Installation and Operation Instructions - TRANSFORMER PDF

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Installation and Operation Instructions - TRANSFORMER PDF

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Marco Godoy

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35kV~750kV Power Transformer 35kV~500kV Reactor Installation and Operation Instructions 1ZDB237000Z-06/2018 SHEN7AIoT aC] SHEN7FAI Scope of applica’ This installation and application instruction manual provides an on-site installation and application guide for 3SkV-750kV power transformers and 35kV-5OOkV reactors of CHINT Electrics Co. Ltd. The main content within this manual details transportation, acceptance, storage, installation, testing, regular maintenance, common trouble-shooting and other related specifications of both the transformer and reactor electronics. The standards of transformer voltage level not covered in this specification are shown in Table 1. Tablet Cross-references of transformer voltage level and execution standard Standards Applicable range of products SKY standard ‘} ===¢ Figure 1 Special spanner for butterfly valve Figure 2 Open end wrench 32 First of all, unscrew the screw on both ends of protecting cap with open end wrench, remove protective cap, as shown in figure 3. Figure 3 233 34 23 Then, turn valve rod 90° to open butterfly valve by special wrench for butterfly valve according to the given direction of OPEN. Or turn valve rod 90° to close butterfly valve according to the given direction of CLOSE, as shown in figure 4. If it is opened difficultly or not closed tightly, engineers may knock the wrench handle bya tool. itis, not allowable to knock the valve directly by a tool or ahammer. Afteropen or close the valve, fit protective cap, and tighten the screw at the both ends, to prevent free rotation of the valve. 3 OG Sette Figureaand Opera 106 Dey 106 Repair Welding for Leakage Repair Welding for Leakage Scope of application This chapter provides guidance for repair welding on site. 2 Quality and safety guide 21 Quality guidelines 2.1.1 Related factory documents, data, and drawings should be conveniently placed to consult at any time. 21.2 Operations should strictly comply with this chapter to ensure product quality. 241.3 If personnel find abnormalities in the mounting process, they must immediately report to a CHINT after-sales engineers. 21.4 Welding operations must be completed by welder holding the correct qualification certificates relating to welding, 215 Before welding, the welder must understand materials of steel for leakage, make sure to choose the correct alloy. 2.2 Safety guide 22.1 On-site construction must follow safety guide of CHINT and local regulations. 2.22 Installation should comply with the principle of "safety frst, to prevent personnel from endangering personal safety. 2.23. Whenusing equipment or instruments, personnel should comply withthe application manwil to prevent unnecessary damage to equipment, instruments or trans formers caused by incorrect operation. In bad weather, personnel should provide protection to on-site vacuum equipment, oil-filter equipment, storage tanks, ete. Warning Welding operators must hold the qualification certificate issued by the correct authorities; When welding, the engineer must have a welding operational license; Ensure that there is the correct fire extinguishing equipment near the ‘work area that is accessible when required. 3 Technical guidelines ‘The guidance of this chapter is only applicable to repair leaky welding line and sand holes of transformer oil tank. It is not applicable to weld leakage of radiator. War a] Any operation related to welding of transformer the customer must contact CHINT to obtain a reliable solution 2441 » 2 3) 4) 5) 6) D) 8) 42 106 Repair Welding for Leakage Technological process Repair of slight leakage Here refer to only a slight leakage (oll leakage), specific steps are as follows: Close all valves between conservator and transformer; Remove the paint in the vicinity of oil leakage. Repair welding; Degrease, clean the welding area; All metal waste should be cleaned after completion of welding; ‘Open all the closed valve; Carry out leak test according to "310 Leakage Test for Seal”; Process touch-up paint operation after welding according to "107 The Use and Touch-up of Paint” Repair of major leak For serious leakage, the customer must contact CHINT for more detailed solution. 25and Opera 107 24 aa 242 243 22 224 222 223 224 Ty 107 The Use and Touch-up of Pi The Use and Touch-up of Paint Scope of application This chapter provides guidance for related operation of field paint Quality and safety guide Quality guidelines Related factory documents, data, and drawings should be conveniently placed to consult at any time. Operations should strictly comply with this chapter to ensure product quality. If personnel find abnormalities in the operation process, they must immediately, report to a CHINT after-sales engineers. Safety guide On-site construction must follow safety guide of CHINT and local regulations, Installation should comply with the principle of “safety first’, to prevent personnel endangering personal safety. When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments or transformers caused by incorrect operation. In bad weather, personnel should provide protection to on- site vacuum equipment, oi-fiter equipment, storage tanks, ete. Materials such as paint, dilute and curing agents must be stored in dry and ventilated place, and be placed far away from a heat source. Solvent is an irritant and corrosive, gloves should be worn when using solvent to avoid direct contacting with the skin. Do not use solvents which contain chlorine or one that is refined by petroleum, During ‘touch-up paint, engineers must wear protective equipment including respirators, painting gloves and conjoined painting suit, etc. War a Paint, solvents and other products used in touch-up paint operations are corrosive and irritating to the skin. Use of these products may create a risk of personal injury, therefore personnel must stctly abide by the relevant safety instructions in the product specification. 2642 424 422 423 424 425 Deen Technical guidelines In the process of transportation and on-site assembly, paint on the surface of the transformer may have some degree of damage. The main steps of local touch-up paint of transformer include cleaning, degreasing and surface treatment. Touch-up paint should be done properly with the correct paint, and the drying time of the coating should be considered, All touch-up paint work must be done in dry weather, with environment temperature of 10°C~35°C and relative humility not more than 75%. For the protective system of paint, please read 1SO12944-5 carefully It is suggested that users inspect the appearance once at least every 5 years to check whether damage and abnormalities exist ‘or not and to confirm whether it needs to be retrofitted or repaired, in order to avoid influencing the transformer appearance. Technological process Cleaning and degreasing Before touch-up paint, engineers must remove transformer oil, glue, dust, etc on equipment. In order to effectively remove dust and oil contamination, skim agent which must be provided or recommended by CHINT should be used in the cleaning process. Paint scratches and iron rust on the surface of the equipment must also be careful cleaned and degreased Touch-up paint During touch-up paint, engineers can use brush, roller or spray gun. It is suggested that paints and solvents be recommended or confirmed by CHINT. Minor damage area of surface paint The damaged area of surface paint must be gently polished by sandpaper (grain size is around 240 mesh), to make a certain degree of rough surface. Paint dust from polishing should be cleaned by dry brush or dust-free cloth After cleaning, spray a layer of paint. Rusted area The corroded area should be polished by sandpaper(grain size is about 80 meshes), until metal surface becomes clean and has no rust deposit. Around the spray area of the rusted area about 2cm must be polished to a metallic luster, and all rust removed. Paint dust from polishing should be cleaned by dry brush or dust-free cloth After cleaning, engineers should spray step by step according to guidance provided by CHINT, pay special attention that should fully meet drying time between the coating layer. Bolt, nut and flat mat When bolts, nuts and flat washers are cleaned and degreased carefully, engineers should paint a layer of primer paint and ensure drying time. After completely drying, grind out a «certain roughness, then spray two layers of paint, and then allow for drying time. Specific area with color mark ‘According to the demand of customer, certain areas of transformer can use specific colors (usually be red or black) to paint. These areas including vent, hoisting gravity mark, serial number of transformer, cil sampling point, hand-wheel, etc After paint is completely dry, check adhesion of touch-up paint area and adhesion shall be less than 1 Warning Construction site does not allow for unsafe factors such as open flames to avoid fire ry 107 The Use and Touch-up of Paint108 24 24a 2a2 22 224 222 223 224 BA 32 324 a) b) a 322 33 Procedure TOT REC Oil Filtering on Site Scope of application This chapter provide guidance for cil filter and storage of transformer installed on site This process is only for the mineral oil used in transformer, refer to specific instructions if use vegetable oil, silicone oil or synthetic esters. Quality and safety guide Quality guidelines Operation should strictly comply with this chapter to ensure the oil quality, If personnel find abnormalities in the operation process, they must immediately report toa CHINT after-sales engineer. Safety guide On-site construction must follow safety guide of CHINT and local regulations. Installation should comply with the principle of “safety first’ to prevent personnel from ‘endangering personal safety. ‘When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments, or transformers ‘caused by incorrect operation. In bad weather, personnel should provide protection to on-site vacuum equipment, oil-flter equipment, storage tanks, etc. Oil from cil fiter operation should be cleaned regularly to avoid environmental pollution, Technical guidelines Instructions ‘After a sampling test if the transformer oil delivered to site sampling test meet “GB 2536 Fluids for Electrotechnical Applications—Unused Mineral Insulating Oils for Transformers and Switchgear’, can be filled directly into the transformer. If any indicators of sample is ‘contaminated, the engineer should filter cil until re-sampling testis completed sufficiently, then the oil can be used. Equipment required for on-site oil processing High vacuum oil filter High vacuum oil filter must have functions of degassing, dehumidification and heating, and meet the following performance requirements: Outlet temperature of the heater (6545) “C; Processing capacity (flow) 26000 L/h, flow is controllable ; ‘Vacuum pump capacity <0.5 mbar. Personnel should check whether the oil filter and line are clean and contamination-free, if there are marks of dust and water stains, these must be cleaned up before use. The il filters must self circulate once with oil before use, the oil once selfcirculated should not be filled into transformer Oil pipe and vacuum pipe Before installation of pipelines, the engineers must inspect whether there are defects such as deformation, perforation in its internal and external walls, whether there are any rust, water, grain and other contaminants. Use suitable transformer oil to rinse and clean pipelines when necessary. When installing the pipe, temporary adapters may be used between flanges and joints. Reference files “GB 2536 Fluids for Electrotechnical Applications-Unused Mineral Insulating Oils for Transformers and Switchgeat 28Procedure TOT REC 4 Technological process 4.1 Connection pipe Vert hale tank High vacuum oir Connect the oil drain pipe in the oil storage tank to the high vacuum filter inlet; connect the high vacuum filter outlet to the oil storage tank top vent and form a loop. Open a small hole on the manhole cover to allow exhaust gases to exit. Measures should be taken to prevent foreign bodies from going into the tank from the small holes. 4.2 When starting the high vacuum oil filter, set the oll temperature at (65 ~ 70°C), When measured inlet temperature of oil filter machine oil must be 60°C, to allow for maximum oi filter efficiency. Counting time from now, sample and test after at least three times cycle. Calculation of oil filter time: if there are 10 tons of oil in an oil tank. The effective flow of oil processing equipmentis 5 tons per hour, time for 3 cycles will be (10+5) x3 = 6, making a cycle at least six hours. 43. [ftest results of oil meet “GB 2536 Fluids for Electrotechnical Applications. Un- used Mineral Insulating Oils for Transformers and Switchgear’, oil can be filled into the transformer. Ifthe oilis contaminated, continue to filter oil untilit passes the test. 2930200 Transport, Acceptance, Storage of Transformer01 Transportation and Acceptance of Transformer 201 Transportation and Acceptance of Transformer 1 Scope of application This chapter provide guidance for loading, transportation, positioning of housing and on-site acceptance of the transformer. 2 Quality and safety guide 24 Quality guidelines 21.1 Related factory documents, data, and drawings should be conveniently placed to consult at any time, 2.1.2 The installation process must be recorded on “Acceptance Record Form of Transformer’. 213 Operations should strictly comply with this chapter to ensure product quality 2.1.4 If personnel find abnormalities in the mounting process, they must immediately report toa CHINT after-sales engineers, 22 Safety guide 221. On-site construction must follow safety guide of CHINT and local regulations. 222 Installation should comply with the principle of “safety first", to prevent personnel endangering personal safety. 223 When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments or trans formers ‘caused by incorrect operation. In bad weather, personnel should provide protection to on-site vacuum equipment, oil-iter equipment, storage tanks, etc. 3 Technical guidelines Transportation of transformer should be entrusted to professional transportation ‘company, the carrer is responsible for using proper means of complete transportation and loading and unloading of transformer, and to ensure that the transformer is intact, and undamaged. 