Wilson - InstallationManual
Wilson - InstallationManual
for distribution
transformers
02
CONTENTS
1 : Introduction 03
1.1 : Cautionary note 03
1.2 : Health & Safety 03
2 : Transformer Components 04
5 : Installation 10
5.1 : Earthing the transformer 10
5.2 : Installing cables 12
5.3 : Installing the breather 14
5.4 : Connecting multicores 15
7 : contact details 21
8 : about us 23
03
1. Introduction
All transformers supplied by Wilson Power Solutions (WPS) UK,
are designed, manufactured and tested with the latest
technology and under strict quality controls, in order to
provide you with a long and trouble free service.
To secure a long lifespan for the transformer it is important to follow proper installation, commissioning and protection procedures
and to ensure that timely maintenance is carried out during transformer operation.
The purpose of this Installation Manual is to provide guidance on the installation and commissioning of oil-filled (mineral and synthetic
ester) transformers.
This guide is necessarily generic in nature, so specific features or parts listed in this guide may be missing from your transformer, and
accessories or auxiliary units on your transformer may be omitted from this guide.
In the event of any doubt, arising questions or any irregularities / deviation from IEC / BS (or equivalent) standard observed, please
refer to WPS for clarification and assistance.
The transformer, along with all its accessories and fittings, should be installed, commissioned and operated under the supervision of a
competent electrical engineer in accordance with relevant statutory requirements and good engineering practice, as well as being
operated within the terms of the specification.
For the UK and International Standards, reference should also be made to the current edition / publication of BSI: Standards
Catalogue, ENA-TS, and IEC: Catalogue of Publication, etc.
No high voltage tests should be applied to any transformer Electricity at Work Regulations - 1989 applies to the UK
without making reference to the original supplier (WPS). Electrical Installation as per ‘Memorandum of Guidance on
the Electricity at Work Regulation’ from HMSO.
A transformer which has been commissioned and then
removed from service for any length of time should be re- Also, refer to the ‘Regulations for Electrical Installation’ BS:
checked to the same standard as when it was first 7671 for installation up to 1000V AC and ‘Safety in Electrical
commissioned prior to being re-energised and placed back Testing’ HS (G) 13 from HMSO, ISBN 011 883 283 0.
into service.
In addition to the instruction given in this manual, BS / IEC /
equivalent standards and local regulation should also be
referred for other details regarding the design, materials and
performance.
2. Transformer Components
This section helps the user to identify individual parts of the transformer
which will be referred to throughout this document. The following images
will indicate the approximate location and style on several different designs.
Items labeled with a letter (A, B, C etc.) indicate standard components are present on all standard transformers, numbers (1, 2, 3 etc.)
indicate optional extras or accessories that may not be on your version.
A E
B 2
1 F,3
C G
D H
Figure 1a - Transformer View from Tap Switch End
05
4 6
5 7
i k
j l
Figure 1b - Transformer View from LV Side
A
9
8
e m
On receipt of the transformer, both at the client's plant or at site, it is necessary to carry out the following checks:
CHECKLIST
Receiving Transformer On-Site Checklist
PART item to be checked y/n
Main Tank Check there are no signs of damage on the transformer that may have occurred during
the transport.
Main Tank Check to make sure that there is no damage to the paint work and that there is no rust
present on the transformer.
Main Tank Check that the characteristics of the transformer detailed on the rating plate
correspond to those of the shipping documents.
Accessories Check each transformer is complete with the accessories stipulated in the contract
(WTI, PRD, etc.).
Terminations Check that all connections are clean and all bushings or connectors are free from
cracks or breakage (if applicable).
Marshalling Box Check there is no damage and all connections are correctly made and undamaged.
IMPORTANT: In the case that any anomalies are found, immediately contact WPS. It will be assumed that the transformer has been
delivered in perfect condition unless any notification is given within 7 days that suggests otherwise. WPS, therefore, cannot be
considered responsible either for what could happen to the transformer during service or for the resulting consequences.
07
• Provision for spatial requirement and ancillary items detailed on corresponding drawings that can be found in this section.
• Adequate ventilation.
• Ambient temperature within the normal operating range, compliant with IEC 60076-1, Section 4 "Service Conditions".
• Protection against exposure to fire, excessive moisture, explosion, etc.
• Provision for regular inspection, maintenance.
The transformer should always be moved and stored in line with the “Transformer handling and storage guide”, which will be provided
with the transformer. The instructions within this section should always be adhered to when performing tasks pertaining to the
transformer.
• Under no circumstances should the transformer be moved with a fork lift. All lifting should be done by either slinging or jacking
with the appropriate connections which are indicated with yellow paint and can be identified in Figure 3.
• When moving the transformer by slinging the centre of gravity might not be central to the transformer and it may be top heavy.
It is important that the transformer is lifted correctly. All slings or chains should be properly positioned and not make contact with
the cable boxes or radiators as shown in Figure 4.
