2XYN460022C1222 Instruction & Manual

ABB
INSTRUCTION
MANUAL
Product
Rated Power
Voltage Ratio
No. of Phase
Voltage Variation
Vector Group
Customer
ABB ref.
Serial No.
:
:
:
:
:
:
:
:
:
Power Transformer
176.25 MVA
220/23 kV
Three Phase
+ 10% to -10% on HV side
YNd11
ISABEL, CHILE
13156
C1222
Prepared by
Approved by
Srutiranjan Sahu
Ajay Sheth
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA, VADODARA, GUJARAT, INDIA
Page - 1
of 2
ABB
CONTENTS
PART
No.
TITLE
PAGES
TITLE SHEET, CONTENTS
2
SECTION – I
1
SAFETY INSTRUCTIONS
10
SECTION – II
2
TEST RESULTS OF TRANSFORMER
1
3
TECHNICAL DATA OF TRANSFORMER AND COMPONENTS,
GENERAL DESCRIPTION OF TRANSFORMER
15
4
TRANSFORMER DRAWING, LEAFLETS AND CATALOGUES
447
SECTION – III
5
DISMANTLING AND TRANSPORT
16
6
MONITORING OF DRY-GAS FILLING OF TRANSFORMERS
DURING SHIPMENT & STORAGE
4
7
RECEIVING INSPECTION AND ARRIVAL ON SITE
8
8
UNLOADING, MOVING, STORING TRANSFORMER AND PRECOMMISSIONING CHECKS.
5
9
TRANSFORMER ASSEMBLY INSTRUCTIONS, ERECTION
EQUIPMENT/ TOOLS
13
10
OIL-SPECIFICATION, TESTING, PURIFICATION AND STORAGE
14
11
ERECTION AND ASSEMBLY
7
12
ACCEPTANCE TEST AND ENERGISATION
6
13
FIELD TEST RECORD AND FIELD QUALITY PLAN
16
14
TROUBLE SHOOTING
10
15
STORAGE
5
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA, VADODARA, GUJARAT, INDIA
Page - 2
of 2
ABB
PART –1
SAFETY INSTRUCTIONS
This document must not be copied without our written permission, and the contents thereof must not be imparted to a
third party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 1 of 10
ABB
SAFETY INSTRUCTIONS
1.1
SAFETY RULES FOR WORKING AT LIVE PARTS
1.2
OBSERVE INSTRUCTIONS IN THIS MANUAL FOR ERECTION,
OPERATION AND MAINTENANCE
1.3
RESPONSIBILITY OF THE TRANSFORMER USER
1.4
RESPONSIBILITY OF THE PERSONNEL
1.5
PERMISSIBLE OPERATION
1.6
GUARANTEE AND LIABILITY
1.7
STATUTORY AND REGULATORY REQUIREMENT ON AIR
CLEARANCES.
1.8
PROTECTION OF TRANSFORMERS
1.8.1
CIRCUIT BREAKERS OF SUFFICIENT CAPACITY ON HV AND LV
SIDES
1.8.2
SURGE DIVERTOR
1.9
DO‘S AND DON‘TS FOR POWER TRANSFORMERS
1.9.1
DO‘S FOR POWER TRANSFORMERS
1.9.2
DON‘TS FOR POWER TRANSFORMERS
1.10
PARALLEL OPERATION
TABLE T 1.2: COMMON PERMISSIBLE COMBINATIONS FOR PARALLEL
OPERATION
This document must not be copied without our written permission, and the contents thereof must not be imparted to a
third party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 2 of 10
ABB
1
SAFETY INSTRUCTIONS
1.1
SAFETY RULES FOR WORKING AT LIVE PARTS
Working at live parts of electrical equipment must only be done if the following safety
rules are carefully observed:
Switch off
Secure against involuntary re-closing
Make sure that equipment is not alive
Connect equipment to earth and short-circuit it
Close parts that are alive, must be covered or blocked off .
1.2
OBSERVE INSTRUCTIONS IN THIS MANUAL FOR ERECTION ,
OPERATION AND MAINTENANCE
It is of vital importance for safe working conditions and for trouble-free operation of the
transformer that all personnel know the basic safety precautions and prescriptions.
This manual contains the most important instructions for safe transformer
operation and should be stored at the transformer site.
All personnel working at the transformer must carefully observe the safety
precautions and the instructions in this manual.
Further on local and national regulations for the prevention of accidents and for the
protection of the environment must be provided and observed.
All safety instructions at the transformer must be clearly readable.
The following terms are used in the manual to draw your attention to special safety
instructions.
DANGER! Indicates a serious imminent danger. If the safety instructions given are
disregarded, heavy injury or death will be the consequence.
WARNING! Indicates a potentially dangerous situation. If the safety instructions
given are disregarded, injury or damage to the equipment might be the
consequence.
CAUTION! Indicates a situation that might become dangerous.
If the safety instructions given are disregarded, the transformer or
the equipment might be damaged.
1.3
RESPONSIBILITY OF THE TRANSFORMER USER
The user is responsible to take care that all personnel working at the transformer fulfill
the following requirements:
The personnel is skilled in operating high-voltage equipment, especially
transformers and has good knowledge of basic rules for safety and prevention of
accidents.
Authorization for assembling, putting into operation, operating, maintenance and
repair works must be clearly stated.
All personnel must have read and fully understood the safety instructions stated in
this manual and confirmed this by signature.
Semi-skilled staff must only work at the transformer if supervised by an
experienced skilled person.
Observance of the safety regulations is checked in regular intervals.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a
third party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 3 of 10
ABB
1.4
RESPONSIBILITY OF THE PERSONNEL
Before starting to work at the transformer all persons are obligated to observe the
following rules:
-
Observance of basic instructions concerning safety and prevention of accidents
Before starting to work, the safety precautions and the warning instructions in this
manual must be read and fully understood. This must be confirmed by signature.
1.5
PERMISSIBLE OPERATION
The transformer is built according to the latest technology and the generally
acknowledged safety rules. It transforms electrical energy. The transformer must only be
operated in accordance with the applicable standards and regulations and within the
range of the electrical data mentioned in PART 3. “TECHNICAL DATA OF
TRANSFORMER AND COMPONENTS”.
Any operating conditions exceeding these regulations are not allowed and can result in
injury or damage to the equipment. Asea Brown Boveri Ltd. cannot accept any
liability arising from improper use of the transformer. Further, improper use
forfeits any guarantee agreements.
Permissible operation also includes:
-
Careful observance of all instructions in this manual and
-
observance of inspection and maintenance intervals
1.6 GUARANTEE AND LIABILITY
Our "General terms of sales and delivery” are applicable. They are given to the
customer together with the contract. We cannot accept liability and exclude any
guarantees for damage to equipment and personnel injury, which is due to the following
factors:
-
Improper use of the transformer.
-
Improper assembly, commissioning, operating and maintenance of the transformer
-
Operating the transformer with faulty protective equipment or with protective
equipment which is not mounted correctly and not fully functioning.
-
Non-observance of the instructions in the operating and maintenance manual
concerning transport, storage, assembly, commissioning, operating and
maintenance of the transformer
-
Unauthorized constructional alterations of the transformer
-
Faulty supervision of accessories, which are subject to wear
-
Faulty repairs
-
Catastrophes due to external reasons and force majeure
This document must not be copied without our written permission, and the contents thereof must not be imparted to a
third party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 4 of 10
ABB
1.7 STATUTORY AND REGULATORY REQUIREMENT ON CLEARANCES IN AIR
For the purpose of safety, Electricity Supply Regulation 1987 clause 10 provides for
appropriate minimum clearances from exposed live metal to ground level, platform level
or other position where men may normally stand for operating, maintenance purpose,
where a portable ladder is used. Arrangement shall be such that there is no danger to an
authorised person when operating.
Where minimum clearances cannot be obtained effective screening must be provided in
order to comply with the above, the following instructions and table of minimum
clearances “D“ must be worked out.
CONDITION –1
When operation / inspection can be effected on ground level minimum clearance‚ D”
must be measured vertically.
CONDITION-2
Where a platform is provided for this purpose, minimum clearance‚ D” must be
measured radially from the nearest edge of platform to the adjacent live conductor.
CONDITION-3
Where no platform is fitted and ladder has to be used, an earthed screen must always
be fitted in consultation with ABB.
TABLE T 1.1
VOLTAGE CLASS
GROUND CLEARANCE
NOT EXCEEDING k V
MIN. ”D‘ METERS
11
2.75
33
3.70
66
4.00
132
4.60
220
5.50
400
8.00
These rules must be taken care particularly in the case of transformer fitted with on load
tap change
The following standards/ specifications also give necessary details from dispatch to
maintenance of transformers and these also must be referred.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a
third party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 5 of 10
ABB
IS 10028- 1985: CODE OF PRACTICE FOR INSTALLATION AND MAINTENANCE OF
TRANSFORMERS.
IS 1866- 1961: CODE OF PRACTICE FOR MAINTENANCE OF INSULATING OIL
BS-CP-1010 : BRITISH STANDARD CODE OF PRACTICE ,GUIDE TO LOADING OF
TRANSFORMERS.
CBI & P MANUAL SECTION A (1987) FOR THE REGULATORY REQUIREMENTS.
1.8
PROTECTION OF TRANSFORMERS
Adequate electrical protection for transformer should be provided to avoid costly
breakdowns and the loss of valuable equipment.
The risk of commissioning the transformers without ensuring due protection should be
avoided.
Generally the transformers should be provided with the following protections
1.8.1
CIRCUIT BREAKERS OF SUFFICIENT CAPACITY ON HV AND LV SIDES:
The setting of breakers shall be so adjusted that the fault current and duration
shall in no case exceed those specified in clause No. 9 of IS 2026. Currents more
than these and of longer duration will cause permanent damage to transformers.
1.8.2
SURGE DIVERTORS OF ADEQUATE CAPACITY SHOULD BE PROVIDED
TO THE TRANSFORMER TERMINALS TO PROTECT FROM OVER
VOLTAGE DAMAGES.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a
third party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 6 of 10
ABB
1.9
DO‘S AND DON‘TS FOR POWER TRANSFORMERS
1.9.1
DO‘S FOR POWER TRANSFORMERS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Check and thoroughly investigate the transformer whenever any alarm or
protection is operated.
Check air cell in conservator
Attend the Leakages if any on bushings immediately.
Examine the bushings for dirt deposits and coats and clean them
periodically
Check the oil in transformer and OLTC for di-electric strength and
moisture content and take suitable action for restoring the quality.
Check the oil level in oil cup and ensure air passages are free in the
breather. If oil is less make up the oil.
Check the oil for acidity and sludge as per IS 1866
If the inspection covers are opened or any gasket joint is to be tightened,
then tighten the bolts evenly to avoid uneven pressure.
Check and clean the relay and alarm contacts
Check the protection circuits periodically
Check the pointers of all gauges for their free movement
Clean the oil conservator thoroughly before erecting
Check the Buchholz relay and readjust the floats and switches etc.
Inspect the painting and if necessary retouching should be done.
Check the OTI and WTI pockets and replenish the oil if required
Remove the air through the vent plug of the diverter switch before you
energise the transformer
Check the oil level in the divertor switch and if found less top up with
fresh oil conforming to specifications.
Check the gear box oil level
Examine and replace the burnt or worn out contacts as per maintenance
schedule
Check all bearings and operating mechanism and lubricate them as per
schedule
Open the equalizing valve between tank and OLTC wherever provided at
the time of filling the oil in the tank.
Connect gas cylinder appropriately if transformer is to be stored for long,
in order to maintain positive pressure.
Fill the oil in the transformer at the earliest opportunity at site and follow
storage instructions
Check the door seals of marshalling box. Change the rubber lining if
required.
Do make sure that internal pressure in the transformer is zero gauge
before opening the manhole cover.
Insulating oil and insulation material for windings and connections are
inflammable. Watch for fire hazards.
Make sure that nothing is kept inside the pockets before authorised
person enters inside the main unit. Also remove wrist watches and
footwear.
There must be protective guard for lamp to be taken inside
This document must not be copied without our written permission, and the contents thereof must not be imparted to a
third party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 7 of 10
ABB
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Keep inspection covers open for supply of fresh air when working inside
When one person is working inside, second person must be outside for
emergency.
Use fix spanners and tie them to the wrist of the person or somewhere
outside the tank
Be careful during connections where bolted joints (jumper connections)
are provided, so that nuts, washers etc. are not dropped inside the tank.
If it is necessary to weld some lugs or brackets etc., those should be
welded to tank stiffeners and strictly under the supervision of ABB
representatives.
De-energise the unit by circuit breakers and line switches while working
on energized unit. Ground the line terminals.
Attach the caution tags „DO NOT OPERATE THE SWITCHES“ while
working on energized unit.
Make sure that the fire-fighting equipments are available at the oil
treatment equipment as well as work place and adjacent to the
transformer.
Transformer tank, control cabinets etc. as well as oil treatment equipment
shall be connected with permanent earthing system of the station
Check oil level in condensor bushing; ensure proper tightness of top
terminal cap of condenser bushings to avoid rainwater entry.
Transport transformers only in upright position
Use tools with working surfaces hardened so that they will not peel or
chip.
Equalise the divertor compartment of the OLTC by connecting equalizing
pipe between flange joints provided on the tap changer head.
Oil drums at site shall be stored in horizontal position with openings
horizontal
1.9.2 DON‘TS FOR POWER TRANSFORMERS
1
2
3
4
5
6
7
8
9
10
11
DO-NOT energise without thorough investigation of the transformer
whenever any alarm of protection has operated.
DO-NOT re-energise the transformer unless the Buchholz gas is analyzed.
DO-NOT re-energise the transformer without conducting all precommissioning checks. The results must be comparable with the results at
works.
DO-NOT handle the off circuit tap switch (if any) when the transformer is
energized.
DO-NOT energise the transformer unless the off circuit (if any) tap switch
handle is in locked position.
DO-NOT leaves off circuit tap switch handle unlocked.
DO-NOT leave tertiary terminals (if any) unprotected outside the tank,
connect them to tertiary lightning arrestors protection scheme when
connected to load.
DO-NOT allow WTI/OTI temperature to exceed 65 deg. C during dry out of
transformers and filter machine temperature beyond 70 deg C
DO-NOT parallel transformer which DO-NOT fulfill required conditions as
specified in TABLE T 1.2
DO-NOT use low capacity lifting jacks on transformer for jacking
DO-NOT move the transformer with bushings mounted
This document must not be copied without our written permission, and the contents thereof must not be imparted to a
third party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 8 of 10
ABB
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
DO-NOT overload the transformer other than the specified limits as per IS
6600
DO-NOT changes the settings of WTI and OTI alarm and trip frequently. The
settings should be done as per the site condition.
DO-NOT leave red pointer behind the black pointer in WTI and OTI
DO-NOT leaves any connections loose.
DO-NOT meddles with the protection circuits.
DO-NOT allow conservator oil level to fall below 1 / 4 level
DO-NOT allow oil level fall in the bushings, they must immediately be
topped up
DO-NOT switches off the heater in the marshalling box except to be
periodically cleaned.
DO-NOT leave marshalling box doors open, they must be locked
DO-NOT allow dirt and deposits on bushings, they should be periodically
cleaned.
DO-NOT allow unauthorized entry near the transformer.
DO-NOT leave ladder unlocked
DO-NOT change the sequence of valve opening for taking stand- by pump
and motor into circuit
DO-NOT switch on water pump(if any) unless oil pump is switched on in
case of OFWF cooling
DO-NOT allow water pressure more than oil pressure in differential
pressure gauge (in case of OFWF cooling)
DO-NOT mix the oil. Unless it conforms to the specification mentioned in
this manual ( PART 10)
DO-NOT allow inferior oil to continue in transformer. The oil should
immediately be processed and to be used only when BDV/PPM and other
properties conform fully to IS 1866 and oil specification.
DO-NOT continue with pink/white silica gel, this should immediately be
changed or regenerated.
DO-NOT store the transformer for long after reaching site. It must be
erected and commissioned immediately. Otherwise follow special
precautions.
DO-NOT leave secondary terminals of unloaded CT open
DO-NOT keep the transformer gas filled at site for a longer period.
DO-NOT take any fibrous material as cotton waste inside while repairing
Do not stand on cleats and leads
DO-NOT weld/braze/solder inside tank
DO-NOT weld any thing to tank wall from outside
DO-NOT weld anything to conservator vessel with flxi separator rubber bag
DO-NOT smoke on or near transformer.
DO-NOT use fibrous cleaning materials as it can deteriorate oil when mixed
with it.
DO-NOT use pipe flanges and valves as lifting or supporting points
DO-NOT drop crates containing porcelain parts
DO-NOT open the transformer during periods of inclement weather or when
condensation is forming on the internal surfaces of the transformer.
Never enter a transformer with dirty or wet clothing
DO-NOT filter oil of energized transformer
This document must not be copied without our written permission, and the contents thereof must not be imparted to a
third party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 9 of 10
ABB
1.10 PARALLEL OPERATION
1.10.1
If it is desired to parallel a transformer, which is not identical in design with
ABB transformer, it is preferable to refer the matter to ABB for advice/guidance.
1.10.2
The voltage ratings/ ratios and impedance values at all taps should match for
the two transformers, which are to be paralleled. Only certain combinations of vector
groups are capable of being paralleled.
The table T1.2 below indicates more common permissible combinations
1.10.3
Reference to the connection diagrams of two transformers should indicate the
terminals to be paralleled
1.10.4
The reversal of two leads on either side of a three-phase transformer will
reverse the polarity changing them in sequence (example: from UVW to VWU or WUV
will swing the vector through 120 deg.)
1.10.5
Phase sequence and polarity can be checked by energizing both
transformers on the primary side before paralleling and measuring the open circuit
voltage appearing across each pair of terminals which will ultimately be paralleled.
1.10.6
IS: 2026 and IS:10561 can also be referred.
TABLE T 1.2
COMMON PERMISSIBLE COMBINATIONS FOR PARALLEL OPERATION
TRANSFORMER (TWO) HV/LV
TRANSFORMER
(ONE)
HV/LV
DELTA/
STAR
STAR/
DELTA
DELTA/
DELTA
STAR/
STAR
DELTA/STAR
YES
YES
NO
NO
STAR/DELTA
YES
YES
NO
NO
DELTA/DELTA
NO
NO
YES
YES
STAR/STAR
NO
NO
YES
YES
This document must not be copied without our written permission, and the contents thereof must not be imparted to a
third party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 10 of 10
ABB
PART 2
TEST RESULTS
OF
TRANSFORMER
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third
party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 1 of 1
ABB
PART 3
Ø
TECHNICAL DATA OF TRANSFORMER
Ø
TECHNICAL DATA OF COMPONENTS
Ø
GENERAL DESCRIPTION OF TRANSFORMER
Ø
PROTECTIVE AND SUPERVISORY INSTRUMENTS
Ø
SPECIFIC INSTRUCTIONS FOR TRANSFORMER INSTALLATION
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB INDIA LTD. MANEJA, VADODARA, GUJARAT, INDIA
PAGE - 1 of 12
ABB
3.0 TECHNICAL DATA OF TRANSFORMER AND COMPONENTS
3.1 TECHNICAL DATA OF TRANSFORMER
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.1.7
3.1.8
3.1.9
3.1.10
3.1.11
3.1.12
3.1.13
3.1.14
3.1.15
3.1.16
3.1.17
3.1.18
3.1.19
3.2
RATED POWER
POWER DEFINITION
VOLTAGE RATIO
VOLTAGES AND CURRENTS
VECTOR GROUP
IMPEDANCE VOLTAGES
NO LOAD CURRENT
MAX. DURATION OF SHORT-CIRCUITS
INSULATION LEVEL
NO-LOAD LOSS
LOAD LOSS
TOTAL LOSSES
RATED FREQUENCY
POWER OF FANS
TEMPERATURE RISE AND AMBIENT TEMPERATURE
ADJUSTMENT OF TEMPERATURE INDICATORS FOR TEMPERATURE
SOUND LEVEL
DIMENSIONS
WEIGHTS
TECHNICAL DATA OF COMPONENTS
3.2.1 OLTC
3.2.2 COOLING EQUIPMENT
3.2.2.1 RADIATORS
3.2.2.2 FANS
3.2.2.3 PUMPS (NOT APPLICABLE)
3.2.3 BUSHINGS: TERMINAL ARRANGEMENT
3.2.4 CURRENT TRANSFORMERS
3.3
GENERAL DESCRIPTION OF TRANSFORMER
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
CORE
WINDINGS
TANK AND COVER
CONSERVATOR
AIR CELL
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB INDIA LTD. MANEJA, VADODARA, GUJARAT, INDIA
PAGE - 2 of 12
ABB
3.4
PROTECTIVE AND SUPERVISORY COMPONENTS
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
3.4.8
3.4.9
3.4.10
3.5
BUCHHOLZ RELAY
DEHYDRATING BREATHER
PRESSURE RELIEF DEVICE
OIL TEMPERATURE INDICATOR: DIAL TYPE
WINDING TEMPERATURE INDICATOR: DIAL TYPE
OIL LEVEL INDICATOR
3.4.6.1 MAGNETIC TYPE
3.4.6.2 PRISMATIC TYPE
VALVES
AIR RELEASE PLUG
CT TERMINAL BOX
EARTHING ARRANGEMENT
3.4.10.1 CORE EARTHING
3.4.10.2 TANK TO TANK -COVER EARTHING
3.4.10.3 EARTHING OF TANK
SPECIFIC INSTRUCTIONS FOR TRANSFORMER INSTALLATION
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB INDIA LTD. MANEJA, VADODARA, GUJARAT, INDIA
PAGE - 3 of 12
ABB
3.0
TECHNICAL DATA OF TRANSFORMER AND COMPONENTS
3.1
TECHNICAL DATA OF TRANSFORMER
3.1.1 RATED POWER MVA:
141/176.25 (ONAN/ONAF)
3.1.2 POWER DEFINITION: According to IEC-60076, Constant Power at all tapings of OLTC.
3.1.3 RATED RATIO: 220/23 kV
Taps on Neutral end of 220 kV side for HV variation
Voltage variation is +10% to -10 %
Number of steps: 16, Number of Position: 17.
3.1.4 VOLTAGES AND CURRENTS (OLTC Tap no.9)
Cooling Stage
Voltage System
Voltage level in kV
Rating in MVA
Line Current in Amp
ONAN
HV
220
141
370.04
ONAF
LV
23
141
3539.51
HV
220
176.25
462.55
LV
23
176.25
4424.39
Please refer to Rating Plate ABB Drawing no. 2XYN294001C1222 voltage and currents of
All other taps.
3.1.5 VECTOR GROUP HV/LV WINDING: YNd11 as per IEC:60076, however refer
Rating & diagram plate for more details
3.1.6 IMPEDANCE VOLTAGES:
HV - LV – 19% minimum @ 176.25MVA Base @ Principle tap-9, lowest & highest tap
(For more details refer rating plate and test report)
All impedances are at 75°C
3.1.7 NO-LOAD CURRENT : Refer Test Report
3.1.8 MAX. DURATION OF SHORT-CIRCUITS (THERMAL): 2 Seconds Maximum
3.1.9 INSULATION LEVEL:
TESTING VOLTAGE
HV
LV
HV-N
Ur (Nominal Rated) kV
220
23
--
AC (Power Frequency) kVrms
460
50
230
LI (Lightning Impulse) kVP
1050
145
550
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB INDIA LTD. MANEJA, VADODARA, GUJARAT, INDIA
PAGE - 4 of 12
ABB
3.1.10 NO LOAD LOSS
: 67 kW (Max.) at 1.0 x Un (100% rated voltage)
3.1.11 LOAD LOSS
: 627 kW (Max.) at 125 MVA base, at 75°C and OLTC tap no.9
3.1.12 TOTAL LOSSES
: 704 kW (Max.) at 120 MVA base and OLTC tap no.9
(Including losses consumed by cooling fans)
Please refer test report for Impedance and Losses at extreme taps.
3.1.13 RATED FREQUENCY: 50 Hz
3.1.14 POWER OF FANS
: 10 kW (Max.)
Total Loss (No load loss + Load loss + Auxiliary loss) : 704 kW
3.1.15TEMPERATURE RISE AND AMBIENT TEMPERATURE IN DEG. 40°C max
Maximum permissible oil temperature rise
: 60 °C
Maximum permissible average winding temperature rise
: 65 °C
3.1.16 ADJUSTMENT OF TEMPERATURE INDICATORS FOR TEMPERATURE
Please refer test report and instrument leaflets
3.1.17 SOUND PRESSURE LEVEL: 64dBA
3.1.18 DIMENSIONS: For details refer General Arrangement Drawing 2XYN460001C1222
Estimated
Length
Breadth
Height
Overall in mm
16307
8652
8294
Transport in mm
8212
3056
4116
3.1.19 WEIGHT (kg):
Core & Windings Assy.(Active part)
78700 approx.
Tank & Fittings
64505 approx.
Total Weight of Oil in transformer
40375 approx.
Total Weight of Transformer with Oil
183580 approx.
Transport Weight (Dry Air Filled)
98000 approx.
Total volume of oil in transformer in litre
47500 approx.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB INDIA LTD. MANEJA, VADODARA, GUJARAT, INDIA
PAGE - 5 of 12
ABB
3.2
TECHNICAL DATA OF COMPONENTS
3.2.1.1 ON LOAD TAP CHANGER
Taps are provided on neutral end of 220 kV side for HV variation to keep LV voltage constant
Make: ABB SWEDEN make
Type: UCGDN
Rated Current: 600 A, Step Voltage: 1587.76 V (phase voltage)
Variation: +10% to -10 %
Number of steps: 16, Number of positions: 17
OLTC Control Supply: 110 V DC
3.2.1.2 MOTOR DRIVE: BUL2 Drive Mechanism, ABB SWEDEN Make
[Please Refer Catalogue for Full Details]
3.2.2 COOLING EQUIPMENT
The transformer is having mixed cooling ONAN/ONAF by means of radiators, and fans.
The radiators are separately mounted through header of the transformer tank by means of
butterfly valves and pipes as shown in general assembly drawing 2XYN460001C1222.
Fans are mounted on radiators. Interlock device is provided in cooling system work to
facilitate automatic switching in of the standby fans, in case the running fan fails. one fan
in each group is provided as standby.
3.2.3 BUSHINGS
: TERMINAL ARRANGEMENT
HV Line:
Rated Voltage: 362 kV, Rated Current: 2500 A
Lightning Impulse: 1175 kVp, Power Frequency (Dry): 560 kVrms
Creepage distance :9120
Make: ABB SECOM
Termination: Oil to Air OIP bushing
HV Neutral:
Rated Voltage: 170 kV, Rated Current: 1250 A
Lightning Impulse: 750 kVP, Power Frequency : 325 kVrms
Creepage distance :5504
Make: ABB SECOM
Termination: Oil to Air RIP bushing
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB INDIA LTD. MANEJA, VADODARA, GUJARAT, INDIA
PAGE - 6 of 12
ABB
LV Line :
Rated Voltage: 36 kV, Rated Current: 8000 A
Lightning Impulse: 170 kVP, Power Frequency (Dry&Wet): 70 kVrms
Creepage distance: 900 mm
Make: COMEM
Termination: Cable Box
3.2.4 CURRENT TRANSFORMERS SUITABLE FOR FREQUENCY 50 Hz
Current transformers for local winding temperature indicator are provided on HV & LV
terminals as shown in rating and diagram plate.
The secondary winding of the current transformers are connected to a terminal box.
Current transformer terminals from terminal box are wired to Marshalling box. WTI CT
terminals wired upto winding temperature indicator mounted in marshalling box. The
secondary windings of current transformers are connected. The connections between
terminals are made by links which also can be arranged to short circuit and earth the
current transformer when disconnected.
Refer Rating & Diagram plate drawing 2XYN294001C1222 for CT details.
3.3
GENERAL DESCRIPTION OF TRANSFORMER
3.3.1 CORE
The magnetic core is of three limbed construction. Each limb being mitred with top and
bottom yokes. The laminations are made from non Ageing Cold Rolled Grain Oriented
Silicon alloy steel. The insulation of lamination is of carlite type. The core has stepped cross
section. The yokes are clamped by means of end frames and yoke bolts of special
construction and limbs are clamped by means of special resiglass tape over clamping plates.
For lifting the core with winding, adequate provision has been made. The yoke bolts, end
frames, clamp plates and core steel are insulated from each other to withstand test voltage of
2.0 kV rms at 50 Hz. for one minute.
3.3.2 WINDINGS
Windings are arranged in concentric formation arranged as below
LV (23 kV) WINDING
: HELICAL(H1) WINDING
HV (132 kV) WINDING
: DISC (D) WINDING
TAP WINDING
: LAYER & LOOP LAYER WINDING
The paper covered copper strips, paper covered & netting tap CTCE conductors are used for
making windings. Windings are compressed adequately before assembly and remain in
position by means of special clamping structure.
The active part is processed using modern sophisticated vapor phase drying oven.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB INDIA LTD. MANEJA, VADODARA, GUJARAT, INDIA
PAGE - 7 of 12
3.3.3 TANK AND COVER
ABB
The tank and cover are welded mild steel conventional type construction, cleaned on inside
and outside to remove scale before painting.
The cover is of bolted construction and remains bolted at the joint between cover and tank.
Adequate number of inspection covers is provided. To make joints oil tight, nitrile rubber
gaskets are used.
The tank and cover are provided with all fittings and accessories as per the General
Assembly drawing.
3.3.4 CONSERVATOR
As the temperature of oil increases or decreases during operation there is corresponding rise
or fall in volume. To account for this an expansion vessel – CONSERVATOR- is connected
to the transformer tank. The conservator is mounted on the cover of the transformer. The
conservator has got capacity between minimum to maximum oil level about 7.5% of the
total oil in transformer. The conservator is mounted with magnetic oil level gauge which
has a low oil level alarm. The dial indicates empty, ¼, at 30 DEG. C, ¾ and full oil level.
The terminals for low oil level alarm and high oil level alarm switches are wired upto
marshalling box. Please refer MOLG catalogue for more details. Also prismatic oil level
gauges are provided on the other end of the conservator.
The conservator is provided with FLEXI separator rubber bag. The conservator is filled
with oil to level appropriate to the filling temperature and in the remaining portion is Air
cell which is connected to atmosphere through a breather. If the volume of oil in the
transformer increases the conservator breathes out air and if the volume of oil in the
conservator reduces, the conservator breathes in air. As the breathing is through air cell, no
moisture comes in contact with the oil thus preventing contamination of oil.
A valve also used for air filling air cell before filling oil in conservator at a pressure 0.035
kg/sq cm. The pipe connecting the transformer tank with conservator projects above the
lowest point in the conservator such that the portion below acts as a sump where the
impurities in the conservator collect. A valve is fitted at the lowest point of the conservator
for draining and sampling of oil. On the feed pipe reed type (Earthquake resistance)
Buchholz relay is mounted. Between conservator and buchholz relay, an isolating valve is
provided.
3.3.5 AIR CELL
It is a flexible separator fitted inside the conservator. Oil being out of the air cell, the
separator is in direct contact with the atmosphere. This type of mounting makes it possible
to compensate for the oil volume displacements due temperature variations and ensures:
an efficient barrier between oil and air
a protection against water vapour
the suppression of any gas bubbles formation in the oil
Air cell is made from coated fabric with external coating resistant to transformer oil and
inner coating resistant to ozone and weathering.
Air cell is made from nylon fabric coated with nitrile rubber. In the event it becomes
necessary to replace or test the air cell for leaks the following method is recommended.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB INDIA LTD. MANEJA, VADODARA, GUJARAT, INDIA
PAGE - 8 of 12
ABB
-
De-energise the transformer
Isolate the conservator by closing relevant valve
Drain the oil from the conservator by closing relevant valves
Install pressure gauge appropriately
Pressurise the air cell by dry nitrogen /air to maximum pressure of 1.5
psi(~1.03kgf/sqcm) and seal. Check the pressure after 6 hours
If leaks are found , air cell to be repaired by patching or replaced by new air cell
For taking out the air cell from the conservator, remove the air cell flange and
loops from hooks provided on inside of the conservator top. Collapse the air-cell
slowly and fold, remove it from conservator very carefully.
In the event air cell is not available immediately, conservator may be used as a conventional
conservator for short period till air cell is replaced.
3.4
PROTECTIVE AND SUPERVISORY COMPONENTS
3.4.1
BUCHHOLZ RELAY
The transformer is fitted with reed type buchholz relay. It is fitted in the pipe from
conservator to tank and is provided with two sets of micro contacts. The device comprises
of a cast iron housing containing the hinged floats, one in upper part and the other in lower
part. Each float is fitted with a micro switch, leads of which are connected to a terminal box
for external connections.
An arrow is cast on the housing to indicate the direction of the conservator. The operation
of buchholz relay should be tested before installation by injecting air at the lower cock (test
cock). After the inspection and tests, any air which may have accumulated in the gas
chamber must be released at the upper pet cock to ensure that the chamber is full of oil. The
top most points are piped to the main pipe on which the buchholz relay is mounted so that
the gases liberated in the transformer are diverted to the buchholz relay without being
trapped anywhere. Please refer to the leaflet on buchholz relay. From the petcock, if any gas
is collected in the buchholz relay, can be drawn off for testing.
BUCHHOLZ RELAY (Gas Operated Relay) : COMEM Make, 80 NB size
Steady oil flow for trip
: 90-160 cm/sec
Gas volume for alarm
: 200 TO 300 CC
Operating instructions
: For more details refer catalogue
Operating instructions
: For more details refer catalogue
3.4.2 SILICA GEL BREATHER
The conservator is connected to the atmosphere through a dehydrating silica gel filled
breather to make sure that the air in the conservator is dry. For general description of the
apparatus please refer to the leaflet.
1) For main conservator
: silica gel breather
Manufacturer
: YOGYA
Model no. _
: DTO 9
Refer catalogue for more details
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB INDIA LTD. MANEJA, VADODARA, GUJARAT, INDIA
PAGE - 9 of 12
ABB
2) For OLTC conservator : Orange Color Silicagel
Manufacturer
: DTO 4
3.4.3 PRESSURE RELIEF VALVE
In case of severe fault in the transformer, the internal pressure may build up to a very high
level which may result in an explosion of tank. To avoid such a contingency two number
pressure relief valves are fitted on the transformer. It is spring loaded and has contacts for
tripping the transformer. Please refer to the catalogue for details. To take away the
discharge piping arrangement is also provided.
COMEM Make pressure relief device
3.4.4 OIL TEMPERATURE INDICATOR: DIAL TYPE
Oil temperature indicator is a distance thermometer operating on the principle of liquid
expansion. It provides local indication of the top oil temperature at the marshalling box. The
connection between the thermometer bulb and the dial indicator is made by flexible steel
capillary tube .The bulb is enclosed in a pocket and the pocket is fixed on the transformer at
the hottest oil region. The pocket has to be filled with transformer oil. The oil temperature
indicator is provided with a maximum pointer and two micro switches one for alarm and
other for trip. Switches are suitable for 240 V AC OR DC. The micro switches are
adjustable to make contact between 50 and 120o C and have fixed differential of 5o C.
The temperature for alarm and trip contact settings shall be as under:
Alarm = 100 deg. C, Trip = 105 deg.C (At an ambient temperature of 40deg. C).
In addition to local oil temperature indication, provision is available for repeat oil
temperature indication at RTCC panel by using a potentiometer in the local OTI and
sending 4-20 mA signals to RTCC panel.
MAKE: COMEM with alarm & trip contacts
3.4.5 WINDING TEMPERATURE INDICATOR: DIAL TYPE
One number WTI is provided for monitoring temperature of winding under running
condition. This indicator operates on the principle of liquid expansion. It provides local
indication at the marshalling box of hot spot temperature of winding. The winding hot spot
to top oil temperature differential is simulated by means of a heater coil fitted around the
operating bellows. A current proportional to the load current is fed to the heater coil from a
current transformer fitted on V phase of HV & LV as shown in the diagram plate. The bulb
is connected by capillary tubing to the local indicator.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB INDIA LTD. MANEJA, VADODARA, GUJARAT, INDIA
PAGE - 10 of 12
ABB
The indicator is fitted with maximum pointer and four micro switches. One is used for
alarm and second is used for trip and third & fourth for cooler control. All the switches are
adjustable on their individual scales over the entire working range of the instrument. All
micro switches are suitable for 240V AC or DC. For details please refer to catalogue on
WTI. The WTI pocket has to be filled with transformer oil.
The temperature for alarm and trip contact settings for WTI shall be as under:
1] Alarm
105oC
2] Trip
110oC
3] Fans “ON“
for ONAF-70oC
At max. Ambient temperature of 40oC
MAKE: COMEM with alarm, trip & fan control contacts.
3.4.6
OIL LEVEL INDICATOR
3.4.6.1 MAGNETIC TYPE:
For main tank conservator:SUKRUT make, with low oil level and high oil level alarm contacts on one flat side of
the conservator.
3.4.6.2 PRISMATIC TYPE: ABB Make on the other flat side of the conservator
3.4.7 VALVES
Both end flanged globe valves
Butterfly valves
Globe valves
Ball Valve
Gun metal Gate valves
: OLTC suction, OLTC conservator drain, Oil surge
relay isolating, Air cell equalizing.
: Radiator isolating.
: Top & bottom oil sampling.
: Sludge removal valve.
: Main tank drain, Main conservator top filter, Main
conservator drain & filling, conservator shut off, top &
bottom filter.
For exact location of all the valves, refer general assembly drawing and valve schedule plate
drawing
3.4.8 AIR RELEASE PLUGS: Two nos. each on the main tank cover & conservator.
3.4.9 CT TERMINAL BOX:
On HV, LV & Neutral terminal turrets as shown in general assembly drawing. If these
boxes are removed for any purpose, those should be fitted in position properly.
3.4.10 EARTHING ARRANGEMENT:
ABB practice of earthing arrangement is indicated as per drawing no. 1ZYN932342.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB INDIA LTD. MANEJA, VADODARA, GUJARAT, INDIA
PAGE - 11 of 12
ABB
3.4.10.1 CORE EARTHING:
Connecting leads from core and end frame are being terminated at the top of the cover. By
connecting to the tank cover, core and end frame get earthed. Insulation resistance between
the leads from core and end frames or between lead from core and earth point can be
checked by 500V meggar. Leads from end frames are brought out for proper earthing of end
frames.
3.4.10.2 EARTHING OF TANK:
Two numbers stainless steel earthing pads are provided on the diagonally opposite sides of
the tank for connection to the station earth by M.S. flat of size 50 x 6 mm. Please refer G.A.
drawing no. for further details.
3.4.10.3 OTHER EARTHING POINTS
Earthing points are also provided on turrets for HV bushings, pipe work-tank, cover to
supports etc.
3.5
PLEASE REFER PART MARKING AND CABLE WIRING DRAWINGS
2XYN467957C1222 & 2XYN468958C1222 FOR FINAL ASSEMBLY AT SITE
3.6
Marshalling box & Cooler Control Box
Tank mounted Marshalling box and cooler control box is provided for transformer. Control
accessories are provided in cooler control box, where as Oil & Winding are mounted on
marshalling box. All wirings from transformer accessories are also terminated to M.box .
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB INDIA LTD. MANEJA, VADODARA, GUJARAT, INDIA
PAGE - 12 of 12
ABB
PART 4
OUTLINE DRAWING, PLATES &
CIRCUIT DIAGRAMS OF
TRANSFORMER
LEAFLETS AND CATALOGUES
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third
party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 1 of 3
ABB
4.1
LIST OF CUSTOMER DRAWINGS
Sr. No.
1
2
3
4
6
7
8
9
10
11
12
13
14
15
DESCRIPTION
General Arrangement
HV Line OIP Bushing
HV-N RIP Bushing
LV Bushing
Rating and Diagram Plate-English
Rating and Diagram Plate-Spanish
Valve Schedule Plate
Foundation Plan
Transport Outline Arrangement
Cable Box drawing
Schematic of Marshalling Box
Schematic of OLTC & RTCC
General Arrangement M.BOx
General Arrangement of RTCC
4.2
LIST OF REFERENCE DRAWINGS
Sr.No.
Description
DRAWING NUMBER REV INDEX
2XYN460001C1222
2XYN275001C1222
2XYN275002C1222
2XYN275003C1222
2XYN294001C1222
2XYN294002C1222
2XYN460036C1222
2XYN460003C1222
2XYN460011C1222
2XYN460015C1222
2XYN464032C1222
2XYN464034C1222
2XYN464033C1222
2XYN464036C1222
F
B
B
B
D
A
B
E
A
C
C
C
C
C
Drawing Number
Rev Index
1
Part Marking
2XYN467957C1222
B
2
Cable Wiring
2XYN468958C1222
A
3
Earthing Arrangement
1ZYN932342
A
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third
party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 2 of 3
ABB
4.3
LIST OF LEAFLETS AND CATALOGUES/O&M MANUALS
Sr.No.
Component
Make
1
WTI & OTI
COMEM
2
Buchholz Relay
COMEM
3
Pressure Relief Device
COMEM
4
Magnetic Oil Level Gauge-Main Tank
SUKRUT
5
Magnetic Oil Level Gauge-OLTC
SUKRUT
6
Cooling Fan
Ziehl Abegg
7
OLTC
ABB, SWEDEN
8
Bushings
ABB & COMEM
9
Silica gel breather
YOGYA
10
Automatic Voltage Regulator
A-EBERLE
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third
party nor be used for any unauthorized purpose. ABB LTD. MANEJA, VADODARA, GUJARAT, INDIA.
Page 3 of 3
1
2
3
4
3527
B
22 $
22 $
3200
C
TERMINAL NOMENCLATURE
TERMINALS
H1, H2, H3
X1, X2, X3
H0
B
500
2324
Jack
3800
5000
C
2950
TOP VIEW
H0
X2
X1
X3
357
94
H1
PHASE-EARTH
1950
290
1150
H2
85 $
CG OF MAIN TANK
DURING ASSESMBLY
7079
ELECTRICAL CLEARANCES IN AIR AS PER IEC (mm)
B
SIGNAL BOX OF PNT FIRE
SYSTEM MOUNTING PROVISION
E
E
7947 - HV U and W phase height
2079.5
3529
6225
E
NOTE:
1. DIMENSIONS EXCEPT RAIL GAUGE AND MINIMUM AIR CLEARANCES HAVE A
TOLERANCE OF # 5%.
2. WEIGHTS HAVE A TOLERANCE OF # 5%.
3. ALL BOUGHT-OUT ITEMS SHALL RETAIN THE SAME PAINT SHADE AS SUPPLIED BY
OEM.
4. PAINT SHADE : RAL7035
5. THERE CAN BE A MINOR CHANGIS REGARDING THE LOCATION OF FITTINGS.
THOSE CHANGES WILL BE INCORPORATED IN AS-BUILT DRAWING.
6.APPROX. TRANSFORMER MASS (EXCLUDING FREE STANDING COOLER BANK) = 148500 KG
7.APPROX COOLER BANK MASS (EACH) = 17540 KG
PHASE-PHASE
2650
290
-
2447
Jack
A
8652 Overall width
1550
8294 -HV V phase height / overall max height
5854 - HVN bushing height
3200
39
850 - LV and HVN bushing position
785
12 RUNS OF XLPE 630SQ MM
60
850
B
8
4502 - LV busbar height
3527
675
A
HV
LV
HVN
7
LEFT SIDE
830
HV
LV
HVN
6
HV SIDE
RIGHT SIDE
D
5
B
H3
D
85 $
CHECK
FOR
INFORMATION
FOR
AS-BUILT APPROVAL
ONLY
FABRICATION
MARSHALLING
BOX
F
16307 Overall length
B
BOX
E
LV SIDE
D
C
B
No.
28.02.20
AS BUILT
RA
APR
24.01.20
NIFPS PROVISION ADDED
RA
APR
24.10.19
MASSES UPDATED
12.10.19
19.09.19
SEISMIC INPUTS INCORPORATED SLK
COMMENTS INCORPORATED
SLK
DATE
PROJECT
APR
RA
REMARKS
APR
APR
DRN
CKED
TITLE:
SOLAR PV PLANT AT SANTA ISABEL CHI
CLIENT:-
E
APPROXIMATE MASSES
CORE AND WINDING PART
78,700 kg
TANK & FITTINGS
64,505 kg
OIL MASS (TOTAL)
40,375 kg
OIL QUANTITY (TOTAL)
47,500 litre
TOTAL TRANSFORMER
183,580 kg
SHIPPING MASS (MAIN UNIT-DRY AIR FILLED)
CONSULTANT:-
EPC
CONTRACTOR
IMPERIA, A-25, MOHAN CO-OPERATIVE
INDUSTRIAL ESTATE, MATHURA ROAD,
NEAR SARITA VIHAR METRO STATION,
DELHI 110044
E-mail : delhi.solarsterlingwilson.com.
Website : www.sterlingandwilson.com.
D
98,000 kg
DRAWING
TITLE:
DRAWING
NO
GENERAL ARRANGEMENT
176.25MVA, 220/23kV TRANSFORMER
C
ALL DIMENSIONS ARE IN MM UNLESS STATED OTHERWISE.
CHECKED
APPROVED
DATE
2
3
4
5
6
7
:
2XYN460001C1222
DRAWN
1
:-
STERLING & WILSON SOLAR LIMITED
SLK
APR
TKG
09.09.2019
8
SHEET
NO
PAPER
SIZE
REV
NO.
NTS
1 OF 2
A2
F
1
2
3
4
5
6
7
8
LIST OF FITTINGS
PART NO.
A
1
40
46
9
45
25
E
7
33
B
24
23
4
LIFTING HOOKS
4
TANK EARTHING PADS
2
JACKING PADS
7
AIR RELEASE PLUG ON TRANSFORMER
10
11
1
**
13
B
14
15
28
16
17
18
19
20
21
8
B
35
22
48
2
16
C
23
SCALE 0.015
B
44
5
34
4
3
B
27
24
26
49
25
B
50
26
27
28
29
19
30
31
11
13
E
20
31
41
**
36
38
52
33
47
34
35
10
36
37
D
37
43
38
39
40
41
42
43
44
45
46
47
48
14
49
B
E
17
15
29
42
51
30
6
50
E
E
18
VALVE POSITION INDICATING PLATE
5
9
51
52
53
1
4
2
EARTHING LINK TOP COVER TO TANK
2
HV LINE BUSHINGS
3
HV NEUTRAL BUSHING
1
LV LINE BUSHINGS
3
***
**
ACCESS FOR CORE TO TANK EARTHING
1
SILICAGEL BREATHER FOR OLTC CONSERVATOR
1
TOP FILTER VALVE DN50
1
TOP SAMPLING VALVE DN15
1
BOTTOM SAMPLING VALVE DN15
1
MAIN CONSERVATOR WITH AIR CELL
1
BUCHHOLZ RELAY ISOLATING VALVES DN80
2
MAIN CONSERVATOR DRAIN VALVE DN50
1
RADIATORS WITH LIFT, AIR RELEASE AND DRAIN PLUG
23+1
RADIATOR ISOLATING BUTTERFLY VALVES DN80
46+2
ON LOAD TAP CHANGER WITH DRIVE MECHANISM BOX
1
THERMOMETER POCKET ON COVER
1
COOLING FANS WITH IP54 TERMINAL BOX
1
250MM DIAL SIZE MOLG WITH LOLA CONTACT FOR MAIN CONSERVATOR
1
PRESSURE RELIEF DEVICE
2
DETACHABLE LADDER
1
BUCHHOLZ RELAY DOUBLE FLOAT, DN80
1
**
& RTD
6
AIRCELL INSTRUCTION PLATE
1
SILICA GEL BREATHER FOR MAIN CONSERVATOR
1
EXPANSION BELLOW (DN80)
1
OLTC CONSERVATOR
D
1
CT TERMINAL BOX
1-SET
SLUDGE REMOVAL VALVE DN32
1
CONSERVATOR TO AIRCELL EQUILIZING VALVE DN25
1
DUMMY FOR PNRV
BOX
FOR
INFORMATION
FOR
AS-BUILT APPROVAL
ONLY
FABRICATION
6
OLTC CONSERVATOR DRAIN VALVE DN25
1
OLTC SUCTION VALVE DN25
1
OSR ISOLATING VALVE DN25
1
PRISMATIC OIL LEVEL GAUGE FOR MAIN CONSERVATOR
1 SET
PRISMATIC OIL LEVEL GAUGE FOR OLTC CONSERVATOR
DRAIN VALVE FOR FIRE FIGHTING SYSTEM
CHECK
1
VALVES FOR NITROGEN INJECTION SYSTEM DN25
1 SET
DN200, BUTTERFLY TYPE
2 SET
CABLE BOX WITH BUSBAR AND POST INSULATORS
1 SET
DGA SERVERON TM1
NIFPS DETECTOR PROVISION
AS BUILT
28.02.20
E
D
NIFPS PROVISION ADDED
12.10.19
SEISMIC INPUTS INCORPORATED SLK
B
No.
PROJECT
APR
RA
COMMENTS INCORPORATED
19.09.19
DATE
APR
RA
MASSES UPDATED
24.10.19
C
APR
RA
24.01.20
APR
SLK
REMARKS
DRN
APR
CKED
TITLE:
SOLAR PV PLANT AT SANTA ISABEL CHI
CLIENT:-
1
17
(PROVISION FOR RPRR)
F
1
FREESTANDING COOLER BANK WITH TOP AND BOTTOM HEADERS AND ISOLATING VALVES
50NB VALVE
C
10+2
MARSHALLING BOX
BATH FOR OTI, WTI
B
1
BOTTOM FILTER CUM DRAIN VALVE DN50
***
A
2
1
8
21
ABB MONOGRAM PLATE
RATING AND DIAGRAM PLATE
6
22
QUANTITY
2
3
53
DESCRIPTION
E
CONSULTANT:-
1
EPC
CONTRACTOR
:-
STERLING & WILSON SOLAR LIMITED
IMPERIA, A-25, MOHAN CO-OPERATIVE
INDUSTRIAL ESTATE, MATHURA ROAD,
NEAR SARITA VIHAR METRO STATION,
DELHI 110044
E-mail : delhi.solarsterlingwilson.com.
Website : www.sterlingandwilson.com.
SCALE 0.015
DRAWING
TITLE:
GENERAL ARRANGEMENT
176.25MVA, 220/23kV TRANSFORMER
DRAWING
NO
DRAWN
CHECKED
APPROVED
DATE
1
2
3
4
5
6
7
:
2XYN460001C1222
SLK
APR
TKG
09.09.2019
8
SHEET
NO
PAPER
SIZE
REV
NO.
NTS
2 OF 2
A2
F
Rated Voltage
Phase to-earth Voltage
Dry Lightning Impulse 1,2/50µs
Wet Switching Impulse
Wet Power frequence AC
Routine test 1min dry 50Hz
Rated Current
Creepage Distance
850 kV
N/A kV
560 kV
2500 A
D2
Threaded hole M8
for pulling wire
825 kg
D2
(mm)
60
60
60
60
D9
D3
D9 Cond.area
(mm)(mm2)
45 45 600
R492
Additional
joint on
request
50
48
330
480
$
Position of
Test tap
Prepared
2017-07-18
Balaji.G.R
2017-07-20
Natalia Gutman
2017-07-20
Approved by
Revision
A-A
H
8 mounting
holes
2
3
N1=6
N1=4
N1=Number of holes M12, equipped with
thread insert with screw lock,
depth 20, for cable lugs.
Responsible department
Balaji.G.R
Modified by
90 $
Position of oil
sample valve
R8
R30
430
45
C
170
*) WITH PILOT HOLE D=5
Current (A)
IEC
IEEE
1600
1360
Lower
draw rod
END SHIELD
1033 5
LOWER DRAW ROD WITH N1=4 OR N1=6
UPPER DRAW ROD
End of
cable
60
2"-12UN
96
EPOXY INSULATED
INSULATED WITH3 mm PRESSBOARD
D3
(mm)
O *)
40
B
25
A1
Cu
Cu/Ag
Cu/Sn
Cu/Ag
Cu
Upper
draw rod
H1 min260
LF170 056-E
LF170 056-D
Max. Rated H2
Current (A)
(mm)
125
2500
125
4000
125
4000
4000
125
3000
125
5000
125
3311 60
COLOUR AIR INSULATOR
BROWN
PGCO/BK
Take over department
Title
GOE 1175-850-2500-0.3
Used in product
GOE 1175-850-2500-0.3
Drawing display updated
4
58
INNER TERMINAL
Outer
terminal
39
DRAW ROD SYSTEM
LF170 059
LF170 057
A
Threaded hole M8
for pulling wire
65
28
1175 kV
350
073-A
073-B
073-G
073-L
073-BA
073-AA
END-SHIELD
LF170 046U
LF170 046UP
305
Outer terminal
265
195
335
209 kV
Ordering Data:
LF170
LF170
LF170
LF170
LF170
LF170
Earthed
layer
362 kV
H2
Mass
OUTER TERMINAL
Earthing hole
M12
6
INNER TERMINAL / OUTER TERMINALDRAW ROD SYSTEM / OUTER TERMINAL
D2
9120 mm
BUSHING
1ZSC902362-AAA
2470
3311 60
485
1035 5
The information contained in this document has to kept strictly
confidential. Any unautorized use, reproduction, distribution
or disclosure to third parties are strictly forbidden.
ABB reservs all rights regarding Intellectual Property Rights.
© Copyright 2013 ABB. All rights reserved.
5
H2
Bushing Data:
B
4
511
A
C
3
2
140
This document is issued by means aofcomputerized system.
The digitally stored original is ctronically
ele
approved. The
approved document has a date entered
in the `Approved'-field.
A manual signature is not required.
1
5
Language
82
Order
Sheet no.
Document no.
No. Shts.
2751369-315
6
1
(1)
D
1
2
3
FOUNDATION DETAILS FOR COMPLETE
A
4
5
6
7
8
3800
TRANSFORMER ASSEMBLY
1900
A
LV SIDE
1600
EARTHING POINT FOR NEUTRAL
EARTHING POINT FOR MAIN TANK
D
3465-Anchor point
2324- Jacking
765
1433
B
C
D
1433
INSTALLATION CENTER OF GRAVITY
OF MAIN TRANSFORMER UNIT
785
1183
25
50
94
1238- Jacking
357
C
1238- Jacking
B
INSTALLATION CENTER OF GRAVITY
OF SINGLE RADIATOR BANK
B
2566-Anchor point
2447- Jacking
3965
1785
Jacking load on each pad 49MT
SEE DETAIL
A
1635
1530
2447-Jacking
D
EARTHING POINT FOR MAIN TANK
150150
CHECK
2324-Jacking
FOR INFORMATION
FOR
AS-BUILT
APPROVAL
ONLY FABRICATION
5000
3800
E
450
HV SIDE
COMMENTS INCORPORATED
17.01.20
D
B
B
C
B
COMMENTS INCORPORATED
19.09.19
No. DATE
PROJECT
Base plate of cooler bank structure
(Part of transformer supply)
SLK
CABLE BOX FOUNDATION REMOVED & ANCHOR POINTS
INCREASED
04.10.19
APR
RA
FOUNDATION DRAWING UPDATED BASED ON
SEISMIC INPUTS
14.10.19
REMARKS
APR
RA
APR
SLK
APR
DRN CKED
TITLE:
SOLAR PV PLANT AT SANTA ISABE
CLIENT:-
E
450
E
BOX
D
5518
ORMER.
D
3985
150150
D
1600
1900
CONSULTANT:-
C
D
NOTE :
1. The level of loading surface should be adjusted with
# 3 mm.
FOUNDATION FOR COOLER BANK
2. The level of loading surface should be formed within one foundation.
WEIGHT ON EACH BLOCK 113344 N (approx.)
3. Earthing terminal for transformer groundiing available on tank.
4. Approx. Transformer mass (excluding free standing cooler bank) = 148500 kg
TRANSFORMER BASE AND
5. Approx Cooler bank mass (each) = 17540 kg
ERTHING TERMINAL LOCATION
176.25MVA, 220/23kV TRANSFORMER
6. Anchor box design and provision required to ensure
Seismic
proper
condition
anchoring
(Civil
under
scope).
2XYN460003C1222
7. One single Monolithic block is recommended for transformer
foundation. and cooler bank
SLK
8. Overall dimensions and weights have tolerence of
# 5%
APR
9. Refer 2XYN931510C1222 for Seismic report.
TKG
**TRANSFORMER SHOULD BE ANCHORED TO AVOID OVERTURING DURING
SEISMI
EPC
CONTRACTOR
:-
STERLING & WILSON SOLAR LIMITED
IMPERIA, A-25, MOHAN CO-OPERATIVE
INDUSTRIAL ESTATE, MATHURA ROAD,
NEAR SARITA VIHAR METRO STATION,
DELHI 110044
E-mail : delhi.solarsterlingwilson.com.
Website : www.sterlingandwilson.com.
DRAWING
TITLE:
DRAWING
NO
:
DRAWN
CHECKED
NTS
NO
PAPER
A2
SIZE
APPROVED
DATE
1
2
3
4
5
6
7
09.09.2019
8
1 OF
3
SHEET
REV
NO.
E
1
2
3
4
5
6
7
8
D
FOUNDATION DETAILS FOR MAIN TRANSFORMER
UNIT
A
A
2- STOPPERS (400X100X50; ST52-3
(NOT IN ABB SCOPE OF SUPPLY)
EMBED STEEL PLATE AS PER CIVIL DESIGN;
MATERIAL: St 52-3
(NOT IN ABB SCOPE OF SUPPLY)
B
B
C
C
D
D
CHECK
A 14
Base of transformer tank
All shear wedges
BOX
FOR INFORMATION
FOR
AS-BUILT
APPROVAL
ONLY FABRICATION
E
D
COMMENTS INCORPORATED
17.01.20
14.10.19
a.Total 3 anchor bolts of M48 per Achor point (No in ABB Scope of supply).
b. Maximum Traction Force per Anchor point is 526446 N.
c. Maximum Shear Force per Anchor point is 329997 N.
SOLAR PV PLANT AT
C
04.10.19
B
19.09.19
No. DATE
PROJECT
SLK
CABLE BOX FOUNDATION REMOVED & ANCHOR POINTS
INCREASED
COMMENTS INCORPORATED
REMARKS
APR
RA
FOUNDATION DRAWING UPDATED BASED ON
SEISMIC INPUTS
APR
RA
APR
SLK
APR
DRN CKED
TITLE:
SANTA ISABE
CLIENT:-
100
E
CONSULTANT:-
20
250
E
EPC
CONTRACTOR
:-
STERLING & WILSON SOLAR LIMITED
150
DRILL HOLES
150
600
IMPERIA, A-25, MOHAN CO-OPERATIVE
INDUSTRIAL ESTATE, MATHURA ROAD,
NEAR SARITA VIHAR METRO STATION,
DELHI 110044
E-mail : delhi.solarsterlingwilson.com.
Website : www.sterlingandwilson.com.
n 52 FOR ANCHOR BOLTS M48.
(ANCHOR BOLTS NOT IN ABB SCOPE OF SUPPLY)
DETAIL A
SCALE 0.084
DRAWING
TITLE:
DRAWING
NO
TRANSFORMER BASE AND
ERTHING TERMINAL LOCATION
176.25MVA, 220/23kV TRANSFORMER
DRAWN
:
2XYN460003C1222
SLK
APR
APPROVED
TKG
DATE
09.09.2019
SHEET
NTS
NO
2 OF
3
**TRANSFORMER SHOULD BE ANCHORED TO AVOID OVERTURING DURING SEISM
CHECKED
1
2
3
4
5
6
7
8
PAPER
REV
A2
SIZE
NO.
E
1
2
3
4
5
6
7
8
FOUNDATION DETAILS FOR SINGLE DRADIATOR BANK
3800- ANCHOR POINT
A
1900
175
E
A
1 MM GAP REQUIRED BETWEEN STOPPERS & BASE PLATE
A8
All shear wedges
175
175
E
175
2- STOPPERS (100x100x30; ST52-3)
8 mm weldment
(NOT IN ABB SCOPE OF SUPPLY)
B
B
3200- ANCHOR POINT
1600
ANCHOR BOX PROJECTION
C
E
HOLES
D
C
n 28 FOR 4 ANCHOR BOLTS OF M24.
a.Total 4 anchor bolts of M24 per Achor point (Not in ABB Scope
of supply).
INSTALLATION
CENTER OF GRAVITY
b. Maximum Traction Force per Anchor point is 65165 Newton. OF SINGLE RADIATOR BANK
c. Maximum Shear Force per Anchor point is 30112 Newton.
D
CHECK
BOX
FOR INFORMATION
FOR
AS-BUILT
APPROVAL
ONLY FABRICATION
E
D
C
B
COMMENTS INCORPORATED
17.01.20
FOUNDATION DRAWING UPDATED BASED ON
SEISMIC INPUTS
14.10.19
CABLE BOX FOUNDATION REMOVED & ANCHOR POINTS
INCREASED
04.10.19
COMMENTS INCORPORATED
19.09.19
No. DATE
PROJECT
REMARKS
RA
APR
SLK
RA
APR
APR
SLK
APR
DRN CKED
TITLE:
SOLAR PV PLANT AT SANTA ISABE
CLIENT:-
E
E
CONSULTANT:-
EPC
CONTRACTOR
:-
STERLING & WILSON SOLAR LIMITED
175
IMPERIA, A-25, MOHAN CO-OPERATIVE
INDUSTRIAL ESTATE, MATHURA ROAD,
NEAR SARITA VIHAR METRO STATION,
DELHI 110044
E-mail : delhi.solarsterlingwilson.com.
Website : www.sterlingandwilson.com.
DRAWING
TITLE:
DRAWING
NO
TRANSFORMER BASE AND
ERTHING TERMINAL LOCATION
176.25MVA, 220/23kV TRANSFORMER
2XYN460003C1222
:
SLK
DRAWN
APR
CHECKED
SHEET
NTS
NO
3 OF
3
**RADIATOR BANK SHOULD BE ANCHORED TO AVOID OVERTURING DURING SEISMICTKGEVENT.**
PAPER
A2
SIZE
APPROVED
DATE
1
2
3
4
5
6
7
09.09.2019
8
REV
NO.
E
1
2
3
4
5
6
7
8
Transport Center of gravity
2159
2169
A
A
100
4116 - Overall height
Transport
Center
of gravity
B
1)
1)
B
1)
1)
1)
Impact recorders
1663
Jacking Pad
Jacking Pad
C
C
2913
5818 - Base length
2866 - Base width
1528
D
CHECK
100
3056 - Overall width
D
BOX
FOR
INFORMATION
FOR
AS-BUILT APPROVAL
ONLY
FABRICATION
No.
DATE
PROJECT
REMARKS
CKED
DRN
TITLE:
SOLAR PV PLANT AT SANTA ISABEL CHI
CLIENT:-
E
E
CONSULTANT:-
4604
EPC
8212 - Overall length
CONTRACTOR
IMPERIA, A-25, MOHAN CO-OPERATIVE
INDUSTRIAL ESTATE, MATHURA ROAD,
NEAR SARITA VIHAR METRO STATION,
DELHI 110044
E-mail : delhi.solarsterlingwilson.com.
Website : www.sterlingandwilson.com.
Note:
1. Transport mass (dry air filled) = 98,000 kg.
2. The transformer shall be dispatched with dry air at positive pressure.
3. The transformer tank is fitted with a pressure regulating device and
pressure gauge for monitoring internal air pressure during transit.
4. Total 8 latching points provided on four sides of tank marked by 1).
3. Transport weight & dimensions have a tolerance of
# 5%.
4. Impact recorders (on returnable basis) are provided on transformer during transport.
7. Total 4 numbers of lifting hooks with capacity 40tons each.
8. SFRA bushings are to be mounted during transport.
DRAWING
TITLE:
DRAWING
NO
TRANSPORT DETAILS
176.25MVA, 220/23kV TRANSFORMER
3
4
5
6
7
2XYN460011C1222
SLK
CHECKED
APR
TKG
10.09.2019
DATE
2
:
DRAWN
APPROVED
1
:-
STERLING & WILSON SOLAR LIMITED
8
SHEET
NO
PAPER
SIZE
REV
NO.
NTS
1 OF 1
A2
A
1
2
3
4
5
6
7
8
5
GLAND PLATE DETAIL
1
4
3
2
1780
650
650
126
8
228
422
228
422
228
A
157 175
175
175
1188
175
175
A
B
B
SEE DETAILA
Holes scribed indicating cable knockots through gland plate.