4 Technological process 41 Operation requirements for li 4.1.1 Stress areas of equipment lifting and unloading must be able to bear the total lifting weight of transformer. Lifting and handling must start from lifting lug and jacking of transformer, if can not ensure the correct position, personnel should consult factory drawing data before lifting, ing and jacking of transformer body 41.2 Before lifting, the personnel must check whether all bolts on the tank are tight, in order to prevent loss or damage caused by deformation of the lifting tank. 4.1.3 The angle between wire and plumb line shall not be greater than 30 °, or engineers must use a balance beam when lifting. Lifting rings should be used in the process of lifting, length of every lifting rope must be equal and meet the safety requirements. Confirming the tolerance of lifting ropes is almost same to prevent unbalancing of transformer. 4.1.4 When lifting the body by hydraulic jack, it should be placed right under lifting plate, and take tums to rise of fall on both sides from the transformer. Each rise height shall not exceed 120 mm, After rising, engineers should place a sleeper and pad into the bottom of the transformer. In order to guarantee the safety of transformer, it is prohibited to use jacks on four jack boards at the same time, Measurements should be ‘taken to prevent turing over of the transformer or vibrating of jack. In the horizontal and vertical direction, the vibration and movement of the body should not be more than 0.5 * 9.8 m/s, 31tl 01 Transportation and Acceptance of Transformer 415 _ In order to prevent separation of jack bearings, personnel should check whether all parts of jack are in good condition before use. Warning Not following the above outlined rules may cause equipment damage and personalinjury, 4.2 Transport requirement for body and accessories 42.1 Before transporting transformer body, the delivery company should conduct a survey jn advance, to identify clear transportation routes and environment of loading and unloading site, and develop contingency plans for related risk. In the process of transportation, personnel must follow the following rules. 42.1.1. In addition to shipping, if the mode of transportation such as roads, railways and inland river are used during transportation, the slope angle for long edge of transformer body shall not be greater than 15°, and angle of short edge shall not be greater than 10” 42.1.2. For highway transportation, according to flatness of road, the speed of carrier vehicle should meet the following requirements: flat road 40km/h, not completely flat road < 20km/h, rugged road < 10km/'h; speed of camier vehicle on the highway is generally controlled at 40km/h, The minimum speed limit of highway > 4dkm/h, driving according to the minimum speed limit, the horizontal and vertical acceleration is not greater than 0.5 + 98mvse Caution ‘Avoid using the emergency brake, 42.13 Railway transportation should follow the relevant provisions of the railway departments. Caution |When transporting and lfting bushing, need to prevent collisions specially. The bushing cannot withstand the acceleration of greater than 3g, 422 _ In the process of transportation, in order to prevent humiclty of transformer housing and accessories, usually two transportation modes with gas and oi filing are used 42.2.1 For transportation of transformer with air filling, dew point of the used dry air should below - 40°C, dew point of nitrogen should below 40°C (purity over 99.9%), When leaving the factory, air pressure should be kept between 0.02 MPa-003 MPa. During transportation, internal pressure value in body shall not be less than 0.01 MPa, otherwise personnel should fil dry air or nitrogen to reach the required value. Ifthe nitrogen residual pressure in nitrogen bottle is not enough to sustain the pressure of body, personnel should replace nitrogen bottles immediately after use 321 Transportation and Acceptance of Transformer Warning If intemal pressure value is lower than 0.01 MPa, which may cause intemal insulation parts of wansormer become damp. All seals should be inspected to ‘ensure there is a good seal to prevent leakage. When the transformer internal pressure rises due tothe hot weather, the pressure should be regularly released ‘to keep the internal pressure value in the range of 0.02 MPa to 0.03 MPa, [> 42.2.2 During transportation with oil filling of transformer, oil tank should be filled into suitable transformer oil, the level of oil should better be higher than the upper iron yoke, fill dry gas required in 4.2.2.1 above oil level. On-load tap-changer must transported with cil filling. Oil level of switching chamber should keep a distance of 100 mm~200 mm away from upper part of switch. Caution If on-load tap-changer is equipped with pipe (E2) connected with body, then the pipe must always be closed. 42. 424 3 Removed components such as header, ascending flanged base, conservator, radiator, bushing transformer should be sealed with cover plate during transportation, For above components with internal insulation, engineers should fill oil or dry gas for transportation When loading or unloading transformer engineers should arrange personnel to observe lift of the truck platform or iting of freight to prevent rollover accidents, etc. Lifting platform and terminals ‘must meet the bearing requirements of platform. When unloading the transformer slope angle for long edge of transformer body shall not be greater than 15°, angle of short edge shall not be dgreater than 10" Warning If the transportation time is more than 3 months, please timely charge the collision recorder to ensure the integrity of record to transport process, Caution If collsion or leakage happened in the process of transportation, may cause product quality risk, please immediately notify the CHINT. 43 434 43. 43. ‘Acceptance check [After discharge of transformer and the accessory box have arrived at the scene, in order to confirm there is no loss oF damage of equipment in process of transportation, personnel must carry out the following inspection. Acceptance of body 41 Usets should check wiether the recetved product are consistent withthe requirements of the contract Alter all parts of transformer have been transported to the scene, engineers should immediately ‘check the number of body and accessory kit according to the packing list, and handle the transfer procedures with the transportation party atthe same time, 2 Check if there are any abnormality in escort record. 33tl 1 Transportation and Acceptance of Transformer 43.1.3 Check whether there is relative displacement between body and truck, whether fixed wire is damaged, whether limit welding plate at the bottom of cil tank is cracking. Check the transformer body if there is any breakage, deformation, cracking, etc, and make the check records at the same time. The inspection process should refer to assembly drawing and transportation map of transformer, After inspection is completed, remove fixed support used in transportation 43.1.4 Check integrity of 3 d collision recorder and completeness of data records, acceleration should be not more than 3g, Except which purchased by customers individually, collision recorder should be brought back to CHINT by operator on site, Caution If there are any abnormality in body, and recorded data of 3 d callsion recorder beyond the specified value, the consignee should negotiate with transportation department to stop unloading, and immed'ately notify CHINT. 43.18 For transformer transported with oil filing, personnel should check seal state and confirm, whether there is leakage. Check gas pressure above the oil level according to the requirements of the 43.1.6 43.1.6 For transformer transported with gas filing, engineers should check whether the intemal ‘92s pressure value of body is in the range of 0.01 MPa to 0.03 MPa. When the internal pressure value of transformer is less than 0.01 MPa, and is not immediately installed after arrived at the scene, personne! should fil dry air or nitrogen (dew point < - 40°C) again till pressure value within the body reach the scope of 0.02 MPa~0.03 MPa. The storage of transformers is carried out according to the “202 Storage of Transformers” For transformer transported with gas filing, when pressure ofthe body is less ‘han or equal to 0.005 MPa, personnel cannot install the transformer, and should immediately contact CHINT for processing, 43.1.7 Sample inspection of transformer body ‘After transformer arrived at the scene, personnel should immediately do an ontology sample testing, inspection showing a test pass can be stored, the test items as shown in table 1. Transformer transported with gas filing should tested with residual oil take from the tank bottom. For transportation with oil of transformer or sub-assemiblies, can sample ‘at sample valve or any other valve. Sampling test results should comply with the provisions in table 1 ‘Table 1 Oll performance index before running of transformer S/N Indicators Tok 50K Test items corbelow | 220K¥ | 330kV-500KV | or Above 1._| Thebreakdown voltage, v/25mm | 240 250 260 270 2 | Dielectric oss factor (90°C) 50.01 50.01 0.005 0.005, 3_| Water contentin oil, ma/t 520 515 s10 10 4 | Gas contentin ol % (volume acon) : - 1 1 If there are any indicators of test results does not meet the requirements, contact CHINT immediately. 34tl 1 Transportation and Acceptance of Transformer 4.3.2. Inspection and acceptance of accessories 4.3.2.1 In general, itis not allowed to open the box before installation of transformer. If it is required to open the box for inspection, the customer should contact CHINT and inform local inspection time in advance, so that can associate with CHINT to inspect. 43.2.2 Users should check whether the number of items is correct according to the packing list of CHINT, at the same time check whether there are any damage or loss of accessory box and make a detailed record. If there are missing or damaged items in the accessory box, the customer should contact the transportation company and CHINT timely. Caution If there is any damage, loss and other abnormal conditions in the above inspection process it should be detailed recorded, photo- graphed on site and signed by both parties (the buyer and the seller), These acceptance record, ‘damaged inventory, photos and other documents should be timely provided te transport company and CHINT, in order to obtain reliable solution, 43.23. User shall be responsible for the safe storage of the items, and should bear the liability for loss and damage. Storage of transformer and accessory box shall be carried out according to *202 Storage of Transformer’ 433 Acceptance of transformer oil 433.1. Check whether the type of transformer oil is correct. It is prohibited to stored with other types of oil. 4332. Check sealing condition of oil tank and make records. 43.3.3. Check whether the volume or weight of oil is consistent with the delivery data provided by manufacturers. 4334 Oil arrived at the scene should be timely accepted, acceptance criteria should strictly comply with “GB 2536-2011 Fluids for Electrotechnical Applications—Unused Mineral Insulating Oils for Transformers and Switchgear’. 4335. Acceptance of export oil should comply with the relevant international standards or criteria stipulated in the contract, 43.3.6 After transformer oil has arrived at the scene, if the factory do all oil test project and have the complete record, so only do some simple test at the scene according to requirements, such as breakdown voltage, dielectric loss, and water content, etc. if the oil is from oil refinery, purchased by the user or the user raises an objection, personnel must do all the oil test items. 4337 Transformer oil should be stored in clean and sealed special tank, different types of oil should be stored separately and marked Warning Itis prohibited to transfer and filter the oil in different oil tank in the fain, snow and fog weather. When filtering the transformer oil or filling il into oi tank, engineers should prevent impurities and water vapor entering and the pollution of the environment. 35tl 01 Transportation and Acceptance of Transformer Caution If any abnormality is found during acceptance, please inform the shipping company and CHINT, to prevent delays. 44 Positioning of the housing 44.1 When rising and falling of the transformer housing require jacking, operations should comply with this chapter 4.1.4, 44.2 There are three kinds of commonly positioning modes of the housing. 2) When slide positioning by spreading rails at the bottom of transformer, engineers should lubricate the rails at first, and pulling speed should be no more than 0.05 kmh; b) When positioning by rollers, installed rollers should be tightly arranged and easy to turn, pulling speed shall not be more than 0.05 km/h; When positioning by dollies at the bottom of the oil tank, engineers should remove the spacing device in advance, and lubricate the car axis, pulling speed shall not be more than 0.1 km/h. The foundation track of transformer must be horizontal, personnel should check whether track spacing and spacing of dolly at the transformer bottom are consistent in advance, to ensure that the dolly wheel accurately embedded into the track: 443 During the period of transformer housing positioning, personnel should pay attention to keep the bushing center consistent with enclosed bus or GIS for subsequent installation, 444 When the transformers have a cooling system with independent frame, personnel should consider the relative position of independent frame for subsequent installation 36202 Storage of Transformer 202 Storage of Transformer 1 Scope of application Once the transformer has arrived at the installation site, it may be necessary to store the equipment. According to the length of the actual storage time, storage conditions are also different. Personnel must ensure that the transformer is in good condition. This chapter provides guidance on the relevant procedures of the transformer storage. 2 Quality and safety guide 21 Quality guidelines 21.1 Related factory documents, data, and drawings should be conveniently placed to consult at any time. 21.2 The installation process must be recorded on “Storage Record Form of Trans- former” 21.3 Operations should strictly comply with this chapter to ensure product quality 21.4 If personnel find abnormality in the mounting process, they must immediately report to a CHINT after-sales engineers. 22 Safety guide 22.1 On-site construction must follow safety guide of CHINT and local regulations. 222 Installation should comply with the principle of “safety first”, to prevent personnel from endangering personal safety. 