19
23
27
31
35
Change-over
selector
coarse
tap selector
Reversing
switch
*) No designation without
change-over selector
14
Position Indicator
15
lnspection glass
16
21
22
23
24
25
26
27
28
29a
29b
29c
31
32
33
Grading rings
34
35
Suction pipe
41
42
43
44
45
51
52
Support cylinder
53
Support plate
54
Fixing screw
55
Lifting lug
56
Transition resistors
operalion latest.
If the number of operations per
year Is 15,000 or higher, we
recommended the use of our oil
filter plant type 51 manufactured
by our principal MR Germany.
<40 ppm
> 30 kV/2,5 mm
<30 ppm
> 40 kV/2,5 mm
Transformer
rated current
M III 350
350 A
100 000
M Ill 500
350 A
500 A
100 000
80 000
MIII 600
350 A
600 A
100 000
80 000
M1 351
350 A
100 000
M1 501
500 A
100 000
M1 601
600 A
100 000
M1 802
500 A
800 A
100 000
80 000
M1 1200
800 A
1200 A
80 000
70 000
M1 1500
1200 A
1500 A
70 000
60 000
M1 1800
1500 A
1800 A
60 000
50 000
Withdrawal
of
the
Diverter Switch Unit
(FIg.4)
5
Fig . 4 Tap Changer head
Fig. 10
Diverter Switch Unit
20 (Fig. 7).
Special design for bell-type
transformer cover. 5 studs MB
with nuts (Fig.8).
In both cases take care of bolts
or nuts and washers.
Carefully lift out the diverter switch
unit using the lifting lugs (FIg.9)
and put it on a flat, clean place.
4.
Cleaning
the
Oil
Compartment,
the
Oil
Conservator and the Diverter
Switch Unit
Oil compartment, oil conservator
Drain the oil compartment
completely. Open the stop valve
between tap changer head and oil
conservator. Drain oil from the
conservator until clean oil flows.
If necessary, flush the oil
conservator tank with clean
transformer oil. Drain the oil
compartment, flush with clean oil,
and drain again completely.
Diverter Switch Unit
Carryout the visual inspection of
divertor swithc external. Clean the
diverter switch unit by flushing
with clean transformer oil.
5.
Inspection
of
the
Dlverter Switch Unit
5.1 Withdrawal position
Before starting the inspection take
note of the switched position of
the diverter switch (=withdrawal
position). Note the position of the
trip lever of the spring energy
accumulator unit (Fig. 10) in order
to regain this position after
reassembly of the diverter switch
unit.
5.2 Measuring the transition
resistor (Fig. 11)
Measures the value of each
transition resistor. The values are
in the order of 0.3 ... 30 ohms.
Measure at the open side of the
diverter switch sector between
the stationary main switching
contacts
8
12
5.7
5.5
5.6
reached or is expected to be
reached before the next
inspection, the contacts shall be
replaced or matched to the other
contacts by interchanging or
milling.
5.8
Determination of contact
wear
Measure and note the thickness
ot the contact layers on the
stationary and movable main
11
6.2
Contact braids
12
13
14
9.
Reinstallatlon ol the
diverter switch unit
Remove the tap changer head
cover.
Lift the diverter switch unit over
the open tap changer head. Lower
it down into the oil compartment
slowly and carefully.
When remounting the diverter
switch unit turn, if necessary, the
insulating shaft slightly until the
coupling engages.
Ensure alignment of marks on the
support plate of diverter switch
unit and in the tap changer head.
Fix the diverter switch unit by the
screws of the support plate.
Standard design: 4 screws MB x
20 (w.s. 13).
Special design for bell-type tank
installation: 5 nuts M8 (w.s. 13).
Both types secured by spring
washers, max. torque 22 Nm.
Reinstall the position indicating
disc (put on clip to shaft end).
15
EMR/OI/M/0010
16
Part-No.