Drilling to be done at site as per cable dimension.
cable support
Supported
from tank
C
C
1660
175P*5 875
=
SCALE 0.042
1058
M12 NUT ,BOLT
& WASHER ASSEEMBLY(MATERIAL STAINLESS STEEL)
FOR CABLE FIXING WITH BUSBAR BASED ON CABLE TERMINATION KIT.
794
GLAD PLATE FROM CABLE FIXING HOLE
LV BUSHING
D
D
CHECK
BOX
FOR
INFORMATION
FOR
AS-BUILT APPROVAL
ONLY
FABRICATION
X
DETAIL A
SCALE 0.200
7
Typical section showing the termination of cables
12 runs of 1 core x 630sq.mm XLPE cable
(not in ABB scope of supply)
CLEARANCE IN AIR FILLED CABLE BOX
Ph to Ph.
350
6
ITEM NO.
E
LV CABLE BOX
3
FLEXIBLE CONNECTOR
4
5
110
10
6
7
SCALE 0.200
NAME
1
2
180
8
9
10
Ph. to Earth
LV DISCONNECTING CHAMBER
BUS BAR
SUPPORT INSULATOR
GLAND PLATE (UNDRILLED)
INSPECTION COVER FOR CABLE BOX
INSPECTION COVER FOR DC CHAMBER
LOUVERS
M12 NUT ,BOLT
& WASHER ASSEMBLY
C
B
No.
SLK
RA
18/10/2019CUSTOMER COMMENTS INCORPORATED
18/10/2019CUSTOMER COMMENTS INCORPORATED
RA
SLK
DATE
PROJECT
DRN
CLIENT:-
E
1
1
3
CONSULTANT:-
3
6
1
EPC
CONTRACTOR
IMPERIA, A-25, MOHAN CO-OPERATIVE
INDUSTRIAL ESTATE, MATHURA ROAD,
NEAR SARITA VIHAR METRO STATION,
DELHI 110044
E-mail : delhi.solarsterlingwilson.com.
Website : www.sterlingandwilson.com.
2
2
2
:-
STERLING & WILSON SOLAR LIMITED
DRAWING
36 SETS
TITLE:
LV CABLE BOX ASSEMBLY
NOTE:
DRAWING NO :
1. GLAND PLATE TO BE DRILLED AT SITE BY CUSTOMER AS PER REQUIREMENT.
2XYN460015C1222
2. CABLE BOX IS SUITABLE FOR 12 RUNS x 1 CORE x 630sq. mm XLPE CABLE PER PHASE.
LINE CURRENT : 4424A
DRAWN
SHEET NO
AND TOLERANCES SHALL BE AS PER GENERAL ARRANGEMENT DRAWING.RA
REQUIRED CROSS SECTION AREA FOR BUSBAR: 34003.SQDIMENSIONS
MM
CHECKED
APR
PAPER SIZE
GIVEN CROSS SECTION AREA FOR BUSBAR: 4000 SQ4.MMFOR OTHER DIMENSIONS, REFER GENERAL ARRANGEMENT DRAWING.
APPROVED TKG
5. ALL HARDWARE EXCEPT CABLE FIXING ARE IN ABB SCOPE OF SUPPLY
REV NO.
BUSBAR CROSS SECTION CALCULATION
DATE
1
2
3
4
5
6
7
CKED
SOLAR PV PLANT AT SANTA ISABEL CHI
320
QTY.
REMARKS
TITLE:
17.10.2019
8
NTS
1 OF 1
A2
C
A
B
C
D
E
F
G
H
1
2
3
4
5
6
7
8
9
10
11
SRS
CKED
AS
AS
FOR
FABRICATION
DRN
AKP
INFORMATION
ONLY
REMARKS
Revised as built
Revised as per customer comment
FOR
APPROVAL
06.03.20
19.09.19
AS-BUILT
CHECK BOX
R2
R1
DATE
SOLAR PV PLANT AT SANTA ISABEL CHILE
TKG
AS
AKP
REV NO.
PAPER SIZE
R2
A3
1 OF 31
NTS
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
DRAWN
09.09.2019
SHEET NO
FOR 176.25MVA TRANSFORMER
SCHEMATIC OF COOLER CONTROL
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464032C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
G
H
1
2
3
4
5
6
7
8
9
10
11
AS
AS
FOR
FABRICATION
CKED
INFORMATION
ONLY
DRN
AKP
SRS
FOR
APPROVAL
Revised
Revised as built
AS-BUILT
CHECK BOX
19.09.2019
06.03.2020
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
R1
DATE
TKG
AS
AKP
REV NO.
PAPER SIZE
R2
A3
1 OF 2
NTS
R2
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
DRAWN
09.09.2019
SHEET NO
FOR 176.25MVA TRANSFORMER
GENERAL ARRANGEMENT OF M.BOX
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464033C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
G
H
1
2
3
4
5
6
7
8
9
10
11
AS-BUILT
CHECK BOX
DATE
R2 06.03.2020
R1 19.09.2019
No.
FOR
APPROVAL
Revised
INFORMATION
ONLY
REMARKS
Revised as built
TKG
AS
AKP
CKED
AS
AS
FOR
FABRICATION
SRS
AKP
REV NO.
PAPER SIZE
R2
A3
2 OF 2
NTS
DRN
SOLAR PV PLANT AT SANTA ISABEL CHILE
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
DRAWN
09.09.2019
SHEET NO
FOR 176.25MVA TRANSFORMER
GENERAL ARRANGEMENT OF M.BOX
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464033C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
G
H
1
2
4
5
6
7
8
9
SCHEMATIC OF OLTC & DIGITAL RTCC
3
10
11
INFORMATION
ONLY
FOR
FABRICATION
Ajay
Ajay
FOR
APPROVAL
SRS
AS-BUILT
CHECK BOX
AKP
AS
AKP
REV NO.
PAPER SIZE
R2
A3
1 OF 12
CKED
Revised as built
DRN
Revised as per customer comment
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
R2 06.03.2020
DATE
R1 19.09.2019
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
SHEET NO
FOR 176.25MVA TRANSFORMER
DRAWN
09.09.2019
NTS
SCHEMATIC OF OLTC & DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464034C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
H
1
2
3
4
5
6
7
8
9
10
11
Revised as per customer comment
Revised as built
DRN
AKP
SRS
CKED
Ajay
Ajay
FOR
FABRICATION
06.03.2020
INFORMATION
ONLY
19.09.2019
FOR
APPROVAL
R2
AS-BUILT
CHECK BOX
R1
DATE
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
AS
AKP
PAPER SIZE
R2
A3
2 OF 12
REV NO.
SHEET NO
FOR 176.25MVA TRANSFORMER
DRAWN
09.09.2019
NTS
SCHEMATIC OF OLTC & DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464034C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
G
H
1
2
3
4
5
6
7
8
9
10
11
Revised as per customer comment
Revised as built
DRN
AKP
SRS
CKED
Ajay
Ajay
FOR
FABRICATION
06.03.2020
INFORMATION
ONLY
19.09.2019
FOR
APPROVAL
R2
AS-BUILT
CHECK BOX
R1
DATE
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
AS
AKP
PAPER SIZE
R2
A3
4 OF 12
REV NO.
SHEET NO
FOR 176.25MVA TRANSFORMER
DRAWN
09.09.2019
NTS
SCHEMATIC OF OLTC & DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464034C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
G
H
1
2
3
4
5
6
7
8
9
10
11
FOR
APPROVAL
INFORMATION
ONLY
FOR
FABRICATION
Ajay
Ajay
AS-BUILT
CHECK BOX
AKP
SRS
AS
AKP
REV NO.
PAPER SIZE
R2
A3
3 OF 12
CKED
Revised as per customer comment
Revised as built
DRN
19.09.2019
06.03.2020
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
R1
DATE
R2
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
SHEET NO
FOR 176.25MVA TRANSFORMER
DRAWN
09.09.2019
NTS
SCHEMATIC OF OLTC & DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464034C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
G
H
1
2
3
4
5
6
7
8
9
10
11
Revised as per customer comment
Revised as built
DRN
AKP
SRS
CKED
Ajay
Ajay
FOR
FABRICATION
06.03.2020
INFORMATION
ONLY
19.09.2019
FOR
APPROVAL
R2
AS-BUILT
CHECK BOX
R1
DATE
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
AS
AKP
PAPER SIZE
R2
A3
5 OF 12
REV NO.
SHEET NO
FOR 176.25MVA TRANSFORMER
DRAWN
09.09.2019
NTS
SCHEMATIC OF OLTC & DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464034C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
G
H
1
2
3
4
5
6
7
8
9
10
11
Revised as per customer comment
Revised as built
DRN
AKP
SRS
CKED
AJAY
AJAY
FOR
FABRICATION
18.01.2020
INFORMATION
ONLY
19.09.2019
FOR
APPROVAL
R2
AS-BUILT
CHECK BOX
R1
DATE
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
AS
AKP
PAPER SIZE
R2
A3
6 OF 12
REV NO.
SHEET NO
FOR 176.25MVA TRANSFORMER
DRAWN
09.09.2019
NTS
SCHEMATIC OF OLTC & DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464034C1222
DRAWING NO :
DATE
APPROVED
A
AKP
SRS
AJAY
AJAY
FOR
FABRICATION
Revised
INFORMATION
ONLY
Revised as per customer comment
FOR
APPROVAL
06.03.2020
AS-BUILT
CHECK BOX
DATE
19.09.2019
TKG
AS
AKP
SHEET NO
R2
A3
7 OF 12
NTS
PAPER SIZE
CKED
R2
DRN
R1
REMARKS
No.
SOLAR PV PLANT AT SANTA ISABEL CHILE
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
DRAWN
09.09.2019
REV NO.
FOR 176.25MVA TRANSFORMER
SCHEMATIC OF OLTC & DIGITAL RTCC
CHECKED
2XYN464034C1222
DRAWING NO :
DATE
APPROVED
G
A
11
B
10
B
9
C
8
C
7
D
6
D
5
E
4
E
3
F
2
F
G
H
1
A
B
C
D
E
F
G
H
1
2
3
4
5
6
7
8
9
10
11
Revised as per customer comment
Revised as built
DRN
AKP
AKP
CKED
AJAY
AJAY
FOR
FABRICATION
06.03.2020
INFORMATION
ONLY
19.09.2019
FOR
APPROVAL
R2
AS-BUILT
CHECK BOX
R1
DATE
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
AS
AKP
PAPER SIZE
R2
A3
8 OF 12
REV NO.
SHEET NO
FOR 176.25MVA TRANSFORMER
DRAWN
09.09.2019
NTS
SCHEMATIC OF OLTC & DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464034C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
G
H
1
2
3
4
AVR
5
6
7
8
9
10
11
SRS
AJAY
AJAY
FOR
FABRICATION
AKP
INFORMATION
ONLY
Revised as built
FOR
APPROVAL
Revised as per customer comment
AS-BUILT
CHECK BOX
06.03.2020
AS
AKP
REV NO.
SHEET NO
R2
A3
9 OF 12
CKED
DATE
19.09.2019
DRN
R2
REMARKS
No.
R1
SOLAR PV PLANT AT SANTA ISABEL CHILE
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
NTS
SCHEMATIC OF OLTC & DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
DRAWN
09.09.2019
PAPER SIZE
FOR 176.25MVA TRANSFORMER
CHECKED
2XYN464034C1222
DRAWING NO :
DATE
APPROVED
1
2
- +
OLTC Upper Limit Reached
- +
3
67
4
-
OLTC in Local mode
3
+
5
69
6
7
70
71
9
10
5
11
12
-
72
76
77
14
79
15
80
13
- +
- +
16
81
7
M.BOX
Failure of Normal source &
Transfer to standby supply fail.
- +
Standby supply fail
+
6
Supply changeover fail
- +
Fan group-2 Fail
- +
Fan Group-1 Fail
- +
Cooler Control Supply Fail
REG-D
+
75
BINARY INPUT
OLTC Control supply fail
190V..250 AC/DC
-
8
- +
(common)
4
74
- +
LTC in Remote Auto mode
- +
OLTC in Remote Manual mode
- +
68
A
+
OLTC Lower Limit Reached
B
-X1
66
Tap changer motor Trip
2
-
Common
82
Common Thermal overload trip
78
OLTC in SCADA mode
73
C
D
E
F
G
H
1
65
Tap Change incomplete
8
9
10
11
Revised as per customer comment
Revised as built
DRN
AKP
SRS
CKED
AJAY
AJAY
FOR
FABRICATION
06.03.2020
INFORMATION
ONLY
19.09.2019
FOR
APPROVAL
R2
AS-BUILT
CHECK BOX
R1
DATE
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
AS
AKP
PAPER SIZE
R2
A3
10 OF 12
REV NO.
SHEET NO
FOR 176.25MVA TRANSFORMER
DRAWN
09.09.2019
NTS
SCHEMATIC OF OLTC & DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464034C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
G
H
1
2
3
4
5
6
7
8
9
10
11
DRN
AKP
SRS
CKED
AJ AY
AJ AY
FOR
FABRICATION
R ev is ed as b uilt
INFORMATION
ONLY
R ev is ed as p er customer comment
FOR
APPROVAL
06.03.2020
AS-BUILT
CHECK BOX
19.09.2019
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
R2
DATE
R1
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
AS
AKP
PAPER SIZE
R2
A3
11 OF 12
REV NO.
SHEET NO
FOR 176.25MVA TRANSFORMER
DRAWN
09.09.2019
NTS
SCHEMATIC OF OLTC & DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464034C1222
DRAWING NO :
DATE
APPROVED
AVR
A
Revised as built
DRN
AKP
SRS
CKED
AJAY
AJAY
FOR
FABRICATION
Revised as per customer comment
INFORMATION
ONLY
06.03.2020
FOR
APPROVAL
DATE
19.09.2019
AS-BUILT
CHECK BOX
R2
REMARKS
No.
R1
SOLAR PV PLANT AT SANTA ISABEL CHILE
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
DRAWN
09.09.2019
TKG
AS
AKP
12 OF 12
NTS
SHEET NO
R2
A3
REV NO.
PAPER SIZE
FOR 176.25MVA TRANSFORMER
SCHEMATIC OF OLTC & DIGITAL RTCC
CHECKED
2XYN464034C1222
DRAWING NO :
DATE
APPROVED
G
A
11
B
10
B
9
C
8
C
7
D
6
D
5
E
4
E
3
F
G
H
2
F
1
A
B
C
D
E
F
G
H
1
3
4
5
6
7
8
9
10
GENERAL ARRANGEMENT OF DIGITAL RTCC PANEL
2
11
06.03.20
REMARKS
Revised as per customer comment
Revised as built
DRN
AKP
SRS
CKED
Ajay
Ajay
FOR
FABRICATION
19.09.19
INFORMATION
ONLY
R2
FOR
APPROVAL
R1
DATE
AS-BUILT
CHECK BOX
No.
SOLAR PV PLANT AT SANTA ISABEL CHILE
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
AS
AKP
PAPER SIZE
R2
A3
1 OF 4
REV NO.
SHEET NO
FOR 176.25MVA TRANSFORMER
DRAWN
09.09.2019
NTS
GENERAL ARRANGEMENT OF DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464036C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
G
H
1
2
3
4
5
6
7
8
9
10
11
Revised as per customer comment
Revised as built
DRN
AKP
SRS
CKED
Ajay
Ajay
FOR
FABRICATION
06.03.20
INFORMATION
ONLY
19.09.19
FOR
APPROVAL
R2
AS-BUILT
CHECK BOX
R1
DATE
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
AS
AKP
PAPER SIZE
R2
A3
2 OF 4
REV NO.
SHEET NO
FOR 176.25MVA TRANSFORMER
DRAWN
09.09.2019
NTS
GENERAL ARRANGEMENT OF DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464036C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
G
H
1
2
3
4
5
6
7
8
9
10
11
Revised as per customer comment
Revised as built
DRN
AKP
SRS
CKED
Ajay
Ajay
FOR
FABRICATION
06.03.20
INFORMATION
ONLY
19.09.19
FOR
APPROVAL
R2
AS-BUILT
CHECK BOX
R1
DATE
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
AS
AKP
PAPER SIZE
R2
A3
3 OF 4
REV NO.
SHEET NO
FOR 176.25MVA TRANSFORMER
DRAWN
09.09.2019
NTS
GENERAL ARRANGEMENT OF DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
CHECKED
2XYN464036C1222
DRAWING NO :
DATE
APPROVED
A
B
C
D
E
F
G
H
1
Right Side view
GASKET PROFILE
2
3
4
Front view
(DOOR OPEN)
5
Left Side view
6
Front view (DOOR CLOSED)
3D VIEW FOR REFERENCE
NOTE:
1. MATERIAL: MIN. 2.5 mm THICK CRCA SHEET.
2. Paint shade (external) : RAL 7035 outside and glossy white inside as per powder coating (1ZYN206004)
Paint thickness (internal & external) : 60 micron minimum
3. Undrilled gland plate and double compression cable glands suitable
For following sizes shall be provided at the bottom.
(a) 1100 volts grade PVC insulated Stranded 2.5 mm2 copper cable with armour :
4. Gland shall be dust proof, screw on and double compression type and made of brass. The gland shall
have provision for securing armour of the cable separately and shall be provided with earthing tag. The
gland shall conform to BS:6121 and shall be nickel plated
5. Degree of Ingress Protection shall be IP-31.
6. Weight of RTCC is appx. 250 Kg.
7. Size & quantity of gland is subject to change in final stage.
8. EARTHING TERMINALTwo Nos. earthing bosses are provided with tapped hole of size
M10.Two plain washers and a bolt of size M10X20 is provided with each earthing boss.
9. The gland shall project at least 25 mm above gland plate to prevent entry of moisture in cable crutch, gland plate shall
have provision for some future glands to be provided later.
9
10
10.All doors, removable covers and plates shall be gasketed all around with neoprene gaskets.Ventilation louvers if
provided shall have screens and filters. The screens shall be made of either brass or GI wire mesh with a graduation of
1 mm or less.applicable for indoor control cubical.
11.Doors shall be gasketted all around with suitably profiled neoprne gaskets.
The gaskets shall be tested in accordance with approved quality plan, IS: 1149 and IS: 3400.
12. EARTHING TERMINALTwo earthing terminals suitable for connection to 75 x 12 mm
galvanised steel flat shall also be provided
8
13. All gasketed surfaces shall be smooth straight and reinforced if necessary to
minimize distortion to make a tight seal.
14. Ventilating Louvers, if provided, shall have screen and filters. The screen shall be fine
wire mesh of brass.
15. Component & its arrangement is subject to change in final stage.
7
11
AS-BUILT
CHECK BOX
FOR
APPROVAL
INFORMATION
ONLY
FOR
FABRICATION
Ajay
Ajay
CKED
AKP
SRS
DRN
Revised as per customer comment
Revised as built
SOLAR PV PLANT AT SANTA ISABEL CHILE
REMARKS
R1 19.09.19
DATE
R2 06.03.20
No.
PROJECT TITLE:
CLIENT:-
CONSULTANT:-
TKG
AS
AKP
REV NO.
SHEET NO
R2
A3
4 OF 4
NTS
GENERAL ARRANGEMENT OF DIGITAL RTCC
STERLING & WILSON SOLAR LIMITED
EPC CONTRACTOR :-
DRAWING TITLE:
DRAWN
09.09.2019
PAPER SIZE
FOR 176.25MVA TRANSFORMER
CHECKED
2XYN464036C1222
DRAWING NO :
DATE
APPROVED
1
2
3
4
5
102
101
103
6
7
8
216
217
104
A
A
563
564
236
228
229
501
B
B
321
502
We reserve all rights in this
nt docume
and in the information contained therein.ction,
Reprodu
use or
disclosure to third parties express
without authority
C
is strictly forbidden.
ABB
570
571
C
572
230
573
574
503504
SR. NO.
231
1
Main & OLTC conservator
HV Loose Turrets
LV Loose DC CHAMBER
LV cable box
2
238
101
102, 103, 104
105
106
1
3
1
1
Buchholtz Relay Pipe
HV&LV Air Vent Pipe
OLTC OSR PIPE
Conservator Equalizer Pipe
Main Conservator Breather Pipe
OLTC Conservator Breather Pipe
OLTC Suction Pipe
Cooler pipe line
Cooler pipe reducer
PRD pipe loose
201 TO 206
207 TO 212
213 TO 215
216, 217
218 TO 221
222 TO 224
228 TO 235
236
237,238
6
6
3
2
4
3
3
8
4
2
H Support
HEADER ASSEMBLY
INCLINED SUPPORT
HORIZONTAL SUPPORT
PIPE SUPPORT 1
PIPE SUPPORT 2
CROSS ANGLE TIE
HORIZONTAL ANGLE TIE
Cross radiator tie long
Cooler pipe support with c clamp
301 TO 302
303
304 TO 307
308 TO 309
310 TO 313
314 TO 317
318
319
320
321
2
1
4
2
4
4
8
2
8
2 sets
Main Conservator Supports
Expansion Bellow Support-1
Expansion Bellow Support-2
OLTC Bevel Gear Support
OLTC Suction Pipe Support
Ladder with anti-climb door
Radiator Ties (1ZYN934020)
501, 502
503
504
505
511 TO 513
529
536
537 TO 560
561
562
563,564
565,566,567
568,569
570
2
4+4
4+4
1
3
1
40
24
1
4
2
3
2
12
601 to 605
606
607
608
5
1
3
3
PIPE WORK
237
3
225 TO 227
COOLER BANK (2 SET ;HV & LV SIDE)
D
4
SUPPORTS
601
233
PART NO.
QUANTITY
MAIN COMPONENT
106
105
DESCRIPTION
232
E
FAN BRACKET WITH 2NOS U-BOLTS EACH
E
604
reviewProduction
COPPER FLATS & FLEXIBLE
5
602
605
603
Based
on
Neutral flat with joint
Neutral flexible
Cable box bus bar
Cable box flexible
Reg.
1ZXX469152
engineering
Design
Inspection
engineering
review
engineering
review
Cable tie horizontal
Cross cable tie
Expansion Bellow Support-1&2
Cable support
cable box support
Header cable tray support
Prepared
235
234
568
565
566
567
2
SETFO
Approved
Take
--
APR
569
Mass
3
4
ALL
THE
DIMENSION
5
ARE
IN
MM
UNLESS
Part number added
Rev
Ind
OTHERWISE
SPECIFIED.
Revision
6
RA
Appd
24/01/20
Date
B
over
Part Marking
department
9808298721
kg
E
Scale
0.020
Language
en
Order
Document
7
D
department
13156
ABB INDIA LIMITED
2XYN468957C1222
Revision
B
1
Responsible
RA
Title
No.
C
No.
8
Page
1
Total
2
1
2
3
4
5
6
307
7
8
317
313
316
A
A
306
218
312
308
211
212
303
210
219
220
B
207
B
209
208
305
221
304
315
We reserve all rights in this
nt docume
and in the information contained therein.ction,
Reprodu
use or
disclosure to third parties express
without authority
C
is strictly forbidden.
ABB
314
309
301
222
C
311
310
302
SCALE
C
0.040
319
223
201
202
204
203
205
206
D
D
224
225
226
E
E
E
227
214
318
reviewProduction
213
320
SCALE
Based
0.040
on
Reg.
1ZXX469152
engineering
Design
Inspection
engineering
review
engineering
review
215
Prepared
Responsible
RA
SETFO
Approved
Take
--
APR
Mass
B
1
2
3
4
ALL
THE
DIMENSION
5
ARE
IN
MM
UNLESS
Part number added
Rev
Ind
OTHERWISE
SPECIFIED.
Revision
6
RA
Appd
24/01/20
Date
Part Marking
department
9808298721
kg
Order
Document
7
0.031
department
13156
ABB INDIA LIMITED
2XYN468957C1222
Revision
B
over
Scale
Title
No.
No.
8
Language
en
Page
2
Total
2
1
2
3
4
5
6
307
7
8
317
313
316
A
A
306
218
312
308
211
212
303
210
219
220
B
207
B
209
208
305
221
304
315
We reserve all rights in this
nt docume
and in the information contained therein.ction,
Reprodu
use or
disclosure to third parties express
without authority
C
is strictly forbidden.
ABB
314
309
301
222
C
311
310
302
SCALE
C
0.040
319
223
201
202
204
203
205
206
D
D
224
225
226
E
E
E
227
214
318
reviewProduction
213
SCALE
Based
0.040
on
Reg.
1ZXX469152
engineering
Design
Inspection
engineering
review
engineering
review
215
Prepared
Responsible
RA
SETFO
Approved
Take
--
APR
Mass
1
2
3
4
ALL
THE
DIMENSION
5
ARE
IN
MM
UNLESS
Rev
Ind
OTHERWISE
SPECIFIED.
Revision
6
Appd
Date
Part Marking
department
9808298721
kg
Order
Document
7
0.031
department
13156
ABB INDIA LIMITED
2XYN468957C1222
Revision
A
over
Scale
Title
No.
No.
8
Language
en
Page
2
Total
2
1
2
3
4
5
6
7
8
A
B
B
We reserve all rights in
ntthis
and docume
in the information contained therein.
ction,Reprodu
use or
disclosure to third parties
without
express
authority
C
is strictly forbidden.
ABB
A
C
C
D
D
CABLE SCHEDULE
S. No.
Main MOLG
3
Oil surge relay
Fans
5
OLTC PRESSURE RELAY
6
7
1
1
1
11
12
14
Pressure relief device (PRD)
2
2
6 core
1
Buchholtz relay
1
1
415V AC 3-Ph 4W supply to DM box
Current transformer (CT)
1
1
b) H0
1
-
1
-
2
c)X1(WTI)
3
1
1ZBA217004-AV
D=10 ;L=173
Based
Part
ID
on
No.
Prepared
Responsible
Approved
Take
Revision
Mass
APR
Rev
1
2
3
4
5
Ind
Revision
6
Appd
Date
ABB
A
INDIA
7
over
-
-
-
-
-
15
10
10
15
15
-
E
-
-
-
- 4 core 15
- 2 core15
- 2 core 15
2 core 15
Material
XYN468958_CABLE_WIRING
RA
15
-
1ZBA135003-X
Cable Supp100
Dimension
Reg.
-
240
-
1
Unit
Item
Quantity
-
15
2 core
a) H2
E
4 core
1
1
220AC SUPPLY TO DGA
8
review
1
20
15
1
review
Production
engineering
1
12
DGA
engineering
Design
review
1
12
PRV OLTC
7
engineering
1
OLTC Magnetic oil level gauge
1 (MOLG)
1
4
Inspection
Cable details (Armoured cable)
Cables/
Total
Total
component
Qty.
2.5 mm2
4.0 mm2
Qty. (m) Qty. (m)
Description
1
2
E
Component
ID
Description
0.1
Mass
Rem
Scale
Title
Cable wiring
0.030
department
department
en
Order
13156
LIMITED
2XYN468958C1222
Document
No.
8
Page
1
Total
1
⊆≡♥⟩ ∂±≈⟩ ⊆≡♥∂←∂°±
⇒↓↓≈⟩




⇒⊆⇒∫ ñ⌠⊄⟩
⊕∅∇∫⇒⇔
⌠


⊕∅∇∫∉
















⊕∅∇
⇒⊆⇒∫
⇒⊆⇒∫
⇒⊆⇒∫
⇒⊆⇒∫
⇒⊆⇒∫
⊕∅∇∫⊕
⊕⇑⇒∫⇐
⌡
⌡

ñ⌠∩⟩

⟩ñ⟩⌡⟩
⊄  ∩ 
√↔≡″
∈♠±↔∂↔ƒ
∉↑↔ √⇔
⇔∂″≡±←∂°±
⊇±∂↔
⇑←≡≈ °±
⊆≡÷ ∇°
∉↑≡↓↑≡≈
⊆≡←↓°±←∂≥≡ ≈≡↓↑↔″≡±↔
⇑⟩♠↑≥∂ °•±
⊄∉⊄⇔
⇒↓↓↑°♥≡≈
⊄×≡ °♥≡↑ ≈≡↓↑↔″≡±↔
⇒∫
⇐⇒⊂⊂⟩
∉⇒√∇ ∪⇒⊂⋅∨⊆
⊂⊄∨∨ ⊂⊄⊇⇔
∨⇒⊆⊄⋅√∇¬
⊄∨⊆√∇⇒
∨⇒⊆⊄⋅√∇¬ ⇐⇒⇑∨
⟩ ⇐⇒⊂⊂
⋅∨∩⟩⊂⇐⊆∨∪
⟩ ⇐⇒⊂⊂
⋅∨∩⟩⊂⇐⊆∨∪
⇒∫
⋅∨∩⟩∇⊇⊄
⇒∫
∉⇒√∇ ∪⇒⊂⋅∨⊆
⇒∫
⋅∨∩⟩∇⊇⊄
∇√⊄⊆√∨⊆⊇⇑⇑∨⊆ ∠∫⊆√∇¬
⇐∠∉∉∨⊆ ⊂⊄⊆√∉
↔≡↑∂≥ √⇔
⇔≡←…↑∂↓↔∂°±
⊄∂↔≥≡
←← ⊗×÷ℜ
⊆≡″⟩
⊂…≥≡
∨⇒⊆⊄⋅√∇¬ ⇒⊂⊂∨⇑∅
±÷♠÷≡
⟩⊂≡×↑
⊆≡♥∂←∂°±
⇔↔≡
≡±
⊄°↔≥ ″←← ⊗×÷ℜ
∠↑≈≡↑
∉÷≡
⊂⊄⇒∇⇔⇒⊆⇔
⇒
⇔°…♠″≡±↔ ∇°⟩
⇒←≡ ⇑↑°♦± ⇑°♥≡↑∂ ↔≈⟩

…°±↔⟩
⊕∅∇ 
∫
INSTRUCTION MANUAL
Oil Temperature Indicator type “OTI / eOTI”
Winding Temperature Indicator type “WTI / eWTI”
5COW423700 – REV_E
I
II
CONTENTS
1.
SAFETY...................................................................................................................... 1
1.1 Safety instructions....................................................................................................... 1
1.2 Specified applications ................................................................................................. 1
1.3 Safety notes on the equipment operation ................................................................... 1
2.
DRAWING .................................................................................................................. 2
2.1 OTI/WTI/eOTI/eWTI .................................................................................................... 2
2.2 Bulbs ........................................................................................................................... 4
3.
OPERATING PRINCIPLE .......................................................................................... 5
3.1 Oil temperature indicator (OTI) – Oil temperature indicator with digital and analog
output (eOTI) .................................................................................................................... 5
3.2 Winding Temperature Indicator (WTI) – Winding Temperature Indicator with digital
and analog output (eWTI) ................................................................................................. 5
3.3 Outputs ....................................................................................................................... 6
3.4 Technical features....................................................................................................... 6
3.5 Tests ........................................................................................................................... 7
4.
INSTALLATION.......................................................................................................... 8
4.1 Flange connection....................................................................................................... 8
4.1 Elastic Suspension (optional) ...................................................................................... 8
5.
ELECTRICAL CONNECTION .................................................................................... 9
5.1 Wiring diagrams .......................................................................................................... 9
5.1.1 OTI – eOTI (2 , 4 contacts) ................................................................................... 9
5.1.2 WTI – eWTI (2 , 4 contacts) ................................................................................. 9
5.1.3 Pt100 .................................................................................................................... 9
5.2 Micro switches and PT100 (optional) ........................................................................ 10
5.2.1 Setting ................................................................................................................. 10
5.3 ΔT calibration for thermal Image (WTI / eWTI).......................................................... 11
5.4 eOTI/eWTI adding terminals ..................................................................................... 11
6.
OPERATION AND MAINTANENCE ........................................................................ 12
6.1 Operation and maintenance...................................................................................... 12
6.2 Storage ..................................................................................................................... 12
APPENDIX A: MODBUS COMMUNICATION................................................................... 13
A1: MODBUS register ..................................................................................................... 13
A1.1 MODBUS address ............................................................................................... 14
APPENDIX B: I2-∆T CURVES .......................................................................................... 15
B1: Example: how to utilize the curve ............................................................................. 15
B2: Nominal CT current: 1 A ........................................................................................... 16
B3: Nominal CT current: 1.5 A ........................................................................................ 17
B4: Nominal CT current: 2 A ........................................................................................... 18
B5: Nominal CT current: 4 A ........................................................................................... 19
B6: Nominal CT current: 5 A ........................................................................................... 20
1. SAFETY
1.1 Safety instructions
Make sure that any personnel installing and operating the thermometers:
- Are technically qualified and competent.
- Fully comply with these assembling instructions.
Improper operations or misuse could cause danger to:
· Life and limb.
· To the equipment and other assets of the operator.
· To the equipment proper, function.
Safety instructions in this manual are shown in three different forms to emphasize
important information.
WARNING
This information indicates particular danger to life and health. Disregarding such a warning can lead to
serious or fatal injury.
CAUTION
This information indicates particular danger to equipment and/or other property of the user. Serious or fatal
injury cannot be excluded.
NOTE
This note gives important and specific information concerning the equipment.
1.2 Specified applications
The thermometer is used for oil-insulated transformers to measure the temperature of
transformer oil (OTI) or the windings temperature (WTI) using the thermal image principle.
It is important to observe the limit values indicated on the nameplate and in the manual
before commissioning the device.
1.3 Safety notes on the equipment operation
Electrical installation is subject to the relevant national safety rules.
It is mandatory to connect the grounding cable because of safety reason.
CAUTION
Installation, electrical connection and fitting the device have to be carried out by qualified personnel and
only in accordance to this instruction manual.
It is responsibility of the user to make sure that the device is used for specified application only.
For safety matters, please avoid any unauthorized and improperly works.
WARNING
All relevant fire regulation must be strictly observed.
1
2. DRAWING
2.1 OTI/WTI/eOTI/eWTI
The dimensions of the following drawings are valid for the devices (with connection flange)
-
OTI: oil temperature indicator
WTI: winding temperature indicator
eOTI: oil temperature indicator with digital and analogue output
eWTI: winding temperature indicator with digital and analogue output
2
Fig. 1
3
2.2 Bulbs
Fig. 2
Fig. 3
4
3. OPERATING PRINCIPLE
3.1 Oil temperature indicator (OTI) – Oil temperature indicator with digital and
analog output (eOTI)
These devices are designed to measure the temperature of the insulating oil inside of
power transformer tanks. It’s possible to fit up to 5 change-over micro switches suitable to
control cooling equipment’s and protection circuits of transformer (alarm and trip).
The bulb of thermometer detects the transformer oil temperature variations generating a
contraction or expansion of the capillary connected to the pointer shaft. The adjustable
switching system connected to the pointer shaft provide the desired alarm/trip signals.
The electronic version of this kind of device, reading the signal from a PT100, give like
available:
- Analogue output 4-20 mA
- Modbus RTU communication (optional)
3.2 Winding Temperature Indicator (WTI) – Winding Temperature Indicator with
digital and analog output (eWTI)
The winding is a “high temperature” component in oil transformers, subjected to fast
temperature changes. Thus, an indirect system is used to measure the winding
temperature because it is dangerous to place a sensor close to the winding. This method
is called Thermal Image principle.
This instrument is designed to measure the temperature of winding by using a special bulb
surrounded by a heating resistance through which passes a current proportional to the
winding current under certain load and temperature conditions. It’s possible to adjust the
heating system by using a potentiometer placed on the instrument dial.
As indicated for OTI, this special bulb detects the temperature variations generating a
contraction or expansion of the capillary connected to the pointer shaft. The adjustable
switching system connected to the pointer shaft provide the desired alarm/trip signals.
It is possible to fit up to four change-over micro switches suitable to control cooling
equipment and protection circuits of transformer (alarm and trip).
The electronic version of this kind of device, reading the signal from a PT100, give like
available:
-
Analogue output 4-20 mA
Modbus RTU communication (optional)
Pt 100 (optional)
5
3.3 Outputs
STANDARD CONFIGURATION
STANDARD
(OTI)
STANDARD
(WTI)
OPTIONS
(eOTI-eWTI)
PT100
MICRO-SWITCHES
1 up to 4 x change over contact
MICRO-SWITCHES
1 up to 4 x change over contact
ANALOG OUTPUT
4-20
mA
(Maximum resistance: 450 Ohm)
COMMUNICATION PORT RS-485
Modbus communication – Appendix A
PT 100 port
Max 2 x OTI / WTI (1 Optional x eOTI / eWTI)
Table 1
3.4 Technical features
Standard connection flange
Material
Color
Dial
Ambient temperature
Degree of protection
Vibration damping
Ventilation valve
Cable gland
Wires
Micro switches, PT100 features
Insulation
4 holes Ø 7 mm, holes wheelbase Ø 175 mm
All the external part are resistant to transformer oils, salt fog and UV
rays **
White RAL 9002**
Tempered glass / Polycarbonate
-40°C to 80 °C
IP65 in accordance with EN60529
Optional anti-vibration supports available
N°2 to prevent the formation of condensation
Up to 3 x M25x1.5
Max 2.5mm2 – advised 4x1mm2 o 6x1mm2 shielded twisted pair cable
2000 V 50 Hz between terminals and earth for a 60 s time
1000 V 50 Hz between terminal in open position
Outputs (OTI/WTI)
Max 2 Pt100
Electronic board features (eOTI – eWTI)
Supply voltage (electronic
24 V dc ±10% polarized
devices)
Power consumption
0,5 W
Analog input (electronic devices)
1 x Pt100
1 x 4..20 mA insulated (dielectric strength between electronic card and
analogical output:2kV)
Analog output (electronic devices) Accuracy : 1.5 % of full scale
Maximum resistance: 450 Ω
1 x Pt100 (optional)
Distance for analogical output
Max 30 m / 98 ft (for different demands contact COMEM)
Serial RS485 Modbus RTU (for more information contact COMEM
Digital output
assistance dept.)
Distance for digital output
Max 30 m / 98ft (for different demands contact COMEM)
Available temperature range*
WTI / eWTI range
0 / +150°C, 0 / +160°C, 0 / +180°C
OTI / eOTI range
-20 / +130°C, -20 / +140°C, 0 / +120°C, 0 / +150°C, 0 / +160°C
* For specific range please contact Comem
** For critical environmental conditions please contact Comem
6
Table 2
Voltage
125 VAC
250 VAC
30 VDC
50 VDC
75 VDC
125 VDC
250 VDC
Micro switches making and breaking capacity
Standard Micro switches
High-performances micro switches
Resistive Load
Inductive Load
Resistive Load
Inductive Load
5A
5A
10 A
10 A
5A
5A
10 A
10 A
5A
5A
10 A
10 A
1A
1A
3A
2.5 A
0.75 A
0.25 A
1A
0.5 A
0.5 A
0.1 A
0.5 A
0.1 A
0.25 A
0.1 A
0.25 A
0.1 A
Table 3
3.5 Tests
Description
Measuring tolerance test and commutation tolerance test
Measuring tolerance test and commutation tolerance test
Leakage test
IP degree
Vibration test
REFERENCE STANDARD
EN50216-11
JB6302 – JB8450
EN50216-11
EN 60259
EN 60721-3-4 class 4M4
CEI EN 60068-3-3 (class 0,
level II)
Seismic test
Climatic test
Dry heat test (60°C 50%RH)
Dry heat test (40°C 93% RH)
Damp heat, steady state
Cold test
Damp heat, steady state
Damp heat cyclic
EMC
Fast transient/burst immunity test
Immunity to Conducted disturbances
Electrostatic discharge
Surge immunity test
Magnetic field immunity test
Immunity test
EN 60068-2-2 cl.6
EN 60068-2-2 cl.6
EN60668-2-78 cl7 and 9
EN 60068-2-1 cl.6
EN60668-2-78 cl7 and 9
IEC 60068-2-30
IEC 61 000-4-4
IEC 61 000-4-6
IEC 61 000-4-2
IEC 61 000-4-5
IEC 61 000-4-3
IEC 61 000-6-2
IEC 61 000-6-4
(EN 55022)
EN61000-4-8
IEC 61 000-3-2
IEC 61 000-3-3
EN 61000-4-11
Emission standard
Power-frequency magnetic field
Harmonic current emission
Voltage fluctuations and flicker
Micro-interruption and voltage variations
Table 4
7
4. INSTALLATION
CAUTION
The operating and the installation requirements described in this manual must be strictly following. If not,
the device can be damaged or a malfunction can occur.
4.1 Flange connection
The standard solution is with a flange connection. Arrange the transformer with a
dedicated place following the scheme in the figure 4. The connection can be done in two
alternative way:
- threaded pin
- screws
Fig. 4
4.1 Elastic Suspension (optional)
In case of high vibration withstand demand, the elastic suspension connection is available.
The actions that have to be followed are:
1. Unscrew the upper rigid locking M14 screw
located on the top of the thermometer (Fig. 5)
Fig. 5
8
2. Assembly the elastic suspension on the top of the
thermometer with a M14 screw that let install the instrument
in the plant (Fig.6-7)
Fig. 6
Fig. 7
5. ELECTRICAL CONNECTION
CAUTION
Qualified and skilled personnel trained in the applicable health and safety regulations of the relevant country
should only perform electrical connections.
WARNING
Dangerous electrical voltages!
It is imperative to deactivate the power supply during wiring of the device.
CAUTION
During the terminal box assembly, use caution not to damage the OR gasket (Fig.15/C). If this occurs, it
must be substituted.
If you do not use all the cable glands, pay attention to close the free cable gland with a plug with gasket.
5.1 Wiring diagrams
5.1.1 OTI – eOTI (2 , 4 contacts)
5.1.2 WTI – eWTI (2 , 4 contacts)
5.1.3 Pt100
9
5.2 Micro switches and PT100 (optional)
1. Removing of the terminal box cover: by unscrewing the four stainless steel captive
screws.
2. Cables layout: the numerations 1, 2, 3, 4, 5 indicate the micro switches progress:
red, blue, green, yellow, white pointer.
3. On the terminal board is written the cables layout for the different micro switches
utilizing the abbreviations:
·
·
·
C = common
NO = normally open
NC = normally closed
4. Connect the micro switches terminals and the earth terminal.
5. If the thermometer is equipped with the PT 100 probe, follow the label about how to
connect it
6. Re-position the terminal box cover.
5.2.1 Setting
To set the micro switches, follow the instructions:
1. Remove the locking ring (unscrew the eight M4 captive screws).
2. Remove the glass or polycarbonate lens.
3. Stop the micro switches setting dial (small black dial) with two fingers and slide the
fractioned micro switches setting pointers until they are located at the desired
temperature. Note that to reduce errors you have to slide the pointers towards
higher temperature value.
4. Replace the glass or polycarbonate lens taking care that the max. temperature
indicating pointer is located on the right side of the temperature indicating pointer
and that the lens itself correctly positioned over the sealing O-ring.
5. Lock the lens with the locking ring.
CAUTION
During the glass/polycarbonate lens removal, use caution not to damage the OR gasket. If this occurs, it
must be replaced.
If you do not use all the cable glands, pay attention to close the free cable gland with a plug with gasket.
10
5.3 ΔT calibration for thermal Image (WTI / eWTI)
Within the instrument’s terminal board there are, as well as earth and micro switches
connection terminals, the terminals T-T and the terminals A-A.
To calibrate the instruments, follow the steps:
1. Remove the jumper A-A.
2. Insert the ammeter probes in terminals A-A.
3. Connect the terminals T-T to the current transformer.
Be sure to use the right Current Transformer (CT) by checking that the CT nominal
current of CT is the one printed on the dial.
4. Regulate the current based on the curve I - ∆T (see Appendix A) rotating the
potentiometer until the read current on the ammeter corresponds to the value in the
curve.
5. Remove the ammeter probes.
6. Replace jumper A-A.
7. Wait few minutes to allow a stabilization of Tw.
8. Check the exactitude of Tw.
CAUTION
Some holes in the capillary bulb allow the oil flow and so the heat exchange providing a fast and accurate
measurement. The bulb must be inserted in a proper thermowell filled with transformer oil.The oil will rise
from the thermowell to the bulb holes covering the resistance.
5.4 eOTI/eWTI adding terminals
Terminal
numbers
SUPPLY VOLTAGE 24 V DC
ANALOG OUTPUT (4-20 mA)
COMMUNICATION PORT RS-485
(MODBUS communication)
Optional Pt100
1(-) – 2(+)
6(+) – 7(-)
3(A+) – 4(B-)
Table 5
ABb
11
6. OPERATION AND MAINTANENCE
6.1 Operation and maintenance
No particular maintenance is required. Only periodical inspections (typical interval 6
months) to verify precision, functions and electrical connections.
In case of working test effected with thermostatic bath, please note that WTI bulb MUST
NOT be immersed in water. The heating resistance surrounds the WTI bulb and water may
cause serious damages to the heating system. The calibration test must be done with oil
or hot air only.
When the instrument is equipped with polycarbonate lens, cleaning must be done with
care in order to avoid scraps on the surface. Use water and soap only.
NOTE
Comem advices to disconnect the eOTI/eWTI during the electrical transformer routine test
6.2 Storage
The devices can be handled without any tools. Handle the device with care.
The thermometers must be stored in the original packing and in a dry place with
temperature in the range -10÷40°C (14÷104 °F).
Upon receiving the device, please check:
· The outer surface of the packaging to ensure that it is intact
· That there are no breakages
If damages are found, please contact COMEM and provide the information from the
shipping list and the serial number.
12
APPENDIX A: MODBUS COMMUNICATION
A1: MODBUS register
Register address
Operation
Notes
Operation for monitoring
0x2000
0x2001
0x2002
0x2003
0x2004
0x2005
0x2006
0x2007
0x200A
R
R
R
R
R
R
R
R
R
Pt100 value
Electronic board switched on time (minutes)
Electronic board switched on time (days)
Max Pt100 value of the current day
Min Pt100 value of the current day
Daily blackout number
Max scale value
Min scale value
Software version
Data logging
0x2100
0x2101
0x2102
0x2103
0x2104
0x2105
R
R
R
R
R
R
Max PT100 value of the day -1
Min PT100 value of the day -1
Max PT100 value of the day -2
Min PT100 value of the day -2
Max PT100 value of the day -3
Min PT100 value of the day -3
0x2134
0x2135
0x2136
0x2137
0x2138
0x2139
R
R
R
R
R
R
Max PT100 value of the day -27
Min PT100 value of the day -27
Max PT100 value of the day -28
Min PT100 value of the day -28
Max PT100 value of the week -5
Min PT100 value of the week -5
0x215C
0x215D
0x215E
0x215F
R
R
R
R
Max PT100 value of the week -23
Min PT100 value of the week -23
Max PT100 value of the week -24
Min PT100 value of the week -24
…….
…….
Event Log
0x2300
0x2301
R
R
0x2303
R
0x2304
…
0x248D
0x248F
0x2490
R
Available event (0 … 100)
Time Stamp 1
Event type 1:
1= alarm;
2 = trip;
3 = threshold trip;
4 = change date
Event 1 value
R
R
R
Time Stamp 100 (the oldest)
Event Type
Event Value
13
Table 6
A1.1 MODBUS address
When are installed two or more units, it is necessary to differentiate the MODBUS address
changing the dip-switches position
The available addresses are
· eOTI 80(default) to 95
· eWTI 96(default) to 111
Fig. 9
4
3
2
1
ADDRESS
eOTI
ADDRESS
eWTI
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
95
94
93
92
91
90
89
88
87
86
85
84
83
82
81
80
111
110
109
108
107
106
105
104
103
102
101
100
99
98
97
96
Table 7
14
APPENDIX B: I2-∆T CURVES
B1: Example: how to utilize the curve
Starting data:
-
DT = 31 °C
-
CT nominal current = 2A
Enter in the graph with the known DT, it is possible to define the I2 (Fig. C)
Fig.C
I2 = 1.2 A
Rotate the potentiometer knob until the ammeter reading is 1.2 A
15
1A
B2: Nominal CT current: 1 A
Gradient (°C)
Stainless steel well
6
15
35
53
Gradient (°C)
Brass well
5
14
33
50
Heating current I 2 (A)
0.3
0.5
0.8
1.0
Notes:
-
Maximum WTI absorption power: 15 VA
-
Oil temperature set: 50 °C
16
1.5 A
B3: Nominal CT current: 1.5 A
Gradient (°C)
Stainless steel well
7
16
37
55
76
96
Gradient (°C)
Brass well
8
17
36
53
73
92
Heating current I2 (A)
0.3
0.5
0.8
1.0
1.2
1.4
Notes:
-
Maximum WTI absorption power: 25 VA
-
Oil temperature set: 50°C
17
2A
B4: Nominal CT current: 2 A
Gradient (°C)
Stainless steel well
3
6
16
23
31
44
59
69
Gradient (°C)
Brass well
3
6
15
21
28
41
57
66
Heating current I2 (A)
0.4
0.5
0.8
1.0
1.2
1.5
1.8
2.0
Notes:
-
Maximum WTI absorption power: 20 VA
-
Oil temperature set: 50°C
18
4A
B5: Nominal CT current: 4 A
Gradient (°C)
Stainless steel well
3
7
13
20
28
38
49
63
Gradient (°C)
Brass well
3
7
12
19
27
37
47
60
Heating current I2 (A)
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
Notes:
-
Maximum WTI absorption power: 20 VA
-
Oil temperature set: 50°C
19
5A
B6: Nominal CT current: 5 A
Gradient (°C)
Stainless steel well
1
3
6
9
14
20
26
34
42
51
Gradient (°C)
Brass well
1
2
5
8
12
17
23
30
38
47
Heating current I2
(A)
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
Notes:
-
Maximum WTI absorption power: 20 VA
-
Oil temperature set: 50°C
20
Strada Regionale 11, Signolo 22
36054 Montebello Vic.No (VI) - Italy
Tel. +39 0444 449311 - Fax -39 0444 449352 – 440359
http://www.comem.com
e-mail:[email protected]
21
WTI-OTI
Thermometers
WTI-OTI
Crucial parameters to be monitored
in large distribution transformers and
power transformers are Winding and Oil
temperature: those give a fundamental
understanding about the overall
performances of your valuable equipment
by avoiding unacceptable thermal
degradation and ensuring a longer lifetime.
WTI-OTI
Accurate and stable measurement through maintenance free
thermometers
Thermometers are based on Bourdon working principle, which
enables a direct and precise conveyance of the temperature
rise from the bulb up to the main dial. The adjustable switching
system connected to the pointer shaft provides the desired
alarm/trip signals.
On OTI, the bulb of thermometer detects the transformer oil
temperature variations generating a contraction or expansion of
the capillary connected to the pointer shaft.
On WTI, given that a direct measurement of the winding
temperature is not feasible, the device make use of thermal
image technology whereas the sensing system comprises a
heat sensitive resistive circuit through which passes a current
proportional to winding current. A potentiometer placed on the
main dial allows to adjust the resistive circuit depending on the
transformer parameters.
2
Advantages:
•
•
•
•
•
•
Accurate and stable measurement
Robust design, no need for re-calibration over the time
Customizable mounting flange
Easy accessibility to wiring box
Compact solution, PT 100 embedded into the sensing system
Up to 4 change over micro-switches suitable to control cooling
equipment and protection circuits.
3
WTI-OTI
Temperature sensing system
The devices work with an expansion type sensing system
compensated for ambient temperature. We adopt particular
cares in components testing in order to ensure a very reliable
measurement along the time:
- Vacuum test (2x10-3 mbar): to verify the quality of the
weldings and the porosity of the material.
- Pressure test (up to 280 bar): to verify the welding and the
performances of the spring.
- Overheating test (up to 20% higher of the scale range for 8
hours): to train the spring and to verify the precision of the
spring.
Indications for assembly
It’s possible to provide the instruments with the following
connections:
- Rigid locking screw M14 located on the top of thermometer.
- Elastic suspension mounted on the top of the thermometer.
- Rear flange for tank wall mounting.
Tests and inspections
The gauges are subjected to insulation test towards earth
as follows between circuit and earth, the minimum dielectric
withstand strenght is 2kV in accordance to EN - 50216/1.
The instruments calibration is carried-out through thermostatic
baths controlled by a computer system.
4
Calibration procedure:
- a check is carried out to see whether the temperature taken by
the instrument under test differs from that taken through the
sample sensor by more than the 70% of the maximum allowed
instrument reading tolerance value. This test is performed by
sequentially plunging thermometer bulb into successive temperature increasing thermostatic baths: 0°C / +20°C / +50°C /
+100°C / +125°C.
- the instrument is heated until the instrument pointer exceeds
by 20% the angular full scale value.
- step 1 is repeated, but inversely.
Microswitches activation test:
The bulb is immersed in a thermostatic bath. The computer
changes the temperature inside the bath and by means
of suitable sensors verifies the commutation tolerance,
the commutation differential, the electrical circuits of each
microswitch. At the end of the test a test report is directly
printed by the computer.
No particular maintenance is required. Only periodical
inspections ( typical interval 6 months ) to verify precision,
functions and electrical connections. In case of working test
effected with thermostatic bath, please note that WTI bulb MUST
NOT be immersed in water. The WTI bulb is surrounded by the
heating resistance and water may cause serious damages to the
heating system. The calibration test must be done with oil or hot
air only. When the instrument is equipped with polycarbonate
lens, cleaning must be done with care in order to avoid scraps
on the surface. Use water and soap only.
Winding and Oil Temperature Indicator
COMEM Technical Data
Standard
Tested and qualified in accordance to EN 50216-11 and JB/T 6302-2005
Material
Housing
All the external pars are resistant to oils, salt fog and UV rays
Capillary and Bulb
Capillary tube: copper or stainless steel
Bulb: bronze or stainless steel
Capillary tube protection
Copper tube
Flexible AISI 304 stainless steel armouring or Rilsan
Lens
Mokrolon Polycarbonate, Multistrate glass or Tempered Glass
Specifications
Painting
RAL 9002
Ambient temperature
-40°C + 70°C
Degree of protection
IP65 according to EN 60529
Optionally IP 66
Ventilation valve
2, to prevent the formation of condensation
Cable gland
Up to 3, M25x1,5
Micro Switches
Up to 4
Output
Measuring range
WTI: 0/+150°C, 0/+160°C, 0/+180°C, -50/+150°C
OTI: -50/+150°C, -20/+130°C, -20/+140°C, 0/+120°C, 0/+150°C, 0/+160°C
Measuring tolerance
1,5% of full scale
Repeat accuracy
1% of full scale value
Remote output
Up to 2x PT 100
5
Overall dimension
OTI / WTI
OTI Bulbs
O.T.I. Bulbs
Fig. 1
O.T.I. equipped with PT 100 sensors bulbs
Fig. 2/3
Fig. 1
Fig. 2
A 3/4 BSP M27x2 Other 3/4 BSP 1’’ BSP M27x2 M22x1.5 Other
A 3/4 BSP M27x2 Other 3/4 BSP 1’’ BSP M27x2
L Min 150mm - Std. 150mm Min 120mm - Std. 150mm
L Min 150mm - Std. 150mm Min 120mm - Std. 150mm
6
M22x1.5 Other
WTI Bulbs
Fig. 1
Fig. 2
A 3/4 BSP M27x2 Other 3/4 BSP 1’’ BSP M27x2
M22x1.5 Other
L Min 150mm - Std. 150mm Min 120mm - Std. 150mm
Electrical characteristics
Micro switches making and breaking capacity
Voltage
125 VAC
Standard Micro switches
High-performances micro switches
Resistive Load
Inductive Load
Resistive Load
Inductive Load
5A
5A
10 A
10 A
250 VAC
5A
5A
10 A
10 A
30 VDC
5A
5A
10 A
10 A
50 VDC
1A
1A
3A
2.5 A
75 VDC
0.75 A
0.25 A
1A
0.5 A
125 VDC
0.5 A
0.1 A
0.5 A
0.1 A
250 VDC
0.25 A
0.1 A
0.25 A
0.1 A
7
Order sheet OTI
Number of pieces
JB/T 6302-2005
EN 50216-11
OTI Standard
Rigid locking screw
Flange
Elastic suspension
-50/+150°C
-20/+130°C
-20/+140°C
0/+120°C
0/+150°C
0/+160°C
Fixing
Scale Diam. 150
Lens type
Makrolon Polycarbonate
Makrolon Polycarbonate with resetting pointer
Multilayers glass with resetting pointer
Tempered glass
1
2
Contacts features
3
4
Standard
High performance
AISI 304
RILSAN
Capillary protection
1
2
4
6
Provided as standard supply.
Other pls. specify…………………………………………………………….............................................
1
2
PT 100
Fig. 1 (female)
Fig. 2 (male)
Fig. 3 (male with well)
Bulb type
¾ BSP
1”BSP
M27 x2
Other
M22X1,5
Bulb thread
…………………
No.
Cable gland
M25x1,5
…………………
Moderate salinity areas acc. to ISO 12944
Environmental protection
8
Other
…………………
Off-shore areas acc. to ISO 12944
Order sheet WTI
Number of pieces
JB/T 6302-2005
EN 50216-11
OTI Standard
Rigid locking screw
Flange
Elastic suspension
Fixing
0/+160°C
0/+150°C
0/+180°C
-50/+150°C
Scale Diam. 150
Makrolon Polycarbonate
Lens type
Makrolon Polycarbonate with resetting pointer
Multilayers glass with resetting pointer
1
Tempered glass
2
Contacts features
3
4
Standard
High performance
AISI 304
RILSAN
Capillary protection
1
2
4
6
Capillary length (mt)
Other pls. specify…………………………………………………………….............................................
1
2
Fig. 1 (female)
Fig. 2 (male)
PT 100
Bulb type
¾ BSP
1”BSP
M27 x2
Other
M22X1,5
Bulb thread
…………………
M25x1,5
No.
Cable gland
…………………
Other
…………………
Moderate salinity areas acc. to ISO 12944
Off-shore areas acc. to ISO 12944
Environmental protection
Nominal current from
current transformer
1A
1.5A
2A
4A
5A
Strada Regionale 11, Signolo 22
36054 Montebello Vicentino (VI) - ITALY
Tel. +39 0444 449311
Fax +39 0444 449352 - 440359
E-mail: [email protected]
www.comem.com
Due to technical product updates, the information
contained in this catalogue may be subject to change
without notice.
© Copyright 2015 COMEM.
All rights reserved.
Ed. 05/2015
Relay
BR
Index
Buchholz relay
General information
2
Overall dimensions according to EN 50216-2 and EN 50216-2_A1
6
Gas sampling device
22
Requirement sheet
23
Gas relay
General information
24
Overall dimensions
26
Requirement sheet
29
Flow relay
General information
30
Overall dimensions
32
Requirement sheet
37
1
Buchholz relay
Transformer outages have a considerable
economic impact on the operation of a
power supply network. Therefore it is the
aim to ensure an accurate assessment of the
transformer condition.
Partial discharges, leakage currents, hot
spots and arcing are phenomena that
contribute to degradation of oil insulating
performances by generating dangerous gas
flow inside the transformer tank.
BR
Internal gas accumulation and oil flow are monitored and kept under
control by the Buchholz relay.
Thanks to COMEM’s proven expertise, we have developed a
reliable Buchholz relay that promptly provide information about
internal malfunctioning giving the possibility to eventually stop
the system prior its destruction.
The Buchholz relay is sited in the pipework between the
transformer and its conservator and it is filled with oil during
normal transformer operation.
When gas is generated in the transformer it rises towards the
conservator and collects in the upper chamber of the relay.
The oil level drops and the top float triggers alarm switch.
Gas shall not freely pass from the relay body and escape into the
pipework before the alarm contact has operated.
Another important functionality of the Buchholz relay is
to operate if oil flow from the transformer tank to the oil
conservator. In case the oil flow speed exceed the pre-set value,
the the flow vent operates and switch the trip contact.
2
Advantages
•
•
•
•
•
Proven “on the field” reliability
No false alarms
Robust reed switch design
Electrical wiring provided with change-over contacts
Additional accessories: Gas sampling device.
3
Buchholz relay
(1)
(8)
(9)
Construction
The housing consists of an aluminum alloy and it is provided
with flanges for the connection of the transformer tank pipe
and the oil conservator pipe. The terminals of the reed switches
are positioned in the terminal box and the perfect sealing is
guaranteed by an OR gasket.
The terminal box cover (1) is fixed to the terminal box with 4
unloosable screws.
There are two floats (8) with their associated switches
encapsulated in glass bulbs.
The flow vent (9) has two permanent magnets.
4
Special features
Upon request our Buchholz relais are available with
4M6 vibration class in accordance with EN 50216-2 and
EN 50216-2_A1, load stress are in compliance to EN60721-3-4
and to C5. Buchholz relais are available with improved corrosion
resistance C5 class according to ISO 12944, suitable for offshore environment and high salinity area.
Installation guidelines
The following table gives guidelines values:
Transformer
Power
MVA
Pipe Nominal
diameter
Volume
of oil
Tons
Up to 5MVA
25
Up to 3,5
From 5 up to 20 MVA
50
From 3,6 up to 14
Over 20 MVA*
80
Over 14,1*
Over 20 MVA*
100
Over 14,1*
* In agreement with the transformer design
Tests
Topic
Type tests
Routine tests
Test description
Standard
Checking of the switching capacity of contacts
Vacuum test
Impulse withstand test of electrical circuits
Calibratione of gas collection scale on relay window to operate alarm contact if required
Determination of the minimum oil flow to operate the contact and the time for closing
Verification of the absence of reaction of contacts to a flow of oil from conservator to the tank
Pressure withstand test
Verification of the absence of reaction of contacts to magnetic field
Vibration test
Short duration power frequency withstand test
Oil leakage test
Operation test
EN
EN
EN
EN
EN
EN
EN
EN
EN
EN
EN
EN
50216-1
50216-2
50216-1
50216-2
50216-2
50216-2
50216-2
50216-2
50216-1
50216-1
50216-2
50216-2
and EN 50216-2_A1
and
and
and
and
and
EN
EN
EN
EN
EN
50216-2_A1
50216-2_A1
50216-2_A1
50216-2_A1
50216-2_A1
and EN 50216-2_A1
and EN 50216-2_A1
5
Buchholz relay
Overall dimensions according to EN 50216-2 and EN 50216-2_A1
G1" 1/2 A
BG25
Weight 2.1 Kg
6
BR25
Weight 2.9 Kg
7
Buchholz relay
Overall dimensions according to EN 50216-2 and EN 50216-2_A1
BR50
Weight 4.9 Kg
8
BR80
Weight 5.8 Kg
9
Buchholz relay
Overall dimensions according to EN 50216-2 and EN 50216-2_A1
BS25
Weight 2.2 Kg
10
BS50
Weight 4.1 Kg
11
Buchholz relay
Overall dimensions according to EN 50216-2 and EN 50216-2_A1
BS80
Weight 4.3 Kg
12
NF25
Weight 3.0 Kg
13
Buchholz relay
Overall dimensions according to EN 50216-2 and EN 50216-2_A1
NF50
Weight 4.8 Kg
14
NF80
Weight 5.5 Kg
15
Buchholz relay
Overall dimensions according to EN 50216-2 and EN 50216-2_A1
C01
Weight 2.2 Kg
16
C1
Weight 2.3 Kg
17
Buchholz relay
Overall dimensions according to EN 50216-2 and EN 50216-2_A1
C4
Weight 5.9 Kg
18
Main features
General data
Material
All the external part are resistant to transformer oils, salt fog and UV rays
Ambient temperature
-40 to 80°C
Oil temperature
-40 to 115 °C
Degree of protection
IP65 in accordance with EN60529
Oil flow speed (oil temperature 20°C)
1.00 ± 0.15 m/s
1.50 ± 0.20 m/s
2.00 ± 0.30 m/s
Switch electrical data (according to EN 50216-2 and EN 50216-2_A1)
Breaking capacity
Voltage
Current
Breaking capacity
220 V d.c. (min. 12V)
2 A for 1000 maneuvers
250 W
L/R<40 ms
230 V a.c. (min. 12V)
6 A for 1000 maneuvers
400 VA
cosФ>0.5
Dielectric strength of contacts
Short duration power frequency
withstand voltage 1 min – kV (r.m.s.)