• It is important to note that the total weight indicated on the transformer rating plate will not include any ring main units/ACB or
other added items. The complete assembled weight can be found on the transformer handling and storage guide in the yellow
box in the bottom right hand corner, stating the shipping weight as shown in Figure 5. If there is any uncertainty, identify all rating
plates on the transformer and accessories, add the weights together and add a suitable safety factor of no less than 10%.
• When moving the transformer via crane it is important to ensure the chains are at the correct length and angle, to ensure the
transformer is not damaged.
On transformers with a conservator (or with 4 lifting lugs) use 4x1500mm chain held at a 35 degree angle (see figure 5a).
For a transformer without a conservator use 2x1500mm chains at an angle of 58 degrees (see Figure 5b).
4x 2x
1500mm 1500mm
Chains Chains
35° 58°
Bund Separation
Wall Distance (b)
✔
transformers for access and to guarantee no reduction of cooling capability.
When positioning transformers next to each other it is important that the outmost boundary does not encroach upon the next
transformer tank. Figure 7 illustrates the minimum clearance required to safely position adjacent transformers.
Transformer Transformer
Transformer Transformer
✘
Figure 7 – Correct and incorrect ways of positioning transformers
10
5. Installation
The following is a guide for the installation of our standard
designs to a site with unhindered access to the equipment.
In the event that your site does not allow for unhindered
access, analyse the risks before proceeding.
6
3
5
4
1 3
2 5
4
4
Figure 8 - Earthing connection construction
It is advised that the sets (nuts, bolts & washers) are removed and the surfaces are inspected to make sure they
are clear from paint, dirt or other substances to ensure a good connection.
If the transformer has been stored for more than two weeks it is advised that the surface is re-cleaned to show
a shiny bare metal surface.
Ensure the earth cable/tape is suitable to be connected to an M12 sets (nuts, bolts & washers) by either
solution, shown below:
Place the earthing cable onto the sets (nuts, bolts & washers) and apply the remaining washer and nut.
Torque to 30Nm with a calibrated torque wrench.
1
2 1
3 2
4 3
4
The transformer will typically be delivered with the cable boxes fully assembled and connected to the transformer. The
following steps should be taken when fitting the cable(s).
CHECKLIST
installing cables
Cable Installation Process y/n
Remove the M10 sets (nuts, bolts & washers) on the cable box cover (1) and slide/lift off the cable box
cover from the cable box. Store all items in a clean, dry, safe place.
Visually inspect the inside of the cable boxes to make sure there is no damage. If the cable box is found
to be damaged do not proceed, contact WPS.
Remove the M10 sets (nuts, bolts & washers) which connect the gland plate (4) to the cable box (make
sure the gland plate is supported to prevent falling).
Cut suitable sized holes in the gland plate (4) to feed the cables (pilot holes have been provided in line
with the connection points). Make sure there is enough cable to reach the terminal and to prepare for
connection. Note – This is not a load bearing termination. Use correct glands to provide support.
Reattach the gland plate (4) to the cable box and tighten all sets (nuts, bolts & washers). Ensure that
each cable is connected to the correct phase. Unless otherwise stated, the phase orientation working
left to right will be:
HV – 1N*, 1U, 1V, 1W
✔ ✘
LV – 2U, 2V, 2W, 2N*
*Phase rotation is correct where neutral is present.
LV: Where possible all cables should be connected on the same side;
Ensure the cable box is clean and dry on the inside before reclosing.
Figure 10 – Breathers
4 4
3 3
Once the breather has been fitted, do not move the transformer. If you wish to move the transformer, uninstall the breather and
reapply the end cap.
CHECKLIST
installing the breather
Breather Installation Process y/n
Check that the contents of the breather (2) are orange -
if you notice any other colour besides orange within the breather inform WPS.
Remove the breather end cap (3) from the pipe and clean the threads if required. Store end cap
safely for re-use.
CHECKLIST
connecting multicores
Multicore Connection Process y/n
Remove the lid of the marshalling box and store in a safe place. If the marshalling box is damaged
inform WPS.
Locate a space on the box where you intend for the cables to enter the box. (WPS recommend to use
the under section of the box).
Drill a hole through the enclosure to accommodate the cable and the gland.
Terminate the cables in the correct terminal in accordance with the wiring diagram.
Check all cables have been secured on both sides of the terminals.
Drain Valve The transformer will be delivered filled with insulating fluid, with the drain valve
closed and a cap covering it as shown below:
Oil temperature indicator The transformers will be delivered with a preset alarm and trip as shown below:
OTI: Alarm 90oC, Trip 100 oC
If other alarm and trip values are required, refer to their product manuals for
installation guidelines.
Winding temperature The transformers will be delivered with a calibrated, preset alarm and trip as
indicator shown below:
OTI: Alarm 100oC, Trip 110 oC
If other alarm and trip values are required, refer to their product manuals for
installation guidelines.
17
CHECKLIST
part Item to be checked y/n
Buchholz relay Visually check that the device is completely filled with oil.