223 When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments or transformers caused by incorrect operation. In bad weather, personnel should provide protection to on-site vacuum equipment cil-fter equipment, storage tanks, etc 3 Technical guidelines After on-site acceptance, transformer should be stored according to the requirements intable 1. Table 1 storage requirements of transformer body Storage requirements Maintain the conditions of gas-filing and oil-filing during transportation Less than 3 months Install oil conservator system, then fill or add oil to the standard oil level More than 3 months | roi conservator. Caution If the requirements in table 1 can not be met, the customer shall notify CHINT for solution,aa 44a 442 202 Storage of Transformer Technological process Storage method with gas filling for transformer After the equipment has arrived at the scene, if the storage time of transformer is less ‘than 3 months, for transformer transported with gas filing, gas pressure of the body should be kept in the range of 0.01MPa~0.03MPa, For transformer transported with oil filling, the pressure between oil level and tank top should be kept in the range of 0.01MPa~0.03MPa. ‘When the transformer is stored with nitrogen, within the first week engineers should check the pressure once a day if there are no abnormalities, check pressure once a week later, engineers must make records for internal pressure values of the oil tank. When the ‘transformer internal pressure dropped to 0.01 MPa and below, personnel should regularly supply dry air (dew point < -40°C) or nitrogen (purity over 99.9%), until the body pressure value isin the range of 0.02 MPa to 0.03 MPa. Caution Ifthe pressure value drops too fast it can indicate that there is leakage. At this, ‘ume engineer should check and find the fault points quickly, focus on inspection of seal plate and gas pipeline, seal again to prevent damp of ‘transformer body tthe same time contact CHINT to confirm if the measures ‘taken are vali 42 424 422 423 424 Method and requirements for oil filing of transformer Transformer stored for more than three months after aival at the scene, whether transported with oi filing or gas filing shall be installed oil conservator system and stored with oilfiling Firstly, completely drain all residual oil at the tank bottom. itis forbidden to fil original residual oil at the box bottom back into transformer. Then install oil conservator system fill suitable transformer oil to standard cil level, install breather on the conservator at the same time and release the airin the oll conservator. When installing oil conservator and filing oil, operations should be conducted according to the ‘chapters "303 Installation of Oil Conservator" and "308 Transformer Vacuum Oil-filing” If the oil conservator can not be installed in time, personnel must apply a vacuum between the top and lid of tank, and then fil dry air (dew point s ~40°C) of nitrogen (purty over 99.9%), ‘whilst keeping the pressure value between 0.01 Mpa to 0.03 Mpa. ifthe temperature on site is high, the pressure in the body will increase, personnel can bleed appropriately to reduce the pressure in the housing, but make sure the pressure value after bleeding is between 0.01 Mpa to 0.03 Mpa finaly refer to this chapter 4.1.2 to monitor and test, During storage with oil filling, check appearance of transformer every ten days; Every three months take an oil sample to test, the sample must meet the requirements in table 2, record at the same time. Table 2 Oil performance index before running of transformer S/N Project Indicators Vottagelevel &Y) | 119 kv orbelow| 220kV | 330KV~500KV | 750KV or above Testitems The breakdown voltage, KW/2Smm) 240 250 260 270 Dielectric loss factor (80°C) 50.01 50.01 50.005 0.005 Water content in oil, mg/L 520 15 =10 10 as contentin cl volume fraction i zi 1 1 38202 Storage of Transformer Caution If any ol leakage is found, personnel should immediately start the process ‘of sealing, at the same time contact CHINT to confirm whether the measures conducted are valid 43 Storage of accessory box 43.1 Storage of immediately installed transformer accessories and oil tank: For the components normally installed after the arrival of the transformer, equipment and tanks do not need special storage. But the storage site shall meet the following requirements: a) Sunshade and ventilation; b) Rain will not deposit on equipment; The floor is clean and relatively fat; d) Can support weight of the packing boxes. Caution itis required to pay great attention to bushing box, prevent cllsion, prohibit ‘overlapping of ether accessory boxes. 432 Storage of transformer accessories and oil tank with delayed installation, 4321. Storage of accessory box If the installation of transformer arriving the scene has been delayed more than three months, the accessory case should be kept indoor as far as possible. If the indoor storage condition is limited, personnel should ensure bushing box and the packing box with secondary equipment stored indoor. Other accessory box can be kept outdoors, but accessory box kept outdoors should be padded higher and far away from ground water, and should cover with tarps on the packing case. Accessory box should be stored in the right way to prevent any form of loss and damage. Before starting installation program of transformer, relevant accessory box shall be sent to be unpacked near the transformers. Place requirements for accessory box 2) Sunshade and ventilation; b) Rain will not deposit on equipment; 0 The flooris clean and relatively lat d) Can support weight of the packing boxes. Caution ‘The bushing and box with secondary equipment must be kept indoors. f not having Indoor preservation conditions, engineer must contact CHINT to get a soltion. 39ry 202 Storage of Transformer 43.22 Storage of oil tank Transformer oil in the factory has been filtered and tested, and safekeeping after the tank arrived at the scene can reduce oil purification procedures on site. Storage place should be indoors, if stored outdoors, personnel should take protective measures for rain and dust, use polyethylene film or waterproof cloth to cover and protect. Anti- leakage suite of oil tank should be placed near the tank. Caution Oil storage should strictly comply with the focal fie requirement, prevent electrostatic, avoid fire caused by contacting with ll fire source, 'No smoking and flame near the tank. 40203 Internal Inspection of Transformer 203 Internal Inspection of Transformer 1 Scope of application This chapter provides guidance for internal inspection of transformer, 2 Quality and safety guide 241 Quality guidelines 2.1.1 Related factory documents, data, and drawings should be conveniently placed to consult at any time. 21.2 The installation process must be recorded on "Inspection Record for Active Part of Transformer’. 213 Operations should strictly comply with this chapter to ensure product quality 21.4 If personnel find abnormalities in the mounting process, personnel must immediately report to a CHINT after-sales engineers. 22 Safety guide 22.1 On-site construction must follow safety guide of CHINT and local regulations. 222 Installation should comply with the principle of “safety first" to prevent personnel from endangering personal safety. 223 When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments or transformers caused by incorrect operation. In bad weather, personnel should provide protection to on-site vacuum equipment ol-fter equipment, storage tanks, etc 3 Technical guidelines 3.1 Overview After transformers have arrived at the scene, when it is required to enter the transformer intemal housing for to inspects, operational processes should strictly comply with this chapter and "102 Related Instructions when Entering Transformer Housings’ 3.2. Discharging Nitrogen within the transformer For transformer transported with nitrogen filling or filing pressure with nitrogen, itis {forbidden for any personnel enter the transformer directly. Entering into the transformer is, only allowed after exhausting nitrogen according to the following methods, The oxygen content in transformer should not be less than 195%. 3.2.1 Discharging Nitrogen within the transformer by vacuuming First exhaust and vacuum the transformer. Then fil it with dry air with dew point <-40°C Until positive pressure is within SkPa~10kPa. When the site have no conditions of dry air filling, engineers should inhale air through breathing hole with drier. 3.22 _ Discharging Nitrogen by filing oil Filing oil from the bottom of the transformers, open the vacuum butterfly valve with the top of the transformer to exhaust. After the transformers are filed with oil and nitrogen is completely discharged, the oil should be extracted, and inhale air through breathing hole with drier. Warning Don'tallow any personnel directly enter transformer transported or pressed with nitrogen filing, a203 Internal Inspection of Transformer 3.3. _ Requirement of extemal environment for inspection to enter the transformer internal a) Clear weather during the day b) _Airrelative humidity is not more than 75%; ©) The environment temperature is not lower than 0°C, temperature inside transformer body is at least 10°C higher than the ambient temperature ; ) Wind speed is less than 4 ©) No possibilty of heavy rain, snow, fog and sand, ete Caution Incase of sudden change of weather, engineer should immediately top the jperations, quickly seal the tank, and fil dry air or nitrogen till positive pressure is 10kPa~20KPa, 3.4 Exposure time When breaking the seal of transformers, personnel should try to shorten exposure time of active part and control exposure time within 4 hours under any circumstances. Exposure time means the time from break vacuum to seal oil tank. If the exposure time of equipment is more than 4 hours, on the premise of the transformer withstanding the vacuum, exposure time can be extended for 2 hours, but the corresponding vacuum time should be extended for 4 hours. Warning ‘When entering the transformer internal housing to inspect, personnel must follow the safety rules inthis chapter. Otherwise, it may cause personal injury. Personnel entering the transformer internal housing must be authorized by HINT. In general, only service engineers assigned by CHINT can enter the transformer. Under special crcumstances, user or personnel of instalation company will need ‘he written authorization of CHINT to enter vansformer, personnel should be ‘vained before enteing, and should wear correct labor protection tides. Installation unit should define director of security, develop contingency plans, ‘to ensure personal safety ofthe personnel entering the transformer housing, Warning Its rains, snows and has sand (greater than level 4), relative humidity is ‘more than 75% its not allowed for internal inspection ofthe transformer and wiring. Only after confirmation that pressure in the transformer is zero, personnel can open the manhole cover. Warning Oxygen content of transformer internal ar must reach 19.5% above, otherwise personnel are not permitted to enter the transformer or inhale the gases in the transformer forced entrance will cause coma injury or death, a2203 Internal Inspection of Transformer 4 Technological process 41 Check whether the core is deformed and insulation of iron yoke and clip pieces is in good condition. 42 Check whether the winding insulation is in good condition, whether showed signs of damage, missing or displacement, whether insulation screens are intact and fastened. 43 Check whether the shielded wire of lead are wrapped firmly, whether insulating paper ‘of winding wire part is in good package. 44 Checker whether the wood pieces on the active part become loose, detached and deformed, whether clamping and binding of lead are firmly and neatly 45 Check whether the tap of switch is connected with tapped lead correctly and firmly, whether there is overbuming, whether conical insulation have damage, whether the bare wire is fastening and contact well, whether the shield is fixed and reliable. Check whether the drain plug of the oil chamber bottom with on-load tap-changer is closed. 46 Check whether all impurities (including nonmetal material) of the tank bottom have been thoroughly cleaned. Use qualified transformer oil to clean tank when necessary. 47 Check whether magnetic shielding of oil tank become loose, detached or rusted, ete. 48 After inspection conducted by entering oil tank internal, transformer should be sealed again, and personnel must vacuumize the body and detect leakage at the same time, finally store according to "202 Storage of Transformer" 48.1 For the transformer which can endure full-vacuum, leak detection should be conducted according to the following method: Until 2 hours after the vacuum degree reaches below 133 Pa or a stable vacuum value, then shut down the vacuum pump and seal the transformer. The vacuum inside the transformer is detected with vacuum gauge until the vacuum value varies to a stable value, and the rise pressure value measured within 30 minutes should be less than 0.2 kPa/h 482 If the leakage detection is qualified, open the vacuum pump to continue vacuuming When the vacuum degree is less than 133 Pa, start calculating vacuum time. Vacuurning time and vacuum degree can be found in the table 3. During vacuuming, personnel should continuously observe whether the oil tank become deformed. Table 3 Vacuum Degree and Timetable Voltage level (KV) Vacuum (absolute value) Vacuum duration time(h) Below 110 kV 0.05MPa 2 110 oF above 133Pa below 224 Caution Failure and defect found during inspection of active part should be solved ‘correctly and recorded in “Inspection Record for Active Part of Transformer’. 43ing Cover Inspection 204 On-site Hoisting Cover Inspection 1 Scope of application This chapter provide guidance for inspection to hoisting cover of transformer installed on site. 2 Quality and safety guide 21 Quality guidelines 2.1.1 Related factory documents, data, and drawings should be conveniently placed to consult at any time, 2.1.2 The installation process must be recorded on “Inspection Record for Active Part of Transformer’ 2.13 Operations should strictly comply with this chapter to ensure product quality, 21.4 If personnel find abnormalities in the mounting process, they must immediately report to a CHINT after-sales engineers. 22 Safety guide 221 On-site construction must follow safety guide of CHINT and local regulations. 222 Installation should comply with the principle of “safety first’, to prevent personnel from endangering personal safety. 223 When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments or transformers ‘caused by incorrect operation. In bad weather, personnel should provide protection to on-site vacuum equipment, oil-lter equipment, storage tanks, etc. 3 Technical guidelines 3.1 Instruction for inspection of hosting cover In order to prevent the active parts of the transformer becoming damp, in general, itis suggested not to conduct hoisting cover inspection. If hoisting cover must be inspected due to special reasons, personnel should operate strictly according to this chapter. Caution It is suggested to enter transformer internal to inspect barrel tank according to "203 Internal Inspection of Transformer’, inspection of hoisting cover is not recommended. 