Lightning impulse withstand
voltage kV (peak)
Between circuits and earth
2
5
Across open contacts
1
3
Alarm signalling Gas Volume
Buchholz relay type
BG25-BR25-NF25-C01-C1
100-200 cm3
NF50-NF80
100-200 cm3
BR50-BR80-C4
150-250 cm3
BS25
170-230 cm3
BS50-BS80
250-300 cm3
19
Buchholz relay
Wiring diagrams
Diagram type “A”
- ALARM CONTACT (terminals 3-4)
NO contact
1
2
3
4
- TRIP CONTACT (terminals 1-2)
NO contact
Alarm circuit
Trip circuit
Diagram type “L”
- ALARM CONTACT (terminals 3-4- C2) change over contact
NO contact: terminals 4-C2; NC contact: terminal 3-4
1
2
C1
3
4
C2
- TRIP CONTACT (terminals 1-2-C1) change over contact
NO contact: terminals 2-C1; NC contact: terminal 1-2
Alarm circuit
Trip circuit
Diagram type “P”
- ALARM CONTACT (terminals C2-3)
NO contact
- ALARM CONTACT (terminals C1-4)
NO contact
1
2
C1
3
C1
- TRIP CONTACT (terminals 1-2)
NO contact
Alarm circuit
Trip circuit
20
4
Diagram type “G”
- ALARM CONTACT (terminals 3-4)
NO contact
- TRIP CONTACT (terminals C2-2)
NO contact
C2
2
C1
1
3
4
- TRIP CONTACT (terminals C1-1)
NO contact
Alarm circuit
Trip circuit
Diagram type “I”
- ALARM CONTACT (terminals 5-6)
NO contact
- ALARM CONTACT (terminals 7-8)
NO contact
1
2
3
4
5
6
7
8
- TRIP CONTACT (terminals 1-2)
NO contact
- TRIP CONTACT (terminals 3-4)
NO contact
Alarm circuit
Trip circuit
Diagram type “V”
- ALARM CONTACT (terminals 5-6)
NC contact
- ALARM CONTACT (terminals 7-8)
NC contact
1
2
3
4
5
6
7
8
- TRIP CONTACT (terminals 1-2)
NC contact
- TRIP CONTACT (terminals 3-4)
NC contact
Alarm circuit
Trip circuit
21
Buchholz relay
Gas sampling device
Insulating materials within transformers and electrical equipment
break down to liberate gases. The distribution of these gases
can be related to the type of electrical fault, and the rate of gas
generation can indicate the severity of the fault. The identity
of the gases being generated by a particular unit can be very
useful information in any preventative maintenance program.
The collection and analysis of gases in an
oil-insulated transformer can indicate the
severity of the default.
The presence of gas inside an oil filled transformer is always a
sign of malfunction and one of the tasks of the Buchholz relay
is to signal this presence. Analysis of the evolved gas can often
give good indication of the type of malfunction but accessing
the Buchholz relay during live operation of the transformer can
be hazardous.
The gas sampling device has been designed to overcome
this problem by siting the unit remote from the Buchholz and
in a readily accessible position typically on the side of the
transformer.
22
Construction
The Comem gas sampling device is manufactured from an
aluminium alloy casting with the following fittings:
- a tempered glass inspection window with graded markings for
volume indication.
- a gas sampling valve (2).
- a bleed valve (3).
- a gas inlet valve for pneumatic testing (5).
- a valve for draining oil from the relay (this can be mounted on
the right or left hand side of the body (6) or (7).
As a routine test all castings are tested by injecting ambient air
at 2.5 bar for 2 minutes. A certificate to this effect is supplied
with the unit. For the sake of standardisation the device is fitted
with the left and right hand valve supports but only one valve.
Customer can then choose which side he prefers.
- with fittings for outside dia. 10 tubes, code 1RDPG00005
(standard);
- with fittings for outside dia. 6 tubes, code 1RDPG00006
(on request);
- with fittings for outside dia. 8 tubes, code 1RDPG00007
(on request).
PRD
Pressure Relief Device
Index
Pressure Relief Device - LPT
General information
2
Overall dimensions according to EN 50216-5/A2
5
Assembling sequence
6
Order sheet
7
Pressure Relief Device - M
General information
8
Overall dimensions according to EN 50216-5/A2
12
Assembling sequence
14
Order sheet
15
Pressure Relief Device - T and Q
General information
16
Overall dimensions according to EN 50216-5/A2
19
Assembling sequence
22
Order sheet
24
How to select the PRD type for your transformer in 3 simple steps
1st Select size
2nd Select protection type
3rd protection material
Depending on volume of oil tank
up to 3000 dm
3
up to 9000 dm3
up to 25000 dm3
50
80
125
up to 40000 dm3
125
up to 45000 dm3
200
no protection needed
“T” model
guard
“T” model
plastic
conveyor duct
“M” model
aluminium alloy
no protection needed
“T” model
guard
“T” model
plastic
conveyor duct
“T” model
stainless steel
no protection needed
“T” model
guard
“T” model
plastic
conveyor duct
“M” model
aluminium alloy
conveyor duct with internal spring
“LPT” model
aluminium alloy
no protection needed
“T” model
guard
“T” model
metallic
1
Pressure Relief Device - LPT
LPT
COMEM’s “LPT” pressure relief device is used to control
the pressure inside tanks. It is important in cases where an
accidental, sudden and uncontrolled increase in pressure creates
the danger of explosion. It is designed to discharge pressure in a
very short time (a few thousandths of a second).
It is widely used in oil-cooled electric transformer metal tanks.
Sudden and violent short circuits inside these tanks, in fact,
instantly generate an enormous amount of gas which cause a
substantial increase in internal pressure. If the pressure cannot
be externally discharged there is danger that the transformer
could explode and potentially cause harm and damage. This
danger can be prevented by installing one or more pressure
relief devices. It is always good practice to install these pressure
relief devices in places where internal pressure values must not
exceed specific safety limits.
The external protection with a perfect seal guarantees that
no drop of oil is dispersed into the environment
Total pressure relief completely opening
Operating performance
The pressure relief device is totally opened each time the
pressure relief device operates at pressure settings between 20
and 175 kPa.
If pressure generated inside the tank is much higher than the
setting, then the further compressed spring allows the closing
disk to create even larger discharge areas when it operates.
Nominal operating pressure: the prefixed overpressure value
shall be established between the supplier and the purchaser
within the standard range of 20 up to 140 kPa, with 10 kPa steps
and 175kPa. Tolerances are - 5 kPa to + 7 kPa for 20-90 kPa and
±10 kPa for 100-175 kPa calibration.
2
Construction
Our pressure relief device is completely protected against
external corrosion and against penetration by foreign bodies
between the cover and protective cap. This ensures perfect
operating efficiency even for extended periods of time.
“LPT” pressure relief device
These consist of a flanged body and a corrosion-proof
aluminium alloy disk. There are two gaskets in the pressure relief
device: a specially-shaped upper gasket and a lip seal.
When the pressure relief device is closed, the upper gasket
is pressed against the disk. The shape of the gasket creates a
perfect seal even if the disk lifts 1-2 mm. The disk also seals
against the lip seal gasket as it moves upwards. If, due to
internal pressure, the disk rises beyond this amount then the
upper seal is no longer maintained while the lip seal remains.
When this happens, the surface of the washer condumed by
internal pressure is increased in area equal to the total force
applied on the spring.
This causes the total and instant opening of the pressure relief
device which consequently discharges excess pressure to the
exterior.
When the pressure has been discharged, the disk pushed back
by the spring lowers down and closes the valve. As the disk
moves downward, it first closes against the side gasket and then
against the upper gasket.
The latter, because of its special shape, is pressed down 1-2 mm
and the disk moves further down breaking the seal on the lip seal
gasket. This releases any pressure that may have been trapped
between the two gaskets. Now the pressure relief device is ready
to work.
Routine tests
It is necessary to carry out operational tests, with compressed air:
• to check the correct functioning of the device at operating
pressure values
• to check the functioning of the optic signal and of the electric
contacts.
Installation guidelines
Our “LPT” pressure relief device comes in 1 size.
The following table gives guideline values:
Volume of oil tank:
Type of pressure relief device
up to 40000 dm
LPT
3
We recommend using multiple pressure relief devices when
oil volumes exceed these levels. Instant pressure relief device
opening implies direct contact between the closing disk and the
oil. For this reason, the pressure relief device is equipped with
a screw to bleed out that may accumulate during oil tank filling
procedures. In order to prevent harm to people or property
due to violent jets of hot oil evacuating from the pressure relief
device, it is good practice for pressure relief device discharges to
be guided towards points that are properly designed to receive
the hot oil. Environmental protection is also another important
issue which should be pursued by everyone. Our protection
duct allows the oil that is evacuated by the pressure relief device
to be drained.
The system’s perfect hydraulic seal guarantees that no drop of
oil is dispersed into the environment, but is, rather, collected
through a pipe into a tank (pipe and tank are not supplied).
The sealing oil duct is made of die-casted aluminium; a terminal
flanged tube made of steel can be also provided if you want
to weld the pipeline air necessary. O-ring gaskets have been
applied for duct sealing.
Detailed assembly instructions are supplied with the equipment.
3
Pressure Relief Device - LPT
The switches have the following characteristics:
Specifications:
Breaking and making capacity (NO and NC contacts)
Voltage
Uninterrupted current Interrupted current
(making capacity)
(breaking capacity)
24 VDC to 220 VDC
2A
100 mA L/R<40 ms
230 VAC
2A
2 A cos φ>0.5
Other characteristics:
Visual signal that the pressure relief device
is open
The pressure relief device is equipped with a visual signal that
shows if it was opened when it is open. This signal consists of a
red knob that protrudes from the central part of the duct when
the pressure relief device is opened. Simply press it down in
order to make it go back to its normal position and reset the
switches.
Electrical signalling switch
Maximum 3 “pressure relief device open signal” contacts can be
mounted upon request. These are fast tripping limit switches
with switching contacts contained inside a watertight room IP65.
The contacts act together with the visual signal.
- The pressure relief device is supplied with a “locking system”
which allows the pressure relief device to be blocked during
the transformer oil leakage test. The locking system has been
tested to withstand max 2 bar pressureand can also be used
during the transformer transport.
WARNING!: the locking system must be removed before
powering-up the transformer.
- The pressure relief device is supplied with a M25x1.5 cable gland.
- Colour: RAL 9002.
Outer surface protection
The outer surfaces are protected against weather corrosion.
Aluminum alloy components are non-corroding, their surface
is protected with a thick layer of paint which offers a high
level of protection against atmospheric agents and can resist
temperature variations between -40 °C and +100 °C. Standard
protection suits moderate salinity areas acc. ISO 12944-5.
Special protection for severe climate applications, off-shore, is
also available upon request.
Contact diagram
- FIRST SWITCH (terminals 12-14-11)
change-over contact:
– 14-11 normally open
– 11-12 normally closed
- SECOND SWITCH (terminals 22-24-21)
change-over contact:
– 23-21 normally open
– 21-22 normally closed
- THIRD SWITCH (terminals 32-34-31)
change-over contact:
– 34-31 normally open
– 31-32 normally closed
4
1st Switch
12
14
2nd Switch
11
22
24
21
3RD Switch
32
34
Ground
31
Overall dimensions according to EN 50216-5/A2
Weight kg 19
5
Pressure Relief Device - LPT
Assembling sequence
RECOMMENDED
TORQUE 8Nm
15 16
14
13
12
17
RECOMMENDED
TORQUE 8Nm
10 11
9
8
7
6
5
4
3
2
1
35
M16
Ø170
A-A
Ø235
6
18
19 20
Ref.
Q.ty
1
1
Code
Description
2
1
5GOD041050
Gasket OR 41050
3
1
5GOD008750
Gasket OR 8750
4
1
125x-6 safety valve
5
6
M16 washer (not supplied)
6
6
M16 grower washer (not supplied)
7
6
8
1
9
1
10
4
5v50606060
UNI 5931 M6X60 screw
11
4
5400800861
M6 washer (plain+elastic)
12
1
5GOD041100
Gasket OR 41100
13
1
LPT type oil duct cover
14
1
Visual signal
15
4
5V50605035
UNI 5931 M5x35 screw
16
4
5RG0600050
M5 washers (plain+elastic)
17
1
5GOD004475
Gasket OR 4475
18
1
5COV464600
LPT type flange with pipe for duct
19
4
5V50612030
UNI 5931 M12x30 screw
20
4
5RB0600120
M12 washer
Transformer cover
M16 nut (not supplied)
5GOD041050
Gasket OR 41050
LPT type oil duct
APPLICATION :
SUKRUT
This indicator is suitable for conservator of oil filled
transformer having Aircell (Flexi separator)
SCOPE :
Indicator continuously reads level of oil inside the
conservator and operates a mercury switch when oil
level drops down near Empty level mark.
OIL LEVEL INDICATOR
MODEL: SO-HE-10-ATMS
CONSTRUCTION & WORKING :
MAIN BODY
The indicator has cast aluminium body with built-in
flange. To avoid leakage of oil and to avoid entry of
contaminated moist air in conservator, a pair of
permanent magnets is used for the operation of
indicator separated by a metallic wall. A roller type
float is used as sensor of level and it is connected to
driving magnet through a bevel gear.
Float, driving magnet and bevel gear remain in oil
inside the conservator. The driven magnet is
positioned outside in air in the housing. The driven
magnet carries a cam and a pointer. The cam is set
to operate the switch near Empty level and the
pointer is set to read the level inside the
conservator. (see schematic Fig.1)
In this model, the dial body can be separated from
the base by loosening 6 screws to have access to
the switch. This model can be mounted in inclined
position only at an angle 150 or 300 as per specific
requirement. The buyer is required to provide the
mounting flange as per Fig. 2. For this model a float
arm suitable for specified diameter of conservator is
supplied. It is not possible to supply adjustable
length type float arm for this model.
The leads from the switch are brought out in a
separate terminal box at the bottom of indicator with
a removable cover. Terminal box is provided with a
hole with 3/4” BSC threads for cable gland.
WITH
MOUNTING FLANGE
SUKRUT
SUKRUT UDYOG
PUNE, INDIA
ROLLER FLOAT
WITH
FLOAT -ARM
TERMINAL BOX
WITH
COVER
FIG. 1
Mounting :
To mount the indicator, buyer has to provide
mounting pad as per Fig. 2.
SCHEMATIC
SWITCH OPERATING CAM
MERCURY SWITCH
METALLIC WALL
DIAL
DRIVING
MAGNET
SPECIFICATIONS :
Liquid in Tank : Transformer oil.
Working :
0
0
Temp.
: -30 to 120 Celsius of oil
2
Pressure
: 0 to 1 kg/cm
Environment : Indoor or Outdoor
SWITCH, DIAL & POINTER
ASSEMBLY
DRIVEN
MAGNET
POINTER
IN AIR
GEAR & PINION
FLOAT
IN LIQUID
0
Travel
: 45 max. See Fig. 3
Margin
: Leave 100 mm beyond Lower Limit and
150 mm above Higher Limit for
Clearance. (See Fig. 3)
Switch :
Type
: Mercury Switch
Calibration :
Dial size
: 250 mm Dia nominal.
Unit
: Calibration in any unit as per
customers requirement is
possible.
Colour
: Black marking on yellow
background OR black marking on
white background OR any other.
0
Spread
: Max 150 (see Fig. 4 view of dial).
ROUTINE TESTS :
Each indicator is tested for
1. Specified levels. 2. Switch operation 3. HV Test
4. Leakage Test.
A combined test certificate is issued for each batch.
Float (sensor) and arm :
Material
: Float - Brass,
Float arm - S.S.
HOW TO ORDER :
We provide a Questionnaire for specifying your requirements.
However, a drawing is acceptable giving all specifications.
Contact Rating : 5 Amps 240 V AC, 0.5 Amp 240V DC
Operation
: See wiring diagram (Fig.5)
OIL LEVEL INDICATOR
MODEL SO HE - 10 - ATMS
ORIENTATION OF MOUNTING PAD FOR 300
(Any other Inclination possible)
By removing these 6 screws dial body
can be separated from base unit.
2 3 4
1
56 7
8
6” NB Pipe
TOP
9 10
12
5
22
5
26
Oil Level at Mark ‘EMPTY’
B
B
0N
15
1
114
FIG. 2
b
136
Approx
12
Use M10 Bolts x 50 Long
with Nuts & Washer - 8 Nos.
110
09.5
Pipe
12 11
13
BOTTOM
075
160
Mounting Pad, Gasket Not Supplied
by ‘SUKRUT’
175
Hardware, Gasket & Cable Gland-Not Supplied
by ‘SUKRUT’
Details at ‘B’
PART LIST :
Sr.No.
1
2
3
4
5
6
7
Description
Housing
Base with Flange
Gasket (Neoprene) 6 mm thick.
Mounting Pad
Bracket
Lever with Gear
Split Pin
FIG. 3
FLOAT TRAVEL
Material.
Cast. Al.
Cast Al.
Rubber.
M.S.
Cast Al
Brass
Brass
Sr.No. Description
Material.
8
Float Arm (9.5 Pipe)
S.S.
9
Bracket for Float
S.S.
10
Roller Float
Brass
11
Cable Gland (3/4” BSC.)
Brass
12
Terminal Box with cover
Cast Al.
13
Ring for Glass
Cast Al..
Item Nos. 3, 4 & 11 are not supplied by Sukrut
FIG. 4
VIEW OF DIAL
FIG. 5
WIRING DIAGRAM
MERCURY SWITCH
OIL LEVEL
AT FULL
INTERNAL WIRING
FULL
150
1
SUKRUT
3/4
2
TERMINALS
PUNE INDIA
EXTERNAL WIRING
0
35C
1/4
0
45 Max
ALARM
EMPTY
100
OIL LEVEL
AT EMPTY
ANY OTHER MARKING IS POSSIBLE
SUPPLY
Contact Rating : 5 Amps 240 V AC,
0.5 Amp 240 V DC
GENERAL NOTES :
1. Indicators of different specifications are not interchangeable. Hence care should be taken while storing
Indicators and their Float with Arms with respective Sr. Nos. This indicator can be used for inclined mounting only,
at any angle specified by buyer.
2. Float & Indicator, loose or assembled, should be handled carefully as they cannot be repaired if damaged.
3. The complaint of damage or demand for spares should be very specific with respect to Sr. No. of indicator.
Lot of correspondence and time can be saved just by informing Sr. No. of concerned Indicator.
4. We continuously review specifications and where appropriate, introduce modifications. We, therefore, reserve
the right to change specifications in this catalogue without prior notice.
SUKRUT UDYOG
9/1 A, ERANDAWANA, PUNE 411 004. (INDIA)
Ph. No.
Fax No.
E-Mail
Website
Cat. No. SOHE10 ATMS
: +91 20 25441514, 25441726
: +91 20 25440231.
: [email protected]
: www.sukrutudyog.com
0706
APPLICATION :
This indicator is suitable for oil filled
Power Transformers & oil filled tanks.
SCOPE :
Indicator continuously reads level inside the
conservator and operates a microswitch when oil
level drops near Empty level mark.
CONSTRUCTION & WORKING :
The indicator has aluminium body with built in
flange for mounting. To avoid leakage of oil and to
avoid entry of contaminated air into tank, a pair of
permanent magnets is used separated by a
metallic wall. A float is used as sensor & is
connected to driving magnet through a bevel gear.
The driven magnet is positioned outside in air in
main body which carries a pointer and a cam. The
pointer is set to read the oil level and the cam is
set to operate the switch near Empty level(See
Schematic). Switch resets automatically when
level of oil is brought to normal. Contacts of switch
are brought outside in terminal box with threaded
hole for fixing cable gland. The body of indicator
with dial and switch is sealed to avoid entry of
moist air. Hence switch is not accessible for
resetting or servicing.
SUKRUT
OIL LEVEL INDICATOR
MODEL: SO-6-M
MAIN BODY WITH
MOUNTING FLANGE
SWITCH, DIAL & POINTER
ASSEMBLY
LABEL
WITH
SERIAL NO.
SPECIFICATIONS :
Liquid in tank :
Transformer oil & other oils.
TERMINAL BOX
WITH COVER
Working :
Temp. -30 to 1000 Cent. of oil.
Press : 0 to 1 Kg/Cm2
Environment : Indoor or outdoor.
Mounting :
To mount the indicator, buyer is required to provide
a pad as per Fig. 4. The position can be selected
on vertical wall of conservator/tank depending on
importance of oil level readings and switching near
Empty level.
Calibration :
Dial Size : 150 mm round (nominal)
Unit
: Any calibration as per Customer’s
requirement is possible.
Colour : Black marking on white background or
any other combination as required.
0
Spread : Max 300 (See Photograph).
FLOAT WITH
FLOAT -ARM
HOLE FOR
CABLE GLAND
FIG. 1
SCHEMATIC
SWITCH OPERATING CAM
MICROSWITCH
METALLIC WALL
DIAL
DRIVING MAGNET
GEAR & PINION
DRIVEN
MAGNET
POINTER
FIG. 2
FLOAT TRAVEL
Switch :
Type : Microswitch
Contact Rating : See wiring diagram. (Fig. 5)
Operation : See wiring diagram (Fig. 5)
OIL LEVEL
AT FULL
MARGIN MIN 65
Float (sensor) and arm :
Float & Float - Arm are made of brass. Float - Arm
is supplied of fixed Length or adjustable length
type as per order.
Margin :
Leave Min. 65 mm beyond lower & higher limit
markings to avoid striking of float to bottom & top
of conservator. (See Fig.2)
FLOAT
IN LIQUID
IN AIR
MARGIN MIN 65
MAX 45
0
MAX 45
0
OIL LEVEL
AT EMPTY
ROUTINE TESTS :
Each indicator is tested for
1. Specified levels. 2. Switch operation 3. HV Test
4. Leakage Test.
A combined test certificate is issued for each batch.
HOW TO ORDER :
We provide a Questionnaire for specifying your
requirements. However, a drawing is acceptable giving all
specifications.
FIG. 3
OIL LEVEL INDICATOR
MODEL: SO - 6 - M
70
8 HOLES, 12 DIA
ON PCD 209.7
12
57
22.5
1/2
SUKRUT
1/4
3/4
5
EMPTY FULL
6
H
4
7
T
NG
LE
295
RM
TA
OA
FL
0
232 DIA
3
1
2
8
FLOAT SIZE
DIA 50 x 75 LG.
COVER
REMOVED
3/4" B.S.CONDUIT
FRONT VIEW
Sr. No. Description
SIDE VIEW
PART LIST
Material Qty.
Sr. No. Description
Material Qty.
1.
Crystal
Glass
1
5.
Lever with Gear
Brass
1
2.
Float
Brass
1
6.
Float Arm
Brass
1
3.
Main Body
Cast Al.
1
7.
Label with Serial No.
Brass
1
4.
Limit Stoppers
Al. Rod
2
8.
Terminals
Brass
FIG. 4
FIG.
FIG. 55
MOUNTING PAD
22.5
SWITCH
SWITCH CONTACT
CONTACT POSITION
POSITION
AT NORMAL
LEVEL
0
AT MIN.
LEVEL
MICROSWITCH
A
8 STUDS, M 10 EQUALLY SPACED
AS SHOWN ON 209.7 P.C.D.
Ø 235
Ø 175
Ø 165
HOLE IN TANK
A
INTERNAL
WIRING
TERMINAL
PLATE
LEAKPROOF
WELDING JOINT
SECTION AT ‘A-A’
MOUNTING PAD & GASKET NOT SUPPLIED BY SUKRUT
EXTERNAL
WIRING
CONTACT RATING 5A 240V AC, 0.25A 240 V DC
SWITCH RESETS AUTOMATICALLY WHEN OIL LEVEL IS BROUGHT TO NORMAL
GENERAL NOTES :
1. Indicators of different specifications are not interchangeable. Hence care should be taken while storing
Indicators and their Float with Arms. This indicator can be used for vertical or inclined mounting as per order.
2. Float & Indicator, loose or assembled, should be handled carefully as they cannot be repaired if damaged.
3. The complaint of damage or demand for spares should be very specific with respect to Sr. No. of indicator.
Lot of correspondence and time can be saved just by informing Sr. No. of concerned Indicator.
4. We continuously review specifications and where appropriate, introduce modifications. We, therefore, reserve
the right to change specifications in this catalogue without prior notice.
SUKRUT UDYOG
9/1 A, ERANDAWANA, PUNE 411 004. (INDIA)
Cat. No. S0-6-M-704
PHONE : (020) 25441726, 25441514
FAX
: (020) 25440231
E-Mail : [email protected]
IN
Movement by Perfection
The Royal League in ventilation, control and drive technology
Product documentation
Type
FN080-ADL.6N.V7P5
Article number
TBD
Article number
TBD
Product documentation
Customer
ABB India
Project
176.25MVA Transformer Chile
ZIEHL-ABEGG Contact
Kai Rittmann
Tel. +49 7940 16 90102
[email protected]
ZIEHL-ABEGG Subsidiary
India
ZIEHL-ABEGG INDIA PVT LTD.
Plot No. E-8, Chakan Industrial Area,
Phase III, Village Kuruli, Tal. Khed,
Chakan, Pune- 410 501, Maharashtra,
INDIA
Phone +91 21 3567 9679
Fax +91 21 3567 9680
www.ziehl-abegg.in
[email protected]
Type
FN080-ADL.6N.V7P5
Article number
TBD
Contents
1.
Product specification - Technical data
3
2.
Characteristic curve
4
3.
Drawing
5
4.
Connection diagram
6
5.
EU-Declaration of conformity
7
www.ziehl-abegg.com/de
23.09.2019
Movement by Perfection │ Bewegung durch Perfektion
2│8
© ZIEHL-ABEGG SE
All rights reserved. Confidential and proprietary document, not to be disclosed or used except in accordance with applicable agreements. No disclosure to third parties, if not
expressively agreed by ZA SE.
Article number
TBD
1. Product specification - Technical data
Article number
TBD
Type
FN080-ADL.6N.V7P5
Designation
Axial fan with sickle blades
3~ 380V ±10% D/Y 50Hz P1 860/480W
2,2/1,05A DI=0% 650/490rpm COSY 0,59 70°C
3~ 380V ±10% D/Y 60Hz P1 1,10/0,52kW
2,4/1,05A DI=0% 680/460rpm COSY 0,69 70°C
3~ 440V ±10% D/Y 60Hz P1 1,30/0,64kW
2,6/1,15A DI=0% 740/510rpm COSY 0,65 65°C
Pstat=0Pa: 680/530/MIN 700/440W 4,7/3,7m3/s
Pstat=0Pa: 730/510/MIN 960/480W 5,1/3,5m3/s
Pstat=0Pa: 780/570/MIN 1100/580W 5,4/3,9m3/s
Rated values
Electrical connection
Terminal box K04
9x 0,75 mm2, 50 cm
Min. operating temperature °C
-40***
Mounting type terminal box
Mounted on fan housing
Cable quality
Li4G4G-J
Type of protection
IP55
Thermal class
THCL155
Connection diagram
1360-108XA
Rating plate
1x fixed
Fitting position
H/Vu/Vo
Motor protection
thermal contact
Quality of bearings
ball bearing with long-time lubrication
Material Rotor
Aluminium
Painting rotor
3 coat painted
colour rotor
RAL 7035 (light grey)
Material blades
Aluminium
Painting impeller
3 coat painted
Colour blades
RAL 7035 (light grey)
Guard grille type
ring grill for suction side in stainless
steel
Other
All connecting elements in stainless steel.
Other
All connecting elements secured with
Loctite.
Painting housing
Bell mouth 3 coat paint
Colour housing
RAL 7035 (light grey)
Painting mot.suspens
Motor suspension 3 coat paint
colour suspension
RAL 7035 (light grey)
Weight kg
63,30
ErP Data
Efficiency ηstatA: 33,5 %
Efficiency grade: Nactual = 40,3 / Ntarget = 40*
*ErP 2015
www.ziehl-abegg.com/de
23.09.2019
Movement by Perfection │ Bewegung durch Perfektion
3│8
© ZIEHL-ABEGG SE
All rights reserved. Confidential and proprietary document, not to be disclosed or used except in accordance with applicable agreements. No disclosure to third parties, if not
expressively agreed by ZA SE.
Article number
TBD
2. Characteristic curve
www.ziehl-abegg.com/de
23.09.2019
Movement by Perfection │ Bewegung durch Perfektion
4│8
© ZIEHL-ABEGG SE
All rights reserved. Confidential and proprietary document, not to be disclosed or used except in accordance with applicable agreements. No disclosure to third parties, if not
expressively agreed by ZA SE.
Article number
TBD
3. Drawing
Dimensions in mm
Shown drawing is just to show the dimensions of the fan.
www.ziehl-abegg.com/de
23.09.2019
Movement by Perfection │ Bewegung durch Perfektion
5│8
© ZIEHL-ABEGG SE
All rights reserved. Confidential and proprietary document, not to be disclosed or used except in accordance with applicable agreements. No disclosure to third parties, if not
expressively agreed by ZA SE.
Article number
TBD
4. Connection diagram
1360-108XA
3~ motor, 2 speeds (Δ/Y switch over) with thermostatic switch (if built in).Without bridge
when using speed change-overswitch.
BN
BU
BK
RD
GY
OG
WH
GNYE
brown
blue
black
red
grey
orange
white
green-yellow
High speed/D-connection
www.ziehl-abegg.com/de
23.09.2019
Low speed/Y-connection
Movement by Perfection │ Bewegung durch Perfektion
6│8
© ZIEHL-ABEGG SE
All rights reserved. Confidential and proprietary document, not to be disclosed or used except in accordance with applicable agreements. No disclosure to third parties, if not
expressively agreed by ZA SE.
Article number
TBD
5. EU-Declaration of conformity
www.ziehl-abegg.com/de
23.09.2019
Movement by Perfection │ Bewegung durch Perfektion
7│8
© ZIEHL-ABEGG SE
All rights reserved. Confidential and proprietary document, not to be disclosed or used except in accordance with applicable agreements. No disclosure to third parties, if not
expressively agreed by ZA SE.
Article number
TBD
The Royal League in ventilation, control and drive technology
Intelligent control technology for any application
ZIEHL-ABEGG system capabilities:
Everything from a single source – perfectly matched for optimal performance
Please contact us. We would be pleased to design an individual solution for your requirements.
We would like to welcome you on our worldwide exhibitions. Please find our next exhibitions here.
www.ziehl-abegg.com/de
23.09.2019
Movement by Perfection │ Bewegung durch Perfektion
8│8
© ZIEHL-ABEGG SE
All rights reserved. Confidential and proprietary document, not to be disclosed or used except in accordance with applicable agreements. No disclosure to third parties, if not
expressively agreed by ZA SE.
1ZSE 5492-155 en, Rev. 4
On-load tap-changers, type UC
User’s manual
Original instruction
The information provided in this document is intended to be general and does not
cover all possible applications. Any specific application not covered should be
referred directly to ABB or its authorized representative.
ABB makes no warranty or representation and assumes no liability for the
accuracy of the information in this document or for the use of such information. All
information in this document is subject to change without notice.
This document must not be copied without our written permission, and the contents
thereof must not be imparted to a third party nor be used for any unauthorized
purpose. Contravention will be prosecuted.
Manufacturer’s declaration
The manufacturer
ABB AB
Components
SE-771 80 LUDVIKA
Sweden
Hereby declares that
The products
On-load tap-changers, type UC
with motor-drive mechanisms, types BUE and BUL
comply with the following requirements:
By design, the machine, considered as a component of a mineral oil filled power transformer, complies
with the requirements of
•
Machinery Directive 89/392/EEC (amended 91/368/EEC and 93/44/EEC) and 93/68/EEC (marking)
provided that the installation and the electrical connection are correctly realized by the manufacturer
of the transformer (e.g. in compliance with our Installation Instructions)
and
•
EMC Directive 89/336/EEC regarding the intrinsic characteristics to emission and immunity levels
and
•
Low Voltage Directive 73/23/EEC (modified by Directive 93/68/EEC) concerning the built-in motor
and apparatus in the control circuits.
Certificate of Incorporation:
The machines above must not be put into service until the machinery into which they have been
incorporated has been declared in conformity with the Machinery Directive.
Date
2013-02-15
Signed by .........................................................................
Hans Linder
Title
Manager Tap-Changers, Local Product Group Unit Components
Introduction
The UC range of on-load tap-changers manufactured by ABB
has been developed over many years to provide maximum
reliability. The simple and rugged design gives a service
life equal to the service life of the transformer. Minimum
maintenance is required for trouble-free operation. The only
parts requiring maintenance are contacts that might need
replacement during the service, the insulating oil and the
motor-drive mechanism.
The design allows ready access to all parts, making
inspection and maintenance quick and simple.
The tap-changers are housed in the transformer tank. The
motor-drive mechanism, type BUE or BUL, is attached to the
transformer tank and connected to the tap-changer by means
of drive-shafts and a bevel gear.
The same motor-drive can operate one, two or three
units on the same transformer. Those units are then
considered as one tap-changer.
Safety warnings
The following warnings and notes are used in the manual:
WARNING
WARNING indicates an imminently hazardous
situation, which if not avoided will result in death or
serious injury. This signal word is to be limited to the
most extreme situations.
WARNING also indicates a potentially hazardous
situation, which if not avoided could result in death or
serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation,
which if not avoided may result in minor or moderate
injury. It may also be used to alert of unsafe practices.
CAUTION may also indicate property-damage-only
hazards.
INFO provides additional information to assist in
carrying out the work described and to provide
trouble-free operation.
4 User's manual UC | 1ZSE 5492-155 en, Rev. 4
Safety precautions
WARNING
Personnel operating and inspecting the tap-changer
must have good knowledge of the apparatus and
must be aware of the risks pointed out in this manual.
Personnel making electrical connections in the motordrive mechanism have to be certified.
WARNING
Small amounts of explosive gases might come out
from the breathing devices (dehydrating breather
or one-way breather). Make sure that no open
fire, hot surfaces or sparks occur in the immediate
surroundings of the breathing devices.
CAUTION
After a trip from a supervisory device, an inspection
must be made by a specialist. The diverter switch
housing must be drained and the diverter switch lifted
and carefully investigated before the transformer is
reenergized.
Operation
– – For resetting of the emergency stop, turn the knob
clockwise and switch on the motor protective switch.
WARNING
The handcrank must not be inserted during electrical
operation.
WARNING
If the tap-changer is not in the exact position and the
handcrank is pulled out, the motor-drive mechanism
will start and go to the exact position if the power
supply is on.
WARNING
If a failure in power supply occurs during operation,
the operation will be completed when the power
returns.
– – The LOCAL/REMOTE switch. In position LOCAL the tapchanger can be operated by the RAISE/LOWER switch. In
position LOCAL remote operation is rendered impossible.
In position REMOTE the tap-changer is operated from the
control room or by a voltage regulator. Local operation is
not possible in remote position.
– – In case of a failure in power supply for the motor-drive
mechanism, it is possible to handcrank the tap-changer.
Put the handcrank on the shaft. Make sure it has entered
the slot in the shaft. Crank in the desired direction as
per the information plate above the shaft. The number
of turns for one step is also shown on the rating plate.
When the handcrank is inserted all electrical operations
are impossible. Continue cranking until the tap-changer
in progress indicator shows POSITION for BUE or white
colour for BUL.
– – The position indicator shows the actual tap-position.
– – The draghands show the max. and min. tap-position
between which the tap-changer has been operating since
last resetting.
–– For BUE: The tap-change in progress indicator shows
POSITION in service position, RAISE when operating in
a raise operation and LOWER when operating in a lower
direction.
– – For BUL: The tap-change in progress indicator shows
RED during operation and WHITE when the tap-changer is
in service position.
– – Thermostat for extra heater (option). We recommend a
setting at +5 °C.
– – Hygrostat for extra heater (option). We recommend a
setting at approximately 60 %.
– – Outlet (option) with earth fault protector.
Normally the tap-changer is controlled by a voltage regulator
and no manual operation of the tap-changer and the motordrive mechanism is needed.
1ZSE 5492-155 en, Rev. 4 | User's manual UC 5
Maintenance schedule
CAUTION
To maintain the high reliability of the tap-changer it is
important that the rules for maintenance given below
are followed.
The maintenance schedule given on the rating plate should
always be followed. The statement on the rating plate is
maintenance after a certain amount of operations or after a
certain time, whichever comes first. In addition to that, an
annual inspection should be carried out.
Maintenance of the tap-changer consists of three steps:
–– Inspection to be carried out by the site personnel once a
year.
– – Overhaul to be carried out by a specialist at intervals stated
on the rating plate.
Breakdown voltages according to IEC 60156, 1995-07,
should be carried out. The test should be performed as soon
as possible after sampling in order to do the test at almost the
same oil temperature as in the tap-changer.
The following values should be fulfilled:
Tap-changer 1)
Dielectric strength
All star point and all BIL 380 kV
≥ 30 kV/2.5 mm
Others
≥ 40 kV/2.5 mm
1) Star point is denoted N, the fifth letter in the type designation. The BIL value is
the first numerical digit in the type designation on the rating plate. For instance:
UCGRN 380/700.
In case the dielectric strength of the oil is lower than the
values given above, proceed as follows:
– – Make sure the sample is analysed immediately after
sampling in order to do the test at approximately the same
oil temperature as in the tap-changer
– – Measure at least five times and take an average.
– – Contact replacement to be carried out by a specialist. The
possible need for replacement is decided during overhaul.
In addition to these three steps, oil samples according to
IEC 60422, 2005-10, should be taken at regular intervals
of 2-6 years for those tap-changers having a maintenance
interval exceeding 7 years.
6 User's manual UC | 1ZSE 5492-155 en, Rev. 4
– – If the values still do not fulfill the requirements, the oil
needs to be treated by filtering. For procedure, see the
Maintenance guide.
A specialist is a service engineer from ABB or an authorized
person trained by ABB for maintenance work on UC tapchangers.
Inspection
Procedure
CAUTION
WARNING
Approval should be given by the site engineer in
charge for inspection as well as for operating the tapchanger.
Checking of the breather and the oil level must be
carried out from ground level since the transformer is
energized.
It is recommended to inspect the tap-changer once a year.
This principally concerns the motor-drive mechanism and
refers to a visual inspection inside the BUE/BUL cabinet to
check that nothing is loose, and that the heater is functioning.
In the motor-drive mechanism a counter registers every tapchange operation. During inspection the counter is read and
noted. If possible, motor and counter are to be tested by
operating one step and then back.
If the tap-changer has its own oil conservator, the breather
and the oil level indicator on the oil conservator are to be
checked according to the instructions from the transformer
manufacturer.
The inspection is to be carried out while the transformer is in
service.
On the conservator the following are to be checked:
–– Oil level
– – Breather
In the motor-drive mechanism the following items are to be
checked:
– – Motor and counter
– – Emergency stop
– – Heater
– – Earth fault protector for the outlet (option)
If the tap-changer is equipped with an oil filter unit, the
pressure drop over the filter is to be checked.
Required tools
The following eq uipment is required for the inspection:
– – Set of screwdrivers
– – Pen and note pad
1. Checking of the breather
WARNING
The breathers and the tube from the conservator
might contain explosive gases. No open fire, hot
surfaces or sparks may be present when removing the
breather.
Check the breather according to the instructions for the
transformer.
2. Checking of the oil level in the conservator
The oil level in the conservator should be according to the
instructions in the transformer documentation.
3. Checking of the motor and the counter
Open the motor-drive cabinet door and turn the selectorswitch to the LOCAL position. Then turn the control switch to
the RAISE (LOWER) position.
Check that the motor works properly, the position indicator
increases (decreases) one step, and the counter advances
one step for each operation. Record the counter’s value. The
counter shows the number of operations performed by the
tap-changer (the overhaul schedule can be determined with
the help of this information).
Turn the control switch to the LOWER (RAISE) position.
Check that the motor also works properly in that direction,
the position indicator decreases (increases) one step and the
counter advances one step more.
Reset the draghands. Read the counter and note the reading.
4. Checking of the emergency stop
Press the emergency stop and the protective motor switch
shall switch off. Reset the emergency stop by turning the
knob clockwise and set the protective motorswitch to ON.
1ZSE 5492-155 en, Rev. 4 | User's manual UC 7
5. Checking of the earth fault protector (option)
If the motor-drive mechanism is equipped with an outlet, the
earth fault protector should be tested by pressing the test
knob on the outlet on BUE or on the separate earth fault
protector on BUL.
6. Checking of the heater
WARNING
Before starting any work inside the motor-drive
mechanism the auxiliary power must be switched off.
N. B. The motor, contactors and heating element may
be energized from separate sources.
8. Trip or alarm from supervisory devices
A tap-changer might be equipped with several different
supervisory devices, such as pressure relay, oil flow relay and
pressure relief device. Every tap-changer will be equipped
with at least one of these devices. Even two or all of these
might be installed. The pressure relay and/or the oil flow relay
will trip the transformer in case their set points are reached.
The pressure relief device might be set to an alarm only or trip
as well.
In case of an alarm but no trip, we recommend blocking the
tap-changer for further operations and call a specialist for
consultation as soon as possible. Plan for a possible outage
to check the diverter switch.
Open the control panel (BUE only).
In case of a trip of the transformer, immediately call a
specialist and do not try to energize the transformer again
until a proper inspection of the diverter switch has been
carried out. Prepare for a diverter switch lift.
Check by feeling with a finger on the protection plate that the
heater has been functioning.
In both scenarios, collect the following information before
calling the specialist:
Close the control panel (BUE only). Reconnect the incoming
auxiliary power.
– – Serial number of the tap-changer
– – Counter reading of the motor-drive mechanism
– – If the trip/alarm came during switching. If so, between
which positions.
– – The load at the time of the trip/alarm
– – Which devices have given the trip/alarm
– – In case there are more than one tap-changer unit, try to
figure out which one has tripped/alarmed.
– – Any special service conditions at the time of the trip/alarm,
such as overload, thunderstorms, etc.
Disconnect the incoming auxiliary power.
Complete the inspection by turning the selector-switch to the
REMOTE position and close the cabinet door.
7. Checking of the oil filter unit (option)
If the tap-changer is equipped with an oil filter unit from ABB:
–– Read the pressure gauge. Check according to the oil filter
manual.
– – Note the reading so the change from year to year can be
seen.
If moisture is suspected to have come into the tap-changer
compartment, the filter insert should be replaced.
If a filter insert replacement is needed, call a specialist.
Also check for leakages. All leakages should be repaired!
8 User's manual UC | 1ZSE 5492-155 en, Rev. 4
Before a specialist arrives, prepare for a lift of the diverter
switch by making sure that a safe disconnection and
grounding of the transformer is done.
In case no local specialist is available, contact the after sales
department. The contact information is found on the last page
of this manual.
1
2
1
3
4
5
6
9
7
10
8
Layout of on-load tap-changer.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Bevel gears
Horizontal drive shaft with protective tubes
Oil valve
Pressure relay
Top section
Vertical drive shaft with protective tubes
Rating plate
Motor-drive mechanism
Diverter switch housing
Tap selector
1ZSE 5492-155 en, Rev. 4 | User's manual UC 9
1
3
2
8
4
6
5
7
9
10
11
8
12
15
14
13
16
Cabinet layout of motor-drive mechanism, type BUE.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Locking device prepared for padlock
Emergency stop
Air vent
LOCAL/REMOTE switch
RAISE/LOWER switch
Outgoing shaft
Lamp (40 W socket E27)
Lifting eye
Counter
10 User's manual UC | 1ZSE 5492-155 en, Rev. 4
10. Tap-change in progress indicator
11. Position indicator with drag hands for max. and min.
position
12. Shaft for hand crank
13. Protective motor switch
14. Door-operated switch for lamp
15. Hand crank
16. Descriptions and circuit diagram
1
2
14
4
3
5
12
6
8
7
16
9
10
11
13
15
6
Cabinet layout of motor-drive mechanism, type BUL2.
1.
2.
3.
4.
5.
6.
7.
Position indicator with drag hands for max. and min.
position
Tap-change in progress indicator
(Red: in progress, White: in position)
Counter
Outgoing shaft with multi-hole coupling half
Shaft for hand crank
Locking device prepared for padlock
(Option) Outlet
8.
9.
10.
11.
12.
13.
14.
15.
16.
Emergency stop
RAISE/LOWER switch
LOCAL/REMOTE switch
Protective motor switch
Air vent
Door-operated switch for lamp
Lamp
Descriptions and circuit diagram
Hand crank
1ZSE 5492-155 en, Rev. 4 | User's manual UC 11
ABB AB
Components
SE-771 80 Ludvika, Sweden
Phone: +46 240 78 20 00
Fax:
+46 240 121 57
E-Mail: [email protected]
www.abb.com/electricalcomponents
© Copyright 2013 ABB, All rights reserved. 1ZSE 5492-155 en, Rev. 4, 2013-04-15
Contact us
1ZSC000562-AAY en, Rev. 1
On-load tap-changers, type UCG and VUCG
Installation and commissioning guide
Original instruction
The information provided in this document is intended to be general and does not
cover all possible applications. Any specific application not covered should be
referred directly to ABB or its authorized representative.
ABB makes no warranty or representation and assumes no liability for the
accuracy of the information in this document or for the use of such information. All
information in this document is subject to change without notice.
This document must not be copied without our written permission, and the contents
thereof must not be imparted to a third party nor be used for any unauthorized
purpose. Contravention will be prosecuted.
Recommended practices
ABB recommends careful consideration of the following
factors when installing on-load tap-changers:
Before you install or commission a unit, make sure that the
personnel doing the job have read and fully understood the
installation and commissioning guide provided with the unit.
To avoid damaging the unit, never exceed the operating limits
stated in delivery documents and on rating plates.
Do not alter or modify a unit without first consulting ABB.
Follow local and international wiring regulations at all times.
Use only factory authorized replacement parts and
procedures.
Safety warnings
The following warnings and notes are used in the manual:
WARNING
Safety precautions
WARNING
Unused transformer oil is harmful. Fumes from
unused warm oil may irritate the respiratory organs
and the eyes. After long and repeated contact with
transformer oil, skin becomes very dry.
Used tap-changer oil from diverter switch housings
and selector switch housings contains harmful
substances. Fumes are irritating to the respiratory
organs and the eyes and are highly flammable. Used
transformer oil may well be carcinogenic.
Avoid contact with the oil and use oil-tight protective
gloves when handling the oil.
First aid:
Skin contact: Wash your hands. Use skin cream to
counteract drying.
In the eyes: Rinse your eyes in clean water.
Swallowing: Drink water or milk. Avoid vomiting. Call
a doctor.
WARNING indicates an imminently hazardous
situation, which if not avoided will result in death or
serious injury. This signal word is to be limited to the
most extreme situations.
Collect used oil in oil drums.
WARNING also indicates a potentially hazardous
situation, which if not avoided could result in death or
serious injury.
In the event of fire: Any fires should be extinguished
with powder, foam or carbonic acid extinguishing
agents.
CAUTION
WARNING
CAUTION indicates a potentially hazardous situation,
which if not avoided may result in minor or moderate
injury. It may also be used to alert of unsafe practices.
Be aware of the risk for slipping caused by oil spillage,
for instance when working on the transformer cover.
Waste and clean-up: Should be absorbed by an
absorber. Treat it as hazardous to the environment.
WARNING
CAUTION may also indicate property-damage-only
hazards.
INFO provides additional information to assist in
carrying out the work described and to provide
trouble-free operation.
The motor-drive mechanism must not be installed in
an explosive atmosphere. The electrical equipment
creates sparks that can cause an explosion.
WARNING
Before any work is carried out on the tap-changer:
Make sure that the transformer is disconnected and
that grounding is properly conducted. Obtain a signed
certificate from the engineer in charge.
WARNING
CAUTION
Before carrying out work on the tap-changer, put
the LOCAL/REMOTE switch on the motor-drive
mechanism to position 0. It is also advisable to shut
the door of the motor-drive mechanism and pad lock
it when work is carried out on the tap-changer. The
key should be kept by the operator. This is done
to avoid an unexpected start of the motor-drive
mechanism.
To avoid seizing, do not operate the tap-changer
during the drying process or afterwards until it is filled
with oil.
WARNING
Before starting any work inside the motor-drive
mechanism, the auxiliary power must be switched off.
NOTE: The motor, contactors and heating element
may be energized from separate sources.
During drying of the transformer
CAUTION
Mounting of gaskets
CAUTION
Sealing surfaces and gaskets must be clean and
undamaged. Diametrically opposed bolts in sealing
joints must be tightened alternately several times,
beginning with a low tightening torque and finally with
the recommended tightening torque as described in
Section 1.8 Tightening torques in this guide.
During oil filling
WARNING
The diverter switch should not be installed during
drying, since the process removes grease needed for
operation.
When oil that has been used in a diverter switch
housing is pumped out, grounded conducting
tubes and hoses should be used to avoid the risk of
explosion due to the gases produced by arcs during
service.
CAUTION
CAUTION
While drying with hot air and vacuum, the maximum
permitted pressure difference for the diverter switch
housing is 100 kPa at the maximum permitted
temperature of 135 °C (275 °F).
Do not fill the diverter switch housing with oil if the
transformer tank is under vacuum and the diverter
switch housing is not.
CAUTION
CAUTION
During drying with the vapor phase process, the cover
of the diverter switch housing and the bottom valve
should be left open. The valve is opened with the
special bottom valve key – a long hexagonal rod. The
maximum permitted temperature is 135 °C (275 °F).
Do not fill the transformer tank with oil if the diverter
switch housing is under vacuum and the transformer
tank is not.
After oil filling
CAUTION
CAUTION
Use the special bottom valve key only (delivered with
the tap-changer) to operate the bottom valve through
the oil draining tube. The use of a stiffer tool may
damage the valve.
Do not energize the transformer earlier than three
hours after oil filling at atmospheric pressure. This
waiting period is needed to allow air bubbles to
dissipate.
During service
WARNING
Small amounts of explosive gases may be emitted
from the breathing devices (dehydrating breather or
one-way breather). Make sure that no open fires, hot
surfaces or sparks occur in the immediate vicinity of
the breathing devices.
WARNING
If a power supply failure occurs during operation, the
operation will be completed when the power returns.
WARNING
The hand crank must not be inserted during electrical
operation.
WARNING
If the tap-changer is not at its exact position and the
hand crank is pulled out, the motor-drive mechanism
will start and go to the exact position if the power
supply is on.
CAUTION
After a pressure relay trip, follow the instructions in
the chapter “Trip or alarm from supervisory devices” in
the user's manual.
CAUTION
The pressure relay is a calibrated monitoring
instrument. It must be handled with care and
protected against careless handling or any kind of
mechanical damage. Do not open the pressure relay
package until just prior to installation on the tapchanger.
Content
1. Introduction...........................................................................................................................8
1.1 Type designation............................................................................................................10
1.2 Required tools...............................................................................................................11
1.3 Required material...........................................................................................................11
1.4 Oil..................................................................................................................................11
1.5 Oil conservator...............................................................................................................11
1.6 Oil filter unit for continuous oil filtration...........................................................................12
1.7 Weights.........................................................................................................................12
1.8 Tightening torques.........................................................................................................12
2. Receiving...............................................................................................................................14
2.1 Unpacking.....................................................................................................................14
2.2 Inspection on receipt......................................................................................................14
2.3 Temporary storage before assembly..............................................................................14
3. Installation in the transformer.................................................................................................15
3.1 Cover-mounting.............................................................................................................16
3.1.1 UCG/VUCG with tap selector size C........................................................................16
3.1.2 UCG/VUCG with tap selector size III or F.................................................................19
3.2 Yoke-mounting..............................................................................................................22
3.2.1 Mounting when the transformer ratio measurement is carried out before drying.......23
3.2.2 Mounting when the transformer ratio measurement is carried out after drying..........25
3.2.3 Mounting on transformer cover (after the drying process)........................................26
3.3 Connection to terminals.................................................................................................28
3.4 Transformer ratio measurement......................................................................................30
3.4.1 Transformer ratio measurement before drying..........................................................30
3.4.2 Transformer ratio measurement after drying.............................................................30
4. Drying....................................................................................................................................31
4.1 Precautions before processing.......................................................................................31
4.2 Precautions after processing..........................................................................................31
4.3 Installation of diverter switch..........................................................................................31
5. Final assembly.......................................................................................................................33
5.1 Mounting of motor-drive mechanism..............................................................................33
5.2 Mounting of external drive shafts....................................................................................37
5.2.1 Mounting of vertical drive shaft................................................................................37
5.2.2 Mounting of horizontal drive shaft for one unit..........................................................39
5.2.3 Mounting of horizontal drive shaft for two units........................................................41
5.2.4 Mounting of horizontal drive shafts for three units....................................................43
5.2.5 Before operation......................................................................................................43
5.3 Supervisory equipment..................................................................................................43
5.4 Assembly of accessories................................................................................................43
5.5 Connection to the oil conservator...................................................................................43
5.6. Connection of tube for oil sampling for VUC..................................................................44
6. Oil filling.................................................................................................................................45
6.1 Filling methods and restrictions......................................................................................45
6.2 Before filling...................................................................................................................45
6.3 Filling at atmospheric pressure.......................................................................................45
6.4 Filling under vacuum......................................................................................................45
6.4.1 Oil conservator filled under vacuum.........................................................................45
7. Electrical connection and testing...........................................................................................47
7.1 General..........................................................................................................................47
7.2 Connecting and testing the motor-drive mechanism and the tap-changer...........................47
7.3 Electrical tests on the transformer..................................................................................47
7.4 After energizing..............................................................................................................47
8. Transport...............................................................................................................................48
8.1 Dismantling before transport..........................................................................................48
8.1.1 Dismantling preparations.........................................................................................48
8.1.2 Removal of the vertical drive shaft...........................................................................48
8.1.3 Removal of horizontal drive shaft for one unit...........................................................48
8.1.4 Removal of horizontal drive shafts for two units........................................................ 48
8.1.5 Removal of horizontal drive shafts for three units.....................................................48
8.1.6 Accessories.............................................................................................................49
8.2 Oil level during transport................................................................................................49
8.2.1 Transformer filled with oil..........................................................................................49
8.2.1.1 Conservator mounted......................................................................................49
8.2.1.2 Conservator unmounted..................................................................................49
8.2.2 Transformer drained................................................................................................49
8.2.2.1 Conservator mounted......................................................................................49
8.2.2.2 Conservator unmounted..................................................................................49
9. Commissioning......................................................................................................................50
9.1 Connection to the oil conservator...................................................................................50
9.2 Mounting the motor-drive mechanism and the drive shafts............................................50
9.2.1 Mounting of the motor-drive mechanism..................................................................50
9.2.2 Mounting of the external drive shafts.......................................................................50
9.2.3 Mounting of the vertical drive shaft..........................................................................51
9.2.4 Mounting of horizontal drive shaft for one unit..........................................................52
9.2.5 Mounting of horizontal drive shafts for two units......................................................53
9.2.6 Mounting of horizontal drive shafts for three units ...................................................54
9.2.7 Before operation......................................................................................................54
9.3 Supervisory equipment..................................................................................................54
9.4 Accessories...................................................................................................................54
9.5 Oil filling.........................................................................................................................54
9.6 Electrical connection and testing....................................................................................54
9.6.1 Motor protection......................................................................................................54
9.6.2 Disk brake...............................................................................................................55
9.6.3 Counter...................................................................................................................55
9.6.4 Position transmitter and other position switches......................................................55
9.6.5 Light........................................................................................................................55
9.6.6 Heater.....................................................................................................................55
9.7 Putting into operation.....................................................................................................55
1. Introduction
The arrangement of on-load tap-changers types UCG and
VUCG, and of the tap-changer system, are shown in Figs. 1
and 2. The tap-changer may consist of one, two or three units
driven by the same motor-drive mechanism. The tap-changer
is delivered in three main parts: diverter switch housing, tap
selector and motor-drive mechanism.
The tap-changer is available in designs for cover-mounting or
for yoke-mounting. Cover-mounting means that the diverter
switch housing is lowered through the hole in the transformer
tank and then bolted straight onto the transformer cover,
followed by mounting of the tap selector. Yoke-mounting
means that the tap-changer is temporarily put on a fork
located on the active part of the transformer. Yoke-mounting
allows the transformer manufacturer to connect the windings
to the tap-changer before drying and without having the
transformer cover-mounted. The transformer cover is then
lowered onto the tank, and the tap-changer is lifted and
bolted to the cover. Use the appropriate instruction for covermounting or yoke-mounting in Chapter 3.
At cover-mounting the diverter switch housing is installed on
the transformer cover before joining with the tap selector. The
exception is the UCG/C and VUCG/C where the tap selector
and the diverter switch housing is joined before the entire tapchanger is lowered through the hole in the transformer cover.
After the transformer drying process, the motor-drive
mechanism and bevel gear are fitted to the transformer tank
and the drive shafts are fitted to complete the assembly of the
motor-drive mechanism, bevel gear and tap-changer before
oil filling and testing.
Position numbers in this guide, for example SA11 (see
Chapter 5), correspond to those on the packing list for the
tap-changer.
All instructions are for one tap-changer unit. When there is
more than one unit on the transformer, carry out the same
procedures for each unit.
Horizontal drive shaft
and protective tubes
Bevel gear
Pressure relay
Vertical drive shaft
and protective tubes
Motor-drive mechanism
Fig. 1. On-load tap-changer system (single-unit shown).
8 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
Oil valve
Horizontal drive shafts
and protective tubes
Bevel gear
Bevel gear
Vertical drive
shafts and
protective tubes
Shielding caps
(only for insulation
level above 380 kV)
Type of connection, N or E
Rating plate
Shielding rings
(only for insulation
level above 380 kV)
Hand crank
(inside the cover)
Motor-drive
mechanism
Not used for selector, size C
Unit -1
Type of connection, B
Unit -1
Unit -2
Type of
connection, T
Unit -1
Unit -2
Unit -3
Fig. 2. Example of on-load tap-changer systems.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 9
1.1 Type designation
UCG..
VUCG..
XXXX/YYYY/C,III,F
XXXX/YYYY/C,III,F
UCG Diverter switch with arc quenching in oil
VUCG Diverter switch with vacuum interrupters
Example: UCGRE 650/900/III
Tap selector size
Type of switching
L Linear
R Plus/Minus
D Coarse/Fine
Impulse withstand voltage to ground
Maximum rated through-current
Type of connection
N Three-phase star point (one unit)
E Single-phase (one unit)
T Three-phase fully insulated (three units)
B Three-phase delta (two units; single-phase and two-phase
Serial No.
Serial No. in the bottom
of the diverter switch
Serial No.
Serial No.
Serial No.
Tap selector size C
Tap selector size III
Fig. 3. Diverter switch housing UCG/VUCG, and tap selectors size C, III and F.
10 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
Tap selector size F
1.2 Required tools
– – Standard set of open-end wrenches (up to 24 mm)
– – Standard set of sockets (up to 24 mm)
– – Standard set of screwdrivers
– – Socket handle
– – Set of pliers, including cutting pliers
– – Dynamometric wrench, 5-85 Nm
– – Sliding caliper
– – Allen key sockets, 2–10 mm
– – Pipe wrench
– – Bottom valve key (delivered with the tap-changer)
– – Lifting device, article no. LL 135 016-A
– – Special hand crank for operating the tap-changer on the
bevel gear, article no. LL 117 016-M
– – Hack saw (only for installation)
– – File
– – Folding ruler/tape measure
– – Air pump with hose, pressure gauge (0–250 kPa) and
connection with internal thread R 1/8”
– – Container, 50 liters
– – Small oil pump with connection to the oil valve. (For
connection size, see the dimensional drawing for the tapchanger.)
1.3 Required material
– – Rags for cleaning
– – Single-phase diagram for tap-changer
– – Gasket for transformer flange
– – Insulating paper
– – Insulating bushings
– – Wooden block as spacer
– – Grease (ball bearing grease) GULF-718 EP, Mobil
Grease 28, SHELL Aero Shell Grease 22 or similar
– – Oil, see Section 1.4
– – Dimensional drawing for the tap-changer for connection
dimensions of the oil valve
– – Flange for connection to the oil conservator flange when
filling under vacuum; see Fig. 38.
– – Oil valves for connection to flange with dimensions
according to Fig. 51. Can be ordered from ABB.
– – Equipment for oil filling
– – Sealing tape
– – Maintenance guide for tap-changer
– – Circuit diagram the motor-drive mechanism
– – Oil filter (when there is a common conservator for both the
transformer and the tap-changer, this can be ordered from
ABB).
1.4 Oil
The oil quality should be I -30° according to IEC 60296:2012,
and comply with IEC 60422:2008. Upon commissioning, the
break-down value should be at least 40 kV/2.5 mm according
to IEC 60156.
Type designation
Oil weight (kg)
(The oil for the conservator is
not included.)
UCG.., VUCG..
380/..., 650/..., 750/...
150
UCG.., VUCG..
1050/...
185
Table 1. Weight of oil in kg.
WARNING
Do not energize the transformer until oil has been
filled according to Chapter 6.
An UCG.B/VUCG.B requires twice and UCG.T/VUCG.T
three times the amount specified above since they have
two and three diverter switch housings respectively.
1.5 Oil conservator
The tap-changer must be connected to an oil conservator.
ABB recommends using a separate conservator for the tapchanger with both the oil and air side separated from the main
conservator of the transformer.
The volume of the conservator should be such that there
is still oil in the conservator even at the lowest expected
oil temperature, and such that no flooding can occur at
the expected highest oil temperature. Even tap-changers
consisting of more than one unit require only one conservator.
A suitable dimension of the tube for connection to the
conservator is an inner diameter of approximately 20 mm.
The tube should be inclined at least 3 degrees to avoid
gas pockets in the tube. A valve in the connection to the
conservator is recommended.
The conservator must be equipped with a breathing device
that does not allow moist air into the conservator and that
permits the gas to dissipate.
The conservator should also be equipped with an oil
level indicator, and an alarm contact for low oil level is
recommended.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 11
1.6 Oil filter unit for continuous oil filtration
If the tap-changer should have an oil filter unit for continuous
oil filtration from ABB, installation and commissioning
instructions are found in the manual delivered with the unit.
1.7 Weights
– – Motor-drive mechanism type BUE: approximately 155 kg
– – Motor-drive mechanism type BUL2: approximately 95 kg
The weights of the motor-drive mechanism and drive-shaft
system are not included in the weights given in Tables 2
and 3.
1.8 Tightening torques
The following tightening torques are recommended:
For metallic screw joints:
M6........... 10 Nm
M8........... 24.5 Nm
M10.......... 49 Nm
M12.......... 84 Nm
For non-metallic screw joints: M10.......... 9 Nm
M12.......... 13 Nm
M16.......... 22 Nm
if not otherwise stated in this guide.
12 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
±10
±10
±10
±10
±10
±10
±10
%
%
%
%
%
%
%
On-load tap changer type designation
UCG.N
UCG.T
UCG.B
UCG.E
Required oil
Selector C
Selector III
Selector F
BIL
Current
in kg
Without oil
Total
Without oil
Total
Without oil
Total
380
300-600
185
319
504
1235
1420
545
730
650
300-600
185
329
514
1415
1600
562
747
1050
300-600
230
349
579
1475
1705
582
812
380
300-600
555
917
1472
985
1540
1185
1740
650
300-600
555
947
1502
1105
1660
1365
1920
1050
300-600
690
1007
1697
1145
1835
1425
2115
380
1200-1500
555
1007
1562
985
1540
1185
1740
650
1200-1500
555
1037
1592
1105
1660
1365
1920
1050
1200-1500
690
1097
1787
1145
1835
1425
2115
380
300-600
370
633
1003
370
740
1010
1380
650
300-600
370
653
1023
430
800
1130
1500
1050
300-600
460
693
1153
450
910
1170
1630
380
300-600
185
289
474
395
580
395
580
650
300-600
185
299
484
455
640
455
640
1050
300-600
230
319
549
475
705
475
705
380
1200-1500
185
319
504
395
580
395
580
650
1200-1500
185
329
514
455
640
455
640
1050
1200-1500
230
349
579
475
705
475
705
Table 2. Weights for type UCG.
On-load tap changer type designation
VUCG.N
VUCG.T
VUCG.B
VUCG.E
Required
Selector C
Selector III
Selector F
BIL
Current
oil in kg
Without oil
Total
Without oil
Total
Without oil
Total
380
450-800
185
344
529
440
625
570
755
650
450-800
185
354
539
450
635
587
772
1050
450-800
230
374
604
470
700
607
837
380
450-800
555
942
1497
1101
1656
1260
1815
650
450-800
555
972
1527
1131
1686
1440
1995
1050
450-800
690
1032
1722
1191
1881
1500
2190
380
800-1800
555
1032
1587
1224
1779
1260
1815
650
800-1800
555
1062
1617
1254
1809
1440
1995
1050
800-1800
690
1122
1812
1314
2004
1500
2190
380
450-800
370
658
1028
816
1186
1060
1430
650
450-800
370
678
1048
836
1206
1180
1550
1050
450-800
460
718
1178
876
1336
1220
1680
380
450-800
185
314
499
367
552
420
605
650
450-800
185
324
509
377
562
480
665
1050
450-800
230
344
574
397
627
500
730
380
800-1800
185
344
529
408
593
420
605
650
800-1800
185
354
539
418
603
480
665
1050
800-1800
230
374
604
438
668
500
730
Table 3. Weights for type VUCG.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 13
2. Receiving
2.1 Unpacking
Check that the packages are free from transport damage.