Designation
009 859 1)
009 859 2)
010 236 1)
011 586 1)
012 5982)
0125992)
012 600
017 3552)
046 942
047 020
047 640
047 652
048 053
049 039
049 113
049 823
051 873 2)
052 206
052 866
056 932 2)
073 284
085 253
090 982
092 120
092 121
260 930
262 331 1)
264 020
400 004
401 044
401 045
401 471
450 330
450 335
450 361
450 500
451 076
451 087
451 325
452 356
453 255
453 977
453 981
550 666
550 711 1)
550 719
560 031 .
Note:
2l
450335
262331
047640
500 A [ (056 932)
600 A [ 085 253
(090982)
451325
011586
"
453977
-----
452356
-------
401044
(401 045)
894 389:4E
Part-No.
Designation
009 859
011 105
012 770
012 801
015 991
015 992
017 355
022 417
022 419
026 157
046 956
046 957
046 970
046 987
047 409
047 412
047 738
048 400
048 633
048 869
049 209
050 101
050 102
050 103
050 319
050 387
050 504
050 535
051 873
053 155
053 667
056 919
057 801
057 802
070 941
093 326
264 013
450 043
450 062
450 101
450 109
450 355
450 356
451 086
451 323
451 325
452 063
452 220
452 350
452 997
452 998
453 447
453 977
453 978
453 979
453 981
550 292
550 293
550 294
550 295
550 665
550 668
560 163
890 476:6E
453977
049209
453 977
1451325
~ 450 355
..
453979
451325
I 050319
I 450 062
"--
....--- - ~
453447 -~
451 323
450101
-----
----264013
453977
452
452220
890 476:6E
Part-No.
009 859
010 725
010 736
011 1OS
015991
015 992
022 013
022 417
022 419
026 157
046 956
046 957
046 970
046 987
046 988
047 409
047 738
048 397
048 400
048 403
048 441
048 633
048 869
048 870
049 209
050 101
050 102
050 103
050 319
050 535
053 155
053 667
056 919
057 801
057 802
070 941
085 252
093 325
264 013
450 062
450 101
450 109
450 334
450 355
450 361
451 086
451 237
451 325
452 063
452 220
452 350
452 997
452 998
453 447
453 977
453 978
453 979
550 292
550 293
550 294
550 295
550 665
550 668
560 163
Designation
Contact tip (tungsten copper)
45397R ~t
453977
..
049209
453977JlJ-
046970
264013
453 447
,--- --~
r:::--~~
451237046988048441-
026157--~,;J
011105
'-----
450101
056919 ~
453977
894 388:5E
Part-No.
Designation
044 271
044 272
044 305
044 611
047 250
047 251
047 256
047 278
047 279
047 283
047 335
047 372
047 449
047 450
047 483
047 615
047 620
047 786
047 787
047 789
047 793
047 797
047 825
049 183
049 230
051 661
051 662
052 690
056 987
057 113
088 382
450 385
450 710
451 444
451 449
451 520
451 730
452 026
452 028
452 210
452 216
452 221
452 256
452 370
452 516
452 601
452 739
452 871
452 872
453 807
453 977
453 978
550 068
550 069
550 070
550 761
Axle
Bushing
Spring holder
Coupling
Pawl I
Pawl II
Slider
Rocker
Bushing
Bushing
Drive shaft
Disc
Eccentric cam
Bolt
Bolt
Rivet plate
Hub
Bushing
Guide bolt
Guide bolt
Guide block
Cocking sledge
Wind-up sledge
Disc
Disc
Disc
Disc
Breech cap
Drive crank
Housing
Bracket compl.
Hex. head screw M8 x 20
Recess head screw M6 x 20
Taper pin
Taper pin
Feather
Rivet, counter sunk
Ball bearing
Ball bearing
Circlip lock ring
Circlip lock ring
Circlip lock ring
Circlip lock ring
Plate spring
Feather
Circlip lock ring
Rivet, round head
Circlip lock ring
Circlip lock ring
Rivet
Hex.nut M6, self-locking
Hex.nut M8, self-locking
Compression spring (1 sector)
Compression spring (2 sectors)
Compression spring (3 sectors)
Pawl tension spring
452516
550068
550069
550070
871
890 784:1E