Ensure that the woodblock has been removed from under the cap as below:
✔ ✘
Pressure relief device Ensure the device has not been operated. The brass coloured pin should be in
the down position, as illustrated below:
Dual secondary voltage The transformer will be delivered set to the lower voltage unless requested
changer otherwise. If lower voltage is not what you require, ensure the tap is changed to
the appropriate setting. The number that corresponds to the tap position is
indicated on the rating plate “SELECTOR SWITCH CONNECTION” and “SWITCH
POSITION” as shown below:
Once the correct voltage has been chosen, check that the switch has been
securely into that position.
Oil level indicator The oil level indicator can either be a magnetic oil gauge (right) or a standard
visual indicator (left). Make sure that the oil is in line with the expected
temperature.
If no oil level can be determined stop all activities and inform WPS.
18
6.2 Commissioning
6.2.1 Purpose
After the satisfactory completion of installation and pre-commissioning checks the following tests must be performed before putting
the transformer into service. Prior to commissioning work refer to the manufacturer’s instruction booklet / product catalogue, etc. for
specific help and information on any accessories supplied. These can be provided on request from WPS.
Between HV Winding and Earth use 5000V or 2500V Insulation Tester (Megger)
Between LV Winding and Earth use 1000V or 500V Insulation Tester (Megger)
Value:______________________________
The IR values obtained should be similar to those indicated in the manufacturers’ test report, which will
have been furnished with the handing-over documents. Be aware that in humid conditions IR values
obtained may be lower due to condensation on the terminal bushings.
If IR values are very low (Minimum value is 1000ohm per volt service voltage), then it may be necessary
to filter the oil / dry-out the winding till the insulation reaches satisfactory values.
Oil samples should be carefully taken from the tank bottom and tested for BDV value.
BDV value of oil should be more than 50kV (rms) for 1 minute in standard test cell.
Value:______________________________
If the BDV value is very low and unacceptable (30kV (rms) or less for 1 minute) then it may be necessary
to dry-out & clean the oil until the insulation reaches satisfactory values.
Note: For very low IR values and low BDV values, it is recommended to contact WPS for a suitable
recovery procedure based on available facilities at site.
19
CHECKLIST
Voltage Ratio Test
Procedure y/n
Apply 3-Phase, 433V/415V AC or a single phase 240V/230V AC supply on the HV side and the Voltage
Ratio at all tap positions. This can be derived using a suitable precision voltmeter connected to the LV
side. A ratio meter, if available, can be used for a more accurate measurement.
Tap 1 ratio:____________________________________
Tap 2 ratio:____________________________________
Tap 3 ratio:____________________________________
Tap 4 ratio:____________________________________
Tap 5 ratio:____________________________________
Tap 6 ratio:____________________________________
The Ratio values obtained should be similar to those indicated in the manufacturer’s test report, which
will have been furnished with the handing-over documents.
HV U Value:____________________________________
HV V Value:____________________________________
HV W Value:___________________________________
LV u Value:____________________________________
LV v Value:____________________________________
LV w Value:____________________________________
Winding Resistance values obtained should be similar to those indicated in the manufacturer’s test
report, which will have been furnished with the handing-over documents.
20
CHECKLIST
Marshalling Box Scheme Check
Procedure y/n
All the auxiliary wiring from the various accessories to the marshalling box shall be checked against the
marshalling box scheme drawing provided.
Operation of all the alarm / trip contacts should be checked by simulating the alarm or trip condition,
checking that the alarm or trip signal appears at the correct terminal at the marshalling box.
After switching on No-load, if the primary side circuit breaker is tripped, investigate the cause thoroughly and re-energise the
transformer only after ensuring that any fault is properly identified and cleared.
If satisfactory (transformer on No-Load) then apply load gradually and observe for any abnormalities for the next 6 to 8 hours.
If the transformer is satisfactory on-load up to 50% for the first 4-8 hours, shut-down the transformer and ensure that all air-release
plugs of tank, radiator, conservator, buchholz relay, bushings, etc., are free of air pockets which might have developed during initial
loading.
NOTE: Suitable financial value can be obtained, particularly for copper. Alternatively, aluminium can be used as a winding conductor.
7. contact details
If you need to contact us for any reason please use the following:
OUR VISION
To be a family company with
a conscience providing
innovative, sustainable energy
infrastructure solutions.
OUR MISSION
We are committed to growing our
business by continuing to deliver
customer driven, tailored solutions
and outstanding levels of service,
whilst investing in the development
of new and improved power
distribution products and services.
23
8. ABOUT US
Wilson Power Solutions is based on
a unique customer and professional
approach that has been developed
over 70 years in the industry.
Today, Wilson Power Solutions is managed by the third
generation of the Wilson family who like their business to
remain agile and friendly. Dedicated to helping customers
find the best power distribution solutions for their
individual needs, we are passionate about our expert
knowledge and committed to giving advice with our
customers’ best interests at heart.
“
We believe in building
lasting partnerships
with our people, our
customers, suppliers
and our communities,
both locally and
internationally.
ERIKA WILSON MANAGING DIRECTOR
”
Wilson Power Solutions Limited
Westland Works
Westland Square
Leeds LS11 5SS UK
T: +44 (0)113 271 7588
E: [email protected]
WILSONPOWERSOLUTIONS.CO.uk