Open the covers of the transport boxes, Remove the
supporting block of wood. If any package is damaged, a
careful investigation must be carried out.
Lift the tap-changer parts by their lifting eyes according to
Fig. 4.
2.2 Inspection on receipt
1. Check that the diverter switch housing, tap selector,
motor-drive mechanism and accessories are undamaged.
2. If transport damage is found, and it is judged that correct
operation of the tap-changer is not possible, a damage
report should be sent to the insurance company. It is also
recommended that photographs be taken of the damaged
parts. Mark the photos with ABB’s reference number and
the serial number of the tap-changer and send them to
ABB.
3. Check that the parts delivered, type designations and the
serial numbers agree with the delivery documents, e.g. the
packing list or ABB’s order acknowledgement. The serial
numbers to be checked are those on the rating plate,
on the diverter switch housing and on the tap selector.
For locations; see Fig. 3. The serial number on the parts
belonging to one tap-changer unit should all be the same.
2.3 Temporary storage before assembly
If the tap-changer is not to be assembled immediately, once
the delivery has been approved, the tap-changer and the
motor-drive mechanism must be stored at a warm and dry
indoor location. Keep the units in their plastic enclosures and
do not remove the drying agent until assembly.
14 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
3. Installation in the transformer
WARNING
Either the cover-mounting method or yoke-mounting method
is used.
The angle between the lifting slings should be no
more than 90°.
WARNING
WARNING
The intermediate gear and the insulating shaft
of the diverter switch housing moves during
operation. Maintain a safe distance during operation
to avoid injuries!
Lowering the complete tap-changer to the floor
without support entails a risk for tipping, personal
injury and equipment damage.
The diverter switch housing and the tap selector are designed
to be lifted by the lifting eyes; see Fig. 4.
Max 90°
Diverter switch housing
Max 90°
Max 90°
Max 90°
Tap selector C
Tap selector III
Tap selector F
Fig. 4. How to lift the diverter switch housing and the tap selector.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 15
3.1 Cover-mounting
The diverter switch housing and the tap selector are delivered
in separate packaging.
3.1.1 UCG/VUCG with tap selector size C
1. Unpack the diverter switch housing and the tap selector,
and remove the drying agent.
2. Fit the gasket into the tap-changer flange on the
transformer cover; see Fig. 6. (This gasket is not included
in the delivery).
3. Remove the transport locking and the lifting eyes with
fasteners from the top section of the tap selector; see
Fig. 8.
8. Lift the tap-changer by the lifting eyes as shown in
Fig. 4 and lower it carefully through the opening in the
transformer top cover; see Fig. 5. Correctly position the
tap-changer for mounting the outer shaft system (see
transformer drawing). The studs on the flange on the
transformer cover shall fit into the holes in the flange of the
diverter switch housing. Fit twenty-four washers and M12
nuts (not included in the delivery); see Fig. 6. Tighten the
nuts.
WARNING
The diverter switch housing and the tap selector
contain moving parts. Observe caution!
CAUTION
Do not operate the tap selector until it is connected to
the diverter switch housing.
4. Lift the diverter switch housing by the lifting eyes and
remove the transport support. Remove the three limbs,
see Fig. 9.
5. Lift the diverter switch housing into position and fit the tap
selector to the diverter switch housing; see Fig. 10. The
tap selector drive pin must fit into the large gear wheel
slot; see view A-A.
Diverter switch
Tap selector size C
Opening in the
transformer cover
CAUTION
The drive crank on the tap selector may only be
moved slightly to engage the slot in the large gear
wheel of the diverter switch housing.
Fig. 5.
6. Insert the fastening screws (six hexagon screws M8x35)
and washers. Tighten the screws.
7. If the tap-changer is equipped with a tie-in resistor
for mounting under the tap selector, the tie-in resistor
is mounted after joining the tap selector to the diverter
switch housing. After mounting the tie-in resistor, the
tap-changer must not be set down so that it stands on
the tie-in resistor. It must be suspended from an overhead
crane, for example.
Top section
Stud M12
Nut M12 (24x)
Washer (24x)
Flange
WARNING
Gasket
Lowering the complete tap-changer to the floor
without support entails a risk for tipping, personal
injury and equipment damage.
Transformer top
cover
Fig. 6.
16 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
~ 3 mm
9. Connect the supplied conductors between the diverter
switch housing and tap selector; see Fig. 10. The
conductor ends and their connecting points have the
same markings. The number of conductors varies
depending on the rated through-current and the type of
connection.
10. If the impulse withstand voltage to ground (BIL) exceeds
380 kV, insulate the connections on the tap selector
by winding paper around them to a thickness of
approximately 3 mm; see Fig. 7. The paper should be
of the same quality as used for insulation of conductors
within the active part of the transformer.
~ 100 mm
Locking nut
Conductor
Spring washer
Insulating paper
Plain washers
Connection point on
the tap selector
Socket screw
CAUTION
Fig. 7.
After mounting the shielding ring, the tap-changer
must not stand on the shielding ring.
11. Continue with section 3.3.
Transport locking
(to be removed)
Driving
crank
Screws (4 pcs)
(to be removed)
Fig. 8. Tap selector size C, top view.
Diverter switch
housing, lower part
Limbs (3 pieces)
Hexagon screws
and nut (3 pieces)
Transport supports
Fig. 9.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 17
Washer
14x30x2,5
Spring washer
Locking nut M12
Socket-head
cap screw M12
Diverter switch
housing
Shielding
rings
F
F
B–B
Conductor
Insulating shaft
B
B
F–F
Conductors
Locking nut M10
Spring washer
Washer 10.5x24x3
D
A
A
Socket-head cap
screw
Large gear wheel
Conductor
C–C
D
Tap selector,
size C
Diverter switch
housing
Current
collector
C
C
Tap selector
Washer 8.4x20x2
Spring washer
Hexagon headed
screw M8x35
Conductors
D–D
Insulating bolt
M16x110
Slot in the large gear wheel
of the diverter switch housing
Insulating
nut M16
Cleats
Driving pin of the tap selector
A–A
Fig. 10. Diverter switch UCG/VUCG, and tap selector, size C.
18 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
3.1.2 UCG/VUCG with tap selector size III or F
1. Unpack the diverter switch housing and the tap selector,
and remove the drying agent.
2. Fit the gasket into the tap-changer flange on the
transformer cover; see Fig. 12. (This gasket is not included
in the delivery.)
3. Lift the diverter switch housing by the lifting eyes as shown
in Fig. 4 and lower it carefully through the opening in the
transformer top cover; see Fig. 11. Correctly position the
diverter switch housing correctly for mounting the outer
shaft system (see transformer drawing). The studs on the
flange on the transformer cover shall fit into the holes in
the flange of the diverter switch housing. Fit twenty-four
washers and M12 nuts (not included in the delivery); see
Fig. 12. Tighten the nuts.
4. Position the tap selector for joining to the diverter switch
housing. Lift by the lifting eyes as shown in Fig. 4.
5. If the tap-changer is equipped with a tie-in resistor
for mounting under the tap selector, the tie-in resistor
is mounted after joining the tap selector to the diverter
switch housing. After mounting the tie-in resistor, the
tap-changer must not be set down so that it stands on
the tie-in resistor. It must be suspended from an overhead
crane, for example.
If the tap-changer is equipped with a tie-in resistor
switch, the switch is mounted under the tap selector
upon delivery. A special support in the box ensures that it
stands on the tap selector bottom. If this special support
is removed from the box, the tap selector can stand on
this when joining to the diverter switch housing. After
joining, the complete tap-changer is lifted and the special
support is removed. The complete tap-changer must not
be set down on the special support. It must be suspended
from an overhead crane, for example.
7. Lift the diverter switch housing into position and fit the tap
selector to the diverter switch housing; see Fig. 14. The
tap selector drive pin must fit into the large gear wheel
slot; see view A-A.
CAUTION
The drive crank on the tap selector may only be
moved slightly to engage the slot in the large gear
wheel of the diverter switch housing.
Diverter switch
Opening in
transformer cover
Tap selector
size III or F
Fig. 11.
Top cover
WARNING
Lowering the complete tap-changer to the floor
without support entails a risk for tipping, personal
injury and equipment damage.
Top section
Nut M12 (x24)
Washer
(x24)
Stud (x24)
6. Remove the transport locking and the lifting eyes with
fasteners from the top section of the tap selector; see
Fig. 13a-b.
Gasket
CAUTION
Transformer
top cover
Do not operate the tap selector until it is connected to
the diverter switch housing.
Fig. 12.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 19
8. Insert four M10x40 screws and washers through the tap
selector upper part to the four supports of the diverter
switch housing. Tighten the screws; see view E-E, Fig. 14.
Transport locking
(to be removed)
WARNING
Drive crank
The diverter switch housing and the tap selector
contain moving parts. Observe caution!
9. Connect the supplied conductors between the diverter
switch housing and tap selector. The conductor ends and
their connecting points have the same markings. Fasten
the conductors with cleats. The number of conductors
varies depending on the rated through-current and the
type of connection.
Screw (to be
removed)
Fig. 13a. Tap selector size III, top view.
WARNING
The wires coming from the transformer’s regulating
winding may not pass through the spaces between
the change-over selector and the fine selector.
10. If the impulse withstand voltage to ground (BIL) exceeds
380 kV, insulate the connections on the tap selector
by winding paper around them to a thickness of
approximately 3 mm; see Fig. 9. The paper should be
of the same quality as used for insulation of conductors
within the active part of the transformer.
11. If the impulse withstand voltage to ground (BIL) exceeds
380 kV, mount the supplied shielding ring (TS 11) at the
bottom plate of the tap selector; see view D–D.
Transport locking
(to be removed)
Screw (to be
removed)
Fig. 13b. Tap selector size F, top view.
CAUTION
After mounting the shielding ring, the tap-changer
must not stand on the shielding ring.
12. Continue with Section 3.3.
20 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
Lifting eyes with
fasteners (to be
removed)
Washer
14x30x2,5
Spring washer
Locking nut M12
Socket-head
cap screw M12
Diverter switch
housing
F
F
B–B
B
Conductor
B
F–F
Insulating
shaft
Conductors
Locking nut M12
Spring washer
E
A
A
Socket-head
cap screw
Washer 14x30x2.5
E
Conductor
C–C
Socket-head cap
screw M8x25
Spring washer
C
C
Locking nut M8
Current
collector
D–D
Tap selector,
size III
D
Shielding ring,
TS 11
Diverter switch
support
D
Tap selector
Cleats
Insulating
nut M16
Washer 10.5x24x3 (x4)
Spring washer
Insulating
stud
M16x120
E–E
Socket-head cap
screw M10x40 (x4)
Slot in the large gear wheel of the
diverter switch housing
Conductors
A–A
Driving pin of the tap selector
Fig. 14. Diverter switch UCG/VUCG, and tap selector III or F.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 21
3.2 Yoke-mounting
(Pre-mounting on active part of the transformer.)
The top section of the diverter switch housing is designed
to be divided into an upper and a lower flange (see Figs. 16
and 18) to fit the yoke-mounting.
Before lifting and joining the diverter switch housing to the
transformer cover, it is placed on a yoke fork (two beams) that
is fastened on the upper transformer yoke; see Fig. 15.
Bevel gear
On-load
tap-changer
The guide pins used on the yoke fork should be
insulated with bushings in order to prevent circulating
current in the yoke fork when the transformer is in
operation.
Mounting of the tap-changer on the yoke fork can be carried
out by two alternative methods depending on when the
transformer ratio measurement is carried out:
Fig. 15. Yoke-mounting principle.
– – Transformer ratio measurement is carried out before the
drying process; see Section 3.2.1.
–– Transformer ratio measurement is carried out after the
drying process; see Section 3.2.2.
For mounting on the transformer cover after the drying
process; see Section 3.2.3.
CAUTION
To avoid seizing, do not operate the tap-changer,
neither during the drying process nor afterwards, until
the diverter switch housing is filled with oil and the tap
selector is immersed in oil.
22 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
Transformer
active part
Yoke fork
3.2.1 Mounting when the transformer ratio measurement
is carried out before drying
1. Assemble the diverter switch housing and the tap selector
according to Section 3.1.3, steps 1, and 4-12.
2. Lift the tap-changer onto the yoke fork (use the lifting eyes
at the top of the tap-changer; see Fig. 4). Place the tapchanger in position for mounting the outer shaft system
(see transformer drawings). Insert and tighten the supplied
guide pins DS 7 and insulating bushings (not included in
delivery) in the lower flange; see Fig. 16. The guide pins
must be secured by center punch marks in the pins.
3. Mount the conductors between the regulating winding and
the tap selector according to Section 3.3.
4. Carry out transformer ratio measurement according to
Section 3.4 in this guide.
5. Remove the diverter switch housing cover (see Fig. 18)
by removing the screws. Store the cover, fasteners and
O-ring at a dust-free location.
6. If the vapor phase process will be used: Remove the plug
in the T-coupling for the oil drainage tube. To open the
bottom valve, let the bottom valve key (DS16), slide down
through the oil drainage tube, and when it has gripped
the valve, rotate it in a counter-clockwise direction until it
stops after approximately 6 turns; see Fig. 19. Refit the
plug.
7. Remove the diverter switch by carefully lifting it straight
out of the diverter switch housing by its lifting eye; see
Fig. 18. Store the diverter switch at a dry and dust-free
location.
WARNING
For VUCG: The vacuum interrupters are sensitive and
the diverter switch must thus be handled with care.
8. Remove the oil drainage tube by hand or by means of a
pipe wrench, placing a cloth between the tube and the
pipe wrench to protect the tube. Store the tube in the
diverter switch housing until it is remounted.
9. Remove the four clamp screws, M10 x 35, and the
washers that hold the bevel gear; see Fig. 18. Note the
position of the bevel gear. Carefully remove the gear
housing, and put the parts in a safe place. Store the bevel
gear at a dust-free location.
CAUTION
Do not remove the locking device for the bevel gear.
10. Mount the locking device DS 4 on the drive shaft of the
tap-changer.
Secure with center
punch marks
Upper flange
Lower flange
42 mm
O-ring
Yoke fork
Diverter switch housing
Insulating bushing
(not included)
Guide pin DS 7
(outer diameter = 12 mm)
Fig. 16.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 23
CAUTION
The drive shaft must not be rotated.
11. The guide bar for positioning the diverter switch in the
housing is secured in the upper flange with screws
and washers. Remove the screws and washers. Store
the guide bar in the diverter switch housing until it is
remounted. Save the screws and washers.
12. Remove the nuts and washers inside the upper flange and
remove the flange by lifting it by the lifting eyes. Store the
upper flange, and the O-ring at a dust-free location. Save
the nuts and washers.
13. The tap-changer is now ready for drying together with the
transformer. Follow the instructions in Chapter 4.
Oil drainage plug
Socket handle
Bottom valve key
DS16,
key width 10 mm
Oil drainage tube
Position
indicator
Red mark
Fig. 17. Bevel gear.
Fig. 19.
Cover
O-ring
Bevel gear
Lifting eye for
the diverter
switch
O-ring
Upper flange
O-ring
Lower flange
Fig. 18.
24 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
Locking device DS 4
3.2.2 Mounting when the transformer ratio measurement
is carried out after drying
1. Assemble the diverter switch housing and the tap selector
according to Section 3.1.3, steps 1 and 4-12.
2. Follow the instructions according to Section 3.2.1,
steps 5-13.
3. Attach the lifting device LL 135 016-A according to
Fig. 20.
Max. 90°
The lifting device must be tilted when attaching.
Lifting device
Lift the tap-changer onto the yoke fork. Place the tapchanger in position for mounting the outer shaft system
(see transformer drawing). Insert the supplied guide bolts
DS 7 and insulating bushings (not included in delivery) in
the lower flange; see Fig. 16. The guide bolts must fit into
the holes in the yoke fork and be secured by punch marks
in the pins. When the tap-changer is in place, remove the
lifting device.
4. Mount the conductors between the transformer winding
and the tap selector according to Section 3.3.
5. The tap-changer is now ready for drying together with the
transformer. Follow the instructions in Chapter 4.
Fig. 20. Attachment of lifting device.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 25
3.2.3 Mounting on transformer cover (after the drying
process)
1. After the transformer cover is mounted, place the gasket
in the flange for the tap-changer. (This gasket is not
included in the tap-changer delivery.)
7. Place the O-ring for the bevel gear in its groove in the
upper flange; see Fig. 22. Remount the bevel gear unit in
the position it had before removal, and make sure that the
pin in the spherical shaft end fits into the drive shaft slot
without rotating the drive shaft. Secure the gear unit in the
flange with its four clamping screws M10x35 and washers.
Do not insert the studs for the upper flange in the
transformer cover flange. This is carried out at step 8.
CAUTION
The gear box must not be forced down. If the
coupling does not engage, lift the gear box and adjust
the setting of the drive pin.
2. Remove the locking device DS 4 from the drive shaft; see
Fig. 18.
CAUTION
Be careful not to drop the locking device and the
screw.
CAUTION
The drive shaft must not be rotated.
3. Place the O-ring in its groove in the lower flange; see
Fig. 16.
4. Place the upper flange over the opening in the transformer
cover. Turn the upper flange so that the flange for the
bevel gear is aligned with the drive shaft. The screws in
the lower flange must fit into the holes in the upper flange;
see Fig. 21.
5. Lift the tap-changer slowly until it just touches the upper
flange. Use lifting device LL 136 016-D. Attach the device
at the lower flange sides. The lifting device must be tilted
when attaching and removing; see Fig. 20.
6. When the flanges touch, fit twenty M8 locking nuts and
washers. Turn the nuts alternately until fully tightened.
Retighten all nuts to 24.5 Nm. After tightening the nuts,
remove the lifting device.
8. Insert 24 studs; see Fig. 21, through holes in the upper
flange, down into the threaded holes in the flange of the
transformer cover. If the studs do not fit, the position of
the tap-changer must be adjusted, which may require
lifting.
Lift by the lifting eyes as shown in Fig. 4. After mounting
the studs, remove the lifting device and tighten the nuts.
9. Mount the oil drainage tube; see Fig. 19. If a pipe wrench
is used, there must be cloth protection between the
wrench and the tube.
10. Mount the guide bar for the diverter switch; see Fig. 18. Fit
the washers and screws and tighten.
11. Remove the plug at the end of the T-coupling (see Fig. 23),
slide down the bottom valve key and close the valve by
turning the key clockwise approximately 6 turns. Tighten
to 40 Nm. Refit the plug.
12. Install the diverter switch according to Section 4.3.
26 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
Locking nut
M8 (20x)
Upper flange
Studs M12 (24x)
Spring washer
Nuts M12
Flat washer
8.4x20x2
Washers
O-ring
Lower flange
Yoke fork
Fig. 21.
Plug
Attachment
clamps
40 Nm
Pin
O-ring
Slot in drive shaft
Fig. 22.
Oil
drainage
tube
Fig. 23.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 27
3.3 Connection to terminals
Connection to the tap selector should follow the connection
diagram supplied with the tap-changer.
In order to obtain maximum reliability for the tap selector
contacts, the temperature rise of the conductors connected
to the tap selector should be kept as low as possible and
should never be more than 30K above the surrounding oil.
CAUTION
All connections should be made carefully and in such
a way that there is no risk that they can loosen. The
conductors must not cause mechanical strain on
the tap selector terminal. Each conductor should be
curved to take up expansion. See Fig. 25.
CAUTION
CAUTION
All terminals must have conductors or connections.
If there are connections between parallel conductors from
the diverter switch on the tap selector terminal, the parallel
conductors from the active part of the transformer should also
be connected on the tap selector terminals (in order to avoid
circulation currents through the tap selector contacts; see
Fig. 27).
If the impulse withstand voltage to ground exceeds 380 kV,
the conductor connections on the tap selector shall be
insulated by winding paper around them to a thickness of
3 mm; see Fig. 9. The paper should be of the same quality
as used for insulating conductors within the active part of the
transformer.
Tap selector
It is advisable that the distance between the cylinders
or the bars of the tap selector and any conductor
be at least 50 mm. The transformer manufacturer is
responsible for maintaining sufficiently large insulation
distances.
When yoke-mounted, inserts (wooden blocks, or
similar) are placed between the yoke fork and the
lower flange of the diverter switch housing (see
Fig. 27), so that the conductors can be mounted
at the correct height. The wooden blocks must be
removed before mounting the tap-changer on the
transformer cover.
Conductors from
diverter switch
Conductors from
active part of the
transformer
Connection
Fig. 24.
28 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
Connection
Tap selector
Terminal
Expansion bend
Faulty
Correct
Fig. 25. Connection of conductors to the selector.
NOTE: The cable for the marked contact
must be attached under the fixed contact
so that space is sufficient up to the top
flange. This is only applies to the top phase.
NOTE: Caps must be used for this
type of connection.
Cable aligned with fixed contact
les
ab
c
llel
ra
Pa
Fig. 26. Connection of conductors to tap selector C.
Lower flange
Yoke fork
beam
Inserts
Fig. 27. Mounting of tap-changer on the yoke fork.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 29
3.4 Transformer ratio measurement
The transformer ratio measurement may be taken before or
after the drying process.
If it is taken before drying, no drive system is mounted. The
tap-changer thus must be operated directly on the shaft
coupling of the bevel gear on the upper flange. A special hand
crank can be ordered from ABB; see Section 1.2.
If it is taken after drying, it is advisable to do this when the
drive system is mounted, after final assembly (see Chapter 5),
to simplify operation of the tap-changer.
3.4.1 Transformer ratio measurement before drying
1. Remove the locking device from the gear unit on the upper
flange; see Fig. 28. Save the locking device for reuse after
transformer ratio measurement. Also remove the cover of
the bevel gear to access the position indicator. Save all
fasteners and the gasket for reuse. Note the position of
the tap-changer.
2. Operate the tap-changer by putting the special hand crank
on the shaft coupling of the bevel gear. Adjust the length
of the handle. Be careful not to damage the coupling.
When operating through the middle position on a tapchanger with the change-over selector, the torque on
the hand crank will be higher.
CAUTION
The tap-changer should be operated through the
whole operating range, both in the lower and raise
direction, when taking the ratio measurement.
CAUTION
Before the process, the tap-changer may be operated
a maximum of three times through the regulating
range as long as it is immersed in oil. After the
process, the tap-changer must be immersed in oil
before operating.
CAUTION
The end-positions must not be overrun during ratio
measurement. When operating the tap-changer
without the drive system, check the designation of
the end-positions on the single-phase diagram and
monitor the position indicator on the bevel gear to
avoid overrunning the end-position.
3. After the measurement, the tap-changer must be operated
in the direction and to the position shown in the singlephase diagram as the delivery position. The right position
designation should be shown in the window in the position
indicator on the bevel gear of the tap-changer, and the
window should exactly face the red mark in the bevel gear
housing; see Fig. 17. Remount the locking device on the
bevel gear and the cover of the bevel gear. Carefully fit the
gasket.
3.4.2 Transformer ratio measurement after drying
Take this measurement after the drive system is mounted.
Operate the tap-changer by means of the motor-drive
mechanism, in the direction and to the position shown in
the single-phase diagram as the delivery position after the
measurement.
Locking device
CAUTION
Check the voltmeter during tap-changer operations.
No rapid voltage drops may occur during operation.
If such drops occur, the diverter switch is installed
incorrectly or the tap-changer is not correctly
connected to the winding.
UCG and VUCG.N or E
Fig. 28.
30 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
UCG and VUCG.T or B
4. Drying
The tap-changer is dried together with the transformer using
one of the following processes: alternating hot air and vacuum,
or vapor phase at a temperature of no more than 135 °C
(275 °F).
3. If a tie-in resistor from ABB is supplied, its screw joints
are to be retightened (tightening torque 15 Nm) and
locked using the method specified by the transformer
manufacturer for similar screw joints.
4.1 Precautions before processing
1. If not done earlier, lift the diverter switch out from the
housing; see Section 3.2.1, steps 5 and 7. The pressure
relay with its test vent and oil filter, if any, should be
removed and protected from dust, e.g. placed in a plastic
bag or in their original packing.
2. Do not expose the diverter switch housing to any pressure
difference between the inside and outside during the vapor
phase process. During the hot air and vacuum process,
the maximum permitted pressure differential is 100 kPa at
a temperature of 135 °C (275 °F).
During the vapor phase process, the bottom valve of
the diverter switch housing should be open. To open the
bottom valve, proceed as follows; see Fig. 19:
a. Remove the plug on top of the oil drainage tube.
b. Use the bottom valve key through the oil drainage tube.
c. Turn the valve counter-clockwise to its stop,
approximately 6 turns.
d. Refit the plug.
e. Remove the O-ring in the lower flange (for mounting on
active part only) before the process.
4.3 Installation of diverter switch
When yoke-mounted, carry out the steps in Section 3.2.3
before installing the diverter switch.
WARNING
For VUCG: The vacuum interrupters are sensitive and
the diverter switch must thus be handled with care.
CAUTION
Check the serial numbers to make sure that the
diverter switch is mounted in the correct housing; see
Fig. 3.
CAUTION
Make sure that the diverter switch housing is clean
and dry, and that no foreign objects (tools, etc.) are
left in the housing.
CAUTION
4.2 Precautions after processing
CAUTION
To avoid seizing, do not operate the tap-changer,
neither during the drying process nor afterwards, until
it is filled with oil.
1. Make sure that all liquid has been drained from the diverter
switch housing after the vapor phase process has been
carried out. When cover-mounted, close the bottom valve;
see Section 3.2.3, step 10. When yoke-mounted, the valve
is closed during refitting of the top section.
CAUTION
Make sure that the bottom valve key is removed after
the valve has been closed.
2. The cleats on the upper section of the tap selector that
hold the conductors between the diverter switch housing
and the tap selector should be retightened (tightening
torque 15 Nm) and locked by a method specified by the
transformer manufacturer for similar screw joints.
Carefully lower the diverter switch into its housing
so that neither the diverter switch nor the housing is
damaged.
The diverter switch is provided with guide slots that fit against
the guide bar and the oil drainage tube in the diverter switch
housing; see Fig. 29. Rotate the diverter switch so the
crescent-shaped guide slot is aligned with the oil draining
tube.
When the diverter switch is lowered, visually check that its
plug-in contacts are aligned with the contacts in the cylinder
wall.
In order to ensure that the diverter switch pin has engaged
the coupling disk, carry out at least three tap change
operations in one direction. A distinct sound is heard when
the diverter switch falls into place.
If no sound is heard, the reason can be that the pin fits
directly into the slot or that the diverter switch might need to
be pushed down while operating the motor-drive.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 31
Carry out another three operations in the same direction while
pushing down the diverter switch.
when lowered to its final position. Only the springs of the
lifting device should be above this level.
For UCG, it may be necessary to push and pull the
lifting device for the diverter switch a little back and
forth while pushing down.
Insert the O-ring for the cover in the upper flange. Mount the
tap-changer cover. Turn the cover so that the guide pin in
the housing is facing the guide hole in the cover. (The cover
must be pressed down in order to overcome the force of the
springs that hold the diverter switch pressed in place.) Fit the
screws and washers and tighten them.
The top part of the diverter switch lifting device should be
below the level of the upper part of the housing for the cover
Buffer springs
Lifting device
Shielding-ring (when the
impulse withstand voltage
to earth exceeds 380 kV)
(not on UCG short
version)
Transition resistors
(Layed down on UCG
short type)
Transition
resistor
Serial number
(on the opposite
side of the
diverter switch)
A
A
Plug-in contacts
Guiding pin
Guiding pin
Plug-in contacts
A
A
Tie rod
Coupling with
driving-pin
Driving pin
UCG
Guiding pins
VUCG
Coupling disc
Notch for the
driving pin
Slot for guiding bar
Holes for
guiding pins
Guiding pins
Guiding bar
for the diverter
switch
Slot for oil
draining tube
Oil draining tube
Diverter switch housing, view from above
Fig. 29.
32 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
A–A
5. Final assembly
5.1 Mounting of motor-drive mechanism
See Figs. 30 and 31.
Proceed as follows:
1. Mount the motor-drive mechanism onto the transformer.
The mounting holes on the transformer should be level
within 1 mm. If adjustment is needed, shims should be
used.
2. Install the bevel gear SA 21 on the edge of the transformer
cover; see Fig. 32.
3. Check that the position indicator on the motor-drive
mechanism shows the same position as the indicator
inside the bevel gear of the tap-changer. (The cover has to
be removed.)
WARNING
Do not energize the transformer before the tapchanger and the motor-drive mechanism are correctly
assembled.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 33
Exact position
Max. deviation
Transformer
The same indicated
tap position
Position indicator
Brake disc
Adjustment nuts
Red mark
Brake assembly
Fig. 30. Position alignment for UCG/VUCG with motor-drive mechanism BUE.
34 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
Exact position
Transformer
Max. deviation
The same indicated
tap position
Indicator flag
4
5
6
7
10 11 12
8 9
3
2
1
13
14
15
16
17
18
19
12 34567
Position indicator
Roller on the brake
arm in the notch of
the cam disc
Brake arm
Cam disc
Contra nut
Brake disc
Adjusting screw
Fig. 31. Position alignment for UCG/VUCG with motor-drive mechanism type BUL.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 35
Connection type T
Unit
–1
SA10
SA10
SA10
Unit
–2
SA25
SA21
SA10
SA25
Unit
–3
SA10
SA10
SA25
SA33
SA17
SA18
SA19
SA20
SA23
SA10
SA22
SA24
SA31
SA30
SA32
SA35
SA34
SA36
NOTE The slot in the
protective tube faces
downwards
Connection type B
Unit
–1
SA10
SA10
SA10
Unit
–2
SA25
SA21
SA10
SA25
SA33
SA17
SA18
SA19
SA20
SA23
SA10
SA22
SA24
SA31
SA30
SA32
Connection type N or E
SA 10Hose clip
Unit
–1
SA 11Coupling halves
SA 12Allen screw M6
SA 13Washer
SA10
SA10
SA25
SA21
SA 14Vertical square shaft
SA 15Vertical protective tube
SA17
SA18
SA19
SA 16Vertical protective tube
SA 17Clamp
SA 18Hex head bolt M10
SA20
SA10
SA23
SA22
SA 19Washer
SA24
SA12, SA13
SA11
SA16
SA14
SA 20O-ring
SA 21Bevel gear
SA25
SA15
SA11
SA12, SA13
SA10
SA 22Horizontal square shaft for unit -1
SA 23Horizontal protective tube for unit -1
SA 24Horizontal protective tube for unit -1
SA 25Information label
SA 30Horizontal square shaft for unit -2
SA 31Horizontal protective tube for unit -2
SA 32Horizontal protective tube for unit -2
Motor-drive mechanism
SA 33Cover
SA 34Horizontal square shaft for unit -3
SA 35Horizontal protective tube for unit -3
SA 36Horizontal protective tube for unit -3
Fig. 32. Shaft system.
36 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
5.2 Mounting of external drive shafts
The external drive shafts consist of square tubes and should
be connected to the spherical shaft ends on the bevel gears
and motor-drive mechanism by means of two coupling halves.
The square shafts and protective tubes must be cut before
mounting.
CAUTION
Before mounting of shafts and couplings, everything
must be cleaned and greased for correct function and
to avoid corrosion.
Apply a thin layer of grease, GULF-718EP Synthetic Grease
or Mobil Grease 28 or SHELL Aero Shell Grease 22 to all
spherical shaft ends and unpainted surfaces of the bevel
gears.
5.2.1 Mounting of vertical drive shaft
1. Mount the bevel gear SA21 on the transformer, with O-ring
SA20, four clamps SA17, hex head bolts M10, SA18 and
washers SA19; see Fig. 32.
2. Determine the distance K2 between the spherical shaft
ends; see Fig. 33.
3. Cut the vertical square shaft, SA14, to length = K2 minus
6 mm. Remove burrs.
4. Cut the protective tubes SA15 and SA16 to the same
length LB2 according to Table 4.
K2 = 200 to 290 mm
K2 = 291 to 600 mm
K2 = greater than 600 mm
K2+180 mm
LB2 =
2
K2+220 mm
LB2 =
2
LB2 =
K2+410 mm
2
Example:
K2 measured at 350 mm. LB2 is then =
350+220
570
=
= 285 mm
2
2
Table 4. Lengths for LB2.
The multi-hole couplings should be greased.
The inclination of the shaft (the square tube) must not be
more than 40 (=70 mm for every 1000 mm shaft length).
The tubes around shafts and couplings are for
protection.
The arrangement of the drive shaft system is shown in Fig. 32.
CAUTION
Make sure that all locking devices (on the bevel
gear, on the tap-changer and in the motor-drive) are
mounted and the tap-changer and the motor-drive are
at the same service position.
Check that the motor-drive mechanism is at its exact position
according to Fig. 30 or 31. (BUE: The red mark on the brake
disk facing the red mark on the brake assembly. BUL: The
roller in the middle of the notch in the cam disk). If not, loosen
the locking device (see Fig. 50) and adjust it to the exact
position. Remount the locking device.
Let the parts of the shaft system that should be
removed before transporting the transformer to the
site keep their identification numbers according to the
packing list to simplify remounting of the shaft system
on site.
5. See Fig. 38. Fit two coupling halves, SA11, on one end of
the square shaft with six screws SA12 and washers SA13.
Push the shaft to the bottom of the fitting in the coupling
halves. Tighten the two screws; A first and then the other.
Fit the two protective tubes, SA15 and SA16, (the larger
diameter at the top) and two hose clips SA10; see Fig. 35.
6. See Fig. 34. Connect the square shaft with the mounted
coupling halves to the shaft of the bevel gear. Mount two
coupling halves SA11 to the other end of the square shaft
and the shaft of the motor-drive mechanism. Push the
shaft to the bottom of the fitting in the coupling halves;
see Fig. 37. Tighten the screws lightly and check that
the shaft can be moved approximately 2 mm in the axial
direction (axial play). Check the dimension shown in
Fig. 36. Tighten the two screws; A first and then the other.
7. See Fig. 35. Mount the tube with the larger diameter,
SA16, to the bevel gear with a hose clip and the other
SA15 to the flange on the motor-drive mechanism with a
hose clip. Leave about 3 mm of play to the flange ring for
water drainage.
The tube with the larger diameter is mounted on the
bevel gear.
Tighten the two screws; A and then the other,
according to Fig. 38.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 37
SA21
SA11
SA10
SA10
SA16
SA16
SA15
SA15
SA10
SA14
SA14
SA26
SA27, SA28
SA29
SA15
SA10
Min. 3, max. 5 mm
K2
BUE
BUL
Fig. 34.
Fig. 35.
A
Max. 3 mm
Drive pin
Max. 6 mm
Fig. 33.
Square
shaft
SA11
SA13
SA12
A
Fig. 36.
Fig. 37.
38 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
Fig. 38.
5.2.2 Mounting of horizontal drive shaft for one unit
The following applies to the fitting of the drive shaft and
protective tube when the tap-changer consists of one unit,
UCG.N/VUCG.N or UCG.E/VUCG.E.
1. Determine the distance K1 between the spherical shaft
ends; see Fig. 39.
2. Cut the horizontal square shaft SA22 to length = K1 minus
6 mm. Remove burrs.
3. Cut the protective tubes SA23 and SA24 at the nonslotted end to the same length LB1 according to Table 5.
Protective tube SA23 has one slotted end.
K1 = 170 to 290 mm
K1 = 291 to 600 mm
K1 = greater than 600 mm
K1+200 mm
LB1 =
2
K1+250 mm
LB1 =
2
LB1 =
K1+500 mm
2
Example:
K1 measured at 400 mm. LB1 is then =
400+250
2
=
650
2
= 325
mm
7. See Figs. 30 and 31. The motor-drive mechanism and the
tap-changer should have the same indicated tap position
and be in their exact positions. Remove the cover of
the gear box on the tap-changer to access the position
indicator.
The motor-drive mechanism and tap-changer are in the
same position when the position indicators on both of
them show the same position.
The motor-drive mechanism is at the exact position since
the steps in Section 5.2 have been carried out.
The tap-changer is in the exact position when the window
where the position is read on the bevel gear is exactly
facing the red mark in the gear box housing.
If the gear box is not at its exact position, loosen the two
screws in the multi-hole coupling on the gear box and find
the position of the screws that positions the opening in the
brass-toothed wheel closest to the red mark in the gear box
housing. The maximum deviation from exact alignment is
given in Figs. 30 and 31. Tighten the screws. Remount the
cover and the gasket of the gear box on the tap-changer; see
Fig. 22.
Table 5. Length for LB1.
WARNING
If K1 is greater than 600 mm, the mounted tubes
must overlap by at least 300 mm. Removal and
inspection of the couplings should be possible when
one of the tubes is pushed into the other.
4. Mount two coupling halves, SA11, on one end of the
square shaft with six screws SA12 and washers SA13.
Push the shaft to the bottom of the fitting in the coupling
halves; see Fig. 37. Tighten the two screws; A first and
then the other; see Fig. 38. Mount the two protective
tubes, SA23 and SA24, the slotted end of SA23 in the
non-overlapping end, and two hose clips SA10; see
Fig. 40.
5. Remove the locking device on the bevel gear of the
diverter switch housing by loosening the two set screws;
see Fig. 42.
6. Connect the square shaft with the mounted coupling
halves to the shaft of the bevel gear SA21; see Fig. 44.
Mount two coupling halves SA11 to the other end of the
square shaft and to the shaft of the bevel gear on the
tap-changer. Push the shaft to the bottom of the fitting in
the coupling halves; see Fig. 37. Lightly tighten the screws
and check that the shaft can be moved approximately
2 mm in the axial direction (axial play). Check the
dimension shown in Fig. 36. Tighten the two screws; A
first and then the other; see Fig. 38.
Assembly with the tap-changer and the motor-drive
mechanism at different operating positions may cause
transformer failure.
WARNING
The bevel gear contains moving gears. Observe
caution!
8. Push the two protective tubes onto the bevel gears and
clamp them with hose clips, SA10; see Fig. 45.
The slot on the protective tube SA23 should be facing
downwards.
Apply the self-adhesive information plates SA25 around
the tubes at about the middle of the tube length.
Carefully turn the multi-hole coupling on the gear box until
the gear box is at the exact position. Find the two holes
matching each other in the multi-hole coupling and refit
the two screws.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 39
LB1
Slotted end
K1
SA14
Fig. 39.
SA24
SA10
SA23
SA11
Fig. 40.
Locking device
Disc
M8 screw
Drive pin
Fig. 41.
Fig. 42. Locking device, single-unit tap-changer.
A
Spherical coupling part
SA12
SA13
SA24
SA10 SA23
Slot
SA21
SA11
Fig. 43.
SA10 SA24 SA25 SA23
SA25
SA10
SA21
Slot facing
downwards
SA23
Fig. 44.
40 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
5.2.3 Mounting of horizontal drive shaft for two units
The following applies to the fitting of drive shafts and their
protective tubes when the tap-changer consists of two
phases UCG.B/VUCG.B. The tap-changer unit, which is
placed closest to the drive mechanism, is called unit -1, and
the second unit -2; see Fig. 32.
Mount the shaft between the motor-drive mechanism and
unit-1 according to Section 5.2.2.
Mount the shaft between unit-1- and unit-2 according to the
following instructions:
1. Determine the distance K3 between the spherical shaft
ends; see Fig. 45.
2. Cut the horizontal square shaft SA30 to length = K3 minus
6 mm. Remove burrs.
3. Cut the protective tubes SA31 and SA32 at the nonslotted end to the length LB3 = (K3+500 mm)/2; see
Fig. 46.
4. Fit two coupling halves, SA11, on one end of the square
shaft with six screws SA12 and washers SA13. Push the
shaft to the bottom of the fitting in the coupling halves;
see Fig. 37. Tighten the two screws; A first and then the
other; see Fig. 47. Fit the two protective tubes, SA31 and
SA32, the slotted end of SA31 in the non-overlapping end,
and two hose clips SA10; see Fig. 46.
5. Remove the locking device on the bevel gear of the
diverter switch housing by loosening the two set screws;
see Fig. 49.
6. Connect the square shaft with the mounted coupling
halves to the shaft of the bevel gear closest to the motordrive; see Fig. 47. Mount two coupling halves SA11 to the
other end of the square shaft and to the shaft of the bevel
gear on the tap-changer. Push the shaft to the bottom
of the fitting in the coupling halves; see Fig. 37. Lightly
tighten the screws and check that the shaft can be moved
approximately 2 mm in the axial direction (axial play).
Check the dimension shown in Fig. 36. Tighten the two
screws; A first and then the other.
The unit should be at the same service position as the
adjacent unit and be at the exact position. Compare
with the adjacent unit and adjust this unit as described in
Section 5.2.3, point 7 if necessary.
WARNING
The bevel gear contains moving gears. Observe
caution!
7. Push the two protective tubes on the bevel gears and
clamp them with the hose clips SA10; see Fig. 48. Apply
the self-adhesive information plates SA25 around the
tubes at about the middle of the tube length.
The slot on the protective tubes should be facing
downwards.
8. Mount the protective cover SA33. Tighten the two set
screws, (taken from the locking device); see Fig. 49.
LB3
K3
A
SA30
Fig. 45.
SA32
SA10
SA31
SA11
Fig. 46.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 41
Disc
Coupling
SA12
SA13
A
SA11
SA10
SA32
SA10
SA30
SA31
Fig. 47.
Locking device
Set screw
Cover SA 33
SA10
SA10
SA25
SA32
SA31
Fig. 48.
Locking device
Set screws
Cover SA 33
Fig. 49. Locking device and cover, multiple-unit tap-changer.
42 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
5.2.4 Mounting of horizontal drive shafts for three units
The following applies to the fitting of drive shafts and their
protective tubes when the tap-changer consists of three
phases UCG.T/VUCG.T or UCGYD/VUCGYD. The tapchanger unit, which is placed closest to the drive mechanism,
is called unit -1, the next unit -2 and the last unit -3; see
Fig. 32.
1. Mount the drive shaft to the tap-changer unit -1 according
to Section 5.2.2, steps 1–8.
2. Mount the drive shaft between unit -1 and unit -2
according to Section 5.2.3, steps 1–8.
3. Mount the drive shaft between unit -2 and unit -3
according to Section 5.2.3, steps 1–8.
The shaft here is SA34, the protective tube closest to
unit -2 is SA35 and the other protective tube is SA36.
When a support bearing is used, follow the appropriate parts
of Section 5.2.3, steps 2–8.
If transformer ratio measurement is to be conducted
after drying, this is a suitable stage to carry it out; see
Section 3.4.2.
5.3 Supervisory equipment
Accessories and safety devices are described in a separate
document, Accessories and protection devices for on-load tapchangers, 1ZSC000562-AAD.
5.4 Assembly of accessories
All parts that have been removed for transport are specified
on the packing list. The openings on the tap-changer are
sealed by a transport cover.
1. Remove the transport covers.
2. Check the O-rings. Make sure that they are pressed into
the bottoms of the grooves on the flanges.
3. Assemble all remaining accessories. Tightening torque for
the nuts is according to Section 1.8.
5.5 Connection to the oil conservator
WARNING
If oil filling is carried out under a vacuum without the
oil conservator, the steps in this section are performed
after oil filling.
The bevel gear contains moving gears. Observe
caution!
5.2.5 Before operation
1. Check again that the tap-changer and the motor-drive
mechanism are at the same position.
2. Remove the locking device for the motor-drive mechanism;
see Fig. 50.
Remove the transport cover on the flange for connection to
the oil conservator. Make sure that the O-ring is in place on
the flange and connect the pipe to the oil conservator. Tighten
the nuts; see Fig. 51.
Locking device
BUE
BUL
Fig. 50. Locking device for motor-drive mechanism.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 43
5.6. Connection of tube for oil sampling for VUC
Preparation for oil sampling is done at the transformer
workshop as part of the tap-changer installation.
– – The oil valve (see Fig. 45) should be removed and reconnected at the end of the draining tube at operable
ground level.
– – The tube, through which oil samples are taken, must be
connected to a sample pipe, see Fig. 47. The tube shall be
of ½ inch.
– – Information regarding the flanges, view A-A and view B-B,
see Fig. 46.
A-A
B-B
O-ring
Ø 44.2 x 5.7
Ø 75
Ø 75
45°
45°
4 x M10
Ø 106
Fig. 51. Oil valve.
Ø 106
Fig. 52. Sample pipe dimensions.
Extra oil valve shall be removed
and used as a sample valve
Tube ½”
UCG top cover
Transformer cover
Oil valve
Fig. 53. Extra oil sampling valve. The valve is removed and then refitted at the end of the sampling tube.
44 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
4 x Ø 11
6. Oil filling
6.1 Filling methods and restrictions
Oil filling can be carried out at atmospheric pressure or under
a vacuum. The wall between the diverter switch housing and
the transformer tank is designed to withstand a vacuum on
one side and atmospheric pressure on the other. It is not
permitted to have a vacuum on one side and the pressure of a
high oil column on the other.
The pressure difference between the inside and
outside of the tap-changer cylinder may not exceed
100 kPa at any time.
Oil filling may be carried out in different ways
depending on what the transformer manufacturer
finds convenient as long as the instructions above are
followed and the tap-changer is filled with oil to the
correct level.
The methods below are recommended, and if they are
followed in detail, no pressure limits will be exceeded
and the oil levels will be correct.
6.2 Before filling
Upon commissioning, open the cover and check that the
diverter switch housing is dry and clean and that the diverter
switch is in place. Check that the bottom valve is closed.
Follow step 11 in Section 3.2.3.
Tightening torque 40 Nm (see Fig. 18).
6.3 Filling at atmospheric pressure
1. Open the conservator valve, if any.
2. Remove the breathing device on the conservator for the
tap-changer.
3. Remove the cover.
4. Pump oil into the diverter switch housing via the oil
valve, see Fig. 53 (for connection dimensions, see the
dimensional drawing for the tap-changer).
5. Refit the cover as per Section 4.3.
WARNING
Do not energize the transformer earlier than three
hours after oil filling at atmospheric pressure. This
waiting period is needed to allow air bubbles to
dissipate.
CAUTION
The valve is located at ground level.
6. Continue to pump in oil until the conservator is filled to its
correct level. Also see Section 1.5.
7. Shut the oil valve and disconnect the pump.
8. Refit the breathing device. Make sure that the connection
to the breathing device is properly sealed.
6.4 Filling under vacuum
Filling under a vacuum is not necessary but may be carried
out with the conservator. After filling under a vacuum, no
standing time is needed. The methods below ensure that no
permitted pressure differences are exceeded.
For vacuum filling without the conservator connected,
contact the manufacturer for advice.
6.4.1 Oil conservator filled under vacuum
1. Establish a connection between the oil conservator for the
transformer and the oil conservator for the tap-changer.
2. Open the valve between all tap-changer units and the
conservator and close the oil valve.
3. Put the transformer under vacuum. (The tap-changer is
put under vacuum automatically.)
4. Let oil in through the oil valve of the tap-changer. (For
connection dimensions, see the dimensional drawing for
the tap-changer.)
5. When the needle of the oil level indicator in the oil
conservator starts to move, close the oil valves on all
units. Open one at a time and close each when the needle
in the oil level indicator starts to move. Fill the conservator
to the right level before closing the oil valve for the last
unit. (This is done to make sure that all units are properly
filled. Differences in flow rates might otherwise cause
some of the units to not completely fill.)
6. When atmospheric pressure is restored in the transformer,
remove the connection between the two conservators
and connect the breathing device to the oil conservator
for the tap-changer. Make sure that the connection to the
breathing device is properly sealed.
When filling more than one unit, fill all of them
according to points 3 to 5.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 45
Pipe connection
Vacuum
Oil
Ø 75
Stud M10
Transformer
Tap-changer
Ø 44.2
Ø 5.7
Oil
O-ring
Ø 20
Fig. 54. Assembly O-ring.
Fig. 55. Oil filling under vacuum.
46 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
7. Electrical connection and testing
7.1 General
Before the transformer is energized, tests must be carried out
to ensure that all mechanical and electrical connections are
correct, and to check the proper function of the motor-drive
mechanism and the tap-changer.
When testing the transformer, the tap-changer can be
operated either by the hand crank or electrically. When
operating electrically, the motor-drive mechanism is
connected according to Section 7.2.
WARNING
Dangerous voltage!
For BUE: Run the motor-drive mechanism and check again
that the red mark on the brake disk stops within the tolerance
of ± 25° from the exact position; see Fig. 30.
For BUL: Run the motor-drive mechanism and check that the
center of the notch in the cam disk stops within ±2 mm from
the center of the roller on the brake arm; see Fig. 31.
WARNING
For adjustment of the motor-drive mechanisms, see
If 2 kV insulation testing is to be performed, some
equipment must be disconnected in order to avoid
damage. Examples of equipment to be disconnected
are the measuring transducer, pressure relay, diodes
(for example, N4) and temperature relays.
7.2 Connecting and testing the motor-drive mechanism and
the tap-changer
Connect the ground connection from the transformer to the
ground terminal on the tap-changer flange.
Connect the ground connector from the transformer to the
ground terminal on the motor-drive mechanism.
Connect the motor supply and the control supply to the
correct terminals on the motor-drive mechanism as shown by
the circuit diagram supplied with the tap-changer.
Operate the motor-drive mechanism by means of the hand
crank to a position at the middle of the range but not in a
through-position ( = a position with a letter in).
Operate the drive mechanism electrically between the endpositions. Check the end-stops. When attempting to operate
electrically beyond the end-position, the motor should not
be started. Check the mechanical end-stop by attempting to
hand crank it beyond the end-position. After a couple of turns
on the hand crank, it should be mechanically stopped. Hand
crank back to the end-position (where the indicator flag is
positioned at the middle for BUE and when the indicator flag
is white for BUL). Operate the tap-changer electrically to the
other end-position and repeat the test procedure above.
WARNING
The transformer must never be energized when the
end-stop is inoperable.
7.3 Electrical tests on the transformer
Acceptance tests on the transformer or commissioning can
now be performed.
Turn the control selector switch to position LOCAL. Now send
a pulse for a RAISE operation.
If the phase sequence is wrong, (three-phase supply),
the motor-drive mechanism will start in the LOWER
direction.
The motor-drive mechanism will stop when it has
made approximately half of the complete operation
and will operate back and forth without the tapchanger changing position until the control selector
switch is turned to position 0.
Maintenance guide 1ZSC000498-ABH.
7.4 After energizing
WARNING
Before any work is carried out on the tap-changer:
Make sure that the transformer is disconnected and
grounding is properly performed. Obtain a signed
certificate from the engineer in charge.
If the phase sequence is wrong, reverse two of the
motor supply cables to attain the correct sequence.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 47
8. Transport
8.1 Dismantling before transport
The tap-changer is usually transported without accessories
(pressure relay, motor-drive mechanism, bevel gear and drive
shafts) to prevent damage to these parts. To make sure that
everything is set up properly on site with a minimum amount
of work, it is important to put the tap-changer at the position
and operated from the position given in the single-phase
diagram delivered with the unit, and to fit locking devices
properly during dismantling at the transformer factory.
Removal of the motor-drive mechanism and drive shafts is
performed in the opposite order of assembly.
8.1.1 Dismantling preparations
Before dismantling, mark the parts to facilitate
identification.
Check the position of the motor-drive mechanism according
to Fig. 30 (BUE) or Fig. 31 (BUL). Use the hand crank to
adjust it to its exact position. Install the locking device on the
motor-drive mechanism; see Fig. 50.
The arrangement of the drive shaft system is shown in Fig. 32.
8.1.2 Removal of the vertical drive shaft
1. Loosen the hose clips holding the protective tubes to the
bevel gear and motor-drive mechanism. Push one of the
protective tubes into the other. Remove the screws holding
the bevel gear SA21. Detach the bevel gear by carefully
lifting it off the shaft while holding the vertical drive shaft.
Detach the vertical shaft including the protective tubes by
lifting it off the coupling of the motor-drive mechanism.
Mark the parts.
2. Pack screws, clamps, protective tubes, shafts, hose clips,
protective cover, coupling halves, bevel gear and seals for
transportation to the site.
8.1.3 Removal of horizontal drive shaft for one unit
1. Lock the bevel gear with the locking device, and two set
screws see Fig. 42.
2. Loosen the hose clips holding the protective tubes to
the bevel gears. Push one of the protective tubes into
the other. Loosen the screws holding the coupling halves
at one end of the shaft and detach them. Detach the
horizontal shaft. Mark the parts.
3. Pack screws, clamps, protective tubes, shafts, hose clips,
protective cover, coupling halves, bevel gear and seals for
transportation to the site.
8.1.4 Removal of horizontal drive shafts for two units
1. Detach the protective cover SA33 on the bevel gear of
unit -2, and lock the bevel gear with the locking device
marked -2, and two set screws; see Fig. 42.
2. Loosen the hose clips holding the protective tubes to the
bevel gears for units -1 and -2. Push one of the protective
tubes into the other. Loosen the screws holding the
coupling halves at one end of the shaft and detach them.
Detach the horizontal shaft between units -1 and -2.
3. Lock the bevel gear for unit -1 with the locking device
marked -1, and two set screws; see Fig. 49.
4. Loosen the hose clips holding the protective tubes to
the bevel gear SA21 and the bevel gear of tap-changer
unit -1. Push one of the protective tubes into the other.
Loosen the screws holding the coupling halves at one end
of the shaft and detach them. Detach the horizontal shaft
between unit -1 and bevel gear SA21. Mark the parts.
5. Pack screws, clamps, protective tubes, shafts, hose clips,
protective cover, coupling halves, bevel gear and seals for
transportation to the site.
8.1.5 Removal of horizontal drive shafts for three units
1. Detach the protective cover SA33 on the bevel gear for
unit -3, and lock the bevel gear with the locking device
and set screws marked -3; see Fig. 42.
2. Loosen the hose clips holding the protective tubes to
the bevel gears of unit -2 and unit -3. Push one of the
protective tubes into the other. Loosen the screws holding
the coupling halves at one end of the shaft and remove
them. Detach the horizontal shaft between units -2 and -3.
3. Lock the bevel gear for unit -2 with the locking device
marked -2 and two set screws.
4. Loosen the hose clips holding the protective tubes to the
bevel gears of units -1 and -2. Push one of the protective
tubes into the other. Loosen the screws holding the
coupling halves at one end of the shaft and remove them.
Detach the horizontal shaft between units -2 and -1.
5. Lock the bevel gear for unit -1 with the locking device
marked -1 and set screws; see Fig. 49.
6. Loosen the hose clips holding the protective tubes to
the bevel gear SA21 and the bevel gear for tap-changer
unit -1. Push one of the protective tubes into the other.
Loosen the screws holding the coupling halves at one end
of the shaft and remove them. Detach the horizontal shaft
between unit -1 and bevel gear SA21. Mark the parts.
7. Pack screws, clamps, protective tubes, shafts, hose clips,
protective cover, coupling halves, bevel gear and seals for
transportation to the site.
48 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
8.1.6 Accessories
If the pressure relay is to be removed, see the assortment
guide, 1ZSC000562-AAD.
8.2.1.2 Conservator unmounted
The oil level of the diverter switch housing should be lowered
to 150 mm below the upper edge of the housing.
If other accessories are to be removed for transport reasons,
pack them in the packages they were delivered in and refit the
transport covers. Fit the O-rings and tighten the nuts.
When the conservator is removed, take off the cover of the
diverter switch housing and drain the oil with a pump to
150 mm below the upper edge of the housing. Refit the cover.
Turn the cover so that the guide pin in the housing is facing
the guide hole in the cover. Make sure the gasket is properly
positioned. Seal all flange connections by fitting gaskets and
covers. Close all valves.
8.2 Oil level during transport
The following adjustments of the oil level should be carried
out when the tap-changer is to be transported.
8.2.2 Transformer drained
When the transformer is transported without oil, the tapchanger should also be transported without oil.
CAUTION
Take care to avoid intake of moist air when oil is
drained. If the ambient air is moist, let incoming air
pass through a dehydrating breather with a slow air
flow to obtain proper dehydration.
8.2.2.1 Conservator mounted
Drain the oil from the diverter switch housing by means of a
pump connected to the oil valve. Let the tap-changer maintain
contact with the ambient air through the breathing device on
the conservator.
8.2.1 Transformer filled with oil
When the transformer is transported filled with oil, the tapchanger should also be transported filled with oil.
8.2.1.1 Conservator mounted
The diverter switch housing should be filled to the normal
operating level, and the valve for the conservator should be
open.
8.2.2.2 Conservator unmounted
Drain the oil as described in Section 8.2.2.1. Now remove
the conservator connection. Seal the diverter switch housing
against ambient air by fitting covers with gaskets and closing
all valves.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 49
9. Commissioning
This chapter describes tasks to be carried out on the tapchanger when the transformer is being installed and tested on
site.
Check all fittings and alignments, even if the shaft
system has been set up in the transformer factory.
The identification numbers on critical parts from the
packing list are specified in the following instructions;
see Sections 5.1 and 5.2.
CAUTION
The motor-drive mechanism must be protected
against condensation.
9.2.1 Mounting of the motor-drive mechanism
See Figs. 30 and 31. Proceed as follows:
Energize the heater when power is available. When
not, put drying agent inside the motor-drive cabinet
and seal the vents.
1. Mount the motor-drive mechanism on the transformer. The
mounting holes on the transformer should be level within
1 mm. If adjustment is needed, shims should be used.
2. Install the bevel gear, SA21, on the edge of the
transformer cover.
3. Check that the position indicator on the motor-drive
mechanism shows the same position as the indicator
inside the bevel gear of the tap-changer.
4. Remove the drying agent inside the cabinet.
Fig. 1 shows the arrangement of the tap-changer, motor-drive
mechanism and drive shafts.
The pressure relay is usually delivered in a separate package
and installed upon commissioning. Depending on the
transport requirements, the transformer may be delivered with
or without the motor-drive mechanism and drive shaft system
attached. The tap-changer may be delivered filled with oil or
without oil. Use the relevant parts of this manual to perform
commissioning.
For information about tools, materials and oil required, see the
relevant parts of Chapter 1.
9.1 Connection to the oil conservator
Follow the appropriate parts of the instructions in Section 5.5.
WARNING
Do not energize the transformer before the tapchanger and the motor-drive mechanism are correctly
assembled.
9.2.2 Mounting of the external drive shafts
The external drive shafts consist of square tubes and should
be connected to the spherical shaft ends on the bevel gears
and motor-drive mechanism by means of two coupling halves.
Connect the cables to the low level alarm contact on the oil
level indicator.
9.2 Mounting the motor-drive mechanism and the drive
shafts
The motor-drive mechanism and drive-shaft system
should have been assembled and disassembled in the
transformer factory according to the instructions in this guide.
Locking devices should have been installed when it was
disassembled. If all locking devices are in place according to
the transport sections in this guide, there should be no need
for adjustments.
CAUTION
Before mounting shafts and couplings, everything
must be cleaned and greased for correct function and
to avoid corrosion.
Apply a thin layer of grease, GULF 718EP Synthetic Grease
or Mobil Grease 28 or SHELL Aero Shell Grease 22 to all
spherical shaft ends and unpainted surfaces on the bevel
gears.
If necessary, Sections 5.1 and 5.2 provide complete
information for fitting and adjusting of the shaft system. The
arrangement of the drive shaft system is shown in Fig. 32.
50 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
The multi-hole coupling should be greased.
The tubes around shafts and couplings are for
protection.
CAUTION
SA18, SA19
Make sure that all locking devices (on the bevel
gear, on the tap-changer and in the motor drive) are
mounted and the tap-changer and the motor-drive are
in the same service position.
SA17
SA21
SA20
Driving pin
Check that the motor-drive mechanism is at its exact position
according to Figs. 30 or 31. (BUE: The red mark on the brake
disk facing the red mark on the brake assembly, BUL: The
roller at the middle of the notch in the cam disk.) If not, loosen
the locking device and adjust it to its exact position. See
Fig. 50. Refit the locking device.
9.2.3 Mounting of the vertical drive shaft
1. Mount the bevel gear SA21 on the transformer with an
O-ring, SA20, clamps SA17 screws and washers; see
Figs. 56 and 57.
2. Fit the square shaft SA14 with protective tubes SA15
and SA16 and hose clips according to Fig. 34. Connect
the square shaft with the mounted coupling halves to the
motor-drive. Mount two coupling halves SA11 to the other
end of the square shaft and the shaft of the bevel gear;
see Fig 34. Push the shaft to the bottom of the fitting in
the coupling halves; see Fig. 37. Tighten the screws lightly
and check that the shaft can be moved approximately
2 mm in the axial direction (axial play). Check the
dimension shown in Fig. 36. Tighten the two screws;
A first and then the other; see Fig. 38.
3. Mount the protective tube with the larger diameter, SA16
to the bevel gear with a hose clip, and the other tube
SA15 to the flange of the motor-drive mechanism; see
Fig. 35. Leave about 3 mm of play to the flange ring for
water drainage.
SA11
SA16
SA10
SA15
SA14
Motor-drive
mechanism
Fig. 56.
SA20
SA18, SA19
SA17
Attachment flange
for the bevel gear
Fig. 57. Bevel gear assembly.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 51
9.2.4 Mounting of horizontal drive shaft for one unit
1. Fit the square shaft SA22, protective tubes SA23 and
SA24 and hose clips according to Fig. 40.
2. Connect the square shaft with the mounted coupling
halves to the shaft of the bevel gear; see Fig. 58. Mount
two coupling halves SA11 to the other end of the square
shaft and the shaft of the other bevel gear. Push the shaft
to the bottom of the fitting in the coupling halves; see
Fig. 37. Tighten the screws lightly and check that the shaft
can be moved approximately 2 mm in the axial direction
(axial play).
Check the dimension shown in Fig. 36. Tighten the two
screws; A first and then the other; see Fig. 38.
3. See Figs. 30 and 31. The motor-drive mechanism and the
tap-changer should have the same indicated tap position
and be at their exact positions.
The motor-drive mechanism and the tap-changer are at
the same position when the position indicators for both of
them show the same position.
The motor-drive mechanism is at the exact position since
the steps in Section 9.2.2 have been carried out.
The tap-changer is at the exact position when the window
where the position is read on the bevel gear is exactly
facing the red mark in the gear box housing.
If the gear box is not at its exact position, carry out
point 5 and loosen the two screws in the multi-hole
coupling on the gear box and find the position of the
screws that positions the opening in the brass-toothed
wheel closest to the red mark in the gear box housing.
The maximum deviation from exact alignment is given in
Fig. 30. Tighten the screws.
WARNING
Assembly with the tap-changer and the motor-drive
mechanism in different operating positions may cause
transformer failure.
4. Push the two protective tubes onto the bevel gears and
clamp them with hose clips SA10; see Fig. 48.
The slot of the protective tube SA23 should be facing
downwards.
The self-adhesive information plates SA25 are at about the
middle of the tube length.
Do not remove the locking device before one end of
the shaft of the bevel gear is connected to the drive
shaft.
SA11
Fig. 58.
52 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
SA21
9.2.5 Mounting of horizontal drive shafts for two units
Mount the shaft between the motor-drive mechanism and
unit-1 according to Section 9.2.4.
Mount the shaft between unit-1 and unit-2, as follows:
1. Loosen the set screws for the locking device of the bevel
gear on the top of the tap-changer; see Fig. 48. Remove
the locking device.
2. Mount the cover SA33 and tighten the set screws (from
the locking device).
3. Fit the square shaft SA30, protective tubes SA31 and
SA32 and hose clips according to Fig. 47.
4. Connect the square shaft with the mounted coupling
halves to the shaft of the bevel gear; see Fig. 47. Mount
two coupling halves SA11 to the other end of the square
shaft and the shaft of the other bevel gear. Push the shaft
to the bottom of the fitting in the coupling halves; see
Fig. 37. Tighten the screws lightly and check that the shaft
can be moved approximately 2 mm in the axial direction
(axial play). Check the dimension shown in Fig. 36. Tighten
the two screws; A first and then the other; see Fig. 38.
If the exact position of the closest unit has been
adjusted, the locking device might have to be
removed (step 6) before step 3 can be carried out.
5. See Figs. 30 and 31. The motor-drive mechanism and the
tap-changer should have the same indicated tap position
and be at their exact positions.
The motor-drive mechanism and the tap-changer are at
the same position when the position indicators for both of
them show the same position.