3.2 Environmental conditions and exposure time 3.21. Environmental conditions a) Clear weather during the day; b) _Airrelative humidity is not more than 75%; ©) The environment temperature is not lower than 0 °C, internal temperature of transformer body is higher than the ambient temperature for at least § °C. 4) Wind speed is less than 4 ©) No possibilty of heavy rain, snow, fog and sand, etc Caution In case of sudden change of weather, engineers should immediately stop the operations, quickly seal the tank, and fill dry air or nitrogen tll positive pressures SkPa ~ 10 kPa,4 ing Cover Inspection 3.2.2 Exposure time Time for equipment being worked on exposed to the air is calculated from the breakage of the vacuum seal until resealing of the oil tank. Reference table 1 of exposure time, personnel should strictly control the exposure time, if the exposure time of equipment exceeds the limit time, on the premise of the transformer withstanding the vacuum, exposure time can be extended for 2 hours, but the corresponding vacuum time should be extended for 4 hours. Table 1 Allow time exposed to the air for active part (air relative humidity < 75% ) Voltage level (KV) Exposure time (h) 220 KV or below 8 More than 330, 6 4 Technological process 4.1 Preparation before hoisting cover inspection Before hoisting the cover, personnel must complete the following preparation work as required 4.4.1 Oil discharge requirements for transformer transported with oil filling Prepare clean oil tank, extract transformer oil in the housing from the valve of tank bottom to the tank, and at the same time make the transformer take in air through breathing hole with desiccant. 41.2 Exhaust requirements for transformer transported with oil filing Demolish equipment for transportation with nitrogen filed firstly, and then release gas from vacuum butterfly valve on the top of the box. Hoisting cover can be conducted when there is no gas jetting Warning To prevent foreign bodies faling into the tank. Staff should avoid sucking releasing gas from transformer. After hoisting cover for transformer transported with trogen fling, ‘engineers should make the air flow around active part at least 15 minutes, then personnel can clase to the transformer fo inspection, 4.1.3. Demolition of the switch Before conducting the hoisting cover personnel must remove connection between diverter switch and oil tank. At the same time, set the switch gear to rated gear before hoisting cover. Removal of the switch, personnel should refer to operation instructions of switch. Temporary protection equipment and the bracket for transportation should be removed, and make records for the follow-up inspection and retrospective use. Warning When dismantling on-load tap-changer must use the matching lifting rope If itis required to lift out the switeh core, personnel must not hit the switch in the process of operation. When the switch state is restored, the position state must be restored the state before lifting the cover 45,414 42 424 422 423 424 43 431 43.44 4312 43.13 432 43.24 43.22 43.23 433 4334 433.2 434 4341 4342 435 436 ing Cover Inspection ‘The working area should be clean and tidy, no water, snow, dirt, ete Hoisting cover The hanger may show stress when lifting the tank, the angle between lifting rope and plumb line should not be more than 30°. In order to maintain balance, a lifting beam can be used to avoid collision accident between the tank wall and other equipment. After lifting the upper part of the tank, the equipment should be settled on the flat wagon or wooden boards, to prevent the box edge from becoming directly in contact with the ground to cause pollution, and will make it easier to reassembling transformer after inspection. ‘After lifting the upper part of the tank and ventilating for 15 minutes, personnel should start to inspect the upper oil-tank. Ladders and other items used for inspection of active part can't be secured by wires, insulation and lead holders. It is prohibited to climb scaffold and leads. All parts on the worked on equipment should be fixed firmly and have not any displacement. Inspection items Core Check whether there is deformation of core, and whether insulation of iron yoke and clip pieces are in good condition. Check whether core is multi-point grounded. Check whether grounding wire of the core leads to the outside of the transformer. Winding Check whether the winding insulation is in good condition and if it has any anomalies from damage, loss and displacement. Check whether all winding circles are in a straight line, and have same clearance, personnel should also check whether there are any foreign bodies in oll passage. Check whether nails and locknut on the winding are tightened. Leads Check whether the lead insulation is wrapped firmly and has no damage and bending, exposed parts of lead have no burr and acute angles. Check whether leads, tanks and coils have appropriate insulation distance and are mounted correctly. Whether the supports of the fixed wire is strong and reliable. f wood pieces have abnormalities or loose, check weather detachment and deformation has occurred, if wire clamping and binding is strong and neat. Switch After lifting the upper part of the tank , personnel should carefully check the switch, including whether tap position is correct and contacts are in good condition, The specific inspection procedure is as follows. Check winether every tap of on-load tap-changer is connected with the coil correctly and firmly, whether dynamic contact park on the right gear and the gear transmission rod, gear and the pin of switching device are intact. Check whether the selector or diverter switch in switching device of on-load tap- changer are in good connection, whether taps are connected correctly and firmly, whether switching device of switch is properly sealed. if necessary, personnel can remove the core of tap-changer for inspection Check whether all bolts are tightened, and take effective measures to prevent the loose. Besides, surface of insulation bolt should not be damaged. Check whether all impurities (including nonmetal material) of the tank bottom have been thoroughly cleaned. Use qualified transformer cil to clean tank when necessary. 464 ing Cover Inspection 43.7 Check whether magnetic shielding of oil tank is loose, detached and rusted, et. 44 Testafter inspe ive part 44.1 Disconnect grounding line of core, and then test resistance of core to the ground, resistance 2200 MA (2500 V megohm mete 442. Check the ground screen of core column and side column (if any). 443 Insulation resistance between test clip pieces and core as well as between clip pieces and oil tank 444 fits found there is water or moisture in oil tank, the tank should be inspected to find out damp parts for processing, insulation of all or part of the active equipment should be tested, test items include insulation resistance, leakage current and dielectric loss. 4.5 Recover the upper oil-tank [After inspection and testing of the equipment, the upper oll-tank can be installed. Firstly personnel should clear the sealing stip of upper and bottom part of tank. Slowly close the cil tank, and screw down the bolt equably along the box edge, requirements for tightening should comply with “104 Assembly of Metal Fastener’ ion of ac 46 Processing after inspection After checking the hoisting cover, the transformer should be sealed again, Vacuum and leak detection for the housing must be carried on at the same time, finally it should be stored according to "202 Storage of Transformer’. 46.1 After starting vacuuming, for the transformer which can endure full-vacuum, leak detection should be conducted according to the following method: Until 2 hours after the vacuum degree reaches below 133 Pa or a stable vacuum value, then shut down the vacuum pump and seal the transformer. The vacuum inside transformer is detected with vacuum gauge until the vacuum value varies to a stable value, and the rise pressure value measured within 30 minutes should be less than 0.2 kPa/h 46.2 _ If the leakage detection is sufficient, open the vacuum pump to continue vacuuming. When the vacuum degree is less than 133 Pa, start calculating vacuum time. Vacuuming time and vacuum degree can be found in the table 2. During vacuuming, engineers should continuously observe whether the oil tank becomes deformed. Table 2 Vacuum Degree and Timetable Voltage level (kV) Vacuum (absolute value) ‘Vacuum duration time(h) Below 110 kV 0.05MPa a 110 oF above Below 133 Pa 224 Caution Failures and defects found during inspection of active part should be solved correct, and recorded in. “Inspection Record for Active Part” 4748.eTe Transformer Installation and Test24 aaa 212 213 214 22 224 222 223 34 32 321 3.22 323 324 Preparing before Installation Scope of application This chapter provide guidance for preparing work before on-site installation of the transformer. Quality and safety guide Quality guidelines Related factory documents, data, and drawings should be conveniently placed to consult at any time. Preparations must be recorded on “Installation Record Form” Operations should strictly comply with this chapter to ensure product quality If personnel find abnormalities in the mounting process, they must immediately report to a CHINT after-sales engineers. Safety guide On-site construction must follow safety guide of CHINT and local regulations. Installation should comply with the principle of “safety first’, to prevent personnel from endangering personal safety. When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments or transformers caused by incorrect operation. In bad weather, personnel should provide protection to on-site vacuum equipment, oil-flter equipment, storage tanks, ete, Technical guidelines In the process of transformer instalation, air contact between transformer active part, and outside air is inevitable, but personnel should try to shorten the exposure time in order to prevent the transformer become damp. Therefore, engineers should prepare fully before installation, and take effective measures to prevent the pollution of transformer interior in the installation process Formulation of stallation plan Before starting operation, the CHINT service engineer should formulate and confirm integral installation plan together with the head on site, including the specific step as well as all resources which needs to be used. Plan can be adjusted during installation, to ensure the installation progress meet the actual situation of the scene. Preparing before installation Installation team should have qualification of transformer installation approved by authority Clear objects and people that have nothing to do with operation field, to guarantee there is plenty of space for hoisting equipment and climbing equipment, etc. All personnel who participate in installation must ensure good mental state before mounting guard, wear overalls, helmets, safety belts and other protective equipment correctly, overalls must be cleaned with no foreign body. All equipment for installation of the date must be ready, such as crane, climbing equipment, vacuumizing facility, oil fiter, all kinds of fastening tools, compress air generator, all kinds of test equipment, etc, and they must be debugged to be available. Check whether the power of the apparatus is sufficient and the phase sequence is correct. Check whether the compressed air generator (for pneumatic tools) is working properly and the length of the pipeline is suitable. 49 and Test 301 Preparing before Installation325 3.26 33 331 332 and Test 301 Preparing before Installation The installation of the transformer components for installation of the date should be unpacked, counted, inspected, cleaned, repaired with paint and other preparatory work, and be placed in place for convenient access. The packing cases with bushing should only be opened before the installation of bushing, After installation, for the parts or components is inconvenient, engineers should complete touch-up paint before installation. Touch-up paint should comply with “107 The Use and Touch-up of Paint” According to the design requirements, when some transformer components should be installed on the object outside of the transformer, engineers should confirm whether the support structure of this object can bear the weight of components and is suitable for installation. For instance, the conservator is required to be installed on ‘the solid wall General sequence of installation In order to reduce the possibility of damping for transformer, generally install external components at first, namely the components can be installed without vacuum breaking, then install components need to break the vacuum. To break the vacuum installation: - Ifthe transformer body has oil, and oil level covered all insulation parts, the transformer can be installed directly, and apply a vacuum to the parts above oil level after the end of the working day. - If there is no oil in transformer housing, engineers should continuously fill ry air(dew point is below -40°C) from a valve of central tank; protection should be done well during instalation, reduce moisture absorption of transformer to the limit. After daily operation, engineers should apply a vacuum or fill oil by vacuuming the housing Bushing installation should as far as possible be conducted after installation of in large- size and heavy accessories, in order to prevent damage caused by bump. Warning If transformer is transported with nitrogen filing or is pressurized with nitrogen and if the internal environment has not been tested to confirm its safety. It is strictly prohibited to enter cil tank for any personnel directly from the manhole or other flange holes, engineers should also avoid inhaling gases in the transformer. 50and Test 301 Preparing before Installation 3.4 Commonly used related equipment and tools, as shown in table 1. Table 1 Main equipment and tools Project Number Name Number Pre-control measures 1 Crane “bracket | Match according to the product. Hoisting equipment 2 Hoist crane set | TYon~3 tons 2 groups, Stone 2 grouns Performance requirements: i ler ability, 3 High vacuum teat | 6000 Uh, velocity is contollabl; Vacuum pump oilfiter Set capacity <50 pa; Outlet temperature ofthe heater (e585) "C Vacuumising fai set | Performance requirements: vacuum speed?600 Lis ‘ we fclty Tse emate vacuum Below 5 Pa. Equipment fro filing 5 Mee mete umidty | TPiece | Measurement of air humidity RH 0-100 (6) lose or tu set, US6or connecting flange when in vacuuming 0 ® Hose ortube Tset peat the valve size It is uses to connect to the flange when fling ol 7 Hose or tube 158 shoul be matched accoraing to valve sie Climbing apparatus 8 Ladder ‘rackets | 118 S meters high, 1 i 3 meters high Fire equipment 8 Fire extinguisher Proper. | Use in the case of accident. Proper. | Use fr leaning surface of transformer and 10 | Gleanwhite cotton | Smut | sub-assemibles Waterproof amas | Proper 11 | Wiserproctcamas | Proper | Use for cover components and tools. Tools to keep cleaning cease cotton Proper | Use for cleaning surface of transformer ” aad amount | and sub-assemblies, Rain plastic or Proper 3 ain plastic Proper | Use winen enter the transformer internal 14 | Rubbershoes with | Proper, | performance requirements: prevent sppery. 1s Fastening too! act | Us forinsaltin ofthe tensormer and Common tools component 16 | Adjustable wrench | 1set__|_ Size range: MB-W48. wv Fleshlight A pieces | Two for large, two for small 51301 Preparing before Installation Project Nomber Name Nenber Precomrol manrares 18 | Torquewench | tset_ | Sierange: M-M24 Common tools 8 Rlonrope | sstings | BEMMZIM 20 | Fleandsand paper | ROPE. | Use for grnding 2 write coth bet Proper 22 | nsuaion crepe paper | POPE. | Used after drying 23 | Insulating paperboard | PrOPer | Drying Consumables 2 08 2kg | Used for clearing up the container 25 | Hnhpuriyitogon | Sofood) treqites 2 rsh 2sat_| Use turing touch-up paints 2” tier teat | Used for secondary wring, Test apparatus 2a | Pemwiraintumest | saat | ay. 2» Moooee test | 2s00v/escome 5224 aaa 213 214 22 224 222 223 3a B41 a) b) ° 312 3.13 32 3.21 3.22 33 331 33.2 333 Installation of Cooling System Scope of application ‘This chapter provides installation guidance for cooling system of transformer. Quality and safety guide Quality g Related factory documents, data, and drawings should be conveniently placed to consult at any time The installation process must be recorded on the “Installation Record Form of Transformer’ Operations should strictly comply with this chapter to ensure product quality If personnel find abnormalities in the mounting process, they must immediately report to a CHINT after-sales engineers. Safety guide On-site construction must follow safety guide of CHINT and local regulations. Installation should comply with the principle of “safety first’, to prevent personnel from endangering personal safety. When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments or transformers ‘caused by incorrect operation. In bad weather, personnel should provide protection to on-site vacuum equipment, oil-filter equipment, storage tanks, etc. Technical guidelines Transformer cooling system generally has the following three categories. Plate radiator ‘There are three kinds of plate radiator as follows: For individual use is Oil Natural Air Natural (ONAN); For incteased fan is oil-immersed forced-air-cooled (ONAF); For increased fan and oil pump is forced oil-circulated air-cooled (OFAF) or forced oil-circulated guided air-cooled (ODAF). Unless special design requirements, usually the radiator should be installed vertically. The radiator can be directly installed on the transformer tank (ONAN, ONAF), of installed on the return pipe of transformer (ONAN, ONAF, OFAF or ODA). Forced oil-circulated air-cooler In general, a set of forced oil-circulated air-cooler (OFAF/ODAF) should be equipped with fan and pump. if not, before installing the cooler, engineers should install the fan and oil pump. Forced oll-circulated ait-cooler can be installed vertically or horizontally. Generally it is installed on the return pipe or independent framework. Water cooler In general, water cooler (OFWF/ODWF) should be equipped with oil pump. Water cooler can be installed vertically or horizontally, generally itis installed on the return pipe or independent framework Water circulation loop and oil circulation loop of water cooler were independent to each other. Water in the water cooler should be provided by external devices. Overview 53 cr 302 Installation of Cooling Systemcr 302 Installation of Cooling System During transportation and storage, radiator, cooler, return pipe, trachea flange and oil pump are all sealed with sealing plate, and butterfly valve on tank wall is closed and sealed. Only before installing component, the flange plate and the sealing device can be dismantled, but the butterfly valve should be kept closed during installation of the cooling system. Caution Before the demolition of sea plate, engineers should place oll drum under the flange, collect the remained oil outflow inthe process of dismantling to avoid environmental potion 414 41S 42 424 422 a) ») 9 423 424 425 43 Before and after the demolition of sealing device, mounting surface and nearby area should be cleaned, in order to prevent the adhesive dust and pollutants entering into the transformer body. After the seal is removed, the piping and components internal must be visually inspected and cleaned if necessary. The device equipped with lifting point can be lifted and moved directly using lifting point. Ifthe lifting point is not available, operation should be conducted according to ‘the general rules of lifting and handling, Stacked radiation fin should use crane to lift top-down and horizontally on by on, then flat on the ground for standby. The installation of all components must comply with CHINT drawings. In general, engineers should install according to the serial number of radiator. In the process of assembly, personnel shall use new gasket Preparation before installation (Open the packing cases related to instalation. After installation, for the parts or components is inconvenient, engineers should complete touch-up paint before installation, Touch-up paint should comply with “107 The Use and Touch-up of Paint” Materials and tools Prepare a set of general assembly drawings. If the radiator is installed on the return pipe or independent framework, engineers should prepare the correct drawings for the return pipe or independent frame; Prepare components handling tools such as hydraulic car and lifting rope is suitable for lifting components Prepare bolt, nut, gasket and all required components. Parts marked in drawings should be sorted and centrally placed at the convenient place, such as stents, return pipe, valve, oil flow relay, oil pump, fan, ete If oil filing accessories such as radiator and oil tube have been rinsed before delivery, and they are in good seal and have no rust, rain and dirt after arriving at the scene, there is no need for cleaning at the scene. Before installation should check the cleaning situation, if necessary, use qualified transformer oil to cleaning circularly. Before the flange cover on and/or under the radiator is removed, the oil stain and dust in the flange and nearby areas should be cleaned. When the radiator need sealing test, personnel can do pressure test at 0.01 MPa ~ 0.03 MPa, test should last for 3h and no signs of leakage. The installation of cooling system on the transformer According to the design of transformer, the radiator can be directly installed on the oil tank or return pipe. 54434 4344 43nd 43.13 Aad 43.15 432 43.21 43.22 44 aad 442 443 aaa 4s 454 42 Assembly of radiator on the oil tank. Before installation of the first set of radiator, engineers should firstly dismantle the cover plate of radiator, and then dismantle the cover plate of corresponding valve on the transformer, remove the original gasket, clean the flange surface and replace new gasket Use the crane lifting from the lug at the top of radiator, be careful to connect the upper and lower flange of radiator with corresponding valve flange of transformer, prevent any bump against plate radiator. When the radiator docking with the transformer to the appropriate location, ‘engineers should maintain the same position. Then install and use a wrench to fasten symmetrically and evenly. Fastening operations should comply with "104 Assembly of Metal Fastener’ Repeat operations according to the assembly requirements of the first set of radiator, Until installation of the last set is completed After installation of all radiator, install stiffener according to the drawings. Then adjust radiator spacing according to the marked size in assembly drawings Assembly of radiator installed on the retum pipe According to the drawings, install return pipe bracket, return pipe, oil pump and oil flow relay in turn. Installation of oll pump and oil flow relay are operated according to *306 Installation of Protection Equipment’ 4.2 and 4.3. Before installing oil flow relay, according to the direction of oll flow, confirm whether the installation direction of oil flow relay is correct. When installing return pipe, it is suggested to install underside firstly, then install the upper side After installation of return pipe, check whether the position of radiator flange is correct according to the drawings. Installation of radiator on the return pipe should comply with this chapter 4.3.1 Installation of radiator on the independent framework ‘Check whether the height of independent framework are consistent with foundation of transformer oil tank, Personnel must use spacer to adjust height to the drawing requirements according to the actual situation of the foundation on site. According to the drawings, install frame, bracket, return pipe, oil pump and oil flow relay in turn. Installation of oil pump and oil flow relay ate operated according to "306 Installation of Protection Equipment” 4.2 and 4.3. Before installing oil flow relay, according to the direction of oil flow, confirm whether the installation direction of oil flow relay is correct. When installing return pipe, itis suggested to install underside firstly, then install the upper side. After installation of return pipe, check whether the position of radiator flange is correct according to the drawings. Oil tube between the transformer and the cooling a corrugated pipe. Corrugated pipe should be properly installed to give natural no-stress state. Then tighten the cooler framework foundation bolt, clamping bolts of return pipe and pipe joints. Installation of radiator on the return pipe refers to this chapter 43.1 Installation of fan Before installation, personnel should check whether connection with each part of fan is loose, whether the blade end is distorted and deformed, whether the clearance with the air duct is even, otherwise should adjust the blade position, Leaf blade should be installed and fastened and easy to be turned, According to the drawings, fix the fan to the fan bracket of radiator. Mark such as arrow for rotation direction of fan blade and nameplate should be unified outwards, for easy viewing, 55 cr 302 Installation of Cooling System453 4, A 302 Installation of Cooling System ‘After installing fan, install the junction box and wiring, personnel should pay attention to ensure that the three-phase wiring sequence must be correct. Otherwise the blower might not rotate or might rotate reverse. After wiring is completed, engineers should seal junction box, in order to prevent the leakage of water from the junction box to ‘cause short circuit of motor, ‘Afterall installations are completed, enginners should conduct tral running itcan be used formally after running is normal. During test run, blade and motor engineers should not have violent vibration or overheating, the turning of the blade should be correct. 56303 24 244 242 243 2a 22 22.1 222 223 SIUC Installation of Oil Conservator ‘Scope of application This chapter provides guidance for installing oil conservator to transformer, Quality and safety guide Quality guidelines Related factory documents, data, and drawings should be conveniently placed to consult at any time. ‘The installation process must be recorded on the “Installation Record Form of Transformer’. Operations should strictly comply with this chapter to ensure product quality. If personnel find abnormalities in the mounting process, they must immediately report to a CHINT after-sales engineers. Safety guide On-site construction must follow safety guide of CHINT and local regulations. Installation should comply with the principle of “safety first’, to prevent personnel from endangering personal safety. When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments or transformers caused by incorrect operation. In bad weather, personnel should provide protection to on-site vacuum equipment, oil-fter equipment, storage tanks, etc Technical g For a transformer equipped with an oil conservator, the conservator is equivalent to an expander, which can carry the change of oil volume caused by the transformer load and the external ambient temperature change. ‘Common conservator mainly has two forms: the capsule oil conservator and conugated oil conservator. Caution For corrugated oil conservator, before on-site installation personnel must inspect according to the requirements in installation and operation instruction of corrugated oil conservator, corrugated oil conservator must be in state of pressing 3.1. Corrugated external oil conservator Theil danber —_Corugtd pe subsenby exhasgot up terial tr / lier | — seat pot as ay i ing pot Connected tanto Congatd ele comeing pipe Figure 1 87 Carlecr ELM Carle 3.1.1 Structure diagram of corrugated external oil conservator is shown in figure 1 3.12 After corrugated external oil conservator arriving at the scene, engineers should check ‘when the oil level indicator indicate the transportation position. If not, shows that the corrugated core body is not in pressing state, so the corrugated core body has possibilty of damage and should report to the CHINT service engineer immediately. 3.13 Before installing conservator, engineers should fully spread the compressed comugated core body and operate according to the following two methods. Method 1: Open the gas outlet pipe and breathing pipe. Fill the breathing pipe with nitrogen gas to expand the corrugation. Method 2: Open the breathing pipe, vacuuming from the gas outlet pipe or main tracheal to spread the ripples. Observe oil level windows in the process of gassing or vacuuming, «il level should be constantly decreases, and stop gassing or vacuuming when the cil level is close to 0. 