The motor-drive mechanism is at the exact position since
the steps in Section 9.2.2 have been carried out.
The tap-changer is at the exact position when the window
where the position is read on the bevel gear is exactly
facing the red mark in the gear box housing.
If the gear box of this unit is not at its exact position,
carry out point 6 and loosen the two screws in the multihole coupling on the gear box and find the position of the
screws that positions the opening in the brass-toothed
wheel closest to the red mark in the gear box housing.
The maximum deviation from exact alignment is given in
Fig. 30. Tighten the screws.
WARNING
Assembly with the tap-changer and the motor-drive
mechanism in different operating positions may cause
transformer failure.
6. Push the two protective tubes onto the bevel gears and
clamp them with hose clips SA10; see Fig. 48. Apply the
self-adhesive information plates SA25 around the tubes at
about the middle of the tube length.
7. Loosen the two set screws (see Fig. 49) and remove the
locking device.
8. Mount the cover SA33. Tighten the two set screws (see
Fig. 44) taken from the locking device.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 53
9.2.6 Mounting of horizontal drive shafts for three units
The following applies to the fitting of drive shafts and their
protective tubes when the on-load tap-changer consists of
three insulated units UCG.T/VUCG.T or UCGYD/VUCGYD. The
on-load tap-changer unit, which is placed closest to the drive
mechanism, is called unit -1, the second unit -2 and the last
unit -3; see Fig. 41.
1. Mount the drive shaft on the on-load tap-changer unit -1
according to Section 9.2.5, steps 1–5. Remove the set
screws according to Fig. 49.
2. Mount the drive shaft between unit -1 and unit -2
according to Section 9.2.5, steps 1-6. Remove the set
screws according to Fig. 49.
3. Mount the drive shaft between unit -2 and unit -3
according to Section 9.2.5, steps 2-7.
The shaft here is SA34, the protective tube closest to
unit -2 is SA35 and the other protective tube is SA36.
Do not remove the locking device before one end of
the shaft of the bevel gear is connected to the drive
shaft.
In cases where a support bearing is used, follow the
appropriate parts of Section 9.2.5, steps 2-5.
9.3 Supervisory equipment
Accessories and safety devices are described in Accessories
and protection devices for on-load tap-changers,
1ZSC000562‑AAD .
9.4 Accessories
Refit all other accessories, if any, that have been removed for
transport. Follow the appropriate parts of Section 5.4.
9.5 Oil filling
Follow the appropriate parts of Chapter 6.
9.6 Electrical connection and testing
Carry out all wiring work and appropriate tests according to
Chapter 7. Remove the drying agent inside the cabinet of the
motor-drive mechanism.
9.6.1 Motor protection
The function of the protective motor switch is checked. For
three-phase AC motors, one of the phase fuses is removed
and the function time of the protective motor switch is
checked by a RAISE or LOWER operation. The protective
motor switch should release within 60 seconds at a current
setting equal to the rated current of the motor at the actual
voltage.
WARNING
9.2.7 Before operation
1. Check again that the on-load tap-changer and the motordrive mechanism are at the same operating position; see
Section 5.1.
2. Remove the locking device for the motor-drive mechanism;
see Fig. 50.
The motor power voltage is dangerous.
CAUTION
If the protective motor switch has not released within
60 seconds, disconnect the power and check the
settings against the rating plate of the motor. Adjust
if necessary and check again when the motor has
cooled down.
WARNING
Assembly with the on-load tap-changer and the
motor-drive mechanism at different operating
positions may cause transformer failure.
The door of the motor-drive mechanism can be
locked with a padlock (not included in the delivery).
Protective motor switches for DC motors and for single-phase
AC motors are not tested.
Do not remove the locking device before one end of
the shaft of the bevel gear is connected to the drive
shaft.
54 Installation and commissioning guide UCG/VUCG | 1ZSC000562-AAY en, Rev. 1
9.6.2 Disk brake
For BUE: Run the motor-drive mechanism and check again
that the red mark on the brake disk stops within the tolerance
of ± 25° from the exact position; see Fig. 30.
For BUL: Run the motor-drive mechanism and check that the
center of the notch in the cam disk stops within ±2 mm from
the center of the roller on the brake arm; see Fig. 31.
For adjustment of the motor-drive mechanisms, see
the maintenance guide: 1ZSE 5492-124 for UCG or
1ZSC000498‑ABD for VUCG .
9.6.3 Counter
Check that the counter is functioning for RAISE and LOWER
operations.
9.6.4 Position transmitter and other position switches
Check the function of the position transmitter and other
position switches.
9.6.5 Light
Check that the light is switched on when the door is opened
and goes out when the door is closed.
9.6.6 Heater
Switch off all power sources and check with a finger that the
heater has warmed up during earlier tests. Switch on the
power afterwards.
9.7 Putting into operation
Set the LOCAL/REMOTE switch to REMOTE. Reset the drag
hands. Make sure that no tools or foreign objects are left in
the motor-drive cabinet or on the transformer cover. Close the
door to the motor-drive.
1ZSC000562-AAY en, Rev. 1 | Installation and commissioning guide UCG/VUCG 55
ABB AB
Components
SE-771 80 Ludvika, Sweden
Phone: +46 240 78 20 00
Fax:
+46 240 121 57
E-Mail: [email protected]
www.abb.com/electricalcomponents
© Copyright 2015 ABB, All rights reserved. 1ZSC000562-AAY en, Rev. 1, 2015-10-30
Contact us
1ZSE 5492-124 en, Rev. 6
On-load tap-changer, type UCG
Maintenance guide
Original instruction
The information provided in this document is intended to be general and does not
cover all possible applications. Any specific application not covered should be
referred directly to ABB, or its authorized representative.
ABB makes no warranty or representation and assumes no liability for the
accuracy of the information in this document or for the use of such information. All
information in this document is subject to change without notice.
This document must not be copied without our written permission, and the contents
thereof must not be imparted to a third party nor be used for any unauthorized
purpose. Contravention will be prosecuted.
Recommended practices
ABB recommends careful consideration of the following
factors when installing on-load tap-changers:
Before you install or commission a unit, make sure that the
personnel doing the job have read and fully understood the
installation and commissioning guide provided with the unit.
To avoid damaging the unit, never exceed the operating limits
stated in delivery documents and on rating plates.
Do not alter or modify a unit without first consulting ABB.
Follow local and international wiring regulations at all times.
Use only factory authorized replacement parts and
procedures.
Safety warnings
The following warnings and notes are used in the manual:
WARNING
WARNING indicates an imminently hazardous
situation, which if not avoided will result in death or
serious injury. This signal word is to be limited to the
most extreme situations.
WARNING also indicates a potentially hazardous
situation, which if not avoided could result in death or
serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation,
which if not avoided may result in minor or moderate
injury. It may also be used to alert of unsafe practices.
CAUTION may also indicate property-damage-only
hazards.
INFO provides additional information to assist in
carrying out the work described and to provide
trouble-free operation.
Safety precautions
WARNING
The Maintenance guide should be read and
understood before any work is started, and the
procedures in this document should be followed at all
times.
WARNING
Before any work is carried out on the tap-changer:
Make sure that the transformer is disconnected and
that grounding is properly conducted. Obtain a signed
certificate from the engineer in charge.
WARNING
Before carrying out work on the tap-changer, put
the LOCAL/REMOTE switch on the motor-drive
mechanism to position 0. It is also advisable to shut
the door of the motor-drive mechanism and pad lock
it when work is carried out on the tap-changer. The
key should be kept by the operator. This is done
to avoid an unexpected start of the motor-drive
mechanism.
WARNING
Before starting any work inside the motor-drive
mechanism, the auxiliary power must be switched off.
NOTE: The motor, contactors and heating element
may be energized from separate sources.
WARNING
In no case should any person go down into the
diverter switch housing. The cleaning of the diverter
switch housing should be carried out by using
brushes and rags and by flushing with oil.
CAUTION
Approval should be given for inspection as well as for
operating the on-load tap-changer.
CAUTION
ABB recommends that only maintenance engineers
trained by ABB carry out contact replacement.
During service
During oil handling
WARNING
WARNING
Small amounts of explosive gases may be emitted
from the breathing devices (dehydrating breather or
one-way breather). Make sure that no open fires, hot
surfaces or sparks occur in the immediate vicinity of
the breathing devices.
Unused transformer oil is harmful. Fumes from
unused warm oil may irritate the respiratory organs
and the eyes. After long and repeated contact with
transformer oil, skin becomes very dry.
WARNING
If a power supply failure occurs during operation, the
operation will be completed when the power returns.
WARNING
The hand crank must not be inserted during electrical
operation.
WARNING
If the tap-changer is not at its exact position and the
hand crank is pulled out, the motor-drive mechanism
will start and go to the exact position if the power
supply is on.
Used tap-changer oil from diverter switch housings
and selector switch housings contains harmful
substances. Fumes are irritating to the respiratory
organs and the eyes and are highly flammable. Used
transformer oil may well be carcinogenic.
Avoid contact with the oil and use oil-tight protective
gloves when handling the oil.
First aid:
Skin contact: Wash your hands. Use skin cream to
counteract drying.
In the eyes: Rinse your eyes in clean water.
Swallowing: Drink water or milk. Avoid vomiting. Call
a doctor.
Collect used oil in oil drums.
CAUTION
Waste and clean-up: Should be absorbed by an
absorber. Treat it as hazardous to the environment.
After a pressure relay trip, follow the instructions in
the chapter “Trip or alarm from supervisory devices” in
the user's manual.
In the event of fire: Any fires should be extinguished
with powder, foam or carbonic acid extinguishing
agents.
WARNING
When oil that has been used in a diverter switch
housing is pumped out, grounded conducting
tubes and hoses should be used to avoid the risk of
explosion due to the gases produced by arcs during
service.
WARNING
The oil in the selector switch compartment may be
hot. Be cautious!
WARNING
There is always a cushion of explosive gases in the
top of the diverter switch housing. No open fire, hot
surfaces or sparks may be present during opening
of the housing or draining from the valve. After the
cover is removed let the gas vent away approximately
15 min before any work is started.
After oil filling
CAUTION
Do not energize the transformer earlier than three
hours after oil filling at atmospheric pressure. This
waiting period is needed to allow air bubbles to
dissipate.
WARNING
Mounting of gaskets
Be aware of the risk for slipping caused by oil spillage,
for instance when working on the transformer cover.
CAUTION
Take care to avoid ingestion of moist air when oil is
drained. If the ambient air is moist, let incoming air
pass through a dehydrating breather with slow air flow
to obtain proper dehydration.
CAUTION
Do not fill the diverter switch housing with oil if the
transformer tank is under vacuum and the on-load
tap-changer is not.
CAUTION
Do not fill the transformer tank with oil if the on-load
tap-changer is under vacuum and the transformer
tank is not.
CAUTION
Leave a gas cushion on top of the oil in the diverter
switch housing.
CAUTION
Sealing surfaces and gaskets must be clean and
undamaged. Diametrically opposed bolts in sealing
joints must be tightened alternately several times,
beginning with a low tightening torque and finally with
the recommended tightening torque as described in
section 1.3 Tightening torque, in this guide.
Content
1. Introduction...........................................................................................................................9
1.1 General..........................................................................................................................9
1.2 Maintenance schedule...................................................................................................10
1.2.1 Inspection................................................................................................................10
1.2.2 Overhaul..................................................................................................................10
1.2.3 Contact replacement...............................................................................................12
1.3 Tightening torque...........................................................................................................12
2. Inspection..............................................................................................................................13
3. Overhaul................................................................................................................................14
3.1 Required tools and materials..........................................................................................14
3.2 Procedure......................................................................................................................14
3.3 Preparations..................................................................................................................14
3.3.1 On-load tap-changer position..................................................................................14
3.3.2 Disconnection and earthing of the transformer.........................................................15
3.3.3 Oil volumes and lifting heights..................................................................................15
3.3.4 Recommended set of spare parts...........................................................................15
3.4 Oil testing and oil draining..............................................................................................15
3.5 Lifting and cleaning the diverter switch................................................................................16
3.6 Cleaning........................................................................................................................17
3.6.1 Cleaning the diverter switch housing........................................................................17
3.6.2 Cleaning the oil filter in the conservator pipe (if any).................................................17
3.7 Oil filtration.....................................................................................................................17
3.8 Checking of the breathing device...................................................................................17
3.9 Checking the contact positions......................................................................................18
3.10 Checking the contact wear..........................................................................................20
3.11 Checking the transition resistors..................................................................................20
3.12 Checking before closing...............................................................................................20
3.13 Installation of the diverter switch..................................................................................20
3.14 Checking and replacing supervisory equipment...........................................................21
3.15 Lubrication of the on-load tap-changer and the drive shaft system....................................22
3.16 Checking of the motor-drive mechanism......................................................................22
3.17 Oil filling.......................................................................................................................22
3.17.1 Filling methods and restrictions..............................................................................22
3.17.2 Before filling...........................................................................................................22
3.17.3 Filling at atmospheric pressure..............................................................................22
3.17.4 Oil level..................................................................................................................22
3.17.5 Restoring the gas cushion.....................................................................................23
3.17.6 Waiting period.......................................................................................................24
3.18 Check of contact timing...............................................................................................24
3.19 Putting into operation...................................................................................................24
4. Contact replacement.............................................................................................................27
4.1 Dismantling the boards..................................................................................................29
4.2 Dismantling the moving main contacts...........................................................................29
4.3 Dismantling the moving transition contacts....................................................................31
4.4 Mounting the moving transition contacts........................................................................32
4.5 Mounting the moving main contacts..............................................................................33
4.6 Replacing the fixed main contacts..................................................................................34
4.7 Replacing the fixed transition contacts...........................................................................34
4.8 Mounting the boards with transition resistors and fixed contacts....................................34
5. Specification of materials.......................................................................................................35
5.1 General..........................................................................................................................35
5.2 Diverter switch housing..................................................................................................35
5.3 Diverter switch...............................................................................................................35
5.4 Tap selectors.................................................................................................................35
5.5 Conductors....................................................................................................................35
5.6 Gearing mechanism.......................................................................................................35
5.7 Drive shaft systems........................................................................................................35
1. Introduction
1.1 General
The UC range of on-load tap-changers manufactured by ABB
has been developed over many years to provide maximum
reliability. The simple and rugged design gives a service
life equal to the service life of the transformer. Minimum
maintenance is required for trouble-free operation. The only
parts requiring maintenance are contacts that might need
replacement during the service life, the insulating oil and the
motor-drive mechanism.
The design allows excellent access to all parts, making
inspection and maintenance quick and simple.
The on-load tap-changer, type UCG, is housed in the
transformer tank. The motor-drive mechanism is attached
to the transformer tank and connected to the on-load tapchanger by means of drive-shafts and a bevel gear, see Fig. 1.
Bevel gear
Horizontal drive-shaft and
protection tube
Pressure relay
Bevel gear
Shielding-rings (when
impulse withstand
voltage to earth
exceeds 380 kV)
Vertical drive-shaft and
protection tube
Insulating shaft
Diverter switch housing
containing the diverter
switch
Hood and screws
Conductors
Hand crank
Motor-drive
mechanism
On-load tap-changer
Shielding-ring (when impulse
withstand voltage to earth
exceeds 380 kV). (Not on tap
selector size C)
Fig. 1. On-load tap-changer and motor-drive mechanism.
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 9
Fig. 2 shows the general arrangement of an on-load tapchanger type UC. The main components are the springoperated diverter switch and the tap selector with sliding
contacts. For maintenance the diverter switch is lifted.
The contacts are then immediately accessible and can be
inspected for wear. The drive-shafts should not be dismantled
when lifting the diverter switch.
Maintenance is normally not required on the parts operating
in the oil of thetransformer tank. However, when the on-load
tap-changer has made one million operations a check of the
tap selector is recommended.
The diverter switch has its own housing separate from
the transformer oil. This is to prevent contamination of the
transformer oil since the diverter switch oil deteriorates due
to the switching operations. The oil needs to be checked and
filtered at regular intervals to maintain adequate dielectric
strength as well as to prevent mechanical wear.
It is necessary to inspect the contacts and clean the insulation
parts of the diverter switch as well as to clean the housing
inside at regular intervals.
The main components of the diverter switch are:
– – Fixed main contacts
– – Moving main contacts
– – Fixed transition contacts
– – Moving transition contacts
– – Transition resistors
– – Spring-driven polygon link system
Besides the maintenance of the diverter switch and cleaning
of the oil, the motor-drive mechanism should be checked and
lubricated.
The pressure relay, the device that protects the transformer
from damages due to excessive pressure in the diverter
switch housing, should also be checked.
One on-load tap-changer of UCG type may consist
of one, two or three units driven by a common
motor-drive mechanism. The instructions in this
guide deals with one unit. If there are two or three
units, all work decribed should be carried on all units
unless otherwise is stated. If more than one diverter
switch is lifted out at the same time, make sure the
right diverter switch is lowered into the right housing
(compare with the serial numbers, see Fig. 2).
10 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
1.2 Maintenance schedule
Maintenance of the on-load tap-changer consists of three
major steps:
–– Inspection
–– Overhaul
–– Contact replacement
1.2.1 Inspection
It is recommended to perform an inspection once a year. This
principally concerns the motor-drive mechanism and refers
to a visual inspection inside the motor-drive cabinet to check
that nothing is loose and the heater is functioning.
In the motor-drive mechanism a counter registers every tapchanger operation. During inspection the counter is read. If
possible, motor and counter are tested by operating one step
and then back.
If the on-load tap-changer has its own oil conservator, the
breather and the oil level indicator are checked according to
the instructions from the transformer manufacturer.
The inspection is carried out while the transformer is in
service.
If the on-load tap-changer is equipped with an oil filter unit
from ABB, it should be inspected once a year according to
the oil filter unit manual.
1.2.2 Overhaul
The contact life and the frequency of operations or the time in
service determine the time interval between overhauls.
The number of operations run by the on-load tap-changer is
recorded by a counter, housed in the motor-drive mechanism
cabinet. The registered number of operations should be noted
at every inspection and overhaul.
The on-load tap-changer should normally be overhauled
regularly at intervals of 1/5 of the estimated contact life. The
relevant information is stated on the rating plate. Hereby, the
contact wear can be followed and necessary preparations can
be made for replacing the contacts.
If the tap-change operations occur infrequently and a very
long time elapses until the number of operations amounts to
1/5 of the contact life, the interval between overhauls should
be limited to the time stated on the rating plate (normally 7
years).
Cover
Diverter switch housing
Oil valve
Pressure relay
Bevel gear
Position indicator
Top-section
Serial No.
Shielding-ring 1)
Earthing terminal
Draining tube
Connection flange for
gas operated relay
Insulating cylinder
Insulating shaft
Shielding-ring
Diverter switch
1)
Shielding-ring 2)
Plug-in contacts
Transition resistors
Fixed and moving
contacts
Bottom section
Serial No.
Guide-pins
Current terminal
Tap selector
Driving disc for the
diverter switch
Bottom valve for
drying process
Intermediate gear
1) Only at impulse withstand voltage
to earth of 650 kV and 1050 kV.
2) Not on UCG of the short type.
Geneva gear
Change-over
selector
Moving fineselector contacts
Current collector
Fixed fine-selector
contacts
Fig. 2. General arrangement of on-load tap-changer, type UC.
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 11
1.2.3 Contact replacement
On the rating plate of the on-load tap-changer the estimated
contact life of the breaking contacts in the diverter switch at
rated load is stated.
The contacts will withstand a very large number of switching
operations. For normal power transformers the number of
operations of the diverter switch is approximately 20 per day,
which means that replacement of the contacts is not normally
necessary during the life of the transformer. (In case of onload tap-changers on furnace transformers, the frequency of
operations may be considerably higher).
CAUTION
The number of operations must in no case exceed
500 000, due to weakening spring tension of the
contacts.
1.3 Tightening torque
The following tightening torques are recommended:
For metallic screw joints:
M6........... 10 Nm
M8........... 24.5 Nm
M10.......... 49 Nm
M12.......... 84 Nm
±10
±10
±10
±10
For non-metallic screw joints:
M10.......... 9 Nm
M12.......... 13 Nm
M16.......... 22 Nm
±10 %
±10 %
±10 %
if not otherwise stated in this guide.
12 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
%
%
%
%
2. Inspection
The inspection mainly consists of a visual check of the motordrive mechanism and the conservator once a year while the
transformer is in service.
In the motor-drive mechanism the following points are to be
checked:
– – Motor and counter
–– Heater
– – The counter’s value
– – Visual check of the toothed belt
See the maintenance guide for motor-drive mechanisms
(1ZSC000498-ABH) for information about the procedure.
On the conservator the following are to be checked:
– – Oil level
– – Breather
WARNING
The breathers and the tube from the conservator
contains explosive gases. No open fire, hot surfaces
or sparks may be present when loosening the
breather.
CAUTION
Approval should be given for inspection as well as for
operating the on-load tap-changer.
1. Check the breathers according to the instructions for the
transformer.
2. Check the oil level in the conservator for the on-load
tap-changer. The oil level should be according to the
transformer documentation.
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 13
3. Overhaul
WARNING
Before any work is carried out on the on-load
tap-changer: Make sure that the transformer is
disconnected and that earthing is properly carried
out. Obtain a signed certificate from the engineer in
charge.
3.1 Required tools and materials
Necessary for the overhaul is the following equipment:
–– Standard hand tools (keywidth up to 19 mm)
–– Standard set of combination spanners
–– Pipe wrench
–– Thickness gauges (0.40; 0.50; 1.20 mm)
–– Small hammer
–– Sliding caliper
–– Spring balance (10 N)
–– Watch (with hand for seconds)
–– Oil can
–– Ohmmeter (1-30 Ohm)
–– Air pump with pressure gauge (0-200 kPa) and connection
to R 1/8” male thread
–– Telpher (at least 150 kg lifting force)
–– Empty and clean barrels for transformer oil (calculate with
max. 225 l for each diverter switch housing)
–– Oil draining and filtering equipment with connections
–– Test equipment according to IEC 00156, 1995-08
–– Two buckets (approximately 10 l)
–– Rags (lint-free)
–– 50 l of new transformer oil (class II according to IEC 00296,
2012-02)
–– Standard lithium complex or calcium complex grease
with EP additive NLGI 2. Temperature range from -30°C
to +100°C. Suggested products: Dow Corning Molykote
Multilub, Gulf Crown EP 2 or similar.
–– Oil (for plain ball and roller bearings)
–– Degreasing agent
–– Protective glooves, oil proof
–– Dimension drawing for the on-load tap-changer
–– Pen and note pad
–– Set of spare contacts (see the spare parts list)
–– Brass shims according to Fig. 7 (12 pcs)
–– New O-ring for the cover (435x8)
When restoring the gas cushion. (section 3.17.5):
–– Small oil pump with connection to the oil valve
–– Empty and clean barrel for transformer oil ( ~ 15 l)
–– Box wrench, 6 mm
14 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
When measuring contact timing, add this equipment:
–– See section 3.18
When replacing contacts (chapter 4), add this equipment:
–– Universal pliers
–– Pipe wrench
–– 4 mm mandrel
–– 5 mm brass mandrel, 320 mm long
–– Steel ruler
–– Round file
–– Torque wrench (10 Nm)
–– Piece of wood, 50 mm thick, 400 mm long
3.2 Procedure
The overhaul procedure includes the following points:
–– Oil testing and oil draining
–– Lifting and cleaning the diverter switch
–– Cleaning the diverter switch housing and the oil filter (if any)
–– Oil filtration
–– Checking the breathers
–– Checking the contact positions
–– Checking the contact wear
–– Checking the transition resistors
–– Checking before lowering the diverter switch
–– Lowering the diverter switch
–– Checking the pressure relay
–– Lubrication
–– Checking the motor-drive mechanism (see the maintenance
guide for motor-drive mechanisms)
–– Oil filling
–– Check of contact timing
–– Putting into operation
3.3 Preparations
If the on-load tap-changer is oil filled under
atmospheric pressure, a waiting period of three
hours is needed before energizing. To save out of
service time of the transformer, carry out all work on
the on-load tap-changer and the oil filling before the
maintenance of the motor-drive mechanism is started.
3.3.1 On-load tap-changer position
Note the position of the on-load tap-changer to enable restart
of the transformer in the right tap position.
3.3.2 Disconnection and earthing of the transformer
WARNING
Before starting any work in the on-load tap-changer
the protective motor switch and the LOCAL/REMOTE
switch must be set at 0.
WARNING
Before any work is carried out on the on-load
tap-changer: make sure that the transformer is
disconnected and that earthing is properly carried
out. Obtain a signed certificate from the engineer in
charge.
3.3.3 Oil volumes and lifting heights
The necessary number of empty drums for collecting and
filtering of the oil in the diverter switch housing should be
kept ready. The drums must be carefully cleaned and free
from water. New oil needed should be of class II according to
IEC 60296, 2012-02.
3.4 Oil testing and oil draining
The diverter switch housing is equipped with an oil valve
placed on the top section. For connection dimensions, see
the dimension drawing for the on-load tap-changer.
WARNING
The oil in the diverter switch housing may be hot. Be
cautious!
Take an oil-sample from the oil valve and carry out the
dielectric strength test according to IEC 60156, 1995-08
(between spherical calottes, distance 2.5 mm). This test is
carried out for deciding whether the oil can be filtered or must
be exchanged.
The dielectric strength of the oil should not be allowed to be
less than 120 kV/cm for an on-load tap-changer in service.
When taking the oil-sample, first drain some oil into a
bucket to clean the valve.
Quantity of oil in the diverter switch housing and lifting height for
the diverter switch
UCG..
380/...
Approx. 170 litres (lifting height 1.4 m)
UCG..
650/...
Approx. 170 litres (lifting height 1.4 m)
UCG..
1050/...
Approx. 205 litres (lifting height 1.7 m)
If the oil conservator of the on-load tap-changer is common
with the oil conservator of the transformer tank, close the
valve in the pipe connection to the oil conservator and open
the oil valve. After a while, open the air release valve. See
Fig. 10.
The volume of the oil conservator is not included.
CAUTION
Alternatively, the oil may be replaced by new oil and the used
oil filtered at some later occasion. A certain quantity of new
oil, at least 50 litres, should be kept ready to replace waste oil
and for cleaning.
CAUTION
Do not energize the transformer until oil has been
filled as per section 3.17 ”Oil filling” in this guide.
3.3.4 Recommended set of spare parts
It is recommended to have a set of contacts for the diverter
switch available during the overhaul, see the spare parts list
for ordering.
Never block the hole in the draining tube!
If the on-load tap-changer is equipped with an oil
filter unit for continuous oil filtration from ABB and
it is maintained and operated according to our
instructions, oil draining and filtering is not needed,
provided that the dielectric strength is at least
160 kV/cm (IEC 60156, 1995-08).
There is a hole in the upper part of the draining tube
to prevent air from being trapped inside the tube
when oil filling. The air sucked in through this hole
when draining might disturb the function of some
types of pumps. In such case, drain the oil using a
hose instead.
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 15
Use the filtering equipment or the pump to drain oil from the
on-load tap-changer into carefully cleaned oil drums. Connect
the pump to the oil valve and drain the oil from the diverter
switch housing and the conservator. Draining can be effected
quickly if filtering equipment is used and at the same time the
whole oil quantity will be filtered once. Remove the cover of
the diverter switch housing while draining.
3.5 Lifting and cleaning the diverter switch
The weight of the diverter switch is approximately 90 kg.
Lift the diverter switch partly so you can flush it with oil. After
careful flushing, lift the diverter switch from the housing and
wipe it with rags. Lift according to Fig. 4.
WARNING
WARNING
There is always a cushion of explosive gases in the
top of the diverter switch housing. No open fire, hot
surfaces or sparks may be present during opening
of the housing or draining from the valve. After the
cover is removed let the gas vent away approximately
15 minutes before any work is started.
Make sure the lifting equipment is properly fixed to the
cover flange before the diverter switch is lifted.
CAUTION
WARNING
When lifting the diverter switch, use a manually
operated telpher to avoid damages on the diverter
switch. Make sure that the end of the tie-rod or its
coupling is kept clear of the inner edge of the flange.
When oil that has been used in a diverter switch
housing is pumped out, conducting tubes and hoses
that are earthed should be used to avoid the risk of
explosion due to the gases produced by the arcs
during service.
If the on-load tap-changer is equipped with an oil
filter unit for continuous oil filtration from ABB and
it is maintained and operated according to our
instructions, the flushing and wiping of the diverter
switch is not necessary.
Drain the remaining oil in the bottom of the housing by using
a hose.
Manually operated telpher
Buffer springs
Lifting eye
Lifting eye
Lifting device
Shielding ring
(only for impulse
withstand
voltages to
earth exceeding
380 kV).
Tie-rod
Coupling
with drivingpin
Fig. 3. Diverter switch, general arrangement.
16 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
Plug-in contacts
Guiding pins
Fig. 4. Lifting arrangement.
3.6 Cleaning
3.6.1 Cleaning the diverter switch housing
Clean the inner walls of the housing by means of a nylon
brush, then flush with oil. Drain the oil. Wipe the bottom and
inner walls with rags.
WARNING
In no case should any person go down into the
diverter switch housing. The cleaning of the diverter
switch housing should be carried out by using
brushes and rags and by flushing with oil.
If the on-load tap-changer is equipped with an oil
filter unit for continuous oil filtration from ABB and
it is maintained and operated according to our
instructions, the cleaning of the diverter switch is not
necessary.
Drain the housing completely by using a hose before oil filling
is carried out.
3.6.2 Cleaning the oil filter in the conservator pipe (if any)
The diverter switch housing and the oil conservator are
connected by a pipe. The diverter switch oil is contaminated
due to the arcing that occurs when the contacts operate.
In case of a common conservator with the transformer the
impure oil in the diverter switch housing must be prevented
from entering the oil conservator. An oil filter is therefore
mounted in the pipe.
3.7 Oil filtration
The drained oil should be filtered until it is cleaned and has
regained the high dielectric strength required. The breakdown value for purified oil should be at least 160 kV/cm
according to IEC 60156,1995-08.
To check the result of the filtering, take test sample after the
oil has been filled into the on-load tap-changer.
If the on-load tap-changer is equipped with an oil
filter unit for continuous oil filtration from ABB and
it is maintained and operated according to our
instructions, no further oil filtration is necessary. Only
take an sample and measure the dielectric strength of
the oil, see section ”Oil testing and oil draining” in this
guide.
3.8 Checking of the breathing device
Check the breathing device according to the instructions from
the transformer manufacturer.
WARNING
The breathers and the tube from the conservator
contains explosive gases. No open fire, hot surfaces
or sparks may be present when loosening the
breather.
The filter, which is mounted in a flange pipe on the top of the
diverter switch housing, is screwed from the inside. It can
easily be screwed out for inspection and cleaning.
The oil filter does not need to be replaced nor cleaned in any
other way than by washing with oil.
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 17
3.9 Checking the contact positions
Those parts of the fixed contacts and the moving contacts
which are exposed to arcing during an operation are tipped by
copper-tungsten.
In a tap position, the moving main switching contacts and the
fixed main switching contacts should have a clearance of min.
0.5 mm as shown in Fig. 5.
For checking the clearance on both sides of the diverter
switch it has to be operated. Operate it by turning the
coupling with a pipe wrench. Note the position of the diverter
switch before operation.
WARNING
Take care to avoid finger injuries when operating the
diverter switch. Oil splash occurs during operation,
especially in the moving direction.
If the clearance is too small you may adjust the clearance by
installing a shim of brass between the board and the current
bar. The shims are included in the spare parts set. The shim
dimensions are also shown in Fig. 5. Operate the diverter
switch to the opposite side when mounting the shims.
18 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
Operate the diverter switch back to the first side and check
the clearance again. If still too small, put in a shim more and
test again.
CAUTION
Never mount more than three shims on each other.
Make sure all washers and screws are put back and tighten.
Proceed with the other side of the diverter switch. When
finished, operate the diverter switch back to the position it
had before the first operation.
Fig. 5 shows the current carriers through the fixed main
contact and the copper part of the moving contact.
Fig. 6 shows the copper-tungsten tips of the transition
contact touching each other in a tap position.
Make sure that all flexible connections, operating springs,
contact springs and all plug-in contacts are in good condition.
Make sure that no bolts have worked loose.
0.5–2 mm
Fixed main
switching contact
Moving main
switching contact
20
14
Copper part
Ø6.4
26
14
Thickness 1 mm
Current bar
Fixed main
contact
Moving main
contact
Board
Fig. 5. Fixed and moving contacts clearance.
Fig. 6. Transition contacts.
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 19
3.10 Checking the contact wear
The contact system consists of fixed and moving contacts.
Check the degree of contact burning on the breaking
contacts.
For a new contact with tips of copper-tungsten (Fig. 7), the
thickness at (A) and (B) is 5.5 mm in the upper end of the
contact. In the lower end, the thickness is 3 mm.
Estimate the degree of contact burning and record this to
enable comparison with the condition at the next overhaul. Do
not file or smooth the burned and pitted contact surfaces.
A contact with a tip of copper-tungsten should be replaced
when the thickness at (A) and (B) in the upper end of the
contact is approximately 0.5 mm. (The thickness in the upper
and the lower end of the tip will be approximately the same
when close to the limit for replacement).
3.11 Checking the transition resistors
Measurement is carried out on the side with open contacts.
Connect one cable from the ohmmeter to a fixed main contact
and the other cable to a fixed transition contact. Measure the
resistance.
Measure the resistance of each resistor branch across the
open switch.
Operate the diverter switch to the other side as described in
section 3.9 and measure the resistance with open contacts.
Check that the resistors are undamaged and compare with
the value on the rating plate. The values must not differ by
more than 10 %.
Check that nothing has worked loose. Operate the diverter
switch back to its previous position.
Also replace contacts which are assumed to wear out before
the next overhaul.
3.12 Checking before closing
Before installing the diverter switch, make sure that no foreign
objects, tools, wires, rags etc. are left in the diverter switch
housing.
The dimensions above are valid for both main contacts and
transition contacts. For contact replacement, see chapter 4
”Contact replacement”.
3.13 Installation of the diverter switch
CAUTION
A
B
Check the serial numbers to make sure that the
diverter switch is mounted in the correct housing, see
Fig. 2.
CAUTION
Make sure that the diverter switch housing is clean
and dry and that no foreign objects (tools etc.) are left
in the housing.
CAUTION
Lower the diverter switch into its housing carefully so
that neither the diverter switch nor the housing are
damaged.
The UCG diverter switch is provided with a guiding slot that
fits against the oil draining tube in the diverter switch housing,
see Figs. 8 and 9.
Rotate the diverter switch so the half-circle shaped guiding
slot is aligned with the oil draining tube.
Fig. 7. Tolerance limits for contact erosion.
20 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
When the diverter switch is lowered, check visually that its
plug-in contacts are aligned with the contacts in the cylinder
wall.
In order to ensure that the diverter switch pin has engaged
the coupling disc, carry out at least three tap change
operations in one direction. A distinct sound is heard when
the diverter switch operates which indicates that the driving
pin of the diverter switch has been connected.
If no sound is heard, the diverter switch might need to be
pushed down while operating the motor-drive.
3.14 Checking and replacing supervisory equipment
Accessories and safety devices that are not standard, but
might be mounted at delivery, are described in instruction
1ZSC000562-AAD.
Springs
Lifting device
Lifting eye
Carry out another three operations in the same direction while
pushing the diverter switch down.
Shielding-ring
(when the impulse
withstand voltage
to earth exceeds
380 kV) (not
on UCG short
version)
The top part of the diverter switch lifting device should be
below the level of the machined surface for the cover when
lowered to its final position. Only the springs of the lifting
device should be above this level.
If a check of contact timing should be carried out, proceed
with that according to section 3.19 before mounting the
cover.
Serial number
(on the opposite
side of the
diverter switch)
A
A
Plug-in contacts
Guiding pin
Insert a new O-ring for the cover in the upper flange. Mount
the on-load tap-changer cover. Turn the cover so the guiding
pin in the housing is facing the guiding hole in the cover.
(The cover has to be pressed down in order to overcome
the spring force of the springs which hold the diverter switch
pressed in place.) Insert screws and washers and tighten
them.
Coupling disc
Guiding pin
Tie rod
Driving pin
Fig. 8. Diverter switch.
Notch for the
guiding pin
Oil draining tube
Holes for
guiding pins
Guiding pins
Slot for the oil
draining tube
Slot for
guiding bar
A–A
Fig. 9. UCG diverter switch housing, view from above.
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 21
3.15 Lubrication of the on-load tap-changer and the drive
shaft system
The bevel gears are greased at delivery and the same type of
grease is used for the couplings of the outer shaft system.
For access to the couplings, loosen the hose-clips and push
the protective tubes together. For access to the bevel gears,
dismount the covers.
WARNING
The bevel gear contains moving gears. Be cautious!
The connection to the oil conservator is designed to
automatically give a gas cushion when filling at atmospheric
pressure.
If new oil, especially degassed oil, is filled into the
diverter switch housing and the number of operations
is low, the gas cushion may be dissolved in the
oil. The oil level in the oil conservator should then
be checked after a month in service and if the oil
level is lower than after the oil filling, (corrected for
temperature differencies), the gas cushion should be
restored according to section 3.17.5 ”Restoring the
gas cushion” in this guide.
WARNING
3.17.2 Before filling
Rotating shafts. Be cautious!
Check and lubricate with grease if necessary. Use standard
lithium complex or calcium complex grease with EP additive
NLGI 2. Temperature range from -30°C to +100°C. Suggested
products: Dow Corning Molykote Multilub, Gulf Crown EP 2 or
similar.
Remount the covers (make sure the gaskets are properly in
place).
3.16 Checking of the motor-drive mechanism
See the maintenance guide for the motor-drive mechanism.
3.17 Oil filling
If check of contact timing is to be carried out, see section
3.18, fill the diverter switch housing with oil up to the level
of the fixed main breaking contacts by easiest possible
method before checking. Oil fill completely according to the
instructions below after check of contact timing.
3.17.1 Filling methods and restrictions
Oil filling can be carried out at atmospheric pressure or under
vacuum. The wall between the diverter switch housing and
the transformer tank is designed to withstand vacuum on one
side and atmospheric pressure on the other side. It is not
allowed to have vacuum on one side and the pressure of an
oil column on the other side.
After maintenance oil is normally filled at atmospheric
pressure. This procedure is described in section 3.17.3. If
filling is to be carried out under vacuum, see the Installation
and commissioning guide.
After oil filling, a gas cushion should remain on the top of the
oil in the diverter switch housing.
22 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
Oil filling may be carried out in different ways
depending on what is convenient as long as the rules
above are fulfilled and the on-load tap-changer is
filled with oil to the correct level with a gas cushion on
the top. The method below is recommended and if it
is followed in detail no pressure limits are exceeded
and oil levels and gas cushion will be correct. If the
on-load tap-changer consists of more than one unit,
fill one at a time.
3.17.3 Filling at atmospheric pressure
See Fig. 10.
1. Close the air release valve
2. Open the conservator valve, if any.
3. Dismantle the breathing device on the conservator for the
on-load tap-changer.
4. Pump oil into the diverter switch housing via the oil valve
(connection dimensions, see the dimension drawing for
the on-load tap-changer). Continue until the conservator
is filled to the correct level at the actual temperature. See
section 3.17.4. If there is more than one unit connected
to the same conservator, fill all of them until the oil level
indicator starts to move and fill up to the right level when
filling the last unit.
5. Shut the oil valve and disconnect the pump.
6. Remount the breathing device. Make sure the connection
to the breathing device is properly sealed.
3.17.4 Oil level
For correct oil level in the oil conservator, see the transformer
documentation.
3.17.5 Restoring the gas cushion
Check the oil level in the oil conservator one month after
oil filling. If the oil level is lower now than when the oil filling
was finished (correct for temperature differencies!) and no
leakages are observed, the gas cushion has been solved in
the oil and has to be restored.
The procedure below is used for on-load tap-changers
without oil filter unit for continuous oil filtration. In case the
on-load tap-changer is equipped with an oil filter unit for
continuous oil filtration from ABB, and it is installed according
to our recommendations, follow the instructions in the oil filter
unit manual.
In case the on-load tap-changer consists of more than one
unit, do the restoring in one unit at a time.
WARNING
The oil in the diverter switch housing may be hot. Be
cautious!
Procedure
1. Close the valve in the tube to the conservator.
2. Connect the oil pump to the oil valve. (For connection
dimensions, see the dimension drawing for the on-load
tap-changer), see Fig. 10.
3. Open the oil valve and the air release valve.
4. Start the oil pump and drain approximately 15 litres of oil
into a clean and dry container.
5. Close the air release valve.
6. Close the oil valve and disconnect the pump.
7. Connect the output side of the pump to the oil valve.
8. Open the oil valve.
9. Open the valve in the tube to the conservator!
10. Pump the earlier drained 15 litres of oil back into the
diverter switch housing.
11. Close the oil valve and disconnect the pump.
12. The level in the oil conservator and the gas cushion are
now restored.
If the on-load tap-changer consists of more than one unit,
proceed with the other one until the last one has been
restored.
WARNING
CAUTION
Before any work is carried out on the on-load
tap-changer: Make sure that the transformer is
disconnected and that earthing is properly carried
out. Obtain a signed certificate from the engineer in
charge.
Avoid to do the restoring in damp weather since
moisture will get into the diverter switch housing. If
the restoring has to be done in such weather, the
incoming air has to be dehydrated and the drained oil
protected from water.
CAUTION
To operate the on-load tap-changer with a too small
or no gas cushion means a risk for a trip of the
pressure relay.
Open end wrench
key width 6 mm
Oil valve
Open
Air release valve
Oil valve
Fig. 10. Air release valve (position may be on another vertical flange).
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 23
3.17.6 Waiting period
The test is to be made on all three-phases and is to be
carried out as follows:
CAUTION
Do not energize the transformer earlier than three
hours after oil filling in atmospheric pressure. This
waiting period is needed to allow airbubbles to
disappear.
3.18 Check of contact timing
Checking the contact timing is a good check of the condition
of the on-load tap-changer, but it is not necessary to check
contact timing at every overhaul. It is recommended to be
carried out after every 500 000 operations.
The test requires:
–– Two indicator lamps (glow discharge lamps for the
minimum possible magnetisation of the transformer)
–– Necessary leads
–– Two stiff insulated leads or bars
Find the exact position of the on-load tap-changer by
adjusting the disc brake as shown in the maintenance guide
for motor-drive mechanisms.
1. Note the number of whole turns and parts of turns on the
hand crank, during a slow manual operation.
2. Note when each tap-selector arm breaks and makes (the
corresponding lamp goes out or lights).
3. Note when the diverter switch flicks over (a distinct sound
is heard).
After this, compare the operations with the contact-timing
diagram applicable to the on-load tap-changer in Figs. 13
and 14.
One operation corresponds to 25 turns of the hand crank on
the motor-drive mechanism, type BUE and 15 turns for BUL.
WARNING
Remove the equipment for contact-time measuring.
Never force DC current through the transformer
windings.
Mount the cover of the diverter switch housing according to
section 3.13.
The insulated leads (or bars) are used for connection to
the moving contact arms of the tap selector via the plugin contacts of the diverter switch (They can be made of an
insulating tube with a lead inside.)
Connect the lamps as shown in Fig. 11.
The diverter switch contacts are designated as shown
in Fig. 12. Determine if x or v contacts are closed. In the
contact-timing diagram for the on-load tap-changer you can
find out the corresponding position. See Figs. 13 and 14.
The diverter switch housing shall be filled with transformer oil
up to the fixed main contacts to secure the correct function
of the dash pots during operation of the diverter switch, see
section 3.17.
At repeated operations in the same direction the selector
arms V and H operate every second time. When the direction
of operation is reversed, the contact arms will be at rest
during the first operation. The operation is then performed by
means of the diverter switch only.
When testing, the operation must be carried out in the
same direction as the previous operation.
24 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
Complete the oil filling according to section 3.17.
CAUTION
If the result is beyond the limits given here, please
contact ABB.
For BUE, the diverter switch must have switched over
before the 20th turn is finished with the hand crank.
For BUL, the diverter switch must have switched over
before the 12th turn is finished with the hand crank.
3.19 Putting into operation
Operate the on-load tap-changer to the position noted in
section 3.3.1. Put the LOCAL/REMOTE switch to REMOTE.
Reset the drag hands. Make sure that no tools or foreign
objects are left in the motor-drive mechanism cabinet. Close
the door. Make sure that nothing is left on the transformer
cover.
Sign the revision protocol and give it to the engineer in
charge and inform that the on-load tap-changer is ready for
energizing.
y
u
Fig. 11. Indicator lamp connection during contact timing test.
x-contacts
v-contacts
Fig. 12. The diverter switch outlet marking.
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 25
Position
Min. 3 turns
Position
–—— Contact closed
Min. 3 turns
Position
Turns of the hand crank of the mechanism
Fig. 13. Example of contact-timing diagram, BUE.
Position
Min. 2 turns
Position
Min. 2 turns
V
H
x
u
y
V
–—— Contact
Fig. 14. Example of contact timing diagram, BUL.
26 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
Turns of the hand crank of the mechanism
Position
4. Contact replacement
CAUTION
ABB recommends that only authorized personnel from
ABB carry out contact replacement.
Replace worn-out main switching contacts and transition
contacts as required. (It is not necessary to replace both main
switching contacts and transition contacts if, for instance,
only the main switching contacts are worn out).
CAUTION
Fixed contacts and its corresponding moving contacts
should always be replaced at the same time.
Also replace contacts which are assumed to wear out before
the next overhaul.
Replacement of contacts is described in the following
sections.
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 27
Fixed main switching
contact
Conical
springwasher
Plain
washer
Fixed transition
contact
Locking washer
(mounted vertically
on some types)
Plain washer
Conical spring
washer
Moving transition
contact
Guide pin
Conical spring
washer
Nut
Plain washer
Connection for transition resistor
Fixed transition
contact
Moving main
switching contact
Fig. 15. Diverter switch, contact design.
28 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
4.1 Dismantling the boards
Dismantle the boards from the frame by removing the six
screws and the locking washers from each board (Fig. 16).
Punch the guide pins with a 4 mm mandrel. Note that the
guide pins are placed high on one board and low on the other
board in order to make the boards non-reversible.
When mounting, use new locking washers and guide pins.
Lift away the boards in the lifting eye, see Fig. 7 with fixed
contacts and transition resistors from the contact-mechanism
(Fig. 17). The boards, which are made of insulating material,
shall be wiped with rags.
4.2 Dismantling the moving main contacts
Dismantle the moving main contacts according to Figs. 18
and 19. Take away split pins, washers and springs in both
ends of shafts 1–3. There is one shaft for each pair of
contacts.
Notice that the outer end of the outer phase have
washers with a larger diameter, see Fig. 18.
Do the same for the contacts on the opposite side.
Pull out shaft 1. Take care of the silver washers. Do the same
with shaft 3. Punch out the middle shaft 2 by means of a
5 mm mandrel of brass. Shaft 2 must then be passed through
the holes for shafts 1 or 3 and remain there until new contacts
are mounted.
Repeat the procedure for the contacts on the opposite side.
Board
Guide
pin
Locking
washer
Fig. 16. Contact replacement, dismantling the boards.
Screw
Fig. 17. Contact replacement, boards lifted away.
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 29
Contact
Washer with
larger diameter
Shaft 1
Shaft 2
Fig. 18. Contact replacement, taking away split pins.
Contact
Shaft 1
Fig. 19. Contact replacement, pulling out shaft.
30 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
Shaft 3
4.3 Dismantling the moving transition contacts
Dismantling of the moving transition contacts should be
carried out according to Figs. 20 and 21.
The transition contacts are held by a common shaft 4 going
through all the contacts.
The shaft 4 is locked with two split pins (Fig. 21). Remove
the split pins and punch out the shaft with a 5 mm mandrel
of brass and take care of the springs, washers and contacts
when the mandrel is pulled out.
Shaft 4
The springs in view A – A, are loosened in the following way:
Punch out the locking pin in one end of the pin with a 2 mm
mandrel. Thereafter the spring holder can be loosened and
the contacts with springs can be removed. Take care of the
pin.
Repeat the above procedure on the other side of the diverter
switch.
Fig. 20. Contact replacement, moving transition contacts.
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 31
4.4 Mounting the moving transition contacts
Mount the moving transition contacts according to Fig. 21.
A replacement contact consists of a contact with mounted
spring.
Punch the shaft through the first bearing hole and put a
contact, spring, insulating washer and another contact on
the shaft as it is continuously punched in. Then proceed with
the next phase. Finally lock it with new split pins. Mount the
springs by means of the pin and new locking pins.
Proceed with the other side of the diverter switch. Put a ruler
on the linings of the tran-sition contacts. No lining should lie
more than 1 mm from the ruler.
If any lining does, adjust these contacts closer to the board
by filing off material on the surface of the contact that lies
against the stop shaft.
When all transition contacts on both sides are mounted, make
sure that the contacts move easily in the bearings and that
the springs are functioning.
Split pins
A
A
Shaft
Spring
Washer
(insulating)
Pin
Contact
Spring
Locking pin
View A - A
Fig. 21. Transition contact construction.
32 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
4.5 Mounting the moving main contacts
Fig. 22 shows how to mount the moving main contacts,
and how to place washers and springs. The contacts are
equipped with copper-tungsten tips.
Proceed with the outer phases. Put the outermost silver
washer and contact on the shaft and punch the shaft into
the bearing hole. Put the next silver washer and contact into
position and punch in the shaft. Mount washers, springs
and split pins. Check that all containing details are correctly
assembled.
CAUTION
The outer end of the outmost phases should have the
washers with larger diameter, (Ø=25 mm) see Fig. 22.
View A – A shows the replacement contact which consist of
two contacts with a mounted spring, mounted on the current
bridge.
Begin with the middle phase. Put the contact and the silver
washers on the shaft and punch the shaft in to the bearing
hole with the 5 mm mandrel. Put the next silver washer and
contact in position and punch in the shaft. Mount washers,
springs and split pins.
Put a ruler on the linings of the moving main contacts. No
lining should lie more than 1 mm from the ruler.
If any lining does, adjust these contacts closer to the board
by filing off material on the surface of the contact that lies
against the stop shaft.
Carry out the same procedure on the other side of the diverter
switch.
A
Washer with
larger diameter
Contact
Contact
Silver
washers
Spring
A
View A - A
Split pin
Insulating washer
Spring
Steel washer
Fig. 22. Moving main contacts with tips of copper-tungsten, washers and springs.
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 33
4.6 Replacing the fixed main contacts
Unscrew the fixed main contacts, see Fig. 15. Mount new
contacts. Use new conical spring washers and locking nuts.
Put the washers as shown in the figure. Press the contacts
against their bracket when tightening the screws. Tightening
torque approximately 10 Nm, (not critical).
Check that the linings of the fixed main contacts are aligned
with the linings of the moving main contacts. If not, loosen
the nuts slightly and adjust the fixed main contacts. Tighten
the nuts. Check (and adjust, if necessary) the alignment of
the transition contacts as described for the main contacts.
Tighten the screws and lock the locking washers.
Proceed with the other side of the diverter switch by first
operating it to the other side as described in section 3.9.
The conical end of the nut should be turned upwards.
4.7 Replacing the fixed transition contacts
Unscrew the screw and nut holding the connection for the
transition resistors.
WARNING
Take care to avoid finger injuries when operating the
diverter switch.
Unscrew the fixed transition contact. Mount new contacts.
Put the washers as shown in Fig. 15. Use new locking
washers. Tighten the screws, tightening torque approximately
10 Nm.
Check (and adjust, if necessary) the diverter switch according
to section 3.9. Operate it and check that the contact
movement is correct. Remount the diverter switch into the
housing according to section 3.13.
Mount the connection for the transition resistors. Tightening
torque approximately 10 Nm. Use new conical spring washers
and locking nuts.
The conicial end of the nut should be turned upwards.
4.8 Mounting the boards with transition resistors and
fixed contacts
To assemble the mechanism and the boards with transition
resistors and fixed contacts, do as follows:
Fixed
main
contact
When the boards are lowered, put one side of the mechanism
on an approximately 50 mm high piece of wood to make the
fixed and moving contacts free from each other (Fig. 23).
Moving
main
contact
The boards should be fixed with new guide pins (4 x 30 mm,
spring-type straight pin slotted). Guide by inserting a 6 mm
mandrel into an adjacent screw hole. Put in and tighten
all screws. Secure the screws with new locking washers
(Fig. 18). The plain washers should be closest to the board.
Piece of
wood
Fig. 23. Contact replacement, mounting the boards.
34 Maintenance guide UCG | 1ZSE 5492-124 en, Rev 6
5. Specification of materials
5.1 General
On disposal of this product, it is recommended that local
environmental regulations in each country are met. For
environmental reasons, materials used are specified.
5.5 Conductors
Material
Approx. amount
Copper
5–10 kg
Cellulose
5.2 Diverter switch housing
5.6 Gearing mechanism
Material
Approx. amount
Steel
15 kg
Material
Approx. amount
Aluminium
75 kg
Steel
15 kg
Copper and alloys
5 kg
Copper and alloys
5 kg
Epoxy resin
35 kg
Transformer oil
150–200 kg
5.7 Drive shaft systems
5.3 Diverter switch
Material
Approx. amount
Steel
8 kg
Material
Approx. amount
Aluminium
2 kg
Steel
25 kg
Brass
2 kg
Copper and alloys
10 kg
Polyethylene
2 kg
Silver
25 g
Tungsten
0–1 kg
Polyester resin
20 kg
Presspan
1 kg
Resistor wire (mainly copper and
5-50 kg
CAUTION
Materials listed in the table above without any
specification of amount are included because
they may cause pollution problems during decommissioning, even in the small quantities used.
nickel alloys with small amounts
of aluminium and manganese)
5.4 Tap selectors
Material
Tap selector C
Tap selector III
Approx. amount
Approx. amount
Steel
5 kg
10 kg
Aluminium
15 kg
40 kg
Copper and alloys
20 kg
50 kg
Silver
70 g
10 g
Polyester resin
5 kg
10 kg
Epoxy resin
15 kg
20 kg
1ZSE 5492-124 en, Rev. 6 | Maintenance guide UCG 35
ABB AB
Components
SE-771 80 Ludvika, Sweden
Phone: +46 240 78 20 00
Fax:
+46 240 121 57
E-Mail: [email protected]
www.abb.com/electricalcomponents
© Copyright 2015 ABB, All rights reserved. 1ZSE 5492-124 en, Rev. 6, 2015-09-15
Contact us
1ZSC000498-ABH en, Rev. 1
Motor-drive mechanisms,
types BUE and BUL2
Maintenance guide
Original instruction
The information provided in this document is intended to be general and does not
cover all possible applications. Any specific application not covered should be
referred directly to ABB or its authorized representative.
ABB makes no warranty or representation and assumes no liability for the
accuracy of the information in this document or for the use of such information. All
information in this document is subject to change without notice.
This document must not be copied without our written permission, and the contents
thereof must not be imparted to a third party nor be used for any unauthorized
purpose. Contravention will be prosecuted.
Recommended practices
ABB recommends careful consideration of the following
factors when installing on-load tap-changers:
Before you install or commission a unit, make sure that the
personnel doing the job have read and fully understood the
Installation and commissioning guide provided with the unit.
To avoid damaging the unit, never exceed the operating limits
stated in delivery documents and on rating plates.
Do not alter or modify a unit without first consulting ABB.
Follow local and international wiring regulations at all times.
Use only factory-authorized replacement parts and
procedures.
WARNING, CAUTION and INFO
WARNING
WARNING indicates an imminently hazardous
situation which if not avoided, will result in death or
serious injury. This signal word is to be limited to the
most extreme situations.
Safety precautions
WARNING
The maintenance guide should be read and
understood before any work is started, and the
procedures in the document should be followed at all
times.
WARNING
Before starting any work inside the motor-drive
mechanism, the auxiliary power must be switched off.
N.B. The motor, the contactors and the heating
element may be energized from separate sources.
During service
WARNING
Small amounts of explosive gas might come out
from the breathing devices (dehydrating breather
or one-way breather). Make sure that no open
fire, hot surfaces or sparks occur in the immediate
surroundings of the breathing devices.
WARNING
WARNING also indicates a potentially hazardous
situation which if not avoided, could result in death or
serious injury.
If a failure in power supply occurs during operation,
the operation will be completed when the power
returns.
CAUTION
WARNING
CAUTION indicates a potentially hazardous situation
which if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe
practices.
The hand crank must not be inserted during electrical
operation.
WARNING
CAUTION may also indicate property-damage-only
hazards.
INFO provides additional information to assist in
carrying out the work described and to provide
trouble-free operation.
If the tap-changer is not in its exact position and the
hand crank is pulled out, the motor-drive mechanism
will start and run to the exact position if the power
supply is on.
Content
1. Introduction...........................................................................................................................7
1.1 General .........................................................................................................................7
1.2 Design...........................................................................................................................7
1.3 Legend..........................................................................................................................7
2. Inspection..............................................................................................................................12
2.1 Required tools and material...........................................................................................12
2.2 Procedure......................................................................................................................12
3. Overhaul................................................................................................................................13
3.1 Required tools and materials..........................................................................................13
3.2 Motor protection............................................................................................................13
3.3 Ground fault protector (option).......................................................................................13
3.4 Counter.........................................................................................................................13
3.5 Heater............................................................................................................................13
3.6 Toothed belt...................................................................................................................14
3.7 Motor cable connections...............................................................................................14
3.8 Overhaul type BUE........................................................................................................14
3.8.1 Disc brake...............................................................................................................14
3.8.2 Brake for the holding contact...................................................................................15
3.8.3 Position transmitter and other position switches......................................................15
3.8.4 Lubrication..............................................................................................................15
3.9 Overhaul type BUL2.......................................................................................................17
3.9.1 Disc brake...............................................................................................................17
3.9.2 Position the transmitter and other position switches................................................17
3.9.3 Lubrication..............................................................................................................17
3.10 Operation test..............................................................................................................18
4. Specification of materials.......................................................................................................19
1. Introduction
1.1 General
The motor-drive mechanisms, types BUE and BUL2,
manufactured by ABB, have been developed over many years
to provide maximum reliability. The simple and robust design
gives a service life equal to the service life of the transformer.
Minimum maintenance is required for trouble-free operations.
The motor-drive mechanism is attached to the transformer
tank and connected to the on-load tap-changer by means of
drive shafts and a bevel gear.
1.2 Design
The design and layout of the motor-drive mechanisms are
shown in Figs. 1 and 2 (BUE) and Figs. 3 and 4 (BUL2).
1.3 Legend
Towards motor-drive upper limit
Towards motor-drive lower limit
LOCAL control
REMOTE control
1ZSC000498-ABH en, Rev. 1 | Maintenance guide BUE/BUL2 7
1
3
2
8
4
6
5
7
9
10
11
8
12
15
14
13
16
Fig. 1. Cabinet layout of motor-drive mechanism, type BUE.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Locking device prepared for padlock
Emergency stop
Air vent
LOCAL/REMOTE switch
RAISE/LOWER switch
Outgoing shaft
Lamp (40 W socket E27)
Lifting eye
Counter
8 Maintenance guide BUE/BUL2 | 1ZSC000498-ABH en, Rev. 1
10. Tap-change in progress indicator
11. Position indicator with drag hands for max. and min.
position
12. Shaft for hand crank
13. Protective motor switch
14. Door-operated switch for lamp
15. Hand crank
16. Descriptions and circuit diagram
Brake
Brake disc
Holding contact
Roll pin
Supporting
shaft
Brake block
Arm system
Brake for holding contact
Drive roller
Cam disc
One turn shaft
Toothed belt
Geneva wheel
Position
transmitter
Contact plate
Motor
Fig. 2. Mechanical design of motor-drive mechanism, type BUE.
1ZSC000498-ABH en, Rev. 1 | Maintenance guide BUE/BUL2 9
1
2
14
4
3
5
12
6
8
7
16
9
10
11
13
15
6
Fig. 3. Cabinet layout of motor-drive mechanism, type BUL2.
1.
2.
3.
4.
5.
6.
7.
Position indicator with drag hands for max. and min.
position
Tap-change in progress indicator
(Red: in progress, White: in position)
Counter
Outgoing shaft with multi-hole coupling half
Shaft for hand crank
Locking device prepared for padlock
(Option) Outlet
10 Maintenance guide BUE/BUL2 | 1ZSC000498-ABH en, Rev. 1
8.
9.
10.
11.
12.
13.
14.
15.
16.
Emergency stop
RAISE/LOWER switch
LOCAL/REMOTE switch
Protective motor switch
Air vent
Door-operated switch for lamp
Lamp
Descriptions and circuit diagram
Hand crank
Operation counter
Roller
(Grease)
Notch
Cam disc
(Grease)
Brake arm
Geneva wheel
Adjusting
screw
Holding
contact
(Grease)
Bracket
Brake disc
Limit switch
Toothed belt
Multi-position switches
(Grease)
Fig. 4. Mechanical design of motor-drive mechanism, type BUL2.
1ZSC000498-ABH en, Rev. 1 | Maintenance guide BUE/BUL2 11
2. Inspection
The inspection mainly consists of a visual check of the
motor-drive mechanism once a year while the transformer is
in service. It is recommended to perform the inspection of
the motor-drive mechanism and the other parts of the tapchanger at the same time. See the respective maintenance
guide.
2. Check that the motor works properly, the position indicator
increases (decreases) one step and the counter advances
one step for each operation. Record the counter’s value.
The counter shows the number of operations run by the
tap-changer (the overhaul schedule can be determined
with the help of this information).
In the motor-drive mechanism, the following points are to be
checked:
3. Turn the control switch to the LOWER (RAISE) position for
1-2 seconds. Check that the motor also works properly in
that direction, the position indicator decreases (increases)
one step and the counter advances one more step. Reset
the drag hands.
––
––
––
––
Motor and counter
Heater
The counter’s value
Visual check of toothed belt
2.1 Required tools and material
The following equipment is required for the inspection:
– – Set of screw drivers
4. Check the emergency stop. Trigger a RAISE or LOWER
impulse and after about one second, press the emergency
stop. The operation should be interrupted. Reset the
emergency stop by turning the knob clockwise and by
switching on the protective motor switch. The started
operation should now be completed. Operate back to the
service position.
2.2 Procedure
WARNING
This work must be carried out from ground level since
the transformer is energized!
5. Check the ground fault protector (option).
If the motor-drive mechanism is equipped with an outlet,
the ground fault protector should be tested by pressing
the test knob on the outlet.
6. Disconnect the incoming auxiliary power.
WARNING
7. Open the control panel.
Before starting any work inside the motor-drive
mechanism, the auxiliary power must be switched off.
N. B. The motor, contactors and heating element may
be energized from separate sources.
1. Open the cabinet door of the motor-drive mechanism and
turn the selector switch to the LOCAL position. Then turn
the control switch to the RAISE (LOWER) position.
12 Maintenance guide BUE/BUL2 | 1ZSC000498-ABH en, Rev. 1
8. Check by feeling with a finger that the elements have been
functioning.
9. Close the control panel and reconnect the incoming
auxiliary power.
10. Complete the inspection by turning the switch to the
REMOTE position and closing the cabinet door.
3. Overhaul
WARNING
Before any work is carried out on the tap-changer:
Make sure that the transformer is disconnected and
that grounding is properly carried out. Obtain a signed
certificate from the engineer in charge.
3.1 Required tools and materials
Necessary for the overhaul is the following equipment:
––
––
––
––
––
Normal hand tools (wrench sizes up to 19 mm)
Standard set of combination wrenches
Sliding caliper
Spring balance (10 N)
Grease (GULF-718 EP synthetic grease, Mobilgrease 28,
Shell-Aero Shell grease 22 or similar
– – Oil (for plain ball and roller bearings)
The motor-drive mechanism should normally be regularly
overhauled at intervals of 300,000 operations. The number
of operations must not exceed 1,500,000, which is the
mechanical lifetime of the motor-drive mechanism.
It is recommended to perform the overhaul of the motor-drive
mechanism and the other parts of the tap-changer at the
same time. See the appropriate maintenance guide for the
tap-changer.
3.2 Motor protection
WARNING
The motor power voltage is dangerous.
The function of the protective motor switch is checked. For
three-phase AC motors, one of the phase fuses is removed
and the function time of the protective motor switch is
checked by a RAISE or LOWER operation. The protective
motor switch shall release within 60 seconds at a current
setting equal to the rated current of the motor at actual
voltage.
If the protective motor switch does not trip within 60 seconds,
switch off the power and adjust the current setting. Repeat
the test when the motor is cold.