3.14 Corrugated external oil conservator can not adopt vacuuming method to fil ll (except for special structure), engineers should adopt method of gas outlet. Method of gas outlet mainly has the following two ways. Method 1: Firstly set the oil level, then fill cil. Before installing oil conservator, use gas filing or vacuuming method (same as 3.1.3) to set the oil level at the required scale, then lose valve of breathing pipe. Keep the gas outlet pipe in open state when filing oil Personnel should immediately close the gas outlet pipe when there is oil coming ‘out Finally, open the breathing pipe; Method 2: Firstly fil ol, then set oil level. After installing conservator to the transformer, when filling cil, close the valve of breathing pipe, open the exhaust valve. When the gas outlet pipe emitting ol, immediately close the gas outlet pipe, stop filing and open the valve of breathing pipe. At this time ifthe oil level is greater than the standard oil level, then open fill/train pipe to drain cil to standard coil level. Ifthe oil level is less than the standard oll level fill oil to standard oil level from fil/drain pipe 3.2 Corrugated internal oil conservator Ayana AP Figure 2 S + | Lal) / AR ean, ||) tons oat oe Burret LI /snctsse Aaa ne tot t/a stein 583.24 322 3.23 3.24 33 331 cr ELM Working principle The structure diagram of corrugated intemal oil conservator is shown in figure 2. Transformer oil is filled in corrugated core body, corrugated core body rises or falls, in vertical direction along with the variety of oil volume, gas at the outside of corrugation connects with atmosphere. Corrugated internal oil conservator can be vacuum and filled oil together with transformer body. In run time, exhaust and injection tubing should be always closed. Corrugated internal oil conservator has been vacuumed before delivery. Corrugated core body is pressed completely during transportation. After arriving at the scene, engineers should check whether the corrugation is in pressing state. If the oil level pointer is higher than the lower limit of oil level, namely corrugation has released vacuum, there is the possibility of damage, engineers should immediately report to the CHINT after-sales engineers. When corrugated internal oil conservator supplying oil by method of gas outlet, engineers should open gas outlet pipe, fill oil while exhausting. When the gas outlet pipe stably flows out transformer oil, close the vent valve. According to the location Of oll level in the conservator, for higher or lower oil level indicator, engineers should adjust the oil level to standard oil level by adding oil or discharge oil through fill/drain tube. When corrugated intemal oil conservator adopting vacuum to fill oil, specific operation should comply with "308 Transformer Vacuum Oil-filling” Capsule oil conservator ‘The product isa fully sealed soft airbag oil conservator. Its working principle is installing cil resistant rubber capsule in the shell of conservator, intra capsular contact with the atmosphere via the breathing pipe and moisture absorption, extra capsular contact with transformer oil. When expansion or contraction of ol in transformer cause rising or falling of oil level in conservator, the capsule acts as respiration to exhaust or inhale to balance pressure inside and outside air bag, to completely separate transformer with air effectively prevent the aging of transformer ol Capsule oil conservator adopt oil gauge with magnetic pointer to indicate the oil level. When the oil level reaches the highest or lowest position, the oil level gauge can alarm timely and accurately, QQAQQ Q > aosion OA re Figure 4 1. Hanger 8, Deposit box 2. Capsule 9, Bracket 3.Pipe joint of moisture absorption 10. Floating ball 4. Ar exhauster 11. Joint of buchholz relay pipe 5. ent plug (or gas outlet pipe) _—12.Joint of fil/drain oll pipe 6 Oil conservator shell 13, Moisture absorption 7. Magnetic oil gauge: 59 Carle332 333 4a 444 442 a) b) o 4) 44a 42 ar EDM USCC Carle Supply oil by exhausting for oil conservator When filling oil into capsule conservator by method of gas outlet, engineers should ‘open the valve of breathing pipe and open the gas outlet pipe valve or vent plug, fill oi and exhaust. When the exhaust flow or vent plug stability flowing out transformer oil, close the gas outlet pipe or vent plug. Then open the breathing pipe, according to the oil level of conservator, adjust oil level to standard cil level by supplying oll or draining oil through fil/drain il pipe. ‘When capsule oil conservator adopts vacuum oil filing, specific methods refers to "308 ‘Transformer Vacuum Oil-filing*. Technological process Preparations Flanges of oil conservator and trachea have been sealed before delivery and engineers ‘an only remove the sealing of the device before installation, and should avoid internal contamination, Materials and tools Prepare a set of oil conservators and assembly drawings of relevant trachea and equipment Prepare lifting and moving lifting rope for related parts; Prepare all the necessary components such as bolts, nuts, gaskets and so on ; Items involved in assembly drawings or connecting trachea drawings should be put in the place for convenient access, such as brackets, connecting trachea, valve, body buchholz relay, on-load tap-changer, etc. Before installing the oil conservator on the transformer. Engineers should install parts such as oil level gauge, the breathing pipe, gas outlet pipe on conservator, and check whether there is any abnormalities on capsule or corrugated core body at the same time. Capsule of capsule oil conservator has been installed in the oll conservator before delivery. When installing oil level gauge for body of capsule oil conservator, rod of oil level gauge must be parallel with the axis direction of the conservator Finaly, parts for touch-up paint should comply with "107 The Use and Touch-up of Paint Installation of bracket for oil conservator Install the bracket of the oil conservator strictly according to the drawing, Caution If the oil conservator is installed on the bracket provided by the users, tengineers should confirm thatthe bracket matched with the oll conservator contact, and canwithstand the weight of cil conservator and cl 6043 434 432 433 a) b) 9 a 434 435 44 a) b) ° 4 2) ar EDM USCC il conservator and connecting pipe Use appropriate lifting rope and crane to lift oil conservator on the scaffold. When the device is equipped with lifting lugs, engineers must use the lifting lug for lifting, ‘When required to install a flange, engineers should remove the seal plate at first, remove the original gasket, clean the flange face, replace the old gasket with a new gasket. Before assembly, visually check whether the intemal wall of the pipeline has impurities or stains, lean up when necessary. Install components according to the order of drawings and labels on connecting trachea labels, these generally include: Fill/drain oil pipe and valves, Main connecting trachea, valve and body buchholz relay through oil conservator to body; Connecting trachea, valve and buchholz relay of body from on-load tap-changer cil chamber to conservator for OLTC Master trachea lead to branch trachea of ascending flanged base. Body buchholz relay and switch buchholz relay must be installed correctly according to drawings. Arrow to indicate correct installation direction is marked on the shell of buchholz relay. Relay must be installed and connected according to the operation instructions of equipment and the drawings of secondary line, After installation of oll conservator and connecting trachea, fasten again according to "104 Assembly of Metal Fastener’, and finally remove the identification tag. Checks after installation and debugging After installing oil conservator and before filling oil, engineers should check the following items: ‘Check whether all bolts, nuts are fastened appropriately. Check whether the gasket is in good state; Check whether al valves are easy to rotate; ‘Check whether installation direction of body buchholz relay or switch buchholz relay is correct, Check that the shut-off valve installation direction is correct. 6 Carle304 Installation of Ascending Flanged Base 304 Installation of Ascending Flanged Base 1 24 24a 213 214 22 224 222 223 4a a) b) o 4) °) Scope of application This chapter provide guidance to install the transformer ascending flanged base on site Quality and safety guide Quality guidelines Related factory documents, data, and drawings should be conveniently placed to consult at any time. The installation process must be recorded on the “Installation Record Form of Transformer’ Operations should strictly comply with this chapter to ensure product quality. If personnel find abnormalities in the mounting process, they must immediately report to a CHINT after-sales engineers. Safety guide On-site construction must follow safety guide of CHINT and local regulations. Installation should comply with the principle of “safety first’, to prevent personnel from endangering personal safety. ‘When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments or transformers caused by incorrect operation. In bad weather, personnel should provide protection to on- site vacuum equipment, oil-filter equipment, storage tanks, etc, Technical guidelines Ascending flanged base of transformer is used to support the bushing and current transformer, and generally has a manhole used to examine and operate bushing and lead. Process flow Before installing ascending flanged base, engineers should prepare for installation according to "301 Preparation before Installation’. Ensure that all equipment are out of the box and have completed the operation of inspection and touch-up paint, Environmental conditions When installing ascending flanged base, because it need to open the flange at the top oF side of transformer oil tank, in order to prevent damp of internal, environment should satisfy the following conditions: Clear weather during the day Air relative humidity is not more than 75%; The environment temperature is not lower than 0 °C, temperature inside transformer body is at least 5 °C higher than the ambient temperature ; Wind speed is less than 4; No possibility of weather change such as rain, snow, fog, sand, ete. Caution In case of sudden change of weather, engineers should immediately stop the operations, quickly seal the tank, and fill dry air or nitrogen til postive pressureis 5 kPa ~ 10 kPa. When having no condition of filling gas, engineers should vacuum to below 133Pa, 2Caution If lis not filed into the transformer body when instaling an ascending flanged base. Moisture proofing measures must be taken in order to avoid the ‘environmental humid air entering th inside of transformer active parts, In order to ensure thatthe transformer active partis not be affected with damp, {ill transformer oll into tank to submerge active part before installation or ‘continue to fil dry ai 42 Materials and tools a) Prepare a set of assembly drawings; b) Prepare lifting and moving lifting rope for related parts; Prepare all the necessary components such as bolt, nut, gasket and so on ; d) Put the required parts centrally in a convenient place according to the assembly drawings and ascending flanged base drawings. Check whether all parts are in accordance with drawings provided by CHINT. 43 Installation of ascending flanged base 43.1. Installation of conventional ascending flanged base Caution The installing sequence of the ascending langed base is unlimited, based Upon the principle of convenience. Engineer should install one by one. 43.1.1. Firstly open a flange sealing plate of oil tank corresponding to ascending flanged base, demolish protection insulation of lead , and check whether the original insulated of lead is intact. Any damage should be handled by CHINT after-sales engineers. 43.12. Then demolish flange sealing plate at the bottom of ascending flanged base, clean flange surface, flange sealing plate at the top of ascending flanged base can only be opened before assembling bushing, 43.1.3 Rise of lifting and moving of ascending flanged base should use tools to lift. Weight of each ascending flanged base may be different, special attention should be paid when lifting, 43.14 For the ascending flanged base installed vertically, can directly use two lifting lugs at the top of ascending flanged base to lift. For ascending flanged base installed gradient, according to the inclination angle, use three lifting ropes to lft ascending flanged base, ‘wo lifting ropes connect to the lug, the third lifting rope is bound to the side wall of ascending flanged base. Engineers should ensure the bottom flange surface of ascending flanged base after lifting parallels to the flange surface of oil tank. 43.1.5 After lifting ascending flanged base to the top of oil tank, engineers should smooth and straight the lead following winding direction of the lead, ensure that lead is not twisted into a knot. Caution When installing, prevent any object falling inside the tank. If objects falling, immediately report CHINT after-sales engineers 6 304 Installation of Ascending Flanged Base43.16 4347 43.18 43.19 432 43.21 43.22 43.23 43.24 43.25 43.26 are 304 Installation of Ascending Flanged Base ‘When elevated located falls to about 50 mm away from flange surface of oil tank, according to the position of grounding screw hole of ascending flanged base tog judge installation position and angle of each ascending fianged base. Then use positioning rod to insert it into the bolt hole corresponding to flange of oil tank through flange bolt hole of ascending flanged base. For the tilt mounted ascending flanged base, positioning rods should better be inserted in bolt hole at the top of flange bolt hole. Continue to drop ascending flanged base , using another location bar to help it align the flange holes. ‘When the flange closed, mount bolts, fastening operations should comply with the "104 Assembly of Metal Fastener” ‘After ascending flanged base docking with the fuel tank, open flange sealing plate of connecting trachea corresponding to ascending flanged base to docking pipe flanges. Sealing plate at the top of ascending flanged base can only be opened before assembling bushing, ‘According to the installation steps of the first ascending flanged base, engineers should complete the installation of other ascending flanged base. After installing all ascending flanged bases, should remove the labels. Installation of indirect ascending flanged base Indirect ascending flanged base should be installed under the guidance of CHINT service engineers, In general, high voltage ascending flanged base of transformer with 330KV or above is indirect structure of central tank outlet. This ascending flanged base requires transportation with oil filing. Therefore, after arriving at the scene, engineers should get the oil sample and ‘esti itis qualified, it shows that the insulating part in the ascending flanged base has not damped, and the oil in the ascending flanged base can be directly filled into the transformer, If itis not qualified, the oi in the ascending flanges base should be fitered again, and can be filed into the transformer until qualified. According to the analysis result of oil sample, engineers should determine whether the insulation parts need special teatment. Before installing indirect ascending flanged base, engineers should check whether the oil level in transformer is under the flange hole of ascending flanged base, Open a flange sealing plate at the both sides of ascending flanged base, replace the black screw of fixed wood with bakelite screw. Then inspect whether the shielded wire at the head of shielded tube is at connecting state and whether the connection should be relieved. Before lifting, engineers should firstly check whether the lug on ascending flanged base lug is in good state, then connect the wire to lug. Flange surface at the bottom of ascending flanged base should be parallel to the flange surface of oil tank. If the inclined angle is too large, need to adjust it. Open the corresponding flange sealing plate of oll tank, and dismantled protective insulation of lead terminal, After lifting ascending flanged base to its flange near the tank flange about 100 mm. Connect the lead terminals. Firstly, half fold 45 semi- conductor package paper for 2 layers, then pack it with crepe paper according to the ‘thickness of insulation layer required in drawing. If the drawing has no requirements, the thickness of insulation layer should be controlled in the range of 2 mm~4 mm. ‘After wrapping, engineer should check whether there are foreign bodies in the ascending flanged base, if not, engineers should close the flange, mount bolts and tighten the flange Installation personnel close to the shield pipe from the top of ascending flanged base, and should connect shielded wire to the shield pipe, then install upper part of elevated section (with CD). 