Protective motor switches for DC motors and for single-phase
AC motors are not tested.
3.3 Ground fault protector (option)
If the motor-drive mechanism is equipped with an outlet, the
ground fault protector should be tested by pressing the test
knob on the outlet.
The overhaul includes the following points:
3.4 Counter
Check that the counter is functioning for RAISE and LOWER
operations.
Before disconnecting the power supply:
– – Motor protection function (Section 3.2)
–– Ground fault protector (option) (Section 3.3)
– – Counter function (Section 3.4)
Check that the position indicator increases (decreases) one
step and the counter advances one step for each operation.
Record the counter's value. The counter shows the number of
operations run by the tap-changer.
After disconnecting the power supply:
– – Heater function (Section 3.5)
– – Toothed belt (Section 3.6)
– – Cable connections (Section 3.7)
– – Disc brake function (Section 3.8.1 for BUE; Section 3.9.1
for BUL2)
– – Position transmitter and other position switches
(Section 3.8.3 for BUE; Section 3.9.2 for BUL2)
– – Lubrication (Section 3.8.4 for BUE; Section 3.9.3 for BUL2)
3.5 Heater
Reconnect the power supply and carry out operation tests
according to the instructions in the tap-changer installation
guide.
WARNING
Before starting any work inside the motor-drive
mechanism, the auxiliary power must be switched off.
N. B. The motor, contactors and heating element may
be energized from separate sources.
Check by feeling with a finger that the elements have been
functioning.
1ZSC000498-ABH en, Rev. 1 | Maintenance guide BUE/BUL2 13
3.6 Toothed belt
Check that the toothed belt is sufficiently tight. If tightening
is required, adjust the motor support. The tightness of the
belt can be checked by a spring balance attached to the belt
halfway between the pulleys (see Fig. 5). At a 10 N load the
belt should yield about 5 mm on BUE, and at a 6 N load the
belt should yield about 2 mm on BUL2.
3.7 Motor cable connections
Check that all cable connections within reach are secure.
3.8 Overhaul type BUE
3.8.1 Disc brake
Wipe the brake disc free from grease.
See Fig. 6. The kinetic energy in the motor and the toothed
wheels should be absorbed by the brake, and the motordrive mechanism should stop with a tolerance of ± 25° as
measured on the brake disc (± 125° measured on the hand
crank).
This can be adjusted by tightening both of the spring bolts
on the brake. Using the hand crank, operate the motor-drive
mechanism until the brake is fully open. At this point the
length of the springs must not be less than 35 mm. If the
brake still does not function with that spring length, oil or
grease has entered the brake linings, which will then need
cleaning.
Yield
Clean as follows: Using a pair of tongs, remove the roll pins
that hold the supporting shafts on the brake blocks; see
Fig. 2. Then remove the shaft and the brake blocks. Clean the
brake linings on the two brake blocks with degreasing agent.
Apply load
Fig. 5. Check of toothed belt.
When refitting the brake, check that the brake disc is
completely free from grease. Adjust the spring force of the
brake until the motor-drive mechanism stops within the
tolerances given above.
Adjusting nuts
Brake disc
Red mark ±25°
from mark on
brake pad
Red mark
Brake pads
Fig. 6. Brake adjustment, type BUE.
14 Maintenance guide BUE/BUL2 | 1ZSC000498-ABH en, Rev. 1
CAUTION
If the motor-drive still does not stop when the brake is
adjusted to a spring length of 35 mm when the brake
is fully open, please contact ABB for advice.
3.8.2 Brake for the holding contact
Check that the brake for the holding contact prevents the arm
system on the holding contact shaft from swinging beyond its
normal position when the roller on the drive arm moves free
from the cam disc; see Fig. 2. At the end of the operation,
contacts for operation in the opposite direction should not
move when the arm system swings back towards its normal
position.
Unpermitted swinging should be prevented by raising the
braking force, i. e. tightening the spring bolt.
An adjusted, increased spring force on the brake makes the
holding contact arm swing back with a different speed, and
the brake for the holding contact must be adjusted.
3.8.3 Position transmitter and other position switches
Clean the contact plates and arms (Fig. 7) from dust and dirt
with a dry cloth.
Check and adjust the resilience of the moving contacts in
the multi-position switches. The moving contact shall in all
positions, have a clearance between the nut and the contact
arm of 0.5–1.1 mm. Adjustment is made with the nuts on the
contact.
3.8.4 Lubrication
See Fig. 8. The bearing points of the brake blocks and the
links should be sparingly lubricated with oil. (Use oil for plain
ball and roller bearings.)
The spur gears, the Geneva wheel with the limit-stop, the
cam discs, the cam bar and the big wheel attached on the
outgoing shaft, are sparingly lubricated with the same type of
grease as for the shaft system when necessary.
Other bearing points do not need lubrication.
Protect the brake disc and the brake linings against
lubricants. Wipe off excess lubricant.
Reconnect the power supplies.
Contact arm
Moving contact
Contact arm
+0.3
0.8 mm
-0.3
Geneva wheel
Contact plate
Fixed contact
View A – A
Fig. 7. Contact arm play.
1ZSC000498-ABH en, Rev. 1 | Maintenance guide BUE/BUL2 15
Grease
Grease
Oil
Oil
Grease
Grease
NOTE: The small bevel gear
for the position indicator shaft
must be greased.
Grease
Fig. 8. Lubrication points, type BUE.
16 Maintenance guide BUE/BUL2 | 1ZSC000498-ABH en, Rev. 1
3.9 Overhaul type BUL2
3.9.1 Disc brake
Run the motor-drive mechanism and check that the center
of the notch in the cam disc stops within ±2 mm from the
center of the roller on the brake arm, see Fig. 9. If it does not
stop within the tolerances, adjust the braking force with the
adjusting screw at the lower end of the brake arm. Loosen
the contra nut. Tightening the screw (clockwise) makes the
stop occur earlier and loosening the screw (counterclockwise)
makes the stop occur later. Tighten the contra nut after the
adjustment.
CAUTION
3.9.3 Lubrication
Lubrication is not needed under normal operating conditions.
All ball bearings have rubber seals and are permanently
lubricated. All cam discs and some gears are made of selflubricating material.
If needed, the gear for the outgoing shaft, the bevel gears
for the hand crank, the Geneva wheels and the bevel gears
for the position indicator can be sparingly lubricated with the
same grease as for the shaft system. (GULF-718EP Synthetic
Grease, Mobilgrease 28, Shell-Aero Shell Grease 22 or
similar). See Fig. 4.
Reconnect the power supplies.
If the motor-drive still does not stop when the brake
is adjusted to min. 15 mm according to Fig. 9, please
contact ABB for advice.
3.9.2 Position the transmitter and other position switches
Check the contact function in all positions for both RAISE and
LOWER operations.
Transparent
cover
Contact arm
Circuit
board
No adjustment of the contacts should be made.
If there is excessive dust, it can be removed from the circuit
boards and the transparent covers with a vacuum cleaner
without disassembling the multi-position switch.
Fig. 10. Check of position transmitter.
Roller on the brake arm in center
of the notch in the cam disc
Brake arm
Cam disc
Contra nut
Adjusting screw
Brake disc
Min. 15
Fig. 9. Brake adjustment, type BUL2.
1ZSC000498-ABH en, Rev. 1 | Maintenance guide BUE/BUL2 17
3.10 Operation test
Operate the motor-drive mechanism, first with manual
operation and then electrically between the limit-positions.
Check the limit-stops by operating the tap-changer to one
of the end-positions. When trying to operate it electrically
beyond the end-position, the motor should not start. Check
the mechanical end-stop by trying to hand crank it beyond
the end-position. After a couple of turns on the hand crank,
it should be mechanically stopped. Hand crank back to the
end-position (where the indicator flag is positioned in the
middle for the BUE, and when the indicator flag shows white
color for the BUL2). Operate the tap-changer electrically to
the other end-position and carry out the same test procedure
as above.
Check the emergency stop by triggering a RAISE or LOWER
impulse and after about one second, press the emergency
stop. The operation should be interrupted. Reset the
emergency stop by turning the knob clockwise and switch
on the protective motor switch. The started operation should
now be completed.
Check the run-through protection with the step-by-step
function disengaged. This is done by first removing the
connection between terminals X4:1 and X4:2 and then
keeping the RAISE/LOWER switch engaged. The motordrive mechanism should stop before the fourth operation is
completed. This check must be performed at least five steps
from the end-position. After the test, reset the time relay by
setting the LOCAL/REMOTE switch to 0 and then back. Reset
the protective motor switch to ON. Reconnect the connection
between X4:1 and X4:2.
Check the step-by-step relay by keeping the RAISE/LOWER
switch engaged in RAISE. The tap-changer shall advance only
one step. Repeat the check for LOWER.
Check the function of the position transmitter and other multiposition switches in all positions.
18 Maintenance guide BUE/BUL2 | 1ZSC000498-ABH en, Rev. 1
4. Specification of materials
BUE
BUL
BUL2
Approx.
Approx.
Approx.
amount
amount
amount
Steel
100–120 kg
55 kg
25 kg
Aluminium and alloys
–
10 kg
5 kg
Copper and alloys
5–10 kg
5 kg
65 kg
Silver
10 g
10 g
x
x
x
x
x
x
Material
Plastics:
chlorsulphonated
polyethylene
polyamide with MoS2
phenol resin laminate
x
polyester
x
x
x
PVC
x
x
x
carbonate plastic
x
x
x
nitrile rubber
x
x
x
fluorine rubber
x
x
x
Rubbers:
CAUTION
Materials listed in the table above without any
specification of amount are included because
they may cause pollution problems during decommissioning, even in the small quantities used.
1ZSC000498-ABH en, Rev. 1 | Maintenance guide BUE/BUL2 19
ABB AB
Components
SE-771 80 Ludvika, Sweden
Phone: +46 240 78 20 00
Fax:
+46 240 121 57
E-Mail: [email protected]
www.abb.com/electricalcomponents
© Copyright 2012 ABB, All rights reserved. 1ZSC000498-ABH en, Rev. 1, 2012-11-15
Contact us
2750 515-1 EN, REV. 13, 2019-05-22
Transformer bushing, type GOE 250 to 2550
Installation and commissioning guide
The information contained in this document may be subject to change without prior warning and should not be considered
as binding on ABB AB’s behalf. ABB AB accepts no liability for any errors that may appear in this document. ABB AB is
not liable for any damage resulting from the incorrect interpretation of this document. This document, or parts thereof, may
not be reproduced or copied without ABB AB’s consent. It may not be distributed to others, or used by unauthorized
parties. Any breaches to the above will be penalized with the support of applicable laws.
Contents
1
2
3
4
Safety
Levels of safety risks ................................................................................................................................................................... 5
1.2
Hazardous working situations ..................................................................................................................................................... 6
1.3
Safety precautions....................................................................................................................................................................... 6
1.4
Competence level........................................................................................................................................................................ 6
Product description
7
2.1
Design ......................................................................................................................................................................................... 7
2.2
Technical specification................................................................................................................................................................. 12
2.2.1
General specifications ............................................................................................................................................... 12
2.2.2
Mechanical loading.................................................................................................................................................... 12
Delivery
15
3.1
Incoming inspection..................................................................................................................................................................... 15
3.2
Transportation ............................................................................................................................................................................. 15
3.3
Storage ........................................................................................................................................................................................ 15
3.4
Lifting ........................................................................................................................................................................................... 16
3.4.1
Lifting the transport box ............................................................................................................................................. 16
3.4.2
Lifting the bushing out of the transport box ............................................................................................................... 17
Installation
19
4.1
Tools ............................................................................................................................................................................................ 19
4.2
Consumables .............................................................................................................................................................................. 19
4.3
Preparations ................................................................................................................................................................................ 20
4.3.1
Lifting the bushing ..................................................................................................................................................... 20
4.3.2
Oil-filling of the bushing for horizontal installation ..................................................................................................... 22
4.4
Horizontal installation of the bushing on the transformer ............................................................................................................ 24
4.5
Installation with draw lead ........................................................................................................................................................... 26
4.6
4.7
5
5
1.1
4.5.1
Calculation of the lenght of the draw lead ................................................................................................................. 26
4.5.2
Installation with draw lead ......................................................................................................................................... 27
Installation with draw rod at transformer factory.......................................................................................................................... 32
4.6.1
Removal of the lower draw rod with bottom contact from the bushing ..................................................................... 32
4.6.2
Installation of the small bottom contact in the transformer ........................................................................................ 36
4.6.3
Installation of the large bottom contact in the transformer ........................................................................................ 38
4.6.4
Installation of the bushing on the transformer ........................................................................................................... 40
Installation with draw rod at site .................................................................................................................................................. 44
4.7.1
Preparations at site ................................................................................................................................................... 44
4.7.2
Installation of the bushing on the transformer at site................................................................................................. 47
4.8
Hydraulic tightening of the draw-rod nut...................................................................................................................................... 51
4.9
Manual tightening of the draw-rod nut ......................................................................................................................................... 55
4.10
Oil-filling....................................................................................................................................................................................... 57
4.11
Installation of the outer terminal .................................................................................................................................................. 58
4.12
Grounding of the bushing flange ................................................................................................................................................. 61
Commissioning
63
5.1
Waiting time before energization ................................................................................................................................................. 63
5.2
Recommended test before energization ..................................................................................................................................... 64
5.2.1
Overview ................................................................................................................................................................... 64
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
3
6
8
9
10
Tightness test of bushing outer terminal.................................................................................................................... 64
5.2.4
Measurement of capacitance and dissipation factor ................................................................................................. 65
5.2.5
Measurement of through-resistance.......................................................................................................................... 68
69
Recommended maintenance ...................................................................................................................................................... 69
Re-packing
73
7.1
Removal of horizontally installed bushings ................................................................................................................................. 73
7.2
Removal of the bushing from the transformer, draw rod ............................................................................................................. 74
7.3
Re-packing of the bushing........................................................................................................................................................... 78
Spare parts and special tools
79
8.1
Summary ..................................................................................................................................................................................... 79
8.2
Spare parts .................................................................................................................................................................................. 79
8.3
Special tools ................................................................................................................................................................................ 81
Disposal and environmental information
83
9.1
Overview ..................................................................................................................................................................................... 83
9.2
Disposal and recycling ................................................................................................................................................................ 83
References
10.1
4
Tightness test between transformer and bushing flange........................................................................................... 64
5.2.3
Maintenance
6.1
7
5.2.2
85
Summary ..................................................................................................................................................................................... 85
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
1 Safety
1.1 Levels of safety risks
Throughout the manual, various types of safety risks are indicated. The most serious level on this scale
provides a warning about serious personal injury or possible death, or major damage to a product, if the
instructions are not observed.
Symbols and their meanings
The following describes the symbols that appear in the manual, along with their meaning.
DANGER!
The yellow, filled warning triangle warns that an accident will occur if the instructions are not
complied with and that it will result in serious personal injury or death and/or major damage to the
product.
It is used, for example, to warn of such dangers as: contact with high voltage, explosion or fire
risk, risk for toxic gases, risk of crushing, impacts, falls from high places, etc.
CAUTION!
The round warning symbol warns that an accident could occur if the instructions are not observed,
and that this could result in personal injury and/or damage to the product.
It is also used to warn of risks that entail burns, eye or skin injuries, impaired hearing, crushing or
slipping injuries, tripping, impacts, falls from high places, etc.
In addition, it is used to warn of functional requirements when assembling or removing equipment
where there is a risk of damage to the product or downtime.
NOTE!
The comment symbol identifies important information and conditions. Also used to indicate any
danger that could lead to property damage.
Torque
The torque symbol indicates tightening torque.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
5
1.2 Hazardous working situations
Hazard
Action
Working close to high voltage.
Disconnect all plant power. Ground all objects at the workplace.
If work must be done close to live plant components, make sure that
the safety distance is in compliance with the applicable safety
regulations.
Working on ladders and platforms.
Work must be done in accordance with the applicable safety
regulations.
Do not use ladders or platforms in poor weather conditions.
Working with heavy objects.
Do not walk under lifted objects.
Make sure that heavy objects are stable before starting work.
1.3 Safety precautions
Precaution
Action
Transformer oil
Collect used transformer oil in drums.
Transformer oil is dangerous. Fumes from hot oil can cause irritation
to the respiratory organs and the eyes. Long and repeated contact
with transformer oil can cause damage to your skin.
Waste and cleaning up
Clean up liquid waste with an adsorbent. Treat waste as hazardous
to the environment.
Fire
Extinguish fires with powder, foam or carbon dioxide.
1.4 Competence level
Installation of the bushing should only be performed by authorized personnel.
CAUTION!
Incorrect installation can lead to catastrophic failure of the transformer.
6
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
2 Product description
2.1 Design
Overview
The GOE is a capacitance graded oil impregnated paper bushing made for immersed oil/air service.
For a detailed description, please refer to the Technical guide, 1ZSE 2750-105.
G001889
General schematics
1
Top housing
2
Porcelain insulator, air side
3
Test tap
4
Extension for current transformer
5
Porcelain insulator, oil side
6
Bottom nut
7
Mounting flange
8
Oil sampling valve
9
Oil plug
10
Oil-level gauge, GOE 1050 to 2600
11
Lifting eye
12
Sight glass, GOE 250 to 950
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
7
Terminal system
The bushing can be configured with one of two terminal systems: the draw-lead system, or the draw-rod
system.
The draw-rod system can be configured with a small, or a large bottom contact.
Terminal system
Option
Draw-lead system
-
Draw-rod system
Small bottom contact
G004488
Large bottom contact
8
A
Draw-lead system
B
Draw-rod system with small bottom contact, N1 = 4
C
Draw-rod system with large bottom contact, N1 = 6
1
Inner terminal
2
Draw lead
3
Draw rod
4
Small bottom contact, N1 = 4
5
Large bottom contact, N1 = 6
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Draw-rod system
The draw rod can be configured with an optional joint (3) to fit transformers with short bushing turrets.
The bottom-contact joint (6) is locked with threadlocking fluid as standard, but can be unlocked as an option.
G006279
Large bushings with long draw rods have one or two upper joints (1), they are always locked with
threadlocking fluid. All joints must be locked with threadlocking fluid when the bushing is in operation
at site.
1
Upper joint (only on large bushings).
2
Lower joint (at flange level).
3
Additional joint (option).
4
Thread is locked with threadlocking fluid.
5
Thread is NOT locked with threadlocking fluid.
6
Bottom-contact joint, locked with threadlocking fluid. Unlocked as option.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
9
Horizontal installation
CAUTION!
Do not install bushings that does not have the oil passage (2) in the horizontal position.
If the bushing will be installed in the horizontal position, then this must be specified in the order. Because
horizontally installed bushings must be fully filled with oil (there is no expansion space for the oil), the oil
must flow freely to and from the transformer tank through an oil passage (2).
The bushing is delivered with expansion space for the oil, and the bushing must be filled at installation.
G004983
When the bushing is delivered, the oil passage (2) is covered with a covering plate (1) and a rubber gasket.
This configuration makes sure that it will be removed at installation on the transformer.
10
Type
Dimension A (mm)
GOE 250 - GOE 450
55
GOE 550 - GOE 950
60
GOE 1050 - GOE 1175
67
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Test tap
The bushing has a test tap that is connected to the outermost conductive layer of the condenser core. The test
tap is used to measure the bushing insulation by capacitance and dissipation factor. The cover connects the
outermost conductive layer to ground, and must always be installed when the bushing is energized.
The maximum one minute test voltage for this test tap is 20 kVrms. The test tap can be used as a power
source, if it is connected to an external capacitance. The operating voltage is limited to 6 kV.
G000388
CAUTION!
Do not energize the bushing without a test adapter or the cover installed. The bushing is grounded
through the cover to prevent damage to the bushing.
1
Stud
2
Cover
3
Grounding spring
4
O-ring
Test adapter, 2769 522-C, optional equipment
G003049
The test adapter 2769 522-C is available for permanent connection to measuring circuits.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
11
2.2 Technical specification
2.2.1 General specifications
Refer to the table for the standard technical specifications of the bushing. For conditions exceeding the
specifications, please contact ABB.
Application:
Transformers/reactors
Classification:
Tranformer bushing
•
Oil impregnated paper, capacitance graded, oil immersed.
•
For outdoor and indoor use.
Ambient temperature limits:
-50 °C to +40 °C, limit temperatures, according to temperature
class 2 of IEC 60137.
Maximum altitude of site:
1000 m (Bushings for other altitudes can be provided on
request.)
Level of rain and humidity:
1-2 mm rain/minute horizontally and vertically, according to
IEC 60060-1 and IEEE Std 4.
Maximum pollution level:
According to the specific creepage distance, and IEC 60815.
Immersion medium:
Transformer oil.
•
Maximum daily mean oil temperature: +90 °C.
•
Maximum temporary oil temperature, at short time
overload: +115 °C.
Oil-level in transformer:
Not lower than 30 mm from the bushing flange.
Maximum pressure of medium:
pg 100 kPa (pg = relative to ambient pressure).
Angle of installation:
0 to 60° from vertical.
(GOE 1300, 1425 and 2550-1675 0° to 30°.)
Test tap:
Test tap with 8 mm male contact pin.
According to IEEE type A.
Conductor:
Center-tube conductor, or draw lead.
Markings:
Conforming to IEC/IEEE.
2.2.2 Mechanical loading
Maximum permitted static load on the outer terminal
The load must be applied below the midpoint of the outer terminal. The total cantilever load must be
perpendicular to the bushing axis. The bushing installation angle can be 0° – 60° from vertical.
Only bushings that are specefied for horizontal installation can be installed at 90° from vertical.
In the axial direction, the bushing can withstand a static load of 20 kN.
NOTE!
The loads described in this section are static loads, for dynamic loads such as earthquakes and
extreme wheather conditions, please contact your ABB sales representative.
12
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
G001888
1
Maximum cantilever load at installation angle 0°
2
Maximum cantilever load at installation angle 30°
3
Maximum cantilever load at installation angle 60°
4
Maximum axial static load
5
Load applied at the midpoint
Type
Test load 1
minute (N)
Maximum cantilever load in operation at
installation angle (N)
0°
30°
60°
Maximum
axial static
load (N)
GOE 250, 380, 650
5700
2800
2300
1700
20000
GOE 950
5000
2500
2000
1500
20000
GOE 1050
13000
6500
4300
3100
20000
GOE 1175
12000
6000
4300
3100
20000
GOE 1300, 1425
9000
4500
2500
-
20000
GOE 1550, 1675,
1800
13000
6500
4300
1500
20000
GOE 2550 - 1600
13000
6500
3700
1600
20000
GOE 2550 - 1675
12200
6100
2900
-
20000
Maximum permitted torque on the outer terminal
The maximum torque that is permitted on the outer terminal is 250 Nm.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
13
14
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
3 Delivery
3.1 Incoming inspection
•
•
Make sure that all items have been delivered, refer to the packing list.
Carefully inspect the bushings for shipping damage.
NOTE!
The bushing has been routine tested in oil, and there can be small quantities of oil remaining on
the oil-side of the bushing. Vaseline is used for lubrication of threads, and at some temperatures
Vaseline can appear as oil.
NOTE!
The oil-level is not shown correctly when the bushing is in the horizontal position.
3.2 Transportation
•
•
•
The bushing must be transported in the transport box.
The bushing must be transported in the horizontal position.
Carefully inspect the bushing for damage after transportation.
3.3 Storage
Short term storage, less than 6 months
•
•
•
The bushing can be stored outdoors, if it is in the transport box.
Keep the transport box protected from water, when the bushing is stored outdoors.
Keep the bushing dry, clean and protected against mechanical damage.
The bushing can be stored in both the vertical, and horizontal positions.
NOTE!
The oil-level is not shown correctly when the bushing is in the horizontal position.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
15
Long term storage, more than 6 months
•
The bushing can be stored outdoors, if it is in the transport box.
Keep the transport box protected from water, when the bushing is stored outdoors.
Keep the bushing dry, clean and protected against mechanical damage.
Lift the bushing to the vertical position with the top end upwards, and put it in a safe stand.
– As an alternative: keep the bushing in the transport box and lift it to an inclined position, with the
top end upwards and at an angle of at least 7°.
•
•
The bushing is delivered from ABB in a transport box, and the bushing is held in place by support blocks and
fiberboard in the box.
G005075
The transport box is marked with Top end, this identifies the end to lift when the bushing is in storage.
3.4 Lifting
3.4.1 Lifting the transport box
G003042
Overview
16
1
Center of gravity
2
Soft lifting slings
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Procedure
1.
Make sure that the crane and the soft lifting slings are approved for the total weight of the transport
box and bushing. Refer to the weight in the packing list.
2.
Attach soft lifting slings (2).
3.
Make sure that the angle of the soft lifting sling is not more than 20°.
4.
Carefully lift the transport box.
5.
Set down the transport box on a flat surface.
End of instruction
3.4.2 Lifting the bushing out of the transport box
G005004
Overview
1
Top end nut
Procedure
1.
Make sure that the crane is approved for lifting the weight of the bushing. Refer to the net weight on
the packing list.
2.
Open the transport box.
NOTE!
The cover is attached with bolts.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
17
3.
Remove the support blocks from the transport box and put them on the ground.
CAUTION!
Make sure that the ground is flat.
Attach a soft lifting sling to the lower part of the
flange and then to the crane hook.
5.
Attach a soft lifting sling to the outer terminal (1)
and then to the crane hook.
G004688
4.
CAUTION!
Attach the soft lifting sling as close to
the top housing as possible, or damage
will occur.
G004689
NOTE!
If the outer terminal is not installed,
please contact ABB.
6.
Carefully lift the bushing.
7.
Make sure that the support blocks are in the same positions as the support blocks in the
transport box.
CAUTION!
Do not apply force to the ceramic insulator, it will break.
8.
Lower the bushing onto the support blocks.
End of instruction
18
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
4 Installation
4.1 Tools
Tool
Part number
Note
Lifting tool
9760 668-A
-
Soft bedding
-
E.g. rubber mat or wood board
Soft lifting slings
-
-
Pull-through cord
9760 669-A
With M8 terminal.
For assembly and disassembly of the
draw rod.
Torque wrench key for hex socket
screws, 16 mm (M10) and 13 mm (M8),
torque 20 to 40 Nm.
-
-
Wrench for hex socket screws 45 mm or
adjustable wrench for 45 mm bolts
or larger.
-
For the test tap cover.
Shackles
-
To fit Ø 28 mm holes, for connection of
the soft lifting slings to the bushing
flange.
Hydraulic jack
PDV2330
For removal, and installation of the
bottom contact. Draw-rod system.
(2769 897-A)
Box spanner
9760 669-B
For removal, and installation of the
bottom contact. Draw-rod system.
Tackle
-
For installation of the bushing at a
specific angle.
4.2 Consumables
Item
Brand
Part number
Note
Oil based Vaseline
Fuchs
1171 5011-102
For treatment of contact surfases. Does
not react with transformer oil.
Mobilgrease 28
MOBIL
1171 4014-407
Lubricates and protects metals against
corrosion. Protects rubber. Does not
react with transformer oil.
Molykote Multilub
Dow Corning
1236 0011-127
For lubrication of draw-rod threads and
bolts on the outer terminal.
Thread-locking fluid
grade 42
-
-
High strength thread-locking fluid,
permanent locking.
Thread-locking activator
grade 47
-
-
Activator for thread-locking fluid
grade 42.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
19
4.3 Preparations
4.3.1 Lifting the bushing
G005005
Overview
1
Lifting tool
2
Soft bedding, e.g. rubber mat or woodboard
3
Shackle
Procedure
1.
Make sure that the crane can lift the bushing. Refer to net weight in the packing list.
2.
Loosen the M8 bolts (1).
G004684
NOTE!
It is not necessary to remove the M8
bolts.
20
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
3.
Remove the M10 bolts (6) and washers (7), and
then remove the outer terminal (6).
G004690
NOTE!
Keep the outer terminal (5), washers
(7) and bolts (6), they will be used
again.
4.
Install the lifting tool (1), the M10 bolts (6) and the
washers (7).
•
For GOE 250 to 950: align the side of the
lifting tool with the oil-level glasses (25).
•
For GOE 1050 to 2550: align the side of the
lifting tool with the oil-level guage (26).
G005056
NOTE!
The lifting tool is thinner than the outer
terminal, use stacks of washers or
shorter bolts to correctly install the
lifting tool.
Torque
40 ±4 Nm
5.
Attach soft lifting slings (8) from the lifting holes
through the lifting tool to the crane hook.
G005015
NOTE!
The diameter of the holes for the
lifting-slings in the lifting tool is
Ø50 mm.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
21
For installation at a specific angle: attach soft
lifting slings with a shackle (9) from the flange to
the crane hook.
7.
Align the crane hook with the lifting tool on the bushing.
8.
Carefully lift the bushing.
G005058
6.
CAUTION!
Make sure that the bushing does not rotate.
9.
Adjust the shackle (9) until the bushing flange has the same angle as the transformer flange.
End of instruction
4.3.2 Oil-filling of the bushing for horizontal installation
Overview
•
•
This procedure applies to bushings that will be oil-filled with an atmospheric process.
This procedure does NOT apply when the bushing will be oil-filled with the vacuum process, refer to
Horizontal installation of the bushing on the transformer, page 24.
This procedure must be done immediately before installation of the bushing on the transformer, because there
is no expansion space for the oil after this procedure is completed. Thus, changes in the ambient temperature
will cause the oil to expand or contract, this will cause damage to the seals in the bushing.
CAUTION!
Do not leave the bushing fully filled with oil.
Installation must be done immediately after the bushing is sealed. If not, changes in the ambient
temperature will cause damage to the seals in the bushing.
22
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Procedure
Install the lifting-tool:
1.
Remove the bolts (6) and washers (7).
2.
Install the lifting tool (1), and align the side of
the lifting tool with the oil-level glasses (25).
3.
Install he bolts (6) and washers (7).
G006666
1.
Torque
40 ±4 Nm
Lift the bushing to the vertical position.
3.
Remove one of the oil-plugs (9).
4.
Add clean and dry transformer oil until the bushing is completely filled.
G006353
2.
CAUTION!
Make sure that the bushing is completely full of transformer oil. Air left in the bushing can
cause damage.
5.
Install the oil-plug (9).
6.
Lower the bushing to the horizontal position.
7.
Install the bushing in the transformer immediately, refer to Horizontal installation of the bushing on the
transformer, page 24.
CAUTION!
Do not leave the bushing fully filled with oil.
Installation must be done immediately after the bushing is sealed. If not, changes in the
ambient temperature will cause damage to the seals in the bushing.
End of instruction
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
23
4.4 Horizontal installation of the bushing on the transformer
Overview
The bushing is installed without removal of the bottom contact.
Procedure
Install the springs (15), the guiding sleeves (16),
the pressing ring (17), and the hex screws (18) to
the bottom contact.
2.
Remove the covering plate (1).
G003036
G006299
1.
24
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
3.
Install the nuts and washers. Tighten the nuts in a
crosswise sequence.
CAUTION!
Make sure that the nuts are tightened
evenly.
G006296
First tighten all nuts to half the torque,
then to the full torque.
Torque
Please refer to the transformer
documentation.
4.
Remove the lifting gear (1):
1.
Remove the long bolts (6), washers (7) and
lifting gear (1).
2.
Install the original bolts (6) and washers (7).
G006297
NOTE!
The lifting gear uses longer bolts (6),
use the original bolts (6) to attach the
outer terminal.
Put the winding cables through the end-shield.
6.
Install the winding cables to the bottom contact.
G005024
5.
CAUTION!
Make sure that there is no tension in the winding cables. Tension in the winding cables will
cause damage to the bottom contact.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
25
Install the end shield:
1.
Push the end shield carefully against the
pressing ring (17).
2.
Turn the end shield approximately 20°, to its
locked position.
G006298
7.
End of instruction
4.5 Installation with draw lead
4.5.1 Calculation of the lenght of the draw lead
Overview
Because of the tolerances in the length of the porcelain, a nominal lenght for the draw lead can not be given.
G000379
The actual distance between the inner terminal and the bottom of the bushing must be calculated.
Procedure
1.
26
Measure the length (L2).
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
2.
Subtract 350 mm from the L2 measurement.
L2 - 350 = draw lead lenght
CAUTION!
Make sure that the draw lead is sufficiently long.
End of instruction
4.5.2 Installation with draw lead
G004512
Overview
1
Bushing
2
Inner terminal
3
Draw lead
4
Pull-through cord
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
27
Procedure
1.
Remove the inner terminal from the bushing.
2.
Remove the nut (19) and washers.
G006520
1.
Solder the draw lead (2) from the transformer
windings to the inner terminal (1).
3.
Carefully clean the bottom end of the bushing, and the inside of the center hole. Look for damage.
4.
Install the springs (15), the guiding sleeves (16),
the pressing ring (17), and the hex screws (18) to
the bottom end of the bushing.
G005016
G004513
2.
Torque
40 Nm
28
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Install the end shield:
1.
Push the end shield carefully against the
pressing ring (17), until the hex screw heads
come through the holes in the end shield.
2.
Turn the end shield clockwise approximately
20°, to its locked position.
G005032
5.
6.
Put the washers and the nut (19) on the
pull-through cord.
G004515
CAUTION!
Make sure that the washers are in the
correct order.
Nut
20
Plain washer
21
Conical spring washer
22
Contact washer
Lower the pull-through cord (10) through the
bushing.
G001893
7.
19
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
29
8.
Apply Molykote Multilub to the pull-through cord
(10), and attach it to the inner terminal (7).
G004516
NOTE!
The terminal (7) has M8 threads.
9.
Hold the pull-through cord (12) in tension, while
lowering the bushing onto the transformer.
CAUTION!
Do not damage the stud bolts on the
transformer. There is a risk of metal
falling into the transformer.
G003058
CAUTION!
Make sure that the draw lead is
entering the bushing correctly. Monitor
the draw lead through the inspection
openings on the transformer.
NOTE!
Plastic sleeves put on two or three of
the stud bolts will help to guide the
flange, and will prevent damage to the
stud bolts.
If necessary, adjust the length of the inner
terminal:
1.
Lift the bushing from the transfomer and
lower the inner terminal with the pull-through
cord.
2.
Remove the bolts (15).
3.
Move the lower part (14).
4.
Apply Molykote Multilub to the threads of the
bolts (15), and install the bolts (15).
CAUTION!
Make sure that there is no tenison in
the straded cable, or too much slack.
NOTE!
The lower part of the inner terminal can
be moved in steps of 30 mm.
30
G004514
10.
Torque
37.5 Nm
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
If the bushing is installed in a non vertical position:
•
For GOE 250 to 950: the sight glasses (25)
must be perpendicular to the angle of the
bushing.
•
For GOE 1050 to 2600: the oil-guage (26)
must point down.
G006197
11.
12.
Install the nuts and washers. Tighten the nuts in a
crosswise sequence.
CAUTION!
Make sure that the nuts are tightened
evenly.
G005043
First tighten all nuts to half the torque,
then to the full torque.
Torque
Please refer to the transformer
manufacturer.
13.
Install the inner terminal:
1.
Apply Molykote Multilub on the threads of the
nut (19).
2.
Install the washers and the nut (19).
3.
Remove the pull-through cord.
4.
Tighten the nut (19).
G005051
NOTE!
The guide pins (23) fit the holes in the
top tube.
Torque
80 Nm
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
31
Remove the M10 bolts (6), the washers (7), and
the lifting tool (1).
15.
Continue with Installation of the outer terminal, page 58.
G004679
14.
End of instruction
4.6 Installation with draw rod at transformer factory
4.6.1 Removal of the lower draw rod with bottom contact from the bushing
Overview
G005052
The bottom contact is usually installed in the bushing when it is delivered from ABB, the first step at the
transformer factory is thus to remove it.
32
1
Upper draw rod
2
Lower draw rod with bottom contact
3
Bottom contact
4
Bushing
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Procedure
Install the shaft (16) on the draw rod (1), and put
the box-spanner (12) on the shaft (16).
2.
Make sure that more than 10 mm of the threads
on the upper draw rod (1) are used.
3.
Put the hydraulic jack (8) on the shaft (16), and
install the nut (17) and washer but do not tighten
it.
G005066
G004873
1.
G005147
NOTE!
The hydraulic jack must be in the
middle of its stroke. If not, the tension
of the draw rod cannot be released
when the draw rod nut is loosened.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
33
4.
Loosen the draw rod nut (10):
1.
Pull the draw rod with 40 kN.
2.
Carefully increase the force until you can
loosen the draw rod nut with your hand.
If 45 kN is reached, and the draw rod nut is
not loose, turn the box-spanner with a
wrench.
DANGER!
Apply the hydraulic pressure carefully.
Incorrectly used high-pressure
hydraulics can break with explosive
force.
G006521
Refer to the instructions for the hydraulic jack.
CAUTION!
Do not remove the compensation
device.
NOTE!
The draw rod is installed with a tension
of 40 kN.
Loosen the nut (17).
6.
Turn the shaft (16) counter clockwise to remove the shaft-socket from the upper draw rod (1).
7.
Remove the hydraulic jack (8) from the bushing.
G005068
G005067
5.
34
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
8.
Apply Molykote Multilub to the threads on the
pull-through cord (12), then connect it to the upper
draw rod.
NOTE!
The terminal on the pull-through cord
(12) has M8 threads.
G004686
NOTE!
Or use a lubricant with equal properties
to Molykote Multilub.
9.
Remove the draw rod nut (10).
G003055
NOTE!
The draw rod will fall out of the bushing
if it is not in the horizontal position.
10.
Pull down the draw rod from the bottom end of the
bushing, and disassemble it at the lower joint (8).
NOTE!
The upper thread (7) is locked with
thread-locking fluid grade 42.
The guiding cone (21) is loose.
11.
G005033
NOTE!
As standard the thread joint (20)
between the draw rod and the bottom
contact is locked with thread-locking
fluid grade 42.
Carefully look for damage at the bottom end of the bushing, and the inside of the center hole.
End of instruction
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
35
4.6.2 Installation of the small bottom contact in the transformer
G005031
Overview
1
Small bottom contact
Procedure
1.
Install the springs (15), the guiding sleeves (16),
the pressing ring (17), and the hex screws (18) to
the bottom end of the bushing.
G005016
NOTE!
The pressing ring (17) cannot be
installed to the small bottom contact.
Torque
40 Nm
36
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Put the winding cables through the end-shield.
3.
Install the winding cables to the bottom contact.
G005024
2.
G005036
CAUTION!
Make sure that there is no tension in
the winding cables. Tension in the
winding cables will cause damage to
the bottom contact.
Torque
68 ±6 Nm
4.
Lift the bushing above the opening in the transformer.
5.
Continue with Installation of the bushing on the transformer, page 40.
End of instruction
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
37
4.6.3 Installation of the large bottom contact in the transformer
Overview
G005017
The end-shield can be installed to both the bottom contact, and the bottom nut of the bushing. This procedure
describes installation on the bottom contact, for installation on the bottom nut, refer to Installation of the
small bottom contact in the transformer, page 36.
1
Large bottom contact
Procedure
Install the springs (15), the guiding sleeves (16),
the pressing ring (17), and the hex screws (18) to
the top of the bottom contact.
G005018
1.
Torque
40 Nm
38
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
2.
Install the winding cables to the bottom contact.
G005019
CAUTION!
Make sure that there is no tension in
the winding cables. Tension in the
winding cables will cause damage to
the bottom contact.
Torque
68 ±6 Nm
Install the end shield:
1.
Push the end shield carefully against the
pressing ring (17), until the hex screw heads
come through the holes in the end shield.
2.
Turn the end shield approximately 20°, to its
locked position.
G005037
3.
4.
Lift the bushing above the opening on the transformer.
End of instruction
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
39
4.6.4 Installation of the bushing on the transformer
Overview
G006788
It is important to install the draw-rod correctly, thus the ends of the draw-rod parts must make contact at (9).
CAUTION!
Do not disassemble the joints (1), these are correctly assembled and locked with tread-locking
fluid by ABB.
Procedure
Connect the upper draw-rod (1) to the lower
draw-rod (4).
G005038
1.
40
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
2.
Make sure that the joint is correctly threaded:
1.
Calculate the nominal distance:
H = L5 - 25 mm(± 2 mm).
2.
Measure the distance H and compare it to
the nominal distance H.
3.
Record the measured distance H and keep it
with the substation documentation.
NOTE!
When the joint is correctly threaded,
2 threads on the upper (7) and
lower (8) threads are visible.
If the bushing has the small bottom contact, then
install the end shield:
1.
Push the end shield carefully against the
pressing ring (17), until the hex screw heads
comes through the holes in the end shield.
2.
Turn the end shield approximately 20°, to its
locked position.
G005039
3.
G006282
Refer to the rating plate for the distance L5.
4.
Hold the pull-through cord (12) in tension, while
lowering the bushing onto the transformer.
CAUTION!
Do not damage the stud bolts. There is
a risk of metal falling into the
transformer.
G003058
NOTE!
Plastic sleeves put on two or three of
the stud bolts will help to guide the
flange, and will prevent damage to the
stud bolts.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
41
If the bushing is installed in a non vertical position:
•
For GOE 250 to 950: the sight glasses (25)
must be perpendicular to the angle of the
bushing.
•
For GOE 1050 to 2600: the oil-guage (26)
must point down.
G006197
5.
Install the nuts and washers. Tighten the nuts in a
crosswise sequence.
G005053
6.
Torque
Please refer to the transformer
documentation.
Install the draw-rod nut (10):
1.
Apply a generous quantity of Molykote
Multilub to the nut (10), and the threads of
the draw rod.
2.
Install the washer (11) and nut (10) on the
draw rod, tighten with your fingers.
3.
Remove excess Molykote Multilub with a rag.
CAUTION!
If the nut (10) is not lubricated correctly,
it will not be tighten to the correct
torque. This can cause the bushing to
fail.
G004300
7.
CAUTION!
Make sure that the centering ring (28)
is in position. It is necessary for the
correct installation of the draw rod.
42
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Tighten the draw-rod nut (10).
G006663
8.
Torque
10 Nm
Remove the pull-through cord (12).
10.
Remove the bolts (6), the washers (7) and the
lifting gear (1).
11.
Tighten the draw-rod nut, refer to Hydraulic tightening of the draw-rod nut, page 51, or Manual
tightening of the draw-rod nut, page 55.
G004679
9.
End of instruction
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
43
4.7 Installation with draw rod at site
4.7.1 Preparations at site
Overview
G004532
This procedure is only applicable if the lower draw rod with the bottom contact (5) is installed in the
transformer.
Procedure
Loosen the M8 bolts (1).
G004684
1.
44
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Remove the M10 bolts (6), and then remove the
outer terminal (5).
3.
Install the lifting tool (1), the M10 bolts (6) and the
washers (7).
G004691
2.
For GOE 250 to 950: align the side of the
lifting tool with the oil-level sight glasses (25).
•
For GOE 1050 to 2550: align the side of the
lifting tool with the oil-level guage (26).
G005056
•
Torque
40 ±4 Nm
Put the pull-through cord (12) through the
box-spanner (13).
G004680
4.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
45
5.
Apply Molykote Multilube to the thread on the
pull-through cord (12), and then connect it to the
draw rod.
G004686
NOTE!
Or use a lubricant with equal properties
to Molykote Multilube.
Remove the M16 nut (10).
7.
With a soft cloth, carefully clean the bottom end of the bushing, and the inside of the center hole. Look
for damage.
8.
Pull down the upper draw rod (1) from the bottom
end of the bushing.
G005040
G003055
6.
46
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Remove the transport cover (13) from the
transformer (11) and the lower draw rod (4).
10.
Lift the bushing to a position above the installation opening on the transformer.
G005041
9.
End of instruction
4.7.2 Installation of the bushing on the transformer at site
Procedure
1.
Apply locking fluid on the threads (8) on the lower
draw-rod (4).
•
If the bottom contact is removed from the
lower draw-rod (4): apply locking fluid on the
threads (20).
Make sure that the guiding cone (21) is in
position.
NOTE!
Use thread-locking fluid grade 42 and
activator grade 47.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
G005042
CAUTION!
Make sure that all joints in the draw rod
are locked with thread-locking fluid.
47
Connect the upper draw-rod (1) to the lower
draw-rod (4).
3.
Make sure that the joint is correctly threaded:
G005038
2.
1.
Measure the distance H and compare it to
the nominal distance H.
2.
Calculate the nominal distance:
H = L5 - 25 mm(± 2 mm).
Refer to the rating plate for the distance L5.
G006282
NOTE!
When the joint is correctly threaded,
2 threads on the upper (7) and
lower (8) threads are visible.
If the bushing has the small bottom contact, then
install the end shield:
1.
Push the end shield carefully against the
pressing ring (17), until the hex screw heads
comes through the holes in the end shield.
2.
Turn the end shield approximately 20°, to its
locked position.
G005039
4.
48
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
5.
Hold the pull-through cord (12) in tension, while
lowering the bushing onto the transformer.
CAUTION!
Do not damage the stud bolts. There is
a risk of metal falling into the
transformer.
G003058
NOTE!
Plastic sleeves put on two or three of
the stud bolts will help to guide the
flange, and will prevent damage to the
stud bolts.
If the bushing is installed in a non vertical position:
•
For GOE 250 to 950: the sight glasses (25)
must be perpendicular to the angle of the
bushing.
•
For GOE 1050 to 2600: the oil-guage (26)
must point down.
G006197
6.
7.
Install the nuts and washers. Tighten the nuts in a
crosswise sequence.
CAUTION!
Make sure that the nuts are tightened
evenly.
G005043
First tighten all nuts to half the torque,
then to the full torque.
Torque
Please refer to the transformer
documentation.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
49
Install the draw-rod nut (10):
1.
Apply a generous quantity of Molykote
Multilub to the nut (10), and the threads of
the draw rod.
2.
Install the washer (11) and nut (10) on the
draw rod, tighten with your fingers.
3.
Remove excess Molykote Multilub with a rag.
CAUTION!
If the nut (10) is not lubricated correctly,
it will not be tighten to the correct
torque. This can cause the bushing to
fail.
G004300
8.
CAUTION!
Make sure that the centering ring (28)
is in position. It is necessary for the
correct installation of the draw rod.
Tighten the draw-rod nut (10).
G005061
9.
Torque
10 Nm
Remove the bolts (6), washers (7) and lifting
gear (1).
11.
Remove the pull-through cord (12).
G004679
10.
50
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
12.
Tighten the draw-rod nut, refer to Hydraulic tightening of the draw-rod nut, page 51, orManual
tightening of the draw-rod nut, page 55.
End of instruction
4.8 Hydraulic tightening of the draw-rod nut
G005065
Overview
8
Hydraulic jack
10
Draw-rod nut
Procedure
1.
Measure the distance (a).
G005049
NOTE!
The bushing is delivered with an
information sheet that specifies the
draw-rod extension (b-a). These values
are measured when the bushing is
manufactured, and are unique to every
unit.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
51
Install the shaft (16) on the draw rod (1), and put
the box-spanner (12) on the shaft (16).
3.
Make sure that more than 10 mm of the threads
on the upper draw rod (1) are used.
4.
Put the hydraulic jack (8) on the shaft (16), and
install the nut (17) but do not tighten it.
5.
Pull the draw rod with 40 kN.
G005147
G005066
G004873
2.
DANGER!
Apply the hydraulic pressure carefully. Incorrectly used high pressure hydraulics can break
with explosive force.
NOTE!
It is not necessary to compensate for variations in ambient temperature.
6.
52
Turn the nut on the upper draw rod (1) with the box-spanner, tighten with your hand.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Loosen the nut (17).
8.
Turn the shaft (16) counter clockwise to remove the shaft-socket from the upper draw rod (1).
9.
Remove the hydraulic jack (8) from the bushing.
G005068
G005067
7.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
53
10.
Make sure that the draw-rod extension is within
the tolerances:
1.
Measure the distance (b).
2.
Calculate the extension of the draw rod:
(b) minus (a).
3.
Compare the calculated draw-rod extension
to the measured extension, refer to the table.
11.
Type
Extension
GOE 250 - 210
3.5 mm ±1.0
GOE 380 - 300
3.5 mm ±1.0
GOE 650 - 500
5.0 mm ±1.0
GOE 950 - 650
7.0 mm ±2.0
GOE 1050 - 750
9.0 mm ±2.0
GOE 1175 - 850
9.5 mm ±2.0
GOE 1300 - 1050
12.0 mm ±2.0
GOE 1425 - 1150
12.0 mm ±2.0
GOE 1550 - 1175
15.0 mm ±2.0
GOE 1675 - 1300
15.0 mm ±2.0
GOE 1800 - 1360
15.0 mm ±2.0
GOE 2550 - 1600
18.0 mm ±2.0
GOE 2550 - 1675
18.0 mm ±2.0
G005050
NOTE!
Please contact ABB for special
bushings.
Measure the value (c), record it for future
reference.
G006303
Keep the document with the substation
documentation.
End of instruction
54
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
4.9 Manual tightening of the draw-rod nut
Overview
This procedure requires the draw-rod nut, washer and threads of the draw rod to be correctly lubricated. The
draw rod will not get the correct tension if the fasteners are not correctly lubricated, this can cause the
bushing to fail. If possible, ABB recommends that the draw rod is hydraulically tightened, refer to Hydraulic
tightening of the draw-rod nut, page 51.
Procedure
Make sure that the draw-rod nut, and threads of the draw rod are correctly lubricaded, and that the
draw-rod nut is tightened to 10 Nm.
2.
Measure the distance (a).
G005049
1.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
55
3.
Turn the nut clockwise until you get the the correct
extension (b).
Distance (b) = (a) + extension, refer to the table.
CAUTION!
Make sure that you do not overtighten
the nut. Use a torque wrench set to
140 Nm.
Type
Extension
GOE 250 - 210
3.5 mm ±1.0
GOE 380 - 300
3.5 mm ±1.0
GOE 650 - 500
5.0 mm ±1.0
GOE 950 - 650
7.0 mm ±2.0
GOE 1050 - 750
9.0 mm ±2.0
GOE 1175 - 850
9.5 mm ±2.0
GOE 1300 - 1050
12.0 mm ±2.0
GOE 1425 - 1150
12.0 mm ±2.0
GOE 1550 - 1175
15.0 mm ±2.0
GOE 1675 - 1300
15.0 mm ±2.0
GOE 1800 - 1360
15.0 mm ±2.0
GOE 2550 - 1600
18.0 mm ±2.0
GOE 2550 - 1675
18.0 mm ±2.0
G005050
NOTE!
One turn of the nut corresponds to a
2 mm extension of the draw rod.
4.
Make sure with a torque wrench that the nut is tightened with a torque of more than 70 Nm and less
than 140 Nm.
5.
Measure the value (c), record it for future
reference.
G006303
Keep the document with the substation
documentation.
End of instruction
56
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
4.10 Oil-filling
Overview
Start this procedure when the transformer oil has reached the bottom of the bushing.
This procedure is applicable to bushings that are installed in a position that is 0° – 60° from vertical.
This procedure is NOT applicable if the transformer is oil-filled with the vacuum process.
G006522
•
•
Procedure
1.
Make sure that the transformer oil-level is
maximum 30 mm from the flange.
G006300
CAUTION!
A lower oil-level will decrease the
cooling of the bushing, and can cause
spontaneus flashover.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
57
2.
Wait until the oil-level (h) in the center-tube has
risen to the same height as the oil-level in the
transformers oil-conservator.
•
If the top of the bushing is lower than the
transformers oil-conservator, wait until oil
flows out from top of the bushing.
G004522
NOTE!
Air is soluble in transformer oil, thus as
much as possible must be released
from the bushing center-tube.
End of instruction
4.11 Installation of the outer terminal
Procedure
1.
Prepare the contact surface and gasket surface:
1.
Carefully clean the contact surface and
gasket surface with a soft cloth.
2.
Apply Vaseline to the contact surface.
3.
Apply Mobilgrease 28 to the gasket surface.
G000403
CAUTION!
Do not use a wire brush on the zinc
coating (9).
58
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
2.
Prepare the contact surface, gasket surface and
O-ring:
1.
Carefully clean the contact surface and
gasket surface with a soft cloth.
2.
Apply Vaseline to the contact surface.
3.
Apply Mobilgrease 28 to the gasket surface
and O-ring (3).
NOTE!
Or use lubricants with equal properties
to Vaseine and Mobilgrease 28.
G006465
CAUTION!
Do not use a wire brush on aluminium
outer terminals. A wire brush can make
scratches in the zinc coating (9).
NOTE!
When the outer terminal (5) is installed
at site for grid operation, replace the
used O-ring (3) with a new O-ring. A
new O-ring is supplied with the
bushing.
Assemble the tightening ring (4), the O-ring (3),
and the outer terminal (5).
4.
Apply Molykote Multilub to the threads of the M8 bolts (1).
5.
Install the M8 bolts (1), and the spring
washers (2).
G005055
3.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Torque
Tighten with your fingers.
59
Apply Molykote Multilub to the M10 bolts (6).
7.
Install the M10 bolts (6) and plain washers (7).
8.
Tighten the M10 bolts (6) in a crosswise
sequence.
G004690
6.
G003053
CAUTION!
Make sure that the outer terminal
moves straight down. Turn each bolt a
little, and then the next bolt, until all
bolts can be tightened to the correct
torque.
Torque
40 ±4 Nm
9.
Tighten the M8 bolts (1).
G004684
Tighten the bolts in a crosswise sequence.
Torque
20 ±2 Nm
10.
Install the external connections. Refer to the documentation from the supplier of the external
connection.
End of instruction
60
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
4.12 Grounding of the bushing flange
Overview
The bushing flange must be grounded to the transformer tank. This prevents electrical discharge between the
bushing flange and the transformer tank under normal service conditions.
There are two alternatives.
DANGER!
Make sure that the grounding is correct. An unsatisfactory grounding can cause damage to
equipment, or death to personnel.
Procedure with a cone point set screw
1.
Apply a large quantity of Mobilgrease 28 to the
cone point set screw (13).
CAUTION!
The quality of the cone point set screw
is important, stainless steel of A4-80
quality is recommended.
G005044
NOTE!
Or use a lubricant similar to
Mobilgrease 28.
2.
Install the cone point set screw (13).
NOTE!
The cone point of the set screw
penetrates the paint. This makes an
electrical connection between the
bushing and the transformer tank,
keeping them at the same potential.
Torque
M12: 40 Nm
End of instruction
Procedure with a flexible cable
1.
Clean the contact surfaces.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
61
Put a flexible cable (14) between the grounding
hole in the bushing flange and a grounding point
on the transformer.
3.
Apply a large quantity of Mobilgrease 28 to the bolt (13).
G005045
2.
CAUTION!
The quality of the bolt is important, stainless steel of A4-80 quality is recommended.
NOTE!
Or use a lubricant similar to Mobilgrease 28.
4.
Install the bolt (13).
5.
Connect the other end of the flexible cable (14) to the transformer.
Torque
M12: 40 Nm
NOTE!
This makes an electrical connection between the bushing and transformer tank, keeping
them at the same potential.
End of instruction
62
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
5 Commissioning
5.1 Waiting time before energization
General requirements for the bushing
•
•
•
If the bushing has been stored in the vertical position with the top end upwards, then no waiting time
is required.
If the bushing has been stored in the horizontal position, or in an inclined position of 7°, then air bubbles
must be removed from the oil before it can be energized. Refer to the table.
The waiting times can be met with the bushing installed on the transformer.
When the bushing is in the vertical position, air bubbles that are trapped in the oil collects at the top.
Storage time in the horizontal
position
Minimum required waiting time in the vertical position
Before service voltage
application
Before test voltage application
Less than one year
12 hours
24 hours
More than one year
7 days
7 days and 12 hours
CAUTION!
If you do not obey this procedure, flashovers or partial discharges can occur inside the bushing.
Waiting times after oil-filling of the transformer
Some waiting time is necessary after the transformer has been oil-filled, before the bushing is energized. The
reason for this is that air bubbles stick to the bushings surface when the transformer is filled with oil, and
flashovers and partial discharges can form in the bubbles. Thus, it is important to let the necessary waiting
time pass, to make sure that all the air bubbles have risen to the surface of the oil before the bushing is
energized. Refer to the table.
The transformer is oil-filled with
Necessary waiting time
The vacuum process
No waiting time is necessary, air bubbles does not
form in vacuum. Refer to the transformer
manuafacturers instructions.
Gas-saturated transformer oil
After the oil-filling process has been completed, wait
for 24 hours before energizing the transformer.
De-gassed transformer oil
After the oil-filling process has been completed, wait
for 6 hours before energizing the transformer.
A reduced oil-level
After the oil-level has been restored, wait 24 hours
before energizing the transformer.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
63
5.2 Recommended test before energization
5.2.1 Overview
The tests should be done to check the insulation, sealing and current path of the bushing.
NOTE!
The tests should be done after installation, but before connecting the outer terminal of the bushing
to the power circuit.
5.2.2 Tightness test between transformer and bushing flange
Several different methods can be used and we thus refer to the instructions given by the company responsible
for field erection. As an example, the tightness of the seal between the transformer and the bushing flange
can be checked when the transformer is oil-filled by using chalk or, perhaps easier, with paper strips.
5.2.3 Tightness test of bushing outer terminal
Overview
Because the outer terminal is often situated above the oil level of the transformer oil expansion system, a leak
at the outer terminal is serious. Water could enter directly into the transformer insulation. It is thus
recommended to do a tightness test after installation of the bushing, both with vacuum and pressure.
Different methods can be used, and ABB refers to the instructions given by the company responsible for the
field erection of the bushing.
Example procedure
1.
Put tracer gas into the center tube before installation of the outer terminal.
NOTE!
The oil level of the transformer must be above the bottom end of the bushing, but below the
bushing flange.
2.
64
Increase the oil level to just below the bushing flange, to raise the pressure in the center tube.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Find leaking gas with gas detector (sniffer) near
the gasket.
G005046
3.
End of instruction
5.2.4 Measurement of capacitance and dissipation factor
Overview
After installation of the bushing, it is recommended to measure the capacitance values for future reference,
such as repairs, service etc. This can be done on an installed bushing because it has an insulated test tap.
Refer to 2750 515-142, “Bushing diagnostics and conditioning”.
•
C1 is the capacitance between the test tap and the outer terminal.
•
C2 is the capacitance between the test tap and ground.
Nominal capacitance
The capacitance (C2) depends on the transformer, and it is not possible to give a nominal value that is valid
for all service conditions. Thus, it is important to measure and record the capacitance (C 2) for future
reference, such as repairs, service etc.
Type
Space for CT = 305 mm
Space for = CT 605 mm
C1
C2*
C1
C2*
GOE 250-210
448
290
594
480
GOE 380-300
448
290
594
480
GOE 650-500
392
300
498
480
GOE 950-650
377
658
466
790
GOE 1050-750
383
390
450
590
GOE 1175-850
420
480
490
840
GOE 1300-1050
536
640
570
896
GOE 1425-1150
536
640
570
896
GOE 1550-1175
500
700
512
700
GOE 1675-1300
500
700
512
700
GOE 1800-1360
500
700
512
700
GOE 2550-1600
558
4610
560
4820
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
65
Type
GOE 2550-1675
Space for CT = 605 mm
Space for CT = 905 mm
C1
C2*
C1
C2*
610
5000
660
5700
* Reference values from ABB Components.
Dissipation factor, tan δ
The dissipation factor varies with the temperature of the bushing body, and thus the measured dissipation
factor must be multiplied with the correction factor given below.
Bushing body temperature °C
Correction factor to 20 °C (IEC)
3-7
0.85
8-12
0.90
13-17
0.95
18-22
1.00
23-27
1.05
28-32
0.10
33-37
1.15
38-42
1.20
43-47
1.25
48-52
1.30
Procedure
1.
De-energize the transformer.
2.
Disconnect the external connections from the outer terminal of the bushing.
3.
Remove the cover (2).
Article number
Cover
2769 522-M
O-ring
1ZSC004442-CAK
G005047
Part
66
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Connect the measuring equipment.
1.
Connect the low voltage cable to the stud (1).
2.
Connect the high voltage cable to the outer
terminal.
3.
Connect the ground cable to the bushing
flange (3).
G005048
4.
5.
Measure the capacitance (C1) between the outer terminal and the stud (1).
NOTE!
Refer to the table for the nominal capacitance (C1), Nominal capacitance, page 65.
6.
Measure the capacitance (C2) between the stud (1) and the flange (3).
•
7.
Record the capacitance (C2) for future reference.
Install the cover (2).
CAUTION!
The test tap is not self-grounding!
The bushing can be destroyed if the test tap is not grounded. Because the capacitance (C2)
is usually relatively small, the test tap must never be open-circuited when applying a
voltage to the bushing. It must always be grounded or connected to an external impedance.
CAUTION!
Do not energize the bushing without the cover or a test adapter installed. The cover
connects the outermost conductive foil to ground and will prevent damage to the bushing.
CAUTION!
Make sure that the cover is correctly installed with the O-ring in place, when the bushing is
not in use. The purpose is to prevent dust and water from entering the tap.
8.
Connect the outer terminal of the bushing to the external connections.
End of instruction
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
67
5.2.5 Measurement of through-resistance
Overview
The method to use for measuring the through-resistance depends on the design of the transformer. In general,
a current is applied from bushing to bushing. The voltage drop from the outer terminal to outer terminal is
measured. The resistance is calculated with Ohm's law, R=U÷I.
(R: total circuit resistance, U: measured voltage drop, I: through-current).
The total through-resistance is the sum of the transformer winding, lead resistance, the bushing conductor,
and contact resistance. The additional resistance from the bushing conductor should not be more than
150 μΩ. Because the through-resistance of the HV winding of a typical power transformer is in the order of
0.1 to 1 Ω, this is a very rough method that can only be used to detect very large faults in the current path,
such as open circuits.
Small faults in the current path can only be detected by making sensitive measurements across each
connection point, or by measuring the temperature increase during operation with an infrared sensitive
camera (thermovision).
The through-resistance of an installed bushing can only be measured from the outer terminal of one bushing,
to the outer terminal of the other bushing on the same transformer winding. The through-resistance will
include the resistance of both bushings, all connections and the transformer winding.
Do the measurement of through-resistance before connecting any of the external circuits.
Because the result of the measurement depends on the temperature and the accuracy with which the
temperature can be measured, this can be a source of errors.
Procedure
1.
Record the temperature of the transformer winding.
NOTE!
The resistance of metals depends on their temperature. Because the transformer winding
usually dominates the total resistance, the average winding temperature at the time of
measurement must be recorded.
2.
Measure the through-resistance from outer terminal to outer terminal.
3.
Calculate the measured resistance to the reference temperature. Then compare the calculated
resistance to the reference resistance.
A difference of less than 2% is acceptable.
NOTE!
The transformer manufacturer gives the reference temperature for through-resistance
measurements.
4.
5.
If the calculated difference of resistance is more than 2% from the reference resistance:
1.
Make sure that the external connections have low resistance, and make sure that the outer
terminal and the internal connections are correctly installed.
2.
Measure the through-resistance again.
If the calculated difference of resistance again is more than 2%:
•
Wait 24 hours and do steps 1 through 5 again.
End of instruction
68
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
6 Maintenance
6.1 Recommended maintenance
General
The bushings are maintenance free, no regular maintenance is necessary.
DANGER!
Risk of electrocution!
Do not go near the bushing while it is energized, or ungrounded. High voltages can kill you.
Make sure that the bushing is de-energized, and grounded before you do work on it.
Cleaning of the insulator surface
If the insulator shed is exposed to very high pollution, it can be necessary to clean the surface. Remove the
pollution with a moist cloth, or a low pressure water jet. If necessary, put isopropyl alcohol on the cloth.
DANGER!
1,1,1 -Trichloroethane or Methyl-chloride are not recommended as detergents, because they are
dangerous to persons and the environment.
G003060
CAUTION!
Do not wash the insulator sheds with a high pressure water jet. This can cause damage to the joints
in the insulator shed, and between the insulator shed and metal parts.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
69
Measurement of capacitance and dissipation factor
Please refer to Measurement of capacitance and dissipation factor, page 65.
Thermovision (infrared camera) check for local overheating on connectors
At the maximum rated current, the bushing outer terminal normally operates at a temperature of about
+35 °C to +45 °C above the ambient temperature. Significantly higher temperatures can be a sign of bad
connections, especially at lower current loading.
Checking of oil leakage
Make a visual inspection for oil leakage during regular station supervision.
Checking of oil-level
The oil-level at normal and high temperatures, must always be above the red area on the oil-level indicator.