644327 43.28 304 Installation of Ascending Flanged Base ‘According to the installation steps of the first ascending flanged base, complete the installation of all other ascending flanged bases. After installing all ascending flanged bases, engineers should remove the labels During installation of bushing, when the distance from bushing flange to flange is about 300 mm, an operator may need to enter into ascending flanged base from the manhole of the ascending flanged base. The engineer then holds the end of bushing to make it enter into the shield pipe, and properly adjusts shield pipe to ensure that the terminal of shield pipe is in the center of ascending flanged base. Bias is within 15 mm in porcelain set tail of bushing, upper edge of live part should enter the shield pipe for at least 30 mm. Tighten wood nuts after adjustment. Caution Indirect ascending flanged base need independent hot oil circulation, operation should comply with 4.2 of "309 Hot-ol Circulation’ After installation.engineers should check whether there is anything left in the ascending flanged base. 6524 24a 213 214 22 224 222 223 32 324 3.22 33 34 35 cr 305 Installation of Bus Installation of Bushing Scope of application This chapter provides installation guidance for transformer bushing on site. Quality and safety guide Quality guidelines Related factory documents, data, and drawings should be conveniently placed to consult at any time. The installation process must be recorded on the “Installation Record Form of Transformer’ Operations should strictly comply with this chapter to ensure product quality. If personnel find abnormalities in the mounting process, they must immediately report to a CHINT after-sales engineers. Safety guide On-site construction must follow safety guide of CHINT and local regulations. Installation should comply with the principle of “safety first” , to prevent personnel from endangering personal safety. ‘When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments or transformers caused by incorrect operation. n bad weather, personnel should provide protection to on- site vacuum equipment, ol-fiter equipment, storage tanks, et Technical guidelines The bushing box can only be opened before the installation of the bushings. Check whether there is sign of cracks and damage at the surface of porcelain bushing, and clean the flange surface and intemal and extemal of the equalizing goal. Check whether oil level indicator of bushing is normal, and there is no leakage of oil conservator. After installation of bushing wearing cable, lead with different structure should be checked according to the following requirements. For the lead with structure of stress cone, the thick point of cone structure of lead wire should be located at the outside of equalizing goal, the finest point should enter into the bushing pipe. But with the space which should be left enough between fuses and catheter of bushing, engineers should not allow excessive conical structure of fuses to block up bushing, and should not allow the finest part of fuses exposed outside the catheter of bushing. For lead with wire out of shield pipe, shield pipe should enter the equalizing goal for more than 20 mm, and is located in right center of equalizing goal. Spacing between shield pipe and bushing should be more than 10mm, Special note: Shield pipe is not allowed to close to the equalizing goal, is not allowed to withstand the bottom of bushing, and lead should not be tightened or knotted. To bushing with guide rod, connect lead and guide rod with bolt, tighten all bolts evenly, correctly install equalizing goal Oil level indicator of bushing should be toward the direction is convenient for observing «il level of bushing The test terminal of bushing should be reliably grounded. 66at add aaa 4tat cr 305 Installation of Bus Process flow The installation of cable bushing ‘After liting bushing from the bushing box, placed it near the installation site. Firstly pad a large piece of wood on the ground, underlay the head and tail of bushing with a soft sleeper or other soft article, and angled the axis of bushing about 3 * to the ground. As shown in figure 1. Soft seer Figure 1 Bushing accessories such as equalizing goal, general cap, pin, steel ring, screw, nuts should be ready, and after confirming the number, they should be categorized and put into a plastic box or plastic bag for standby. There are four lug holes in the bushing flange. When vertically installing the bushing, Use two opposite lugs; When obliquely installing the bushing, use two adjacent lugs. Choose one §-ton wire rope. The one end should be connected to the shackle; and then make the end hang the shackle to the casing flange lug. Another end is hanged con the hook of the crane, Once the hook is about 1.5m above the ground, Fixing method of bushing Fix by reverse chain Lift head of bushing installed obliquely by reversible chain, in order to adjust the angle in the assembly process, engineer should prepare a piece of wire about 1 meter with rings at two ends. Bound it one circle around the joint between porcelain skirt on the head of bushing and metal part and then set out, as shown in figure 2. Then use hook of reversible chain to hook the wire. The top of the chain should hang on the same crane hook with the one hanged on the rear of bushing, Bushing after lifting is shown in figure 4 Regulating cain Figure 2442 ‘Hook 2-chain 3-Nyon strap. 4 Nylon hommock Casing pipe Ging of casing ine cr 305 Installation of Bus Fix by direct binding Pull the lifting rope to the casing head; and then bind firmly the casing porcelain skirt; binding position should be decided according to the lifting angle of the binding, so ‘that the casing is consistent with the ascending flanged base angle. If it is not consistent, itis required to adjust it. Bind of vertical installed bushing should be directly tied to the junction between head of metal parts and porcelain shed. As shown in figure 3. State after lifting up is shown in figure 5. sing — Bandage Figure 3 Mat soft sponge or cotton with at least 100mm thickness at the end of bushing, start the crane and stand the bushing, ‘When the bushing head is about 2 meters away from the ground, where the traction line of the lead wire goes into the bushing from bushing head and where it exits the bushing out from the tail end. Lead is hung on the hook of bushing by a pulley, and is placed directly on the hook without a pulley. Bind a clean white cloth to the traction rope of lead. Pull the white cloth into bushing by pulling traction rope of lead, wipe the intemal of bushing with white cloth through bushing, until there is no longer any dirt on the white cloth, ‘Wipe bottom of porcelain bushing with a white cloth, until there is no longer any dirt on white cloth, use of alcohol can be used when necessary. Start driving to lft the bushing slowly. When the bottom porcelain of bushing is about 800 mm away from the ground, install the equalizing goal. Lift the bushing above to ascending flanged base. 1.Aylon wtf pullng 2g 3-Cble ord &-Phase ln cable S.Hook Glifanhonack 7Ayon bap. &-apactane cas spe Siting of casing pe Figure 4 Figure 5 68aan 4aa2 443 aaa 4aas 42 424 422 423 EDS CEC TuLT') When bushing bottom is about 600mm away from the ascending flanged base, firstly screw about 10 mm bolt of lead traction rope into screw hole of conductive rod head, then wear conductive rod from the lower catheter of bushing. Then pull the other end of lead, make the lead in torsion, Continue to lower the bushing. When porcelain is set at the bottom of the bushing ‘entering the ascending flanged base, operators should hold the bottom porcelain sets and direct bushing down, During lowering of bushing, engineers should continuously pull traction rope of lead, When the bushing flange will dock with the elevated bridge flange, adjust the angle of bushing, penetrate flange screw of ascending flanged base into fiange screw hole of bushing. Continue lowering down the casing until the casing flange contacts completely with the flange of ascending flanged base. Mount all nuts. Pull out the conductive rod of the lead from the bushing head, according to the requirements of 32, check the matching bushing tail leads. After everything is checked ‘out, remove lead traction rope of lead. Finally, fasten nut of bushing flange, install bushing terminals. Installation of bushing wear rod Before installing the wear rod casing, remove equalizing goal and set it on lead. Lift bushing to ascending flanged base and fix it, binding and lifting of bushing should ‘comply with this chapter 4.1 ‘Connect lead and bushing terminal from hand hole, fasten it according to the request of "104 Assembly of Metal Fastener” Caution Before intemal cutting of hand hole, engineers should firstly bind the fastening ‘wal to the wrist by white cloth to prevent the tools faling into the oil tank. Before connecting, engineets should count the number of screws, nuts and flat pads, in order to check the number after connecting and avoid leaving ‘them in the tank. 4.3 Assembly of other bushings (ther types of bushing should operated according to installation instructions of bushing. Caution After lead lug connected with the guide bar of bushing, too short or too Jong lug shall be handled, Connection piece can not be straightened, the bending degree cannot be too large and drooping, 69213 214 22 224 222 223 32 33 34 aa EUS CCU ma em Mut Installation of Protection Equipment Scope of application This chapter provides guidance for instalation of protection equipment and cooling control system. Quality and safety guide Quality guidelines Related factory documents, data, and drawings should be conveniently placed to consult at any time. The installation process must be recorded on the “Installation Record Form of Transformer’ Operations should strictly comply with this chapter to ensure product quality. If personnel find abnormalities in the mounting process, they must immediately report to a CHINT after-sales engineers. Safety guide On-site construction must follow safety guide of CHINT and local regulations. Installation should comply with the principle of “safety firs’, to prevent personnel from endangering personal safety. ‘When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments or transformers ‘caused by incorrect operation. in bad weather, personnel should provide protection to on-site vacuum equipment, oil-fiter equipment, storage tanks, etc Technical guidelines All transformers are equipped with secondary equipment to ensure its safe operation. ‘According to the customer requirements and design requirements, secondary equipment of each transformer is not the same, some of equipment is fragile and should be carefully operated. Due to the diversity of type for secondary equipment, this chapter only describes the general installation method. Operation of special and more sophisticated models should refer to drawings and equipment specifications provided by CHINT. Installation of gasket should comply with "703 Installation of Gasket’. Fastening of device must comply with "104 Assembly of Metal Fastener*. If there are special requirements for fastening in equipment instruction, follow the instructions. ‘When wiring secondary equipment, all operation related to wiring of cable and equipment should comply with "307 Assembly of Secondary Line’. Technological process Equipment listed in this chapter is common secondary equipment. Other equipment which might be used must be operated according to installation drawings and equipment manuals provided by Chint. Fan Before installing fans, check whether the fan blade can rotate freely by the way of turing with hand. Ifa certain of resistance is found, visually inspect whether there are abnormality of motor bearing, and report to a CHINT service engineer. After inspection and confirming there is no error, according to the drawings, install the fan in the correct, position. Fan motors and terminal boxes usually have open holes which are sealed in transportation, ‘After installation ofthe fans, the seals should be removed 70aed EUS CCU ma em Mut 42 Figure 1 Fan Oil pump When oil pump is transported and stored separately, entrance of both ends should be sealed by sealing plate. il pump should be installed when installing return pipe. When installing the oil pump, firstly check whether the arrow on the motor is consistent with oil flow direction, transformer oil must always return bake to transformer through the lower part of return pipe. Then remove the sealing plate, visually check whether oil pump internal is clean, no rust, dust, water, impurities and other pollutants, and clean it up when necessary. Figure 2 Oil pump nEUS CCU ma em Mut 43 Oil flow relay 44 45 Figure 3 Oil flow relay Before installing the ol flow relay, check whether direction of baffle is correct according to the flow direction of the oil in the cooling pipe. Error of baffle direction should be promptly corrected, this operation must be completed according to equipment specifications provided by oil flow relay manufacture, Then check by the way of tuming the blades. When instaling Con the retum pipe, ensure the rubber gasket sin correct position. Oil level gauge Ifthe oil level gauge was independently packaged, before install oil conservator on the transformer, the oil level gauge should be installed on the oil conservator. Before installing the oil level gauge, check whether the pointer can act correctly according to the instruction. Figure 4 Oil level gauge Buchholz relay The buchholz relay is an important protection device of the transformer. When installing main connecting tube between oil tank and oil conservator, engineers must install the main buchholz relay. Before installation, according to the instructions provided for the buichholz relay, check whether the contact is in correct action Installation position of buchholz relay must refer to the drawings, the arrow on the shell must point to oil conservator ‘When installing, firstly remove the seal plate at two ends, visually check whether the internal of buchholz relay has rust, dust, water, impurities and other pollutants and clean when necessary. ‘When tightening bolts engineers should be cautious and operate according to the ‘equipment manual. f the tightening torque is too large it may cause damage to the buchholz relay. n46 Figure § Buchholz relay Protective relay with on-load tap-changer Protection relay with on-load tap-changer is important protection equipment of transformer. When installing connecting trachea between on-load tap-changer and conservator, install protective relay. Before installation, according to the instruction of protective relay with on-load tap- changer, check whether the contact is in correct action. Installation position of relay with switch protection must refer to drawings. The arrow Con shell must point to oil conservator. When installing firstly remove the seal plate at both ends, visually check whether the internals of the switch protective relay has rust, dust, water, impurities and other pollutants and clean when necessary. Tightening bolts should be cautious and operate according to the equipment manual. If the tightening torque is too large, may cause damage to the relay with switch protection. Figure 6 Protective relay with on-load tap-changer B and Tes 306 Installation of Protection Equipmentaed EUS CCU ma em Mut 47 48 Shut-off valve In general, shut-off valve is installed on the main connecting pipe between cil conservator and buchholz relay of body. When installed on the cooling pipe, shut-off valve and cil pump should be installed in the same oll hose. Before installation, according to the instructions of shut-off valve, check whether the contact isin correct action. The installation position of shut-off valve must refer to the drawings, and arrow on the shell must point to oil conservator. When installing, firstly remove the seal plate at both ends, visually check whether the internal of switch protective relay has rust, dust, water, impurities and other pollutants and clean when necessary. After installation, check whether setting of shut-off valve are correct. Figure 7 Shut-off valve Pressure relief valve Pressure relief valve can be installed horizontally or vertically. According to size and oil amount of transformer, the transformer can be equipped with many pressure relief valves. Caution Pressure relief valve can bear vacuum, engineers should nat be removed when ‘vacuuming. When testing positive pressure, itis required to close buttery valve of pressure relief valve or instal limited tooling to prevent incorrect Special attention should be paid to fasten flange, too much fastening torque may damage the pressure relief valve. Figure 8 Pressure relief valve Figure 9 Pressure relief valve with on-load tap-changer 149 494 492 410 a) b) Bcd 306 Installation of Protection Equipment Control cabinet Control cabinet is generally installed on the body for transportation. And gas outlet hole and respirator is closed. ‘When using the heater in the control cabinet, engineers should open gas outlet holes and wear a respirator and take out the drier. If engineers can not use the heater, then should keep the cupboard door, air vents and respirator closed, and regularly inspect the status of drier silica gel, replace it if necessary Figure 10 Control cabinet ‘Operating mechanism and driving mechanism of on-load tap-changer Operation mechanism and related driving mechanism of on-load tap-changer (drive shaft, gear box, connecting pieces) have been installed and debugged in factory, they only need inspection as follows. Check whether the drive mechanism has collision traces, visual test should be horizontal lat and vertical straight; ‘Check whether on-load tap-changer and gear of control cabinet is consistent. Figure 11 On-load tap-changer 75ai and Tes 306 Installation of Protection Equipment ‘Temperature controller for winding and oil level According to requirements of drawing, dial of temperature controller can be installed inside of control cabinet or directly on the base of tank wall. Temperature controller comprises capillary tube, heat sensitive sensor and dial plate. These components are fragile and must be carefully handled, There are pointers to show the start of cooling system respectively, alarm and trip temperature in the dial. Before installing thermostat, check whether the temperature setting is consistent with drawings, If not set, report CHINT service engineer. Thermostat should not be calibrated on site, unless customers have special requirements. Caution Should not tear pull, squeeze or bend the capillary, engineers should not Use the capillary to pull the temperature controller of oil level ot winding ‘emperature controller. Anz When installing the thermal sensor on the thermometer base, engineers should ccheck whether there are foreign bodies in it. Then fill with suitable transformer oil, ensure the oil level reaches to about 2/3 depth of base after insertion of the sensor. Figure 12 Temperature controller Moisture absorption Moisture absorption device mainly has two types: common and free maintenance. If itis normal type, the cil level in the oil cup at the bottom should be in the right scale. Oil cups cannot be tightened too much, otherwise may cause breather impairment of transformers Installation and connection of maintenance free type are in accordance with equipment specification, 76EUS CCU ma em Mut ai Figure 13 Normal moisture absorption Figure 13 Normal moisture absorption 4.13 On-line monitoring system When customers have special requirements, transformer should configure on-line ‘monitoring system. In most cases, this device is connected to the valve on oil tank through its sensor. Caution Sensors can't bear the vacuum, engineers should be installed after vacuum ‘il-filing of transformer, If the transformer needs vacuuming, engineers must close the valve of instalation sensor at fist, and then dismantle the sensor, Figure 15 Online monitoring device ”306 Installation of Protection Equipment 414 Gas sampler Install the gas collection box according to postion marked in drawing, Reasonably arrange and fix brass between the buchholz relay and gas collection box. Then connect gas collecting ‘tube and sampling valve, finally close sampling valve. Figure 16 Gas sampler 7824 24a 213 214 22 224 222 223 32 a) b) ° 33 331 a) by ° a are EM me Cl mC Assembly of Secondary Line Scope of application This chapter provide guidance to configure the secondary line. Quality and safety guide Quality guidelines Related factory documents, data, and drawings should be conveniently placed to consult at any time. The installation process must be recorded on the “Installation Record Form of Transformer’ Operations should strictly comply with this chapter to ensure product quality. If engineers find abnormality in the mounting process, engineers must immediately report to CHINT after-sales engineers. Safety guide ‘On-site construction must follow safety guide of CHINT and local regulations. Installation should comply with the principle of “safety firs’, to prevent personnel from endangering personal safety. When using equipment or instruments, personnel should comply with the application manual to prevent unnecessary damage to equipment, instruments or transformers caused by incorrect operation. In bad weather, personnel should provide protection to on-site vacuum equipment, cl-fiter equipment, storage tanks, etc Secondary wiring of transformer have been completed in the factory. Large transformer may need splitting equipment during transportation, so need secondary wiring on site. Wiring operation should refer to drawings, auxiliary figures and equipment specifications, and the wiring operators are required to be skilled and can read and understand drawings and charts Cable wiring Cable of the transformer used to connect equipment and control cabinet should comply with the general standard of cable and customer requirements. Generally cable consists of rmulti-strand copper wire and PVC or PRC insulating tube. There are three common types of cable of transformer as below: Standard PVC/PRC cable; Armored cable; Shielded cable Cable wiring Wiring form There may be several types of wiring according to the requirement of the customer: Cable is directly welded to fix on the iron hoop of oil tank and bracket; Cable is arranged in bridge box; Cable is arranged in flexible pipe; Cable is arranged in rigid tube. 79are eS RC CL ine Caution [No matter what form of wiring, it is required to avoid easly damaged area. According to diferent postion of secondary equipment, the cable wiring should have a certain order. After wiring, secondary lines should be arranged neatly and orderly, 332 33.21 3322 34 34d 342 343 344 4a 42 a) b) 9 43 a) Configuration on site General circumstances Usually control cabinets and components are dependent on the transformer, even independent cooling system, its witing should also completely conforms to the requirements of assembly drawings and secondary line drawings. Special circumstances In special circumstances, if the transformer is located in a building, a closed room, or in the underground, some accessories (such as cooling system) may be far away from the ‘transformer. In this case, the cable wiring must be adjusted according to the drawings and the actual situation of the scene. Grounding Grounding of transformer Power transformer commonly has 2~4 earthing terminal located at the diagonal or comers of tank bottom, but only one terminal is grounding Grounding for upper and bottom part of tank The upper and bottom part of tank are bridged by the copper bar. Grounding of accessories Installation of some accessories such as lightning arrester and transformer might also require separate grounding, For other grounding, operation should comply with the drawings and equipment manual Technological process Debugging ‘All materials for witing must be carefully packaging to avoid damage in transportation. Before connection, engineers should carefully check the integrity of cable and terminal, and test the insulation resistance, Check whether the control cabinet is damaged or polluted. Cable is easy to damage, engineers should be careful when handling, can not damage ‘the insulation layer. When cutting a certain size of cable, by all means avoid operation in the water or humidity environment. When arranging cablesengineers should ensure that no moisture enter the control cabinet or junction box, and sealing must be well done after wiring Preparations ‘The following wiring materials should be prepared in advance, materials are required to be in good condition and easy to use: Cable tray box or rigid pipes; Flexible corrugated pipe; Crimping tools for wiring, such as cable clamp, cable joint, labels, waterproof cable connectors and terminals, et. Cable wiring In case of wiring of different devices, itis required to choose proper type of cable, section and number of wires. 80b) ° d 2) D a 44 44d 4a2 443 4a 4s 45a 452 453 46 464 462 463 464 a7 are eS RC CL Connect the cable along the cable bracket to the terminal in the control cabinet; Necessary length of cable should be measured and a certain allowance in the two ends should be left; Necessary measures should be taken after two ends of the cable are cut; According to the drawing requirements, label at the each end of the cable for identification; When planning cable layout path, engineers should pay attention to that the bending radius (inside) shall not be less than 12 times of cable diameter; Repeat the above operation until all cable arrangements are completed Making of wiring terminals First, open the junction box of the equipment and remove the outiet terminal lid in the junction box and then run the cable from the outiet terminals into connection box. Compare the length inside the box and make the cable outside of connection box remain certain degree of relaxation, to ensure that the terminalis not affected by the stress and can also reserve a length for equipment troubleshooting, Secondly, deal with cable ends Stipa section of cable insulation layer, make every wire has suitable length and can be separated. f there is a heat shrinkable tube, it is required to use it block the gap between the cable and the peeled leading wire, Thirdly, deal with leading wire ends. On each conductor, peel off appropriate length of insulating layer to match the depth of connection sleeve. The calibrated wire stripping tool must be used in process so that the insulating layer can be stripped accurately without damaging the strand Finally, use a crimping tool to press and connect the cable joint carefully. Check that length of the wire into wiring set is proper, and confirm that the bare wire is completely inserted into the wiring set. No conductor is exposed outside, and edge of the wiring should be pressed completely. If the connecting sleeve is conductive, the heat shrinkable tube should be used to set up each connecting sleeve with terminal showing only. Connecting cable in device terminal Connect each leading wire terminal to the wiring terminal of the device. Attention should be paid to phase sequence, color or number. Mark cables with identification tag according to the drawings. ‘Adjust position of cables in the terminal box and fix it, and then tighten the cable terminal and finally close the junction box. Repeat the above operations until all devices are connected well Wiring of control cabinet The bottom of the control cabinet is equipped with a cable bushing which can make the ‘able enter into the control cabinet. In general, the first cable should penetrate from the rear ‘mounting holes of control cabinet, which is beneficial to arrangement of the rear cable. First of al, remove the lid ofthe cable joint in the bottom ofthe control cabinet Selecta cable connection, measure the length of cable length, leave allowance of 300 mm, let the cable ‘outside the junction box keep a certain degree of relaxation to ensure that the terminalis not affected by the stress, can also reserve a length for equipment troubleshooting Methods of making wiring terminal is the same in 44.2~4.4.4, Repeat the above operations until all terminals are connected well If there are some unused joints in the control cabinet, it is required to seal them, Current transformer connection Secondary winding of the current transformer must be short ciuited before and during transportation, until the final connection is completed. To ensure that a pair of terminals in secondary winding of each current transformer have load connection or short-circuit connection, 81 ine

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