If the oil-level is in the red area (10), clean and dry transformer oil must be added. For the correct oil-level,
please contact ABB. Adding oil is only allowed when the temperature of the bushing is between +5 °C and
+35 °C.
G005057
CAUTION!
Be careful when the oil plug is removed, contamination can enter the bushing.
Use a new gasket with the oil plug (9). Tighten the oil plug (9) to 20 Nm.
CAUTION!
Make sure that the oil plug is correctly installed, and that there is no leakage.
70
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
Taking oil-samples
Taking oil samples is generally not recommended.
G000400
Take an oil sample only if a problem is known, for example a high power factor over C1, or visible oil
leakage. Please refer to product information 2750 515-142 "Bushing diagnostics and conditioning".
Take the oil sample from the oil valve (8) in the flange, and close the oil valve (8).
CAUTION!
Make sure that the oil valve (8) is correctly closed.
NOTE!
It is generally not necessary to add oil after an oil sample is taken. But it can be necessary to add
oil when many oil samples have been taken.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
71
72
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
7 Re-packing
7.1 Removal of horizontally installed bushings
Overview
This procedure applies to bushings that are connected to the transformer oil-system. It is important to remove
a small quantity of transformer oil to make space for thermal expansion.
Procedure
Remove the bushing from the transformer, refer to Removal of the bushing from the transformer, draw rod,
page 74.
2.
Drain a small quantity of transfomer-oil.
3.
Install the covering plate (1) and the gasket over
the oil-passage.
G003036
1.
Torque
M12 50 ±5 Nm
4.
Put the bushing in the vertical position.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
73
Remove the oil-plug (9).
6.
Remove transformer oil until the oil-level is correct for storage.
G006353
5.
CAUTION!
Make sure that the oil level is correct. If not, changes in the ambient temperature will cause
damage to the seals in the bushing.
NOTE!
The correct oil-level is between the sight-glasses.
7.
Install and tighten the oil-plug (9). Use a new gasket.
Gasket part number: 2152 899-132
CAUTION!
Use only a gasket that is made from nitrile rubber, with a hardness of 70 shore. Other
materials will cause oil-leakage.
End of instruction
7.2 Removal of the bushing from the transformer, draw rod
Procedure
1.
74
Install the lifting tool, refer to Lifting the bushing, page 20.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
2.
Put the pull-through cord (12) through the
box-spanner (13).
NOTE!
ABB Components recommends that
the hydraulic jack is used for the
removal of the bottom contact, refer to
Removal of the lower draw rod with bottom
contact from the bushing , page 32
steps 1 through 8.
3.
G004924
NOTE!
The terminal on the pull-through cord
(12) has M8 threads.
Apply Molykote Multilub to the thread on the
pull-through cord (12), then connect it to the draw
rod.
G004686
NOTE!
Or use a lubricant with equal properties
to Molykote Multilub.
Remove the M16 nut (10) on the draw rod with
the box spanner (13).
G003055
4.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
75
Remove the nuts and washers.
6.
Lift the bushing from the transformer.
G005053
5.
G006428
CAUTION!
Do not damage the stud bolts, there is
a risk of metal falling into the
transformer.
7.
Disassemble the draw rod at the lower joint (8).
Use the key grip on the lower draw rod.
DANGER!
Make sure that the upper draw rod
does not fall down when the lower
joint (8) is disassembled.
NOTE!
The bushing can have an optional joint,
or the bottom contact unlocked (20),
refer to the specifications for your
bushing.
G005033
NOTE!
The upper thread (7) is locked with
thread-locking fluid grade 42.
The guiding cone (21) is loose.
76
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
8.
Pull up the draw rod, and install the washer (11)
and nut (10).
G004300
CAUTION!
Make sure that the centering ring (28)
is in position, it is necessary for the
correct installation of the draw rod.
9.
Remove the pull-through cord (12).
10.
Lower the bushing to the floor.
CAUTION!
Make sure that there is soft bedding, or support blocks on the floor.
Install the lower draw rod (4) in the transport
cover (13).
12.
Install the transport cover (13) on the transformer turret (11).
G004681
11.
End of instruction
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
77
7.3 Re-packing of the bushing
G001910
Overview
Procedure
1.
Put plastic wrap on the draw-rod, and attach it to the transport box.
CAUTION!
Do not put the draw rod into the bushing, the threads on the draw rod will scratch the inside
of the center-tube conductor.
2.
Lift the bushing. Refer to Lifting the bushing out of the transport box, page 17.
3.
Lower the bushing into the transport box.
CAUTION!
Make sure that the there is soft bedding in the transport box.
CAUTION!
Make sure that the oil valves and test tap does not make contact with the transport box, or
other objects.
4.
Attach the bushing to the transport box in the same way as when it was delivered.
CAUTION!
Make sure that the bushing cannot move or rotate in the transport box.
5.
Close the transport box.
NOTE!
Refer to Lifting the transport box, page 16 and Transportation, page 15.
End of instruction
78
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
8 Spare parts and special tools
8.1 Summary
If the bushing is damaged, we recommend that it is returned to ABB for repairs and re-testing. Some parts
that are damaged or lost during transportation or installation, can be ordered from ABB.
8.2 Spare parts
Cover
For the test tap.
Part
Article number
Note
1
Cover
1ZSC004579-AAA
-
2
O-ring
1ZSC00442-CAK
-
G006192
Position
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
79
Oil-plug 2522 731-A
Part
Article number
Note
1
Oil-plug
2121 738-18
-
2
Gasket
1ZSC001591-AAC
-
G006193
Position
Cover for oil-plug 2522 731-A
For new design of the top chamber.
This cover gives protection to the oil-plug 2522 731-A.
Article number
Note
1
Cover
2522 732-42
M24
2
Gasket
2152 795-67
-
G006277
Position Part
80
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
8.3 Special tools
Lifting tool
Article number
Note
Lifting tool
9760 668-A
-
Part
Article number
Note
Pull-through cord
9760 669-A
With M8-terminal.
G006196
Part
G006198
Pull-through cord
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
81
Hydraulic jack
Article number
Note
Hydraulic jack
PDV2330
-
Part
Article number
Note
Box-spanner
9760 669-B
-
G006275
Part
G006276
Box-spanner
82
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
9 Disposal and environmental information
9.1 Overview
This chapter specifies the materials used in the bushing. Comply with local environmental regulations on
disposal of this product, the materials used are specified for this purpose.
9.2 Disposal and recycling
ABB strives to minimize the product's impact on the environment throughout its entire life cycle. Technical
and product development focuses on environmental aspects. The ecocycle approach is striven for, and
consideration is taken to the materials' environmental impact and recycling alternatives. The manufacturing
processes are selected to be as safe for the environment as possible.
Disposal of worn-out equipment
Worn-out equipment must be disposed of in an environmentally sound manner.
Much of the material, or the energy content in the material, can be recycled if it is sorted and cleaned. The
quantity of material that can be recycled varies depending on the technical resources and capabilities in each
country. Non-recyclable components should be sent to an approved environmental waste treatment plant for
destruction or disposal.
DANGER!
Be careful when dissembling the bushing.
There is a large quantity of mechanical energy stored in the bushing from its assembly,
disassembly of the bushing can cause it to break with explosive force.
The bushing has these parts and materials
•
•
•
•
•
•
•
•
The conductor is made of copper or low-alloy aluminum.
The terminals are made of copper or low-alloy aluminum.
The terminals can be plated with silver, tin, gold or nickel, with a thickness up to 20 μm.
Transformer oil, refer to IEC 60296, class 2.
The condenser core is made of paper and 1 % aluminum foil, impregnated with transformer oil.
The top housing, top end nut, test tap and flexible connection are made of aluminum alloys.
The flanges are made of aluminum.
The press ring for the oil-level sight glass is made of plated brass.
The oil-level sight glass is made of glass.
The insulators are made of quartz-silicate or alumino-silicate based porcelain.
Porcelain
After cleaning, the porcelain can be sent for disposal or used for other purposes, such as for use as
filling material.
Electronics
Electronics equipment should be sent to an approved recycling plant, or sorted into different component
materials for correct processing.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
83
Metals
Metals should be sorted according to type and surface coating, and sent to an approved recycling plant. After
the removal of paint or other surface coatings, clean metal can usually be melted down and used in new
products. Many metal components of iron, steel and aluminum are large and easy to identify, e.g. support
structures. ABB strives to reduce the use of precious metals and the release of environmentally hazardous
metals.
The recycling of precious metals is particularly important. Metals such as copper and silver are expensive,
and are only present in small quantities in the earth's crust. Copper is primarily used in current conductors,
contacts and cables. Some contacts are silver plated. Fumes from some metals can cause environmental
damage, this applies to zinc and nickel, which are used sparingly as surface coatings.
Plastics
The different types of plastic should be separated and sent to an approved environmental waste treatment
plant or recycling plant. The energy content in thermoplastics and thermosetting plastics can often be
recovered through combustion at a plant built for the purpose. Thermoplastics can usually be melted down
and reused without significant loss of quality. Composites can be fractioned and used as filling materials in
other materials, or be disposed of.
Oils and greases
Before disposal of the bushing, oil, grease and similar products must be removed and sent to an approved
environmental waste treatment plant or recycling plant. By utilizing gravimetric forces, oil waste can be
separated into oil, water and a range of contaminants. In many cases, the oil can then be reused. As an
alternative, the energy content in oil can be recovered through combustion at a plant designed for
the purpose.
Rubber
Send rubber to an approved environmental waste treatment plant, either for disposal or reuse for
different purposes.
Rubber is used in seals and gaskets.
Other materials
Sort other materials and send them to an approved environmental waste treatment plant.
84
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
10 References
10.1 Summary
•
•
•
•
Markings: Conforming to IEC/IEEE.
Bushing diagnostics and conditioning, 2750 515-142.
Test adapter, Installation and maintenance guide, 1ZSC000563-ACD.
Transformer oil, IEC 60296, class 2.
Installation and commissioning guide
2750 515-1 EN, REV. 13, 2019-05-22
85
ABB AB, Components
SE-771 80 Ludvika, Sweden
© Copyright 2019 ABB, All rights reserved.
Specifications subject to change without notice.
2750 515-1 EN, REV. 13, 2019-05-22
www.abb.com/transformercomponents
2750 515-115 EN, REV. 7, 2019-08-12
Transformer bushing, type GSA-OA
Installation and maintenance guide
The information contained in this document may be subject to change without prior warning and should not be considered
as binding on ABB AB’s behalf. ABB AB accepts no liability for any errors that may appear in this document. ABB AB is
not liable for any damage resulting from the incorrect interpretation of this document. This document, or parts thereof, may
not be reproduced or copied without ABB AB’s consent. It may not be distributed to others, or used by unauthorized
parties. Any breaches to the above will be penalized with the support of applicable laws.
Contents
1
2
3
4
Safety
Levels of safety risks ................................................................................................................................................................... 5
1.2
Hazardous working situations ..................................................................................................................................................... 6
1.3
Safety precautions....................................................................................................................................................................... 6
Product description
Design ......................................................................................................................................................................................... 7
2.2
Technical specifications ............................................................................................................................................................... 10
2.2.1
General specifications ............................................................................................................................................... 10
2.2.2
Mechanical loading.................................................................................................................................................... 12
Delivery
Incoming inspection..................................................................................................................................................................... 13
3.2
Transportation ............................................................................................................................................................................. 13
3.3
Storage ........................................................................................................................................................................................ 13
3.4
Lifting ........................................................................................................................................................................................... 14
3.4.1
Lifting the transport box ............................................................................................................................................. 14
3.4.2
Lifting the bushing out of the transport box ............................................................................................................... 15
Installation
17
4.1
Tools ............................................................................................................................................................................................ 17
4.2
Consumables .............................................................................................................................................................................. 17
4.3
Preparations ................................................................................................................................................................................ 18
Lifting the bushing ..................................................................................................................................................... 18
Installation on the transformer ..................................................................................................................................................... 20
4.4.1
Installation with draw lead ......................................................................................................................................... 20
4.4.2
Installation with solid-rod conductor .......................................................................................................................... 24
4.4.3
Oil-filling..................................................................................................................................................................... 30
4.4.4
Installation of the outer terminal ................................................................................................................................ 31
4.4.5
Grounding of the bushing flange ............................................................................................................................... 34
Commissioning
37
5.1
Waiting time before energization ................................................................................................................................................. 37
5.2
Recommended tests before energization.................................................................................................................................... 37
5.2.1
Overview ................................................................................................................................................................... 37
5.2.2
Tightness test between transformer and bushing flange........................................................................................... 37
5.2.3
Tightness test of bushing outer terminal.................................................................................................................... 38
5.2.4
Measurement of capacitance and dissipation factor ................................................................................................. 38
5.2.5
Measurement of through-resistance.......................................................................................................................... 42
Maintenance
6.1
7
13
3.1
4.3.1
6
7
2.1
4.4
5
5
1.1
Re-packing
7.1
45
Recommended maintenance ...................................................................................................................................................... 45
47
Re-packing of the bushing........................................................................................................................................................... 47
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
3
8
9
4
Spare parts
49
8.1
Summary ..................................................................................................................................................................................... 49
8.2
Spare parts .................................................................................................................................................................................. 49
8.3
Special tools ................................................................................................................................................................................ 50
Disposal and environmental information
51
9.1
Overview ..................................................................................................................................................................................... 51
9.2
Disposal and recycling ................................................................................................................................................................ 51
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
1 Safety
1.1 Levels of safety risks
Throughout the manual, various types of safety risks are indicated. The most serious level on this scale
provides a warning about serious personal injury or possible death, or major damage to a product, if the
instructions are not observed.
Symbols and their meanings
The following describes the symbols that appear in the manual, along with their meaning.
DANGER!
The yellow, filled warning triangle warns that an accident will occur if the instructions are not
complied with and that it will result in serious personal injury or death and/or major damage to the
product.
It is used, for example, to warn of such dangers as: contact with high voltage, explosion or fire
risk, risk for toxic gases, risk of crushing, impacts, falls from high places, etc.
CAUTION!
The round warning symbol warns that an accident could occur if the instructions are not observed,
and that this could result in personal injury and/or damage to the product.
It is also used to warn of risks that entail burns, eye or skin injuries, impaired hearing, crushing or
slipping injuries, tripping, impacts, falls from high places, etc.
In addition, it is used to warn of functional requirements when assembling or removing equipment
where there is a risk of damage to the product or downtime.
NOTE!
The comment symbol identifies important information and conditions. Also used to indicate any
danger that could lead to property damage.
Torque
The torque symbol indicates tightening torque.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
5
1.2 Hazardous working situations
Hazard
Action
Working close to high voltage.
Disconnect all plant power. Ground all objects at the workplace.
If work must be done close to live plant components, make sure that
the safety distance is in compliance with the applicable safety
regulations.
Working on ladders and platforms.
Work must be done in accordance with the applicable safety
regulations.
Do not use ladders or platforms in poor weather conditions.
Working with heavy objects.
Do not walk under lifted objects.
Make sure that heavy objects are stable before starting work.
1.3 Safety precautions
Precaution
Action
Transformer oil
Collect used transformer oil in drums.
Transformer oil is dangerous. Fumes from hot oil can cause irritation
to the respiratory organs and the eyes. Long and repeated contact
with transformer oil can cause damage to your skin.
6
Waste and cleaning up
Clean up liquid waste with an adsorbent. Treat waste as hazardous
to the environment.
Fire
Extinguish fires with powder, foam or carbon dioxide.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
2 Product description
2.1 Design
Overview
The GSA type is a transformer bushing. It is made for immersed oil to air service. The bushing is of the dry,
gas-free type, with a resin impregnated paper RIP condenser core as the primary insulation, and silicone
rubber (SiR) sheds as outdoor insulation. Bushings of this design can be installed at any angle from vertical
to horizontal.
For a detailed description, please refer to the Technical guide, 1ZSE 2750-111.
G000128
General schematics
1
Outer terminal
2
Outdoor insulator (SiR)
3
Mounting flange
4
RIP condenser core
5
Conductor
6
Test tap
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
7
Test tap
The bushing has a test tap that is connected to the outermost conductive layer of the condenser core. The test
tap is used to measure the bushing insulation by capacitance and dissipation factor. The cover connects the
outermost conductive layer to ground, and must always be installed when the bushing is energized.
The maximum one minute test voltage for this test tap is 2 kVrms. The test tap can be used as a power source,
if it is connected to an external capacitance. The operating voltage is limited to 600 V.
G000411
CAUTION!
Do not energize the bushing without a test adapter or the cover installed. The bushing is grounded
through the cover to prevent damage to the bushing.
1
Stud
2
Grounding spring
3
Cover
4
O-ring
Test adapter, 1ZSC003881-AAC, optional equipment
G001876
The test adapter 1ZSC003881-AAC is available for permanent connection to measuring circuits. Please refer
to Test adapter – Technical guide 1ZSC000563-ACS and Installation and maintenance guide
1ZSC000563-ACD.
8
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
Arcing horns, optional equipment
Arcing horns are available as optional equipment, they are made of galvanized steel.
G004587
Refer to the table for the gap distances (K) of standard arcing horns, other gap distances are available on
request.
Bushing type
K (mm)
C (mm)
H (mm)
GSA 52
230-440
315
112
GSA 73
400-620
315
112
GSA 123
620-960
315
114
GSA 145
700-1080
380
224
GSA 170
820-1290
380
224
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
9
2.2 Technical specifications
2.2.1 General specifications
Refer to the table for the standard technical specifications of the bushing. For conditions exceeding the
specifications, please contact ABB.
10
Application:
Transformers
Classification:
Tranformer bushing
•
Resin impregnated paper, capacitance graded, oil
immersed.
•
For outdoor and indoor use.
•
Temperature class E (120 °C) according to IEC 60137.
Ambient temperature limits:
-40 °C to +40 °C.
Maximum altitude of site:
1000 m (Bushings for other altitudes can be provided on
request.)
Level of rain and humidity:
1-2 mm rain/minute horizontally and vertically, according to
IEC 60060-1 and IEEE Std 4.
Maximum pollution level:
According to the specific creepage distance, and IEC 60815.
Immersion medium:
Transformer oil.
•
Maximum daily mean oil temperature: +90 °C.
•
Maximum temporary oil temperature, at normal load:
+100 °C.
•
Maximum temporary oil temperature, at short time
overload: +115 °C.
Oil-level in transformer:
Not lower than 25 mm from the bushing flange.
Maximum pressure of medium:
pg 100 kPa (pg = relative to ambient pressure).
Angle of installation:
From horizontal to vertical.
Test tap:
Test tap with 4 mm male contact pin.
Capacitance C2 of test tap:
<5000 pF
Arcing horns:
Optional
Conductor:
Solid-rod conductor or draw lead.
Markings:
Conforming to IEC/IEEE.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
List of bushings applicable to this installation guide
Type
GSA-OA 52/2000
GSA-OA 73/2000
GSA-OA 100/1600
GSA-OA 123/1600
GSA-OA 145/1600
GSA-OA 170/1600
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
Article number
/0
LF 130 052
-BA
/0.3
-BB
/0.5
-BC
/0
LF 130 073
-BA
/0.3
-BB
/0.5
-BC
/0
-DA
/0.3
-DB
/0
LF130 100
-BA
/0.3
-BB
/0.5
-BC
/0
LF 130 123
-BA
/0.3
-BB
/0.5
-BC
/0
-CA
/0.3
-CB
/0.5
-CC
/0
LF 130 145
-BA
/0.3
-BB
/0.5
-BC
/0
LF 130 170
-BA
/0.3
-BB
/0.5
-BC
/0
-CA
/0.3
-CB
/0.5
-CC
11
2.2.2 Mechanical loading
G004711
Maximum permitted static load on the outer terminals
12
Type
Type test load 1 minute (N)
Maximum cantilever operating
load (N)
GSA-OA 52/2000
4000
2000
GSA-OA 73/2000
4000
2000
GSA-OA 100/1600
4000
2000
GSA-OA 123/1600
4000
2000
GSA-OA 145/1600
4000
2000
GSA-OA 170/1600
4000
2000
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
3 Delivery
3.1 Incoming inspection
•
•
Make sure that all items have been delivered, refer to the packing list.
Carefully inspect the bushings for shipping damage.
3.2 Transportation
•
•
The bushing must be transported in the transport box.
Carefully inspect the bushing for damage after transportation.
3.3 Storage
Short term storage, less than 6 months
•
•
•
•
Make sure that the bushing is wrapped in the original (or equivalent) moisture-proof wrapping.
If the drying agent inside the wrapping has been exposed to the atmosphere, replace it.
The bushing can be stored outdoors, if it is in the transport box.
Keep the transport box protected from water, when the bushing is stored outdoors.
Keep the bushing dry, clean and protected against mechanical damage.
The bushing can be stored in both the vertical, and horizontal positions.
Long term storage, more than 6 months
•
•
•
•
•
•
Use a transport container on the oil side of the bushing, this has to be ordered separately.
Put drying agent in the transport container.
Make sure that the air side of the bushing is wrapped in the original (or equivalent) moisture-proof
wrapping.
If the drying agent inside the wrapping has been exposed to the atmosphere, replace it.
The bushing can be stored outdoors, if it is in the transport box.
Keep the transport box protected from water, when the bushing is stored outdoors.
Keep the bushing dry, clean and protected against mechanical damage.
The bushing can be stored in both the vertical, and horizontal positions.
The outer terminal must be installed on the bushing.
The bushing is delivered from ABB in a transport box, and the bushing is held in place by support blocks and
fiberboard in the box.
The transport box is marked with Top end.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
13
3.4 Lifting
3.4.1 Lifting the transport box
G000701
Overview
1
Center of gravity
2
Soft lifting slings
Procedure
1.
Make sure that the crane and the soft lifting slings are approved for the total weight of the transport
box and bushing. Refer to the weight in the packing list.
2.
Attach soft lifting slings (2).
3.
Make sure that the angle of the soft lifting sling is not more than 20°.
4.
Carefully lift the transport box.
5.
Set down the transport box on a flat surface.
End of instruction
14
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
3.4.2 Lifting the bushing out of the transport box
G000096
Overview
Procedure
1.
Make sure that the crane is approved for lifting the weight of the bushing. Refer to the weight on the
rating plate.
NOTE!
Light bushings can be lifted by hand.
2.
Open the transport box.
NOTE!
The cover is attached with bolts.
3.
Attach a soft lifting sling to the bottom end housing, as close to the flange as possible, and then to the
crane hook.
CAUTION!
Do not put the soft lifting slings on the silicone insulator, damage will occur.
4.
Attach a soft lifting sling to the outer terminal and then to the crane hook.
5.
Carefully lift the bushing.
6.
Lower the bushing onto soft bedding.
End of instruction
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
15
16
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
4 Installation
4.1 Tools
Tool
Part number
Note
Lifting tool
2183 789-2
For solid rod conductor Ø 49 mm. Max
load 125 kg.
Soft bedding
-
E.g. rubber mat or wood board
Soft lifting slings
-
-
Pull-through cord
9760 669-A, -D
With M8 terminal.
For assembly and disassembly of the
draw rod.
Torque wrench key for hex socket
screws, 16 mm (M10) and 13 mm (M8),
torque 20 to 40 Nm.
-
-
Wrench for hex socket screws 30 mm or
adjustable wrench for 30 mm bolts
or larger.
-
For the test tap cover.
Tackle
-
For installation of the bushing at a
specific angle.
4.2 Consumables
Item
Brand
ABB part
number
Note
Oil based Vaseline
Fuchs
1171 5011-102
For treatment of contact surfases. Does
not react with transformer oil.
Mobilgrease 28
MOBIL
1171 4014-407
Lubricates and protects metals against
corrosion. Protects rubber. Does not
react with transformer oil.
Molykote 1000
Dow Corning
1171 2016-618
For the sealing and lubrication of the
contact on the outer terminal.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
17
4.3 Preparations
4.3.1 Lifting the bushing
G000217
Overview
1
Lifting tool
2
Soft bedding, e.g. rubber mat or woodboard
3
Lifting eye
Procedure
1.
Make sure that the crane can lift the bushing. Refer to net weight in the packing list.
2.
Loosen the M8 bolts (1).
G004717
NOTE!
It is not necessary to remove the M8
bolts.
18
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
3.
Remove the M10 bolts (4) and washers (5), and
then remove the outer terminal (6).
G001869
NOTE!
Keep the outer terminal (6), nuts (5)
and bolts (4), they will be used again.
4.
Remove the item (7):
1.
Attach the pull-through cord to item (7).
2.
Remove item (7) and the divided ring (6).
NOTE!
Item (7) is the inner terminal, or
soild-rod conductor.
G006174
NOTE!
Keep item (7) and the divided ring (6),
they will be used again.
5.
Install the lifting tool (1), and install the bolts (7)
with the washers (5).
G001870
NOTE!
The bolts (7) are not supplied with the
lifting tool (1), use three M10x20 bolts.
Torque
40 ±4 Nm
6.
Align the crane hook with the lifting tool on the bushing.
7.
Carefully lift the bushing.
CAUTION!
Make sure that the bushing does not rotate.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
19
8.
Lower the bushing onto soft bedding.
CAUTION!
Make sure that the bottom contact does not come in contact with the ground, or the floor.
The bottom contact is made of soft metal.
End of instruction
4.4 Installation on the transformer
4.4.1 Installation with draw lead
G004712
Overview
20
1
Bushing
2
Inner terminal
3
Draw lead
4
Pull-through cord
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
Procedure
1.
Solder the draw lead from the transformer
windings to the inner terminal
G006170
NOTE!
As an alternative, the draw lead can be
crimped to the inner terminal.
Carefully clean the bottom end of the bushing, and the inside of the center hole. Look for damage.
3.
Lower the pull-through cord (10) through the
bushing.
4.
Apply Molykote 1000 to the pull-through cord (10),
and attach it to the inner terminal (7).
G000098
2.
G006849
NOTE!
The terminal (7) has M8 threads.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
21
5.
Hold the pull-through cord (12) in tension, while
lowering the bushing onto the transformer.
CAUTION!
Make sure that the draw lead is
entering the bushing correctly. Monitor
the draw lead through the inspection
openings on the transformer.
G004713
CAUTION!
Do not damage the stud bolts on the
transformer. There is a risk of metal
falling into the transformer.
NOTE!
Plastic sleeves put on two or three of
the stud bolts will help to guide the
flange, and will prevent damage to the
stud bolts.
When installing the bushing at the transformer
factory:
1.
Make sure that the bushing is installed in the
correct orientation.
2.
Make permanent markings (16) on the
bushing flange and the transformer turret.
G006164
6.
7.
Install the bolts and washers. Tighten the bolts in
a crosswise sequence.
•
When installing the bushing at site, make
sure that the marking (16) on the bushing
flange lines up with the marking on the
transformer turret.
CAUTION!
Make sure that the bolts are tightened
evenly.
G006365
First tighten all bolts to half the torque,
then to the full torque.
Torque
M12 50 ±5 Nm
1/2” UNC 55 ±5 Nm
22
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
Put the divided ring (6) in the slot in the inner
terminal (7).
9.
Carefully lower the inner terminal (7) with the
pull-through cord (10) until the divided ring (6)
touches the bushing top surface.
G004591
8.
G004716
NOTE!
The divided ring is held in position only
by the weight of the inner terminal.
Install the outer terminal as soon as
possible.
Remove the M10 bolts (6), the washers (7), and
the lifting tool (1).
11.
Continue with Installation of the outer terminal, page 31.
G004714
10.
End of instruction
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
23
4.4.2 Installation with solid-rod conductor
G006166
Overview
1
Bushing
2
Solid-rod conductor
3
Pull-through cord
Procedure
1.
Loosen the captive screws (11), and disassemble
the solid-rod conductor.
G004787
NOTE!
The captive screws (11) cannot be
removed from the upper solid-rod
conductor (7).
24
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
2.
Solder the winding cables (2) from the transformer
to the end of the solid-rod conductor (12).
G006175
NOTE!
As an alternative, the winding cables
can be crimped to the solid-rod
conductor.
3.
Apply insulation to the winding cables and the
lower solid-rod conductor.
G006360
NOTE!
The insulation must cover the recess in
the lower solid-rod conductor.
Carefully clean and inspect the oil end (16) of the
bushing, and the inside of the bushing.
G006167
4.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
25
Lower the pull-through cord (10) through the
bushing.
6.
Attach the the pull-through cord (10) to the
solid-rod conductor (7).
7.
Pull up the upper part (7) of the solid-rod
conductor until the joining surface (17) is
accessible.
G006168
G004788
G006165
5.
26
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
8.
Clean the contact surfaces (17) on the lower (12)
and the upper (7) parts of the solid-rod conductor.
Apply Mobilegrease 28 to the contact
surfces (17).
G006169
NOTE!
Or use a lubricant similar to
Mobilegrease 28.
9.
Connect the upper (7) and lower (12) parts of the
solid-rod conductor:
1.
Apply Mobilgrease 28 to the threads of the
captive screws (11), and the washers.
2.
Assemble the solid-rod conductor, and
tighten the captive screws (11).
G006417
NOTE!
Or use a lubricant similar to
Mobilegrease 28.
Torque
35-40 Nm
10.
Hold the pull-through cord (12) in tension, and at
the same time lower the bushing onto the
transformer.
NOTE!
Plastic sleeves put on two or three of
the stud bolts will help to guide the
flange, and will prevent damage to the
stud bolts.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
G004713
CAUTION!
Do not damage the stud bolts. There is
a risk of metal falling into the
transformer.
27
When installing the bushing at the transformer
factory:
1.
Make sure that the bushing is installed in the
correct orientation.
2.
Make permanent markings (16) on the
bushing flange and the transformer turret.
G006164
11.
12.
Install the bolts and washers. Tighten the bolts in
a crosswise sequence.
NOTE!
When installing the bushing at site,
make sure that the marking (16) on the
bushing flange lines up with the
marking on the transformer turret.
First tighten all bolts to half the torque,
then to the full torque.
G000204
CAUTION!
Make sure that the bolts are tightened
evenly.
Torque
M12 50 ±5 Nm
1/2” UNC 55 ±5 Nm
Put the divided ring (6) in the slot in the solid-rod
conductor (7).
G000101
13.
28
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
Carefully lower the inner terminal (7) with the
pull-through cord (10) until the divided ring (6)
touches the bushings top surface.
15.
Remove the pull-through cord.
16.
Remove the M10 bolts (6), the washers (7), and
the lifting tool (1).
17.
Continue with Installation of the outer terminal, page 31.
G004714
G004716
14.
End of instruction
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
29
4.4.3 Oil-filling
Overview
Start this procedure when the transformer oil has reached the bottom of the bushing.
•
This procedure is NOT applicable if the transformer is oil-filled with the vacuum process.
G006859
The purpose of this procedure is to remove as much air as possible from the center tube of the bushing.
Because air is soluble in transformer oil, air will go into the transformer oil and will cause its performance to
deteriorate. The amount of air that can be removed depends on the bushings position in relation to the
transformers oil-conservator.
Oil spillage
Oil spillage attracts dirt and this can reduce the performance of the electrical insulation. Large quantities of
oil can cause the silicone rubber to expand and deform. Remove oil-spills with paper towels.
CAUTION!
Do not allow oil that has been in contact with silicone-rubber to enter the transformer. It can
contain small amounts of silicone oil that will reduce the surface tension of the transformer oil,
this will cause foaming in forced oil circulation.
Procedure
1.
Make sure that the transformer oil-level is
maximum 25 mm from the flange.
G006367
CAUTION!
A lower oil-level will decrease the
cooling of the bushing, and can cause
spontaneus flashovers.
30
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
2.
Wait until the oil-level (h) in the center-tube has
risen to the same height as the oil-level in the
transformers oil-conservator.
•
If the top of the bushing is lower than the
transformers oil-conservator, wait until oil
flows out from top of the bushing.
G004720
NOTE!
Air is soluble in transformer oil, thus as
much as possible must be released
from the bushing center-tube.
End of instruction
4.4.4 Installation of the outer terminal
Procedure
1.
Carefully clean the contact and gasket surfaces with a soft cloth, and then apply Mobilgrease 28.
CAUTION!
Do not use a wire brush on aluminium surfaces, or zinc coated surfaces. A wire brush can
make scratches in the surfaces.
2.
Carefully clean the contact and gasket surfaces
with a soft cloth, and then apply Mobilgrease 28 to
the contact surfaces and the O-ring (3).
NOTE!
When the outer terminal (5) is installed
at site for grid operation, replace the
used O-ring (3) with a new O-ring. A
new O-ring is supplied with the
bushing.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
G006409
NOTE!
Or use a lubricant with equal properties
to Mobilgrease 28.
31
Assemble the tightening ring (4), the O-ring (3),
and the outer terminal (5).
4.
Apply Molykote 1000 to the washers (2) and (10), and the threads of the M8 bolts (1).
5.
Install the M8 bolts (1), the spring washers (2),
and the plain washers (10).
6.
Put the outer terminal (5) on the bushing.
7.
Apply Molykote 1000 to the washers, and to the
threads and the shank of the M10 bolts (2).
G000702
3.
G000103
Torque
Tighten with your fingers.
G000105
NOTE!
Or use a lubricant with equal properties
to Molykote 1000.
8.
Install the M10 bolts (2) and plain washers.
Tighten the bolts in a crosswise sequence.
Torque
40 ±4 Nm
CAUTION!
Do NOT use an impact driver / wrench!
32
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
9.
Prepare the contact surface of the outer terminal for the external connection:
1.
Carefully remove oxide with a wire-brush.
2.
Clean with a soft cloth.
3.
Apply Vaseline.
NOTE!
Or use a lubricant with equal properties to Vaseline.
10.
Install the external connections. Refer to the documentation from the supplier of the external
connection.
End of instruction
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
33
4.4.5 Grounding of the bushing flange
Overview
The bushing flange must be grounded to the transformer tank. This prevents electrical discharge between the
bushing flange and the transformer tank under normal service conditions.
There are two alternatives.
DANGER!
Make sure that the grounding is correct. An unsatisfactory grounding can cause damage to
equipment, or death to personnel.
Procedure with a cone point set screw
1.
Apply a large quantity of Mobilgrease 28 to the
cone point set screw (13).
CAUTION!
The quality of the cone point set screw
is important, stainless steel of A4-80
quality is recommended.
G006171
NOTE!
Or use a lubricant similar to
Mobilgrease 28.
2.
Install the cone point set screw (13).
NOTE!
The cone point of the set screw
penetrates the paint. This makes an
electrical connection between the
bushing and the transformer tank,
keeping them at the same potential.
Torque
M12: 40 Nm
End of instruction
34
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
Procedure with a flexible cable
Clean the contact surfaces.
2.
Put a flexible cable (14) between the grounding
hole in the bushing flange and a grounding point
on the transformer.
3.
Apply a large quantity of Mobilgrease 28 to the bolt (13).
G006172
G006861
1.
CAUTION!
The quality of the bolt is important, stainless steel of A4-80 quality is recommended.
NOTE!
Or use a lubricant similar to Mobilgrease 28.
4.
Install the bolt (13).
5.
Connect the other end of the flexible cable (14) to the transformer.
Torque
M12: 40 Nm
NOTE!
This makes an electrical connection between the bushing and transformer tank, keeping
them at the same potential.
End of instruction
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
35
36
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
5 Commissioning
5.1 Waiting time before energization
Waiting times after oil-filling of the transformer
Some waiting time is necessary after the transformer has been oil-filled, before the bushing is energized. The
reason for this is that air bubbles stick to the bushings surface when the transformer is filled with oil, and
flashovers and partial discharges can form in the bubbles. Thus, it is important to let the necessary waiting
time pass, to make sure that all the air bubbles have risen to the surface of the oil before the bushing is
energized. Refer to the table.
The transformer is oil-filled with
Necessary waiting time
The vacuum process
No waiting time is necessary, air bubbles does not
form in vacuum. Refer to the transformer
manuafacturers instructions.
Gas-saturated transformer oil
After the oil-filling process has been completed, wait
for 24 hours before energizing the transformer.
De-gassed transformer oil
After the oil-filling process has been completed, wait
for 6 hours before energizing the transformer.
A reduced oil-level
After the oil-level has been restored, wait 24 hours
before energizing the transformer.
5.2 Recommended tests before energization
5.2.1 Overview
The tests should be done to check the insulation, sealing and current path of the bushing.
NOTE!
The tests should be done after installation, but before connecting the outer terminal of the bushing
to the power circuit.
5.2.2 Tightness test between transformer and bushing flange
Several different methods can be used and we thus refer to the instructions given by the company responsible
for field erection. As an example, the tightness of the seal between the transformer and the bushing flange
can be checked when the transformer is oil-filled by using chalk or, perhaps easier, with paper strips.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
37
5.2.3 Tightness test of bushing outer terminal
Overview
Because the outer terminal is often situated above the oil level of the transformer oil expansion system, a leak
at the outer terminal is serious. Water could enter directly into the transformer insulation. It is thus
recommended to do a tightness test after installation of the bushing, both with vacuum and pressure.
Different methods can be used, and ABB refers to the instructions given by the company responsible for the
field erection of the bushing.
Example procedure
1.
Put tracer gas into the center tube before installation of the outer terminal.
NOTE!
The oil level of the transformer must be above the bottom end of the bushing, but below the
bushing flange.
Increase the oil level to just below the bushing flange, to raise the pressure in the center tube.
3.
Find leaking gas with gas detector (sniffer) near
the gasket.
G006173
2.
End of instruction
5.2.4 Measurement of capacitance and dissipation factor
Overview
After installation of the bushing, it is recommended to measure the capacitance values for future reference,
such as repairs, service etc. This can be done on an installed bushing because it has an insulated test tap.
Refer to 2750 515-142, “Bushing diagnostics and conditioning”.
•
C1 is the capacitance between the test tap and the outer terminal.
•
C2 is the capacitance between the test tap and ground.
NOTE!
The transport container must be removed before measuring the capacitance and dissipation factor
(tan δ).
38
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
Nominal capacitance
The capacitance (C2) depends on the transformer, and it is not possible to give a nominal value that is valid
for all service conditions. Thus, it is important to measure and record the capacitance (C 2) for future
reference, such as repairs, service etc.
GSA-OA 52
Article number
Space for CT = 0 mm
Space for CT = 300 mm
Space for CT = 500 mm
C1
C1
C1
LF 130 052-BA
215
-
-
LF 130 052-BB
-
417
-
LF 130 052-BC
-
-
543
Space for CT = 0 mm
Space for CT = 300 mm
Space for CT = 500 mm
C1
C1
C1
LF 130 073-BA
325
-
-
LF 130 073-BB
-
512
-
LF 130 073-BC
-
-
636
LF 130 073-DA
303
-
-
LF 130 073-DB
-
460
-
Space for CT = 0 mm
Space for CT = 300 mm
Space for CT = 500 mm
C1
C1
C1
LF 130 100-BA
294
-
-
LF 130 100-BB
-
397
-
LF 130 100-BC
-
-
488
Space for CT = 0 mm
Space for CT = 300 mm
Space for CT = 500 mm
C1
C1
C1
LF 130 123-BA
216
-
-
LF 130 123-BB
-
319
-
LF 130 123-BC
-
-
369
LF 130 123-CA
200
-
-
LF 130 123-CB
-
260
-
LF 130 123-CC
-
-
356
GSA-OA 73
Article number
GSA-OA 100
Article number
GSA-OA 123
Article number
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
39
GSA-OA 145
Article number
Space for CT = 0 mm
Space for CT = 300 mm
Space for CT = 500 mm
C1
C1
C1
LF 130 145-BA
233
-
-
LF 130 145-BB
-
326
-
LF 130 145-BC
-
-
386
LF 130 145-CA
254
-
-
LF 130 145-CB
-
417
-
LF 130 145-CC
-
-
400
Space for CT = 0 mm
Space for CT = 300 mm
Space for CT = 500 mm
C1
C1
C1
LF 130 170-BA
311
-
-
LF 130 170-BB
-
404
-
LF 130 170-BC
-
-
467
LF 130 170-CA
312
-
-
LF 130 170-CB
-
404
-
LF 130 170-CC
-
-
467
GSA-OA 170
Article number
Dissipation factor, tan δ
The dissipation factor varies with the temperature of the bushing body, and thus the measured dissipation
factor must be multiplied with the correction factor given below.
40
Bushing body temperature °C
Correction factor to 20 °C (IEC)
0-2
0.76
3-7
0.81
8-12
0.87
13-17
0.93
18-22
1.00
23-27
1.07
28-32
1.14
33-37
1.21
38-42
1.27
43-47
1.33
48-52
1.37
53-57
1.41
58-62
1.73
63-67
1.43
68-72
1.42
73-77
1.39
78-82
1.35
83-87
1.29
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
Procedure
De-energize the transformer.
2.
Disconnect the external connections from the outer terminal of the bushing.
3.
Remove the cover (2).
4.
Connect the measuring equipment.
G000106
1.
5.
1.
Connect the low voltage cable to the stud (1).
2.
Connect the high voltage cable to the outer terminal.
3.
Connect the ground cable to the bushing flange (3).
Measure the capacitance (C1) between the outer terminal and the stud (1).
•
Record the capacitance (C1) for future reference.
NOTE!
Refer to the table for the nominal capacitance (C1), Nominal capacitance, page 39.
6.
Measure the capacitance (C2) between the stud (1) and the flange.
•
7.
Record the capacitance (C2) for future reference.
Measure the dissipation factor:
1.
Start the measurements with a low sensitivity setting on the measuring bridge.
2.
Gradually increased the sensitivity setting on the measuring bridge to the highest possible.
3.
Calculate the dissipation factor with the correction factor, refer to Dissipation factor, tan δ,
page 40.
NOTE!
In some cases, external interference can make it difficult to set the measuring bridge to
zero.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
41
8.
Install the cover (2).
CAUTION!
The test tap is not self-grounding!
The bushing can be destroyed if the test tap is not grounded. Because the capacitance (C2)
is usually relatively small, the test tap must never be open-circuited when applying a
voltage to the bushing. It must always be grounded or connected to an external impedance.
CAUTION!
Do not energize the bushing without the cover or a test adapter installed. The cover
connects the outermost conductive foil to ground and will prevent damage to the bushing.
CAUTION!
Make sure that the cover is correctly installed with the O-ring in place, when the bushing is
not in use. The purpose is to prevent dust and water from entering the tap.
9.
Connect the outer terminal of the bushing to the external connections.
End of instruction
5.2.5 Measurement of through-resistance
Overview
The method to use for measuring the through-resistance depends on the design of the transformer. In general,
a current is applied from bushing to bushing. The voltage drop from the outer terminal to outer terminal is
measured. The resistance is calculated with Ohm's law, R=U÷I.
(R: total circuit resistance, U: measured voltage drop, I: through-current).
The total through-resistance is the sum of the transformer winding, lead resistance, the bushing conductor,
and contact resistance. The additional resistance from the bushing conductor should not be more than 10 to
100 mΩ. Because the through-resistance of the HV winding of a typical power transformer is in the order of
0.1 to 1 Ω, this is a very rough method that can only be used to detect very large faults in the current path,
such as open circuits.
Small faults in the current path can only be detected by making sensitive measurements across each
connection point, or by measuring the temperature increase during operation with an infrared sensitive
camera (thermovision).
The through-resistance of an installed bushing can only be measured from the outer terminal of one bushing,
to the outer terminal of the other bushing on the same transformer winding. The through-resistance will
include the resistance of both bushings, all connections and the transformer winding.
Procedure
1.
Record the temperature of the transformer winding.
NOTE!
The resistance of metals depends on their temperature. Because the transformer winding
usually dominates the total resistance, the average winding temperature at the time of
measurement must be recorded.
2.
42
Measure the through-resistance from outer terminal to outer terminal.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
3.
Calculate the measured resistance to the reference temperature. Then compare the calculated
resistance to the reference resistance.
A difference of less than 2% is acceptable.
NOTE!
The transformer manufacturer gives the reference temperature for through-resistance
measurements.
4.
5.
If the calculated difference of resistance is more than 2% from the reference resistance:
1.
Make sure that the external connections have low resistance, and make sure that the outer
terminal and the internal connections are correctly installed.
2.
Measure the through-resistance again.
If the calculated difference of resistance again is more than 2%:
•
Wait 24 hours and do steps 1 through 5 again.
End of instruction
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
43
44
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
6 Maintenance
6.1 Recommended maintenance
General
The bushings are maintenance free, no regular maintenance is necessary.
DANGER!
Risk of electrocution!
Do not go near the bushing while it is energized, or ungrounded. High voltages can kill you.
Make sure that the bushing is de-energized, and grounded before you do work on it.
Cleaning of the insulator surface
If the insulator is exposed to very high pollution, it can be necessary to clean the surface. Remove the
pollution with a moist cloth. If necessary, put isopropyl alcohol on the cloth.
DANGER!
1,1,1 -Trichloroethane or Methyl-chloride are not recommended as detergents, because they are
dangerous to persons and the environment.
CAUTION!
Do not wash the insulators with a high pressure water jet. This can cause damage to the insulators.
Measurement of capacitance and dissipation factor
Please refer to Measurement of capacitance and dissipation factor, page 38.
Thermovision (infrared camera) check for local overheating on connectors
At the maximum rated current, the bushing outer terminal normally operates at a temperature of about
+35 °C to +45 °C above the ambient temperature. Significantly higher temperatures can be a sign of bad
connections, especially at lower current loading.
Checking of oil leakage
Make a visual inspection for oil leakage during regular station supervision.
After repairs
ABB recommends that the capacitance is measured after repairs have been done, after maintenance of
connected equipment, or after work near the bushing is completed.
It is important to compare the capacitance before energization with the capacitance that was measured at
commisioning. A change in capacitance gives indication of a fault. Refer to Measurement of capacitance and
dissipation factor, page 38.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
45
46
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
7 Re-packing
7.1 Re-packing of the bushing
G000096
Overview
Procedure
1.
Lift the bushing. Refer to Lifting the bushing out of the transport box, page 15.
2.
Lower the bushing into the transport box.
CAUTION!
Do not apply force to the polymeric insulator, deformation will occur.
CAUTION!
Make sure that the there is soft bedding in the transport box.
CAUTION!
Make sure that the test tap does not make contact with the transport box, or other objects.
3.
Attach the bushing to the transport box in the same way as when it was delivered.
CAUTION!
Make sure that the bushing cannot move or rotate in the transport box.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
47
4.
Close the transport box.
NOTE!
Refer to Lifting the transport box, page 14 and Transportation, page 13.
End of instruction
48
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
8 Spare parts
8.1 Summary
If the bushing is damaged, we recommend that it is returned to ABB for repairs and re-testing. Some parts
that are damaged or lost during transportation or installation can be ordered from ABB.
8.2 Spare parts
Cover
For the test tap.
Part
Article number
Note
1
Cover
2749 528-B
-
2
O-ring
1ZSC001606-AAW
-
G006192
Position
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
49
8.3 Special tools
Lifting tool
Article number
Note
Lifting tool
2183 789-2
-
Part
Article number
Note
Pull-through cord
9760 669-A
With M8-terminal.
G006839
Part
G006198
Pull-through cord
50
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
9 Disposal and environmental information
9.1 Overview
This chapter specifies the materials used in the bushing. Comply with local environmental regulations on
disposal of this product, the materials used are specified for this purpose.
9.2 Disposal and recycling
ABB strives to minimize the product's impact on the environment throughout its entire life cycle. Technical
and product development focuses on environmental aspects. The ecocycle approach is striven for, and
consideration is taken to the materials' environmental impact and recycling alternatives. The manufacturing
processes are selected to be as safe for the environment as possible.
Disposal of worn-out equipment
Worn-out equipment must be disposed of in an environmentally sound manner.
Much of the material, or the energy content in the material, can be recycled if it is sorted and cleaned. The
quantity of material that can be recycled varies depending on the technical resources and capabilities in each
country. Non-recyclable components should be sent to an approved environmental waste treatment plant for
destruction or disposal.
Porcelain
After cleaning, the porcelain can be sent for disposal or used for other purposes, such as for use as
filling material.
Electronics
Electronics equipment should be sent to an approved recycling plant, or sorted into different component
materials for correct processing.
Metals
Metals should be sorted according to type and surface coating, and sent to an approved recycling plant. After
the removal of paint or other surface coatings, clean metal can usually be melted down and used in new
products. Many metal components of iron, steel and aluminum are large and easy to identify, e.g. support
structures. ABB strives to reduce the use of precious metals and the release of environmentally hazardous
metals.
The recycling of precious metals is particularly important. Metals such as copper and silver are expensive,
and are only present in small quantities in the earth's crust. Copper is primarily used in current conductors,
contacts and cables. Some contacts are silver plated. Fumes from some metals can cause environmental
damage, this applies to zinc and nickel, which are used sparingly as surface coatings.
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
51
Plastics
The different types of plastic should be separated and sent to an approved environmental waste treatment
plant or recycling plant. The energy content in thermoplastics and thermosetting plastics can often be
recovered through combustion at a plant built for the purpose. Thermoplastics can usually be melted down
and reused without significant loss of quality. Composites can be fractioned and used as filling materials in
other materials, or be disposed of.
Oils and greases
Before disposal of the bushing, oil, grease and similar products must be removed and sent to an approved
environmental waste treatment plant or recycling plant. By utilizing gravimetric forces, oil waste can be
separated into oil, water and a range of contaminants. In many cases, the oil can then be reused. As an
alternative, the energy content in oil can be recovered through combustion at a plant designed for
the purpose.
Rubber
Send rubber to an approved environmental waste treatment plant, either for disposal or reuse for
different purposes.
Rubber is used in seals and gaskets.
Other materials
Sort other materials and send them to an approved environmental waste treatment plant.
52
Installation and maintenance guide
2750 515-115 EN, REV. 7, 2019-08-12
ABB AB, Components
SE-771 80 Ludvika, Sweden
© Copyright 2019 ABB, All rights reserved.
Specifications subject to change without notice.
2750 515-115 EN, REV. 7, 2019-08-12
www.abb.com/transformercomponents
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 1
10/4/2013 10:13 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 2
10/4/2013 10:05 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
2 of 2
10/4/2013 10:05 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 2
10/4/2013 10:13 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
2 of 2
10/4/2013 10:13 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 2
10/4/2013 10:13 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
2 of 2
10/4/2013 10:13 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 2
10/4/2013 10:13 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
2 of 2
10/4/2013 10:13 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 2
10/4/2013 10:14 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
2 of 2
10/4/2013 10:14 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 2
10/4/2013 10:14 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
2 of 2
10/4/2013 10:14 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 2
10/4/2013 10:14 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
2 of 2
10/4/2013 10:14 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 2
10/4/2013 10:14 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
2 of 2
10/4/2013 10:14 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 2
10/4/2013 10:15 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
2 of 2
10/4/2013 10:15 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 2
10/4/2013 10:15 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
2 of 2
10/4/2013 10:15 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 2
10/4/2013 10:15 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
2 of 2
10/4/2013 10:15 AM
http://pdf.directindustry.com/pdf/eberle/voltage-regulator-reg-d/15254-1...
1 of 1
10/4/2013 10:15 AM
PART 5
DISMANTLING AND TRANSPORT
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 33 -
5
DISMANTLING AND TRANSPORT
5.1
RESPONSIBILITIES AFTER TRANSFORMER TEST AND PREPARATION FOR SHIPMENT
GENERAL OVERVIEW +FIGURE F5.1+APPENDIX A5.1
5.2
METHODS OF TRANSPORTATION
5.3
TRANSPORT MODES
5.3.1 TRANSPORT WITH DRY AIR FILLING + DRAWING 1ZYN 4601-204
5.3.2 INSTRUCTIONS FOR FILLING DRY AIR (AT WORKS)
5.4
HANDLING DURING LOADING AND ON SITE
5.4.1 LIFTING TRANSFORMERS
5.4.2 SUSPENDING TRANSFORMERS + FIGURE: F 5.2
5.4.3 MOVING TRANSFORMERS
5.4.4 TRANSPORT OF ACCESSORIES
5.4.5 TRANSPORTATION EQUIPMENT AND TOOLS
5.5
SHIPPING ARRANGEMENTS
5.5.1 GENERAL
5.5.2 SHIPPING BRACES
5.5.3 BUSHINGS
5.5.4 CURRENT TRANSFORMERS
5.5.5 SHUT OFF DEVICES
5.5.6 TIGHTNESS SURVEILLANCE
5.6
PACKING LIST AND TRANSPORT MONITORING
5.6.1 GENERAL
5.6.2 PACKING LIST
5.6.3 ASSEMBLY PACKAGES
5.6.4 TRANSPORT MONITORING
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 34 -
-
INDEX
Section
Description
5.1.1 Scope
5.1.2 Shipping Information
5.1.2.1 Packing List
5.1.2.2 Shipping braces and covers
5.1.3.0 Transportation
5.1.3.1 General
5.1.3.2 Impact Recorder (If Applicable)
5.1.3.3 Other Data
5.1.4.0 Successful Shipment Verification
5.1.4.1 General
5.1.4.2 Impact Recorder
5.1.4.3 Other Checks
5.1.4.3.1External Inspection
5.1.4.3.2Internal Inspection
5.1.5.0 Arrival at Customer’s Mounting Pad
5.1.5.1 General
5.1.5.2 Storage on Site
5.1.6.0 Re-Assembly Instructions
5.1.6.1 Oil Handling and Filling
5.1.7.0 Commissioning Tests
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 35 -
5.0
5.1
DISMANTLING AND TRANSPORT [REF: 1ZBA 4601-200]
RESPONSIBILITIES AFTER TRANSFORMER TEST AND PREPARATION FOR SHIPMENT GENERAL OVERVIEW.
5.1.1 SCOPE
Provide a specification outlining the actions to be taken and the documentation to be delivered to
meet the Customer’s needs after a transformer has been tested and subsequently prepared for
shipment.
Guidelines will be offered, and where applicable example documents provided, to allow the Power
Transformer Plants to meet Customer expectations in the transportation, verification of successful
shipment, installation, commissioning, operation and life cycle management of their equipment.
This specification will detail in general terms the information and services a Customer requires to
complete the relationship after the transformer has been successfully tendered, designed,
manufactured, tested and prepared for shipment.
5.1.2
5.1.2.1
SHIPPING INFORMATION
PACKING LIST
Who Uses a Packing List?
Manufacturer - to catalogue parts removed for shipment and to confirm the removed, required parts
have been packaged for delivery.
Transport Company - to identify packages to be picked up and delivered, to assess shipping cost.
Customer - to confirm that the required parts have been received, to aid in re-assembly.
What should be on a Packing List?
Identification of all parts, dimensions and weights of major components and accessory boxes.
Shipped components can be grouped into major and accessory parts.
Major parts would include the stripped down transformer, conservator, bushings, surge arresters,
coolers and drums of top up oil. These parts may be packaged (boxed or on skids) to allow for
convenient transport.
Accessories would include all parts removed for shipment from the transformer and the major
components such as all required hardware, gauges, devices, valves, spare components, etc. These
parts are packed in boxes.
The packing list must include the weights and dimensions of the major
components and packed boxes to allow the Transport Company to cost the move and for the
specification of cranes at the Customer’s site.
There must be a correlation between the parts shipped, and the completed transformer, to facilitate
re-assembly of the equipment.
A determination should be made if there is a need to differentiate between the packing list for a truck
shipment versus a rail shipment or other transport mode. Export packing will require a different
packing list (and packing instructions) than a packing list for domestic transport. See SECTION 5.6
[REF: 1ZBA 4601-201] for additional Packing List guidelines.
5.1.2.2 SHIPPING BRACES AND COVERS
Shipping covers and sometimes special braces are required to prepare the transformer for shipment.
These braces and covers must be removed after arrival at Customer’s site during the re-assembly
process. The covers and braces are identified in the shipping documentation and are painted a
contrasting colour, such as yellow, for easy identification.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 36 -
5.1.3 TRANSPORTATION
5.1.3.1 GENERAL
Transportation from the factory to the Customer’s site, nearest rail siding or nearest port is often
arranged by the manufacturer. If the transformer is not delivered directly to a mounting pad at the
Customer’s site, crane handling and/or heavy equipment moving capability as well as additional
transport will be required.
Once at the mounting pad, a large capacity crane and/or heavy equipment moving capability for the
main unit, and small crane capability for the transformer accessories will be required.
The manufacturer must be prepared to make arrangements with reputable, reliable transport, crane
and heavy equipment moving companies on behalf of the Customer for the complete voyage from
factory to Customer’s mounting pad.
The Customer or Customer’s agent may wish to establish some or all of the transportation and off
loading arrangements, but the manufacturer must be in a position to assist when required.
For critical shipments by rail, sometimes a rider is required. The rider accompanies the transformer
(generally riding in the train’s caboose) and can monitor the condition of the journey as well as report
to the manufacturer and Customer on trip progress.
5.1.3.2 IMPACT RECORDER (If applicable)
The use of a three dimension impact recorder (also known as a bump recorder or accelerometer) to
monitor the quality of the trip and to chronicle potential excessive shocks to the transformer, is in
many cases a Customer specified requirement.
The impact recorder should be mounted on the transformer cover (rather than the rail car) to provide a
representative record of the impact shocks that the transformer will receive on its journey. Also, if
the transformer is moved from one mode of transportation to another, the impact recorder can travel
the entire journey from the factory to the Customer’s mounting pad.
Core form transformers are to be shipped upright, with the transformer mounted on the rail car or
truck such that the long axis is in the same direction as the direction of travel.
Plan view of a Transformer placed on a Rail Car or Truck
<<<<Direction of Travel>>>>
Transformer Rail Car or T rack
Figure 5.1
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 37 -
The impact recorder must be mounted on the transformer to ensure: the Longitudinal
Acceleration direction lines up with the direction of travel the Lateral Acceleration direction
lines up with the direction a right angles to the direction of travel the Vertical Acceleration will
detect the up and down movement.
Care must be taken to properly set-up and mark the start-up of the impact recorder at the factory.
This same care is critical when marking the impact recorder tape at change of transportation mode
and/or at final removal at the Customer’s pad. In the event of the transformer being exposed to
excessive mechanical shock, a properly set-up and monitored impact recorder can help pinpoint the
time, place, level and direction of the potentially damaging forces.
5.1.3.3
OTHER DATA
Prior to shipping the transformer, tests for future comparison at change of transportation mode
and/or at final unloading at the Customer’s pad should be made. These tests and checks must
include the following:
core ground insulation resistance (megger)
water content (ppm) and dielectric strength (kV) of the oil shipped in unit, if applicable
pressure gauge reading, if applicable
temperature gauge reading, if applicable
dew point reading (- o C), if applicable
This information must be included with the shipping documentation to allow easy access and
reference for comparison.
5.1.4.0 SUCCESSFUL SHIPMENT VERIFICATION
5.1.4.1 GENERAL
After leaving the factory, whenever the transformer and components are transferred from one mode
of transportation (rail car, truck, ship, etc.) to another or when they reach the final destination, checks
must be made to confirm that shipping damage has not been sustained. These checks must be
made before the equipment is moved from the transport mode. Since transformers are shipped
partially disassembled, electrical testing to confirm fitness cannot be performed at this stage. Care
must be taken to properly and completely perform the limited amount of inspection that can be done
at this time.
In the event of apparent or suspected damage, claims must be made against the transport
carrier, and ABB and Customer are to be notified immediately.
5.1.4.2 IMPACT RECORDER (If Applicable)
Separate instructions are be given in APPENDIX A5.1 AT THE END OF THIS PART, to be used
when impact recorder is provided, on removing the impact recorder at final destination. Acceptable
impact levels for the Longitudinal, Lateral and Vertical Acceleration will be defined by the individual
Factories.
If the transformer and components are being inspected at an interim point, at a change of
transportation mode, the impact recorder tape should be marked with a line and the date, time and
signature of an inspector indicted on the tape below this line. The impact recorder should not be
removed from the transformer and the tape examined until the transformer has reached it’s final
destination.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 38 -
5.1.4.3 OTHER CHECKS
If Shipping weight and dimension limits allow, smaller transformers are shipped with all or most of
the oil required in the main tank. Some of these smaller units may also be shipped with dry air in the
gas space on top of the oil, this gas will be at a positive pressure when the transformer leaves the
factory.
To reduce shipping weight, larger units are totally drained of oil and then filled with dry gas air to
maintain winding and insulation dryness during transit. Of the gas filled units, some will be filled in
the factory and then be equipped with temporary gas cylinders for adding gas to the tank during
transit as needed. Other gas filled units will leave the factory with an initial filling only and no
supplementary cylinders added. In all cases, the gas filled units will leave the factory with a positive
pressure of dry gas.
For transformers shipped in oil, check for oil leaks at valves, flanges, bushings and welded seams. If
evidence of oil leaks are observed, take an oil sample for moisture content and dielectric strength
analysis. The laboratory results can be compared to the results obtained at the factory prior to
shipment.
For transformers shipped in oil with a gas layer on top of the oil, perform oil leak checks and draw oil
from suspect units. In addition, theses transformers will be equipped with a vacuum/pressure gauge
to monitor the gas layer pressure.
This gauge must be checked and value of pressure/vacuum
noted along with the oil temperature as read from the top oil temperature gauge.
Although the
transformer leaves the factory with the gas at a positive pressure (2 - 3 psi), the pressure reading
may be negative if transformer is exposed to colder temperatures or conversely read a higher
pressure if the ambient temperature is higher. The worst case condition is a reading of zero
pressure which may be indicating a leak. If the gauge reads zero, take and oil sample for moisture
and dielectric strength analysis. (a dew point measurement of this gas is meaningless)
For transformers shipped dry gas filled , the monitoring of the vacuum/pressure gauge and the
temperature gauge is critical and is often checked at various stages of the journey.
A leak will compromise the winding and insulation integrity. The pressure and temperature gauge
values must be recorded and compared to the readings obtained in the factory prior to shipment.
The transformers are shipped with a positive pressure but a negative (vacuum) reading may occur if
the ambient temperature is substantially lower than recorded in the factory. The worst case condition
is a reading of zero pressure which may be indicating a leak. In conditions of zero pressure or a
pressure/temperature relationship that conflicts with the factory results, a dew point measurement
must be taken. The dew point measurement will establish the moisture content of the gas which can
be compared to the measurement made in the factory prior to shipment., PART 6 [REF: 1ZBA 4601203 and 1ZBA 4601-204] for further information on monitoring dry gas filled units during shipment.
The following is a general listing of tests and checks that should be performed on shipped
transformers. Not all checks are required for all shipping variations.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 39 -
5.1.4.3.1 EXTERNAL INSPECTION
Any external evidence of damage or evidence indicating the possibility of hidden damage must be
reported to the carrier’s representative and to an ABB representative before off-loading the
transformer. Take pictures of external damage. The receiver must assume all responsibility for
offloading damaged transformers. The external inspection prior to off-loading the transformer should
include the following.
Measure the core insulation resistance to ground.
when measured at 1000 V DC, corrected to 20 oC.
The minimum acceptable value is 500 k ohms
Are all tie rods undamaged and nuts tight, all cables tight. Is
all blocking tight and in good condition.
Is there any evidence of load shifting in transit.
Does the impact recorder tape indicate any impacts beyond the acceptance zones on the tape.
Are there indications of external damage such as broken glass on gauges, broken welds on flanges.
Is the paint finish damaged.
Are all fittings, which were shipped attached, still in place and undamaged (see the outline
drawings).
Is there any evidence of oil leakage around valves, fittings, flanges and tank seams.
Is the pressure in the gas filled transformer tank acceptable according to PART 06. [REF: 1ZBA
4601-203 or 1ZBA 4601-204].
Inspect bushings which are assembled to the tank, or are in crates or boxes for signs of breakage,
are they chipped or otherwise damaged.
Is oil level in bushings normal.
Check the Packing List to confirm delivery of all major components and accessory boxes.
Do crates or boxes show evidence of damage or moisture entrance.
Check the temporary shipping silica gel breather, moisture ingress will be indicated by the normally
blue coloured silica gel desiccant turning pink.
Check that detached radiators, coolers and pumps have openings closed of with blind flanges and
plugs.
If there is no evidence of shipping damage, proceed to off-load the transformer. If shipping damage is
found, contact the nearest ABB Power Transformers representative for further instructions prior to
off-loading the transformer.
Written notations of apparent loss and damage must be made on the carrier’s delivery receipt.
Concealed damage must be reported immediately to the delivering carrier with a request for an
inspection.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 40 -
See Product Information for specific Receiving Inspection - PART 7 OF THIS MANUAL:
REFERENCES:
1ZBA 4601-207 Transformer Designed with Oil Conservator, Shipped Dry-Gas Filled, Partially
Disassembled
5.1.4.3.2 INTERNAL INSPECTION
During the inspection process, if internal damage is indicated or requires confirmation, an internal
inspection may be required. This internal inspection should only be carried out by factory personnel
or a recognized service organization under factory personnel guidance.
Entry into oil filled or temporary gas filled transformer tank requires training and experience and must
not be attempted by non factory-approved personnel. Special procedures must be followed for
safety and equipment integrity reasons.
5.1.5.0 ARRIVAL AT CUSTOMER’S MOUNTING PAD
5.1.5.1 GENERAL
Upon arrival at the Customer’s site, the transformer and accessories must be inspected to confirm
that shipping damage has not been sustained. Refer to Section 5.1.4.above. At this point some
Customer’s will require as a standard procedure, an inspection, refer to Section5.1.4.3.1.and
5.1.4.3.2 After confirmation of successful shipment, the transformer and components can be
unloaded.
Depending on the main unit weight and the site conditions, a crane may be used to off-load the
transformer or it may be jacked and rolled into place onto the Customer’s mounting pad. PART 8:
[REF 1ZBA 4601-202], for guidelines about Unloading and Moving a Transformer.
5.1.5.2 STORAGE ON SITE
There may be occasions when the transformer and components arrive on site before the Customer is
able to begin re-assembly. This time delay can be weeks or several months.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 41 -
The delivered equipment must be maintained and monitored to ensure that the as built and as
transported conditions are preserved to ensure successful and safe installation when re-assembly
can be completed. PART 8:[REF: 1ZBA 4601-211], Storage on Site Before Assembly.
5.1.6.0 RE-ASSEMBLY INSTRUCTIONS
Although it is not practical to provide an all encompassing procedure for the re-assembly of the often
complex and individual transformer configurations, PART 11 [REF:1ZBA 4601-212], Transformer
Assembly Instructions, provides a general overview. See also PART 10 [REF:1ZBA 4601-218], Oil
Conservators Without Air Cell and PART 10:[1ZBA 4601-219], Oil Conservators With Air Cell, for
further assembly instructions.
5.1.6.1 OIL HANDLING AND FILLING
See PART 10:[1ZBA 4601-213], Receiving and Handling Transformer Oil on Site - Quality Control
for an overview of oil requirements. For filling transformers and components with oil see PART 10
REF: [1ZBA 4601-214, Final Oil Filling on Site - Atmospheric Pressure and PART 10: [REF: 1ZBA
4601-215], Vacuum Oil Filling on Site.
5.1.7.0 COMMISSION TESTS
After the transformer has been fully assembled and filled with oil, commissioning tests must be
performed to confirm fitness prior to energization. See PART 12 [REF: 1ZBA 4601-216],
Acceptance Testing and Energization for a general overview of test to be performed and utilize
PART 13 [REF:1ZBA 4601-217], Field Test Record to report the test data findings.
APPENDIX :A5. 1 Impact Recorder Receive and Return Instructions.
Before unloading the transformer or reactor, the recorder chart must be inspected by a qualified
technician. The unit must not be off-loaded unless the chart reading is within the safe limits, (see
sketch below), and there is no visible signs of damage. No liability will be accepted by ABB
unless this instruction is followed. Exceptions to these instructions must be authorized by the
shipper (ABB).
Safe Limits
Vertical
Acceleration
To be defined by
individual Factories.
Will vary from Country to
Country.
-5g
C/L
Lateral Acceleration
+5g -5g
C/L
+5g -10g
Longitudinal
Acceleration
C/L
+10g
The recorder has been set to operate for a range relative to the center line (C/L) of ± 5g vertical
acceleration, ± 5g lateral acceleration, and ± 10g longitudinal acceleration. For the vertical and
lateral portion of the chart each graduation represents 1g. For the longitudinal portion of the chart,
each graduation represents 2g.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 42 -
To determine the tape speed, refer to the recorder nameplate, then refer to the tape speed marking
on the side of the tape to determine the daily running record.
Removing Recorder From Transformer
Open the recorder cover and turn off the electrical switch.
Record the finish of the tape movement by drawing a line across the tape.
date, and sign the tape below the line.
Inspect the tape for indications of rough handling.
Record the time, the
Inspect the car for signs of damage and record findings on the end of the impact recorder tape.
If there is any indication of potential shipping damage, either through signs of damage on the car or
by impact recorder readings outside of the acceptable limits, then contact the shipper (ABB) for
instructions (ABB Factory phone #)
Return the Impact Recorder to: ABB Power Transformer Division, MANEJA, VADODARA Mark on
the PARCEL “Delicate Instrument, Handle with Care”.
5.2
METHODS OF TRANSPORTATION
The selection of the most suitable method of transportation for the transformer is dependent on size,
weight, customer‘s wishes, and on local conditions.
The following points should always be observed during transport:
5.2.1
A maximum inclination of 30 degrees
A maximum acceleration which equals a shunting impact of approximately (7 miles/ 11.25 km
per hour the permissible speed for heavy loads)
5.2.2
A maximum surface load on cover of 1000 kg/m2
These figures must not be exceeded.
Suitable measures must be taken to prevent the transformer from sliding during transport. For
example: Placing the transformer on soft wooden boards or beams, and anchoring it with chains
and/or wire ropes in both longitudinal and transverse axes.
The anchoring equipment should be appropriated to the size and weight of the transformer. The
positions of lifters, hauling can be used as anchoring points
5.3
TRANSPORT MODES
Depending on its size and weight, the transformer is transported either with oil filling (lowered oil
level) or with dry gas filling for these transformers. In the factory, all transformers are carefully
dried, filled with degassed and dried oil, and subjected to a series of several tests before delivery.
The instructions given in this section are intended to prevent damage occurring during transport, and
to illuminate the reasoning behind the measures to be carried out when the transformer arrives on
site, which are described in the following sections.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 43 -
5.3.1
TRANSPORT WITH DRY AIR FILLING
Transformers which, with an oil filling would exceed the permissible or economical maximum
transport weight, are transported without oil filling. In order to prevent moisture penetrating
the transformer tank, it is filled with dry air while the oil is being drained off, and when the
gas filling is completed, the tank is connected to one or more dry gas cylinders, which are
secured to the tank, and are fitted with reducing valve and a positive pressure valve to
provide a constant positive pressure inside the transformer tank (Please refer drawing No.
1ZYN 4601-204).
The valves are adjusted to give a positive pressure of approx. 0.035 bar. The dry gas cylinders
have, e.g., a content of 50 litres at a pressure of approx. 200 bar.
To protect the active part against moisture the transformer is filled with dry air at a positive pressure
of 0.175 kg/sq cm( 2.5 psi) at ABB works before despatch.
THE INTERNAL PRESSURE AT THE TIME OF SHIPMENT IS INDICATED ON DOCUMENTS
PROVIDED WITH THE TANK.
All openings resulting from the removal of fittings for shipment are sealed with suitable gasketted
blanking plates during transport. Transformer despatched according to this method may normally be
stored upto 3 months after arrival at site or else where.
The high pressure of 120 to 140 kg/sqcm is reduced to low pressure of 0.175 kg/sqcm using
regulator, regulator is fixed at factory. One gauge is provided to indicate the cylinder gas pressure
where as other gauge is provided to indicate tank pressure.
When the tank pressure falls below 0.15 kg/sqcm due to leakage / fall of ambient temperature , the
gas from cylinders must be fed manually, to build up required pressure in the tank.
The gas consumption during transport and possible storage is difficult to estimate as it depends on
ambient temperature variation, possible leakages as well as on the duration of transport and storage
When the pressure in the first cylinder falls below 10 kg/sqcm this should be considered as empty
and immediately its valve should be closed and another cylinder filled properly with gas, should be
connected, if required..Dry air to IS: 1747 with 50 ppm moisture and 1% oxygen by volume should be
used. Dry air should be continuously maintained at a positive pressure during storage of transformer.
INSTRUCTIONS FOR FILLING DRY AIR CYLINDER (AT WORKS)
Lower the oil level to the minimum necessary to dismantle the items such as bushing and turretswhich must be removed for shipping. Pull 500 mm mercury vacuum after blanking of all openings.
Continue to supply dey air until it maintains a steady pressure of 0.17 +0.02 kg/sq.cm above
atmosphere.
Pressure of dry air gas shall be maintained at 0.17 +0.02 kg/sq cm at reference temperature.
Pressure should be monitored by taking three readings within 24 hours to ensure that there is no
leakage of gas.
Shut off the gas supply valve and fit dry air cylinder through dry air regulatory valve. The gas should
have moisture content of max. 250 ppm (weight) and contain max. 0.3% (volume) of foreign
admixtures.
The transformer tank filled with dry gas must on no account be opened during transport, nor must the
gas cylinder be removed, if it cannot be reconnected within 48 hours. If the transformer tank has an
obvious leak, or if the gas cylinder shows a significant pressure drop during transport, make sure that
the leak is sealed, and inform ABB
5.4
HANDLING DURING LOADING, AND ON SITE
Caution! Transformers must only be transported in an upright position.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 44 -
5.4.1 LIFTING TRANSFORMERS
Hydraulic hoists may only be used at the jacking pads provided (see outline drawing). Lifting must be
carried out simultaneously and uniformly for at least two adjoining jacking pads.
Note: Pipe flanges and valves must never be used as lifting or support points.
5.4.2
SUSPENDING TRANSFORMERS
Every transformer is fitted with lifting bolts for suspension purpose (see outline drawing). When suspending
transformers on crane hooks, observe the following points:
The transformer must be suspended from
points shown in the outline drawing.
The ropes must never form smaller angle
than 60 degrees to the horizontal. Thus,
dimension „L“ must be equal to or larger
than dimension „M“ (As shown in Fig. 5.2).
FIGURE 5.2:
ROPE LENGTH FOR TRANSFORMER SUSPENSION
5.4.3 MOVING TRANSFORMERS
Transformers are moved or relocated on moving devices or on skids.
When skids are used, armoured rollers can be placed under the transformer, or sliding surfaces (with
the aid of lubricants) can be used.
Note: The presence of paint or dirt on the sliding surfaces or on the skids will increase the frictional
resistance and lead to a sharp increase in the tractive forces required.
5.4.4 TRANSPORT OF ACCESSORIES
For components which must be removed for transport see outline drawing.
Accessory components which are transported without packing must only be lifted by the suspension
lugs provided.
Accessory crates, especially those containing porcelain parts, must not be dropped and must be
protected against slipping.
5.4.5 TRANSPORTATION EQUIPMENT AND TOOLS
For transporting, sliding, moving or relocating a transformer, the following tools and equipment will
be needed:
hydraulic jack, hardwood planks
hardwood beams, softwood beams
electric cable winch or grippers
guide pulleys
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 45 -
wire ropes, shackles
transport rails, tie bars
connecting links.
5.5
SHIPPING ARRANGEMENTS
5.5.1 GENERAL
Large Power Transformers are normally shipped on special low bed trailor. General rules for
unloading transformers from their vehicles are given in PART 8 .
Also, always check the Packing List, which includes a transport outline drawing for the
transformer, with shipping dimensions, weights, etc. indicated. Accessories will be
despatched separately by road, oil drums by road. Major quantity of oil by tankers (road
transport) when supply is in the scope of ABB or as agreed in contract..
Important Notes:
a) After dismantling the sub-assemblies like Bushing assembly, conservator assembly,
radiator assembly, header assembly, A-frame assembly, roller assembly etc, all the hardware
and gaskets pertaining to that sub-assembly shall be packed and put in the same crate as
that of the sub-assembly.
b) Each crate has to be marked legibly with the names of the contents packed and suitable
signs shall be marked for opening the boxes.
5.5.2 SHIPPING BRACES
For protection, all openings resulting from shipping disassembly must be closed, oil-tight
and gas-tight, with caps or blind flanges during transport. Temporary shipping covers, braces
and similar hardwares must be replaced or removed before the transformer is energized.
5.5.3 BUSHINGS
In cases where bottom-connected bushings have been disassembled for shipping, the
bushing leads are supported by temporary shipping braces, which are an integral part of the
blind flange cover. For bushings with draw-through bushing leads, the lead is looped and
fastened to the support structure above the core and coils, or fastened to the bushing flange
cover. The bushing leads, lead structure and coils can be severely damaged if you attempt to
remove the covers without first disconnecting the shipping supports.
5.5.4 CURRENT TRANSFORMERS
Current transformers must be short-circuited and earthed (grounded) for Shipping.
5.5.5 SHUT-OFF DEVICES
Shut-off devices shall be in transport position, and throttle valves shall be closed for
shipping.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 46 -
5.5.6 TIGHTNESS SURVEILLANCE
Extreme care has been taken to prevent moisture entering the transformer. It is important to
regularly check tank pressure during shipping and storage times to verify that no indication
of leaks appears. For gas-filled compartments, the instructions are given in PART 6
5.6
PACKING LIST AND TRANSPORT MANUAL
5.6.1 GENERAL
In order to meet shipping clearances and to avoid transport damage, some accessories-bushings for
instance- are often disassembled from the tank during shipment and packed separately. Detailed
information on this is given in this instruction. The Packing List also describes, how the dismantled
parts of a large transformer are packaged and marked.
The shipment consists of „the Heavy Parcel“-that is, the sealed transformer tank, containing the
core and coils - and the dismantled parts in crates and boxes.
5.6.2 PACKING LIST
The Packing List is a drawing-numbered document. A full set is contained in a separate box
together with other technical documentation. Each crate or box has the separate sheets of its own
contents packed.
The table carries the identification of the items by name, quantity, and article number or equivalent.
In order to meet shipping clearances and to avoid shipping damage, some accessoriesbushings for instance- are often disassembled from the tank during shipment and packed
separately. Detailed information on this is given in the Packing List enclosed with despatch
documents.
5.6.3. ASSEMBLY PACKAGES
The parts are organized in Assembly Packages. An Assembly Package consists of all parts which
are needed for a certain group or operation during the assembly, which shall be completed in a
sequence without interruption. „Bushings“ and „Oil preservation systems are examples of Assembly
Packages. Everything belonging to a certain Assembly Package is packed together in a group of
crates and boxes. Those parcels are identified on the Packing List as belonging to that Package.
The advantage with this system is that only a few pieces have to be opened at a time. Remaining
crates and boxes are to be left closed until they are needed. This keeps the parts under protection
and in good order.
The numbering of the Assembly Packages shows the recommended order of progress which our
Field Service organization has found practical. Of course it is possible to proceed in a different order,
depending on conditions on the site.
At the end of the list of Assembly Packages you find references to the set of fresh gaskets to be
used during assembly, touch-up paint, and a box with documents.
5.6.4. TRANSPORT MONITORING
The monitoring instructions deal with lifting and bracing of the Heavy Parcel, and various items of
checking and visual inspection. Two of these monitoring duties are the following:
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 47 -
The tank is filled with dry air to a slight over-pressure this has to be monitored en route. The final checkpoint is, when the shipment is received on site.
The numbering of the Assembly Packages shows the recommended order of progress which
our Field Service organization has found practical. Of course it is possible to proceed in a
different order, depending on conditions on the site.
At the end of the list of Assembly Packages you find references to the set of fresh gaskets to be
used during assembly, touch-up paint, and a box with documents.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 48 -
PART 6
MONITORING OF DRY-GAS FILLING OF
TRANSFORMERS DURING SHIPMENT
AND STORAGE
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 49 -
INDEX
6.0
MONITORING OF DRY-GAS FILLING OF TRANSFORMERS DURING SHIPMENT AND
STORAGE
6.1
PRESSURE GAUGE AND FILLING COCK
6.2
PRESSURE LIMITS + FIGURE F 6.1
6.3
MONITORING UNDER STORAGE
6.4
INSPECTION AND REPORTING
6.5
LONG-TIME STORAGE. CHANGE OF GAS CYLINDERS
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 50 -
6.0
MONITORING OF DRY-GAS FILLING OF TRANSFORMERS DURING SHIPMENT AND
STORAGE
This transformer is shipped without oil and with accessories and fittings removed. The tank has been
filled with dry gas to a slight over-pressure in the factory. It is important that the transformer remains
perfectly sealed during shipment and storage. The gas- over pressure shall be monitored at regular
intervals. [REF: 1ZBA 4601-203, 1ZBA4601-204]
6.1
PRESSURE GAUGE AND FILLING COCK
A pressure gauge and filling cock unit are fitted on the side of the tank.
The pressure gauge has a range range
0 -210 kg/sq cm on dry air cylinder side and
kg/sqcm towards transformer tank side
6.2
0 to 2.5
PRESSURE LIMITS
The gas pressure in the tank when the transformer leaves the factory is 20 kPa (0.2 atm 3psi) at a
temperature of about 20°C (65-70°F). This pressure will change with the ambient temperature as
shown in the figure F6.1. Even at -25°C there shall be a small positive over pressure and in a warm
climate the pressure still is about 30 kPa.(0.306 kgf/sqcm)
30
20
Over pressure kPa
10
0
-20
-10
0
10
20
30
Centigrades
=
FIGURE F 6.1
EXAMPLE: CORRECT PRESSURE AT DIFFERENT AMBIENT TEMPERATURES
If, after an inspection, the pressure is completely lost, there must be a serious leak somewhere. It is
possible that there may even have been under-pressure at some time (due to a sudden temperature
drop), and moisture may have entered the tank. Complete loss of gas -filling pressure must be
reported immediately for further action.
I
f the pressure read on the gauge is not completely lost, but has fallen below 5 kPa (0.05 atm, about
1 psi), then the tank shall be filled up with dry gas to the original reading of about 20 kPa.
The guaranteed dryness of the filling gas shall be such that the dew-point is below -40°C (= -40°F).
Before filling, the plastic hose used shall be blown clean with gas from the bottle.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 51 -
6.3
MONITORING UNDER STORAGE
When the transformer is under storage for a considerable time, the filling pressure shall be checked
and recorded once a month.
This transformer is shipped without oil and with accessories and fittings removed. The tank has
been filled with dry air to a slight over-pressure in the factory. It is important that the transformer
remains perfectly sealed during shipment and storage.
6.4
INSPECTION AND REPORTING
The pressure control unit shall be inspected at the prescribed check points during shipment. It shall
be checked that
- The pressure in the tank stays above the minimum limit
- There is still considerable pressure in the storage bottle
If the over-pressure in the tank is completely lost, and the cylinder is empty, then there is a serious
leak. It is possible that there may even have been under-pressure at some time (due to a sudden
temperature drop), and moisture may have entered the tank . Complete loss of gas-filling
pressure must be immediately reported for further action.
6.5
LONG-TIME STORAGE. CHANGE OF GAS CYLINDERS.
When the transformer is in transit or stored at the site for a considerable time, the tank pressure shall
be checked and recorded once a month.
The pressure in the storage gas cylinder may decrease with time. If it reaches 1 MPa (10
atmospheric pressure) it should be substituted against a new bottle.
The bottle gas shall have a guaranteed dryness corresponding to a dew-point not above
-40°C (= -40°F). This may be checked from the sampling cock if a dew-point meter is available.
The procedure is as follows:
- Close first the shut-off valve towards the tank Then shut the main valve on the bottle
- Disconnect between bottle and reduction valve and install the new bottle
Check that the reduction pressure is correct by bleeding the sampling cock and closing again Open valve towards the tank
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 52 -
PART 7
RECEIVING INSPECTION
AND
ARRIVAL ON SITE
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 53 -
7.0
RECEIVING INSPECTION AND ARRIVAL ON SITE
7.1
RECEIVING INSPECTION
[1ZBA4601- 207]
7.2
ARRIVAL AT SITE, UNPACKING AND CHECKING OF THE CONSIGNMENT
7.2.1 ARRIVAL ON SITE
7.2.2 UNPACKING AND CHECKING OF THE CONSIGNMENT
7.2.2.1 REMOVING THE PACKING MATERIAL
7.2.2.2 INTERNAL INSPECTION
7.2.3 TIGHTNESS
7.3
CHECK LIST AND LOG SHEET
7.3.1 CHECK LIST - CHECKING THE CONSIGNMENT ON ARRIVAL
7.3.2 LOG SHEETS TO BE USED FOR CHECKING TRANSFORMER ON RECEIPT
7.4
SITE ACTIVITY CHART
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 54 -
7.1
RECEIVING INSPECTION
[1ZBA4601-207]
COPIES OF ABB SPECIFICATIONS ARE ENCLOSED
[REFERENCES]:
1ZBA 4601-207 Transformer Designed with Oil Conservator, Shipped Dry -Gas Filled, Partially
Disassembled
7.2
ARRIVAL AT SITE, UNPACKING AND CHECKING OF THE CONSIGNMENT
7.2.1 ARRIVAL ON SITE
Note Use the packing list enclosed with the consignment to check contents for
completeness.
Any pressure loss in transformer tanks filled with dry air must be included in the acceptance report.
In the case of attached dry air cylinders, an excess pressure of 0.05 bar should be maintained as
minimum.
7.2.2 UNPACKING AND CHECKING OF THE CONSIGNMENT
7.2.2.1 REMOVING THE PACKING MATERIAL
Use suitable tools to remove the transformer packing. Packing material of accessories should be
stored as it might be used later in case of return shipment for repairs or overhaul. Accessories must
be kept in their transport containers until final assembly in order to avoid moisture absorption.
Insulating transformer oil must be stored in accordance with the latest regulations until final oil filling.
See as well PART 10. ”OIL“.
7.2.2.2 INTERNAL INSPECTION
An internal inspection is necessary if transport damage is suspected. Flanged covers of bushing
assembly openings and inspection covers must be removed. Core and winding supports, active part
supports and cleats and leads must be checked for damage.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 55 -
Page Left Blank
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 56 -
Danger!
Before removing the tank cover or any other cover, make sure that there is no
overpressure inside the tank.
Note Before any work is carried out inside the tank, always consult ABB.
Danger!
If any tools or other objects are left out inside the tank, they can cause
shortcircuits and failure of transformer.
7.2.3 TIGHTNESS
Oil-filled transformers should be checked for oil traces indicating a leak.
7.3
CHECK LIST AND LOG SHEET
[PLEASE ALSO FOLLOW INSTRUCTIONS UNDER DO‘S AND DON‘TS MENTIONED EARLIER
IN PART 1.9]
7.3.1 CHECK LIST - CHECKING THE CONSIGNMENT ON ARRIVAL
Serial number …...…………..
Type of transport:
Without oil
Dry air positive pressure
a) in the tank
…..……bar, present
Not present
O
b) in dry air cylinder
….…….bar, present
not present
Silica gel in breather
not present
is blue form
O
is pink/white
O
Support of core -and-coil assembly
In order
not in order
O
not checked
O
Leads
in order
not in order
O
not checked
O
Core-and-coil assembly
is dry
is not dry
drying is required
O
O
O
O
O
O
O
O
O
O
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 57 -
Core earthing
in order
not in order
not checked
O
O
O
Shock recorder not provided
provided, no excess strain detectable
provided, excess strain detectable
O
O
Damages
a) at the tank
not present
present and reported to ABB
O
O
b) at the accessories
not present
present and reported to ABB
O
O
c) at the painting
not present
slightly damaged
severely damaged
damages reported to ABB
O
O
Accessories
properly provided
not completely provided and reported to ABB
O
O
O
O
Insulating oil
properly provided
not properly provided
Signature of customer
Date
O
O
/
ABB assembly engineer /Representative
Date
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 58 -
7.3.2 LOG SHEETS TO BE USED FOR CHECKING TRANSFORMER ON RECEIPT
ITEM
CASE
NO.
TYPE OF CHECK
OBSERVATION
SIGNATURE
& DATE
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 59 -
7.4
SITE ACTIVITY CHART
RECEIPT AT
SITE
MEASURING OF
NITROGEN PRESSURE
CHECK OIL LEVEL AS
APPLICABLE
ERECTION
OIL FLUSHING OF
COOLERS / COOLER
ASSEMBLY
ERECTION
EVACUATION AND
OIL FILLING
OIL FILLING
OIL BDV AND
WATER CONTENT
OIL BDV AND
WATER CONTENT
OIL FILLING UNDER
VACUUM AND TOPPING UP
AIR RELEASING
OIL FILTRATION
COOLER BANK
STANDING TIME
COMMISSIONING
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 60 -
PART 8
UNLOADING, MOVING, STORING
THE TRANSFORMER
AND
PRECOMMISSIONING CHECKS
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 61 -
8.0
UNLOADING, MOVING, STORING THE TRANSFORMER AND PRE- COMMISSIONING CHECKS
8.1
INSPECTIONS BEFORE UNLOADING
8.2
EXTERNAL INSPECTION
8.3
UNLOADING AND MOVING THE TRANSFORMER+
[REF:1ZBA4601-202]
8.4
STORAGE OF TRANSFORMER
8.4.1
STORING OF COMPONENTS AND ACCESSORIES BEFORE COMPLETE ASSEMBLING
8.4.1.1 STORING INDOORS IN A DRY ROOM
8.4.1.2 STORING OUT DOORS
8.4.1.3 INSTALLATION
8.4.2
8.5
STORAGE ON SITE BEFORE ASSEMBLY + PRODUCT INFORMATION
1ZBA 4601-211
PRE-COMMISSIONING CHECKS
FIGURES
F 8.1 EXAMPLE TRANSFORMER SHIPMENT SHOWING TIE-RODS BLOCKINGS.
F8.2 BLOCKING
F 8.3 TYPICAL JACKING PAD
F 8.4
TYPICAL EXAMPLE TRANSFORMER RAISED.
TRANSFORMER
CRIBBING PLACED UNDER
F 85
TYPICAL EXAMPLE: TRANSFORMER RAISED. CRIBBING AND ROLLING PLACED UNDER
TRANSFORMER
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 62 -
8.0
UNLOADING AND MOVING THE TRANSFORMER INSPECTIONS BEFORE UNLOADING
EXTERNAL INSPECTION
Any external evidence of damage or evidence indicating the possibility of hidden damage must be
reported to the transporter’s representative and to an ABB representative before unloading the
transformer. Take pictures of external damage. The receiver must assume all responsibility for
unloading damaged transformers. The external inspection prior to unloading the transformer should
include all of the following.
Are all tie rods connected to vehicle, undamaged and nuts tight?
Is all blocking tight and in good condition?
Is there any evidence of load shifting in transit?
Does the impact recorder (when provided) tape indicate any impacts beyond the acceptance zone
on the tape?
Are there indications of external damage such as broken glass on gauges, broken welds on flanges?
Is the paint finish damaged?
Is there any evidence of oil leakage (if units are shipped in oil)? Is
the pressure in the gas-filled tank acceptable?
Is oil level in bushings normal?
Is the Driving Mechanism of OLTC and shaft are aligned properly? Is there any visible
damage?
8.2
EXTERNAL INSPECTION continued
Do crates or boxes show any evidence of damage or moisture entrance?
If there is no evidence of shipping damage, proceed to unload the transformer. If shipping damage is
found, contact the nearest ABB representative for further instructions prior to unloading the
transformer. If any damaged parts are noticed lodge claim with under-writing and report to ABB
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 63 -
8.3
UNLOADING AND MOVING THE TRANSFORMER
PRODUCT INFORMATION 1ZBA 4601-202 ENCLOSED
8.4
8.4.1
STORAGE OF TRANSFORMER
STORING OF COMPONENTS AND ACCESSORIES BEFORE COMPLETE ASSEMBLING
Independent of the duration of the storing time, the directions below apply for dismounted
components and accessories, as well as for material to be used in connection with the
assembling work.
8.4.1.1 STORING INDOORS IN A DRY ROOM
In such a room, the following articles should be stored Insulating material such as paper,
pressboard, bakelite, wood, cotton tape etc. Insulated details as paper insulated conductors,
pressboard insulated shielding bodies etc. Chemicals as solvents, glues, varnishes, hardness etc.
Breathers and drying agents Terminal boxes, connection boxes, control cabinets Turrets with built in
current transformers. Radiators Gas relays, oil -level indicators, thermometers, pressure valves etc.
Pipes to oil conservator, pipes to radiators, pipes to turrets etc. Bushings Marshalling box, OLTC
motor drive, fans, pumps, instruments and fittings Control cabinets (Heating elements provided shall
be connected to supply)
8.4.1.2 STORING OUT DOORS
The components mentioned below may be stored outdoors. They should be placed above ground
and covered with tarpaulin etc. Oil conservator with blanking plates for all openings Radiators
and coolers with blanking plates for all openings Structures, A frames, pipe supports, oil
conservator supports, radiators, control cabinets etc.
8.4.1.3 INSTALLATION
Before starting with the assembly the transformer must be transported to its foundation.
For this purpose use the pulling lugs and jacking pads provided (see outline drawing). Before moving
the transformer, take care to observe the instructions in the respective section of this manual.
The foundation should be designed to allow the transformer to stand level. The assembly
location must have the ventilation space necessary for proper functioning of the cooling system. The
transformers should always be separated from one another and from all walls and partitions to permit
free circulation of air. Please also refer IS:10028 [CODE OF PRACTICE FOR INSTALLATION AND
MAINTENANCE OF TRANSFORMERS]
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 64 -
After the transformer has been moved to its final position, fit the fixing devices, if any. Mounting of
wheels under transformer is to be done as per roller arrangement drawing.
Valves which may affect the loading gauge or which may be subjected to damages should be
dismounted before delivery. Remount the valves - the positionings appearing from GENERAL
ASSEMBLY DRAWING. The gaskets surfaces shall be cleaned well and new gaskets fitted. Check
that all valves are closed.
When exchanging a damaged bushing or other component on the cover of a fully oil filled
transformer, we should proceed according to the following:
Close the valve in the pipe between the transformer and the oil conservator. Pump oil from the
transformer tank into the oil conservator so that the oil quantity which need to be drained off to lower
the oil enough below the transformer cover is pushed to the conservator. As the oil is being
transferred from tank to conservator, fill up the tank with dry air via suitable valve on the cover or in
turrets.
Exchange the faulty bushing and then transfer the oil from conservator to tank by opening the valve in
the pipe between conservator and main tank. De-air the bushings and turrets.
STORAGE ON SITE BEFORE ASSEMBLY
PRODUCT INFORMATION 1ZBA 4601-211 ENCLOSED
8.5
PRE-COMMISSIONING CHECKS
The following are salient points to be checked before commissioning
Check all the gasketed joints to ensure that there is no leakage of transformer oil at any point.
Check any breakages of porcelain. Bushings with cracks or any other defects should be immediately
replaced. Oil level in condenser type bushings should be upto the level mark on oil gauge on side of top cap.
Check the tightness of top cap for condensor bushing.
Release trapped air through air release plugs and valves fitted for the purpose on various fittings like
headers, radiators, and oil communicating bushings, buchholz petcock etc.
Check alarm and trip contacts of buchholz relay, WTIs, dial type thermometer, magnetic oil level gauge, oil
flow indicator, pressure relief device etc.
Ensure that conservator is filled upto the filling level mark on prismatic oil level gauge side and
corresponding to the pointer reading on MOLG side. Special attention to be paid for conservator with flxi
separator.
Make sure that neutral bushings are effectively earthed.
Tank and cooler bank should be earthed at two pints
Check the direction of rotation of fan blades to ensure right blast towards radiators.
Check the direction of rotation of pumps.
Ensure that silica gel in the breather is active and colour is blue and oil in the breather cup is present.
Check that the thermometer pockets on tank cover, header etc. are filled with oil.
CTs secondary terminals must be shorted and earthed if not in use.
Check that the proper terminals in the marshalling box are connected to WTI CT terminals
Check for tightness of all external electrical connections
Check for the arcing horn gap on bushings if provided.
Clear off extraneous materials like tools, earthing rods, pieces of clothes, waste etc
Lock the rollers for accidental movement on rails.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 65 -
PART 9
TRANSFORMER
ASSEMBLY
INSTRUCTIONS,
SUGGESTED ERECTION EQUIPMENT / TOOLS
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 66 -
9.0
TRANSFORMER ASSEMBLY INSTRUCTIONS, ERECTION EQUIPMENT / TOOLS
CONTENT
9.1
SCOPE [REFERENCE 1ZBA 4601-212]
9.2
SAFETY NOTATIONS
9.3
GENERAL
9.4
PREPARATION
9.5
EXTERNAL ASSEMBLY
9.5.1 RADIATORS, COOLERS AND PUMPS
9.5.2
NEW GASKETS
9.5.3 MOUNTING THE NITROGEN BLANKET OIL PRESERVATION SYSTEM
9.5.4 LOAD TAP-CHANGERS
9.6.
INTERNAL ASSEMBLY
9.6.1.1 GENERAL PRECAUTIONS
9.6.1.2 ASSEMBLY INSTRUCTIONS FOR BUSHINGS
CONDENSER BUSHINGS FOR 245 kV AND 145 kV CLASS
LOW VOLTAGE BUSHINGS
CHECKING BEFORE MOUNTING THE BUSHINGS
CHECKING THE SECONDARY LEADS OF CTS
9.6.2 BUSHING INSTALLATION
9.6.3 BUSHING CURRENT TRANSFORMERS
9.7
CLOSING THE TRANSFORMER AND FINAL DEWPOINT MEASUREMENTS
9.8
ELECTRICAL TESTS
9.9
ERECTION EQUIPMENTS/ TOOLS
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 67 -
9.0
TRANSFORMER ASSEMBLY INSTRUCTIONS
9.1
SCOPE [REFERENCE PRODUCT INFORMATION 1ZBA 4601-212]
These instructions are intended to help in the installation of transformers to maintain their quality and
reliability.
The recommendations are not a complete manual for all the operations during the field assembly of
a large transformer.
It is assumed that competent and responsible supervision and
workpersonnel are available for the job - that good order, cleanliness and personal safety
precautions are observed - in accordance with common sense and local regulation.
The following text highlights a few particular procedures and precautions that are specific for the ABB
Transformer make, or are of critical importance for a good result.
9.2
SAFETY NOTATIONS
Safety notations are intended to alert personnel of possible personal injury, death, or property
damage. They have been inserted in the instruction text prior to the step in which the condition is
cited.
The safety notations are headed by one of three hazard intensity levels
1) Danger
2) Warning
3) Caution
PLEASE ALSO REFER TO “PART 1”, SAFETY INSTRUCTIONS FOR DETAILS.
9.3
GENERAL PRECAUTIONS
The transformer should not be opened during periods of inclement weather or when
condensation is forming on the internal surfaces of the transformer. Never
enter a transformer with dirty or wet clothing. Clean cloth overshoes or
nitrile rubber overshoes should be worn.
Tools must have working surfaces hardened so that they will not peel or chip during normal use;
also, working surfaces must not be coated in any way such as painting or plating. Tools that are
polished metal or have black oxide body finish are preferred .
To prevent accidental disassembly during normal use, all tools with movable parts must use double
side flush-riveted joints and or all fasteners or moving parts must be retained by staking or deforming
the last thread by welding or coating.
Tools such as hammers and screwdrivers must have one piece heads. Molded-on plastic or
fiberglass handles are preferred; if the handle is wood, it must be retained by a wood or plastic
wedge.
Nameplates or tags attached to tools should be removed. If a nameplate is necessary for tool
identification, the plate must be non -metallic and be secured with non-conducting tape.
While the transformer is open, do not permit anyone access to the transformer until they have
emptied all pockets, checked for loose objects, and removed watches, rings, and other objects.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 68 -
Dry air must be used to ventilate the inside of the tank when it is opened for internal fitting. The air
must have a dew point less than -40 C and sufficient airflow for the number of operators in the tank
must be maintained.
Do never use nitrogen or other gases than air for ventilation.
Nitrile gaskets should be changed during the assembly operations. New gaskets are provided with
transformer detail parts
The mechanical relief devices shall be installed prior to beginning the assembly operations to
prevent excessive pressure build-up on the tank.
The transformer tank shall be grounded prior to beginning any assembling operations.
9.4
PREPARATION
The transformer base shall be supported on the foundation pad or piers as appropriate.
9.5
EXTERNAL ASSEMBLY
The items removed and shipped separately are listed on the General Assembly, or packing list. The
items generally removed and shipped separately are the bushings, cooling equipment, forced oil
pumps (if the transformer has an OFAF rating), arresters and arreseter mounting brackets and the
sudden pressure relay. The number of accessory items removed will vary depending on the physical
size of the transformer.
All air or gas fittings and all oil fitting joints that are preassembled at the factory must be
checked for leaks and resealed.
9.5.1 RADIATORS, COOLERS AND PUMPS
Radiators, coolers, the associated oil pumps and piping shipped as detail items that are assembled at
the final location must be thoroughly inspected prior to installation to be certain that no water or
foreign material is in the oil space. Avoid opening the equipment when it is at a temperature
lower than the ambient air in order to prevent condensation.
The radiators or coolers should be installed on the transformer the same day they are opened. Do
not permit the cooling apparatus to stand exposed after opening for inspection. The detailed
illustrations for mounting and piping arrangements are shown on the General assembly drawing.
Use new gasket material when installing the radiators, coolers, or pumps.
9.5.2 NEW GASKETS
USE NEW GASKET MATERIAL, SUPPLIED ALONG WITH TRANSFORMER WHEN
INSTALLING THE RADIATORS, COOLERS OR PUMPS
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 69 -
9.5.3
MOUNTING THE NITROGEN BLANKET OIL PRESERVATION SYSTEM
(If Applicable)
9.5.4.1 GENERAL
MR TYPE Tap-Changers are usually shipped mounted on the transformer
WARNING:
DO NOT OPEN ANY COVERS OR FITTINGS UNLESS THE INTERNAL
PRESSURE IS AT ZERO GAUGE. FAILURE TO RELIEVE THE
PRESSURE COULD CAUSE THE PART BEING REMOVED TO BE A
HAZARDOUS FLYING OBJECT. ALWAYS RELIEVE INTERNAL
PRESSURE SLOWLY THROUGH VALVES.
Before placing Tap-Changers in service, read the appropriate Tap-Changer instruction leaflet. The
leaflets are included in PART 4.2. Always follow the inspection and filling instructions given in the
Tap-Changer instruction leaflet.
9.5.4.2 TAP-CHANGERS MOUNTED FOR SHIPMENT
No internal assembly operations or taping are required.
Fill the Tap -Changer compartment as instructed in the Tap-Changer instruction leaflet.
OLTC should not be operated unless otherwise its divertor compartment is filled with oil.
9.6
INTERNAL ASSEMBLY
9.6.1.1 GENERAL PRECAUTIONS
Necessary confined entry procedures should be followed in compliance with company policy or local
regulations.
CAUTION
Be certain the internal pressure in the transformer is a zero gauge before
opening the manhole cover.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 70 -
CAUTION
To prevent contamination of the transformer, only the manhole and the
opening for the item being installed should be opened. Cover all other
openings with dry pressboard or a clean plastic sheet. This will also
minimize the flow of dry air from the unit.
9.6.1.2 ASSEMBLY INSTRUCTIONS FOR BUSHINGS
9.6.1.2.1CONDENSOR BUSHINGS FOR 245 kV AND 145 kV CLASS:
These are supplied by ABB Sweden.
Please refer to the installation and maintenance manual of supplier for details.
9.6.1.2.2 LOW VOLTAGE BUSHINGS
Bushing provided with stem type design should be assembled by opening the inspection cover. Any
special instructions required for LV bushings can be referred in Part-3 of this operation and
manintenance manual.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 71 -
9.6.1.2.3CHECKING BEFORE MOUNTING THE BUSHING:
Check that detachable turrets, pockets/bushing mounting plates etc. Are properly mounted as per
the general assembly drawing. Leads and other hardware items for connections are available and
bushing CTs are properly assembled inside the turrets. Check that secondary leads from CTs are
connected to respective terminal boards.
9.6.1.2.4 CHECK THAT SECONDARY LEADS OF CTS
9.6.2 BUSHING INSTALLATION
On large transformers, the bushings will be removed for shipment to meet shipping clearances and
to avoid shipping damage to the bushings. The bushing leads may be supported by temporary
shipping braces which are an integral part of the blind flange. The flange will be indicated with a
warning note if this method is used. The bushing leads must be disconnected from these
temporary braces before the blind flange covers or shipping covers are removed.
CAUTION
Failure to disconnect the leads from the temporary shipping braces before the blind
flanges or shipping covers are lifted can cause damage to the leads, bridge
structure and associated coils, and may necessitate return of the transformer to
the factory for repair and retesting.
9.6.3 BUSHING CURRENT TRANSFORMERS
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 72 -
WARNING
AN ENERGIZED CURRENT TRANSFORMER IS DANGEROUS IF THE
SECONDARY IS AN OPEN CIRCUIT. DEATH OR SERIOUS INJURY CAN
RESULT FROM CONTACT WITH THE TERMINALS.
THE SHORT CIRCUITING DEVICES MUST BE CONNECTED TO THE APPROPRIATE
TERMINALS IN THE CONTROL CABINET IF THERE IS NO LOAD CONNECTED TO THE
TRANSFORMER.
9.7
CLOSING THE TRANSFORMER AND FINAL DEWPOINT MEASUREMENTS
When taking dewpoint measurements, it is advisable to take the measurement in the early morning
hours prior to sunrise. When this is done, the insulation temperature can be taken to closely match the
gas temperature.
When taking the dewpoint during periods of extreme ambient temperature
variation or during the afternoon hours, the insulation temperature should be measured directly after the
dewpoint is taken.
9.8
ELECTRICAL TESTS
CAUTION
If the transformer tank is not filled with oil, the test voltage on the windings must
be limited to low voltage preferably 415 volts on HV side.
Measure the power factor and capacitance of the bushings before installing the bushings
in the transformers. Refer to the appropriate bushing instruction leaflet for the proper
procedures.
2.
Measure the core resistance to ground.
The minimum acceptable value is 500 kOhm when measured at 1000 volts.
3.
Measure the core clamp resistance to ground.
The minimum acceptable value is 500 kOhm when measured at 1000 volts.
4.
Measure the ratio of all bushing current transformers and verify proper polarity.
5.
Check the turns ratio of the transformer (TTR) at all tap positions.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 73 -
The measured turns ratio should be + 0.5 % of the nameplate voltage ratio.
FOR OIL FILLING PLEASE REFER TO OTHER PARTS 10 AND 11.
9.9
SUGGESTED ERECTION EQUIPMENTS/ TOOLS
ONE OR TWO NOS. MOBILE CRANES HAVING A FREE VERTICAL LIFT SUITABLE FOR
LIFTING HV BUSHINGS AND LIFTING CAPACITY OF 3 TONNES EACH. STEEL/ MANILA /
NYLON ROPES AND “D “ SCHACKLES FOR LIFTING 3
TONNES WEIGHT FILTER MACHINE
OF CAPACITY MINIMUM 6000 LITRES PER HOUR IN EXCELLENT WORKING CONDITION. IT
MUST BE CAPABLE OF HEATING TRANSFORMER OIL UP TO 80 DEG. C (HEATING SHOULD
BE INDIRECT) AND MUST BE EQUIPPED WITH INBUILT HIGH VACUUM DEGASSING
CHAMBER FILTER ELEMENTS. THE FOLLOWING ACCESSORIES SHOULD ALSO BE
PROVIDED NON-COLLAPSABLE HOSEPIPES OF ADEQUATE LENGTH AND SIZE PROVIDED
WITH NIPPLES / ADAPTORS.
- TWO NOS. FLANGES EACH OF SIZES 25, 50 AND 80 MM PIPE SUITABLY THREADED FOR
CONNECTING THE HOSE PIPES AND PROVIDED WITH HOLES FOR FASTENING ON MAIN
UNIT VALVES
-THE INCOMING ELECTRICITY SUPPLY CAPACITY MUST BE ADEQUATE TO OPERATE THE
MACHINE WITH ALL ITS HEATERS “ON”.
VACUUM PUMP OF CAPACITY 1500-2500 LPM WITH BOOSTER OF 600- 900 cub-m /hour AND
CAPABLE OF ULTIMATE VACUUM OF I X 10 -3 [TEN TO POWER MINUS THREE] MILLI BAR],
ALONG WITH FOLLOWING ACCESSORIES
-NON-COLLAPSIBLE HOSES WITH SUITABLE FLANGES FOR CONNECTING TO MAIN TANK CONDENSER FOR CONDENSATION OF MOISTURE
-SUITABLE GAUGE FOR MEASURING UPTO 10 -3 PRESSURE MILLI BAR TO CONFIRM
EFFICIENCY OF VACUUM PUMP
WHENEVER REQUIRED STORAGE TANK FOR TRANSFORMER OIL OF ADEQUATE CAPACITY
PROVIDED WITH 50 MM BOTTOM DRAIN - CUM FILTER VALVE AND ANOTHER 50 MM TOP
VALVE. THE TANK SHOULD HAVE AN AIRTIGHT INSPECTION COVER AT THE TOP AND
MUST BE PROVIDED WITH A BREATHER AND OIL LEVEL SIGHT WINDOWS.
TANK SHOULD BE PAINTED WITH OIL RESISTANT PAINT FROM INSIDE AND MUST BE
CLEANED THOROUGHLY BEFORE STORING THE OIL. CAPACITY OF STORAGE TANK
SHOULD BE EQUAL TO THE TOTAL OIL QUANTITY OF COMPLETE UNIT.
ADEQUATE NUMBER OF ALUMINIUM TRAYS FOR SALVAGING TRANSFORMER OIL
LEAKAGES
9.9.7 TWO SETS OF FIXED ENDED SPANNERS METRIC SIZES 4 TO 36
9.9.8 TWO COMPLETE SETS OF RING ENDED SPANNERS METRIC SIZES 4 TO 36
9.9.9
ONE COMPLETE SET OF ALLEN KEYS SET OF SCREWDRIVERS, CENTERING TUMMIES,
FLAT ENDED TUMMIES, PIPE WRENCHES, PLIERS, HAMMERS, ADDERS, HOLE PUNCHES,
OTHER TOOLS NORMALLY REQUIRED FOR SUCH WORK. SIX MM THICK 3 PLY NYLON
ROPES OF 15 METRES LONG
9.9.11 HOLDITE, ARALDITE, AND QUICK SETTING M-SEAL
9.9.12 OIL TEST SET IN GOOD WORKING CONDITION HAVING 2.5MM GAUGES FOR ADJUSTING
THE SPHERE GAP
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 74 -
9.9.13 FIVE kV MEGGAR PREFERABLY MOTOR DRIVEN AND CAPABLE OF READING UP TO 50000
MEGA OHMS HAND DRIVEN 500 VOLT MEGGAR CAPABLE OF READING UPTO ATLEAST 50
MEGA OHMS TWO NOS. MULTI METERS PREFERABLY DIGITAL TYPE HAVING FOLLOWING
RANGES AC VOLTAGE: 0 - 2.5, 0 - 25, 0- 100, 0 - 250, 0- 1000
AC CURRENT: 0- 100 milli AMPS, 0- 1 A, 0 - 10 A
9.9.16 SINGLE/ 3 PHASE SUPPLY WITH DP SWITCHES
9.9.17 2.5 MM SINGLE CORE COPPER LEADS (APPROXIMATELY 50 METERS) THREE LITERS OF
CARBON TETRA CHLORIDE
9.9.19 MUSLIN CLOTH AND WASTE CLOTH IN SUFFICIENT QUANTITY AS REQUIRED AT SITE.
9.9.20 HOT AIR BLOWER FOR DRYING PORCELAIN BUSHINGS
9.9.21 VACUUM HOSEPIPES FOR OIL CONNECTIONS SHOULD BE OF OIL RESISTANT MATERIAL.
NATURAL RUBBER SHOULD NOT BE USED.
THEY SHOULD WITHSTAND FULL VACUUM.
NECESSARY ADAPTERS FOR CONNECTING TO FILTER MACHINE OUTLET, FILTER
MACHINE, INLET, FILTER VALVES ON MAIN UNIT, BUCHHOLZ RELAY PIPE, OIL FILLING PIPE
ON CONSERVATOR, ETC.
9.9.22 INSTRUMENTS FOR CHECKING HUMIDITY.
ADEQUATE LENGTH OF 10 MM INNER DIA. PVC PIPE SUITABLE FOR VACUUM WITH
SUITABLE ADAPTORS FOR CONNECTING THIS PIPE TO STANDARD 25 MM OR 50 MM
FLANGED VALVES.
9.9.23 PULLING WINCHES / PULLING EYES
9.9.24 STEEL ROPES
9.9.25 STEEL PLATES
9.9.26 RAILS 90 LBS/YARD GREASE
9.9.27 WOODEN SLEEPERS
9.9.28 HYDRAULIC/ MECHANICAL SCREW JACKS WITH LOCKING ARRANGEMENT, CAPACITY OF
EACH SHOULD BE MINIMUM 50 % OF THE TOTAL WEIGHT OF MAIN UNIT WITH OIL. POWER
PACK SYSTEM TO OPERATE ALL THE JACKS SIMULTANEOUSLY
9.9.29 MEASURING TAPES MINIMUM 25 METRES LONG
9.9.30 LEVEL TUBE/ LEVEL BOTTLE (PLASTIC)
9.9.31 STAINLESS STEEL/ SUITABLE GLASS BOTTLES FOR OIL SAMPLES
9.9.32 DRY AIR CYLINDER WITH REGULATOR AND PRESSURE GAUGES
9.9.33 WELDING MACHINE
9.9.34 GAS CYLINDERS WITH NOZZLES, TORCH FOR GAS CUTTING OXY ACETYLENE
9.9.35 PRESSURE/ VACUUM EQUALISATION PIPES AND VALVES
9.9.36 ADAPTERS 80 TO 25 MM THREE NOS.
EACH 80 TO 50 MM THREE NOS.
EACH 50 TO 25
MM THREE NOS.
EACH
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 75 -
9.9.37 VALVES: 25 MM FLANGED TYPE WITH POSITION INDICATORS AND LOCKING DEVICES 50
MM FLANGED TYPE WITH POSITION INDICATORS AND LOCKING DEVICES
9.9.38 ADAPTERS SUITABLE FOR VALVE AND PRESSURE GAUGE BUSHING LIFTING EQUIPMENTS
AS SPECIFIED IN THE INSTRUCTIONS ON BUSHINGS VACUUM GAUGE RANGE 0 - 50 MILLI
BAR WITH LEAST COUNT OF ONE MILLI BAR TUBE: 5 INNER DIA TRANSPARENT TUBE TO
USE AS OIL GAUGE SHALL BE CAPABLE OF WITHSTANDING FULL VACUUM.
9.9.39 TINTED GLASS BOTTLES WITH GROUND GLASS STOPPER ALUMINIUM CANS WITH SCREW ON CAPS (PREFERABLE FOR LONG TRANSPORTATION DISTANCES) UNTINTED GLASS
BOTTLES, WRAPPED IN NON -TRANSPARENT FOILS FOR PROTECTION AGAINST LIGHT.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 76 -
PART 10
OIL
SPECIFICATION
TESTING
PURIFICATION
RECEIVING AND HANDLING
FILLING ON SITE AND
VACUUM OIL FILLING
ON SITE
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 77 -
10
OIL
10.1 GENERAL
10.2
SPECIFICATION FOR INSULATING OIL + TABLE T
+TABLE T 10.2: SPECIFICATION FOR INSULATING OIL
10.1 DIELECTRIC STRENGTH
10.3 TESTING OF THE OIL + TABLE T 10.3
10.4 INTERPRETATION OF TESTS ON OIL + TABLE T 10.4
10.5 OIL SAMPLING +FIG F10.1
10.6 LABORATORY TESTING
10.7 DIELECTRIC STRENGTH + TABLE T10.5, T10.6, T10.7
10.8 OIL PURIFICATION + FIG F10.2
10.9 STORAGE
10.10 LABELLING, HANDLING, SAFETY AND DESTRUCTION OF INSULATING OIL
10.11 OIL FILLING
10.11.1
OIL FILLING RECEIVING AND HANDLING OF TRANSFORMER OIL ON SITE
[PRODUCT INFORMATION 1ZBA 4601-213]
10.11.2
FINAL OIL FILLING ON SITE - ATMOSPHERIC PRESSURE [PRODUCT
INFORMATION 1ZBA 4601-214]
10.11.3
OIL CONSERVATORS WITHOUT AIR CELL [PRODUCT INFORMATION
1ZBA 4601-218]]
10.12 VACUUM OIL FILLING ON SITE [PRODUCT INFORMA TION 1ZBA 4601 -215]
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 78 -
10.1 GENERAL
.
GENERAL REQUIREMENTS
10.2 SPECIFICATION FOR INSULATING OIL
The insulating oil must meet the values given in Tables T10.1 and T10.2 below, before being filled
into the tank.
TABLE
T 10.1: DIELECTRIC STRENGTH
Breakdown voltage
Operating voltage
New transformers prior to the first
energization
(kV)
IEC 156
kV / 2.5 mm
Transformers
having been in
service
IEC 156
kV / 2.5 mm
> 170
50
50
70 - 170
50
40
< 70
50
30
MATERIAL SPECIFICATION FOR TRANSFORMER OIL
This material specification describes the requirements on unused, uninhibited, Insulating mineral oil
of standard quality and grade. It essentially corresponds to IS 335. The oil may be used in
transformers and in reactors.
10.2.1. HEALTH ASPECTS
The oil may be harmful. See directions for labelling, handling, safety and destruction below in 10.10
10.2.2. GENERAL REQUIREMENTS
The oil shall consist of severely solvent refined and/or severely hydrotreated mineral oils. It shall be
clear and free from sediment and suspended matter.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 79 -
TABLE T 10.3: TIME INTERVALS FOR OIL CHECKINGS
YEARS AFTER
INITIAL
OPERATION
OPERATING VOLTAGE (kV)
73 - 170
> 170
TEST (A) TO (F)
TEST (A) TO (G)
(G)
(G)
(G)
TEST (A) TO (F)
(G)
in 3 year intervals(G)
in 5 year intervals :all
tests (A) TO (F)
TEST (A) TO (G)
73
0(initial operation)
1
2
3
4
5
6
afterwards
10.4
TEST (A) TO (F)
TEST (A) TO (F)
in 5 year intervals
INTERPRETATION OF TESTS ON OIL INTERPRETATION CRITERIA: TABLE T 10.4
Criteria
Operation
voltage
Test
method
Breakdown voltage
> 170 kV
70 - 170 kV IEC 156
< 70 kV
Water content
> 170 kV
ISO R 760
< 170 kV
Dielectric
all voltages IEC 247
dissipation factor
IEC 250
Neutralization value all voltages IEC 296
Interfacial tension
10.5
in 2 year intervals(G)
in 5 year intervals:
all tests (A) TO (F)
IEC 296
Permissible
limiting value
> 50 kV
> 40 kV
> 30 kV
< 20 mg / l
< 30 mg/l
< 0,2 (20 %)
at 90 °C
< 0,5 mg
KOH/g oil
> 15 mN/m
Measures to be
taken if values are
not permissible
Filtering
Drying
(Purification)
Drying
(Purification)
Exchange of the oil
Exchange of the oil
Exchange of the oil
OIL SAMPLING
Samples of oil must only be taken at the provided extraction points (drain valves / oil sampling valves as
shown in the outline drawing).
Oil sampling can be done from top, middle and lower part of tank. Suitable pipe work is provided
inside transformer tank for sampling from the parts and the three sampling valves are provided at
easily accessible heights .
Before taking an oil sample clean the drain valve and slowly drain off at least 5 liters of oil. This oil is not
suitable for sampling as it may lead to wrong evaluation of the condition of the complete oil filling. Take test
samples only after the above mentioned amount of oil has been drained.
Use clean and dry sample containers only. Be sure to remove all residue of cleaning fluids. Before filling the
sample container, rinse it with the oil to be sampled. Protect the oil sample from light. The following sampling
containers are recommended:
- Tinted glass bottles with ground glass stopper
- Aluminium cans with screw-on caps (preferable for long transportation distances)
- Untinted glass bottles, wrapped in non-transparent foils for protection against light
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 83 -
Take at least 1 litre of oil for testing. Samples to be tested for water-, gas- or air content must be
taken in special containers as shown in Fig.1 to prevent leakage or penetration of gases and water.
Fig. F10.1 EXAMPLE OIL SAMPLING FOR TESTING OF GASES AND WATER
1 OIL DRAIN VALVE
Oil
drain valve
2 ADAPTER FLANGE
3 SYNTHETIC RUBBER HOSE
Synthetic rubber hose
4 HOSE CLIP
Hose clip
5 GLASS BOTTLE Glass bottle
10.6 LABORATORY TESTING
For a comprehensive determination of the serviceability of the insulation oil, full chemical and
physical analysis is required. Such analyses are usually performed in specially equipped
laboratories only. Testing of the dielectric strength is described below in 10.7
10.7
DIELECTRIC STRENGTH
10.7.1 IEC-METHOD
The IEC test gap consists of two 12.5 mm (=0.5 inch) spheres, or VDE semispheres, spaced 2.5 mm (0.1
inch) apart. The test cup is filled slowly to avoid the formation of air bubbles. The oil should have a
temperature of 15-25°C (59-78°F). Testing is started right after completion of the filling. The test voltage of 2
kV/s is raised six times consecutively, each time until breakdown occurs.
A fter each breakdown the oil in the gap is stirred with a clean, dry glass rod of 2 mm (0.080 inch)
diameter. The average value of the six results is considered to be the dielectric strength of the oil
which must comply with the values of table one. If any one of the six breakdown voltages lies more
than 15% below the specified value the test must be repeated with a new sample:
The dielectric strength of the oil can be improved by filtering and drying.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 84 -
10.7.2 ASTM D-1816 METHOD
This method is compatible with the IEC method; it also employs spherically capped electrodes
spaced at 0.080 or 0.040 inch. Six breakdowns are performed and the average value of the last five is
the valid value. (That of the first breakdown is disregarded).
10.7.3 ASTM D-877 METHOD
This method specifies 1-inch-diameter circular disc square-edged electrodes spaced at 0.1inch. One
breakdown on each of five samples is made. This method is not recommended for oil tests by ABB
because it has, during repeated tests, been established as non -responsive to contamination and even to
water in oil.
10.7.4 GAS ANALYSIS ON TRANSFORMER OIL
Incipient faults in oil filled transformer are usually the result of electrical or thermal excess stress of
either transformer oil or insulating materials. It is known that such excessive stresses produce a
mixture of gases characteristic of which give an indication of the type of faults and materials
associated with the faults. It is recommended that analysis of dissolved gases in transformer oil by
gas chromatographic equipment is made at the time of commissioning and then at an interval of
maximum six months
10.7.5 ANALYSIS METHOD
10.7.5.1 SAMPLING OF OIL FROM TRANSFORMERS
Oil in transformers can be sampled through drain or sampling valve near bottom of tank. Special care shall
be taken not to introduce air, foreign matter or dirty oil into sampling container. For this purpose,
first
0.5 to 1.0 litre of oil from the transformer shall be over-flown through the oil container. Shape of the
sampling container and sampling method shall be in accordance with standard procedures and IS:
9497
Sampled oil shall not be exposed to air before analysis.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 85 -
10.7.5.2 GAS ANALYSIS : TABLE T 10.5
Gases to be analysed and criteria for the gases found in transformer oil are tabulated below.
1
Gases to be analysed normally
O2, N2 , H2,CO, CO2, CH4
2
Gases to estimate abnormality
H2, CH4, C2H2,C2H4,C2H6
3
Gases to estimate deterioration
CO, CO2, CH4
10.7.5.3 GAS CONTENT IN OIL BY FAULTS
TABLE T 10.6
SL
NO
DECOMPOSIBLE GASES IN TRANSFORMER
OIL
TYPE OF FAULTS
1
OVER HEAT OF OIL
CH4, C2H4,H2, (C2H6,C2H2,C3H6,C3H8)
2
ARCING IN OIL
H2, C2H2, (CH4,C2H4)
3
OVER HEAT OF SOLID
INSULATING MATERIAL
OVER HEAT OF SOLID
INSULATING MATERIALS
ARCING OF OIL AND
PAPER COMBINATION
CO, CO2, ( H2, C2H4)
4
5
CH4, C2H4, CO, CO2,H2
H2, C2H2,CO, ( C2 H4)
GASES IN ( ) SHOWS CONTENTS WHICH APPEAR RARELY
10.7.5.4 PERMISSIBLE CONCENTRATIONS OF DISSOLVED GASES IN THE OIL OF A
HEALTHY TRANSFORMER (IN PPM)
TABLE T 10.7
GAS
LESS THAN 4 YEARS
IN SERVICE
4 -10 YEARS IN
SERVICE
HYDROGEN H 2
METHANE CH4
ETHANE
C2H6
ETHYLENE C2H4
ACTYLENE C2H2
CARBON MONOXIDE
CARBON DIOXIDE
110- 150
50- 70
30- 50
100- 150
20- 30
200- 300
3000- 3500
200- 300
100- 150
100- 150
150- 200
30- 50
400 -500
4000-5000
MORE THAN
10 YEARS IN
SERVICE
200- 300
200- 300
800 -1000
200- 400
100- 150
600- 700
9000- 12000
NOTE: 1
PLEASE REFER IS:10593 FOR DISSOLVED GAS ANALYSIS, FAULT IDENTIFICATION AND
REMEDIAL ACTION. AND ALSO REFER IS 3638, IEEE STANDARD C57.104-1991, IEC 599,
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 86 -
NOTE 2:
TRANSFORMER OVER HEATING CAN LEAD TO CELLULOSE DECOMPOSITION AND PRODUCTION
OF CO AND CO2. THESE TWO GASES ARE ALSO PRODUCED DURING THERMAL DECOMPOSITION
OF OIL. THERFORE ANALYSIS OF GAS MEASUREMENT OF CO AND CO2 CANNOT BE USE D AS
UNAMBIGUOUS INDICATION OF PAPER DEGRADATION.
IN ADDITION TO CO AND CO2, THE
AGEING PROCESS OF THE PAPER PRODUCES SEVERAL OIL SOLUBLE BYPRODUCTS, MOST
NOTABLY THE FURANIC COMPOUNDS (FFA). THE MONITORING OF FURANIC COMPOUNDS BY
ANNUAL SAMPLING OF OIL AND USING HIGH PERFORMANCE LIQUID CHROMOTOGRAPHY (HPLC)
IS RECOMMENDED AS A PREVENTIVE MEASURE.
10.8
OIL PURIFICATION
Oil purification comprises drying, de-gassing and filtering. Drying removes free and dissolved water,
de-gassing removes dissolved gasses and filtering removes all floating solids above a size to be
defined.
Oil purification is done under vacuum. Therefore, only purification plants must be used which employ
vacuum processing. Vacuum oil purification plants remove all water from the oil through evaporation under
vacuum, while degassing the oil at the same time.
Fig. F 10.2 shows the usual circulation method employed for field oil purification. To prevent the oil
from re-absorbing moisture while in the tanks, vacuum-proof tanks should be used and a vacuum
maintained above the oil surface. Thereby the oil is also prevented from being saturated with air. If
no vacuum-proof tank is available, mount a silica gel breather on each tank to minimize moisture
ingress. The oil purification is finished when the dielectric strength of the oil meets the specified
value.
Sufficient tanks must be available to hold the total oil volume. However, even then purified and
nonpurified oil is mixed constantly during the purification process. In addition, it is possible that
pockets of untreated oil might remain in a tank. In any case, oil circulation is rather time consuming.
The "Alternating Tank Method" avoids this disadvantage, but it requires two tanks, each large
enough to hold the total oil volume. The tanks should be vacuum proof, or equipped with silica gel
breathers. The oil is processed from one tank into the other via the oil purification plant which
considerably reduces the processing period.
FIG. F10. 2 FLOW DIAGRAM FOR TRANSFORMER OIL PROCESSING
1 Oil tank (preferably vacuum tight)
2 Oil purification plant
3 Connection to vacuum pump or silica gel breather
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 87 -
10.9 STORAGE
Insulating oil must be stored in clean containers designated for oil storage; Mixing with other type of
oil such as used oil, cable oil, lubricating oil, fuel oil and contamination with solids must be strictly
avoided. Even small quantities of contaminants can considerably impair the insulating properties of
the oil. Containers used for oil storage should be individually and carefully examined for cleanliness
and tightness. The containers must be protected against penetration of moisture during storage.
If cleaning of containers must be done on site, the following procedure must be employed:
1)
2)
3)
Rinse the container thoroughly with lead-free gasoline or kerosene until the solvent shows no
discoloration after using.
Drain the container completely and dry it.
Immediately after drying, seal the container to avoid moisture condensation.
Oil drums should be stored at site in horizontally laid down condition. In order to avoid
environmental pollution special care should be taken to prevent leaking of the drums.
10.10 LABELLING, HANDLING, SAFETY AND DESTRUCTION OF INSULATING OIL
10.10.1
GENERAL
This document offers general recommendations on safe handling practices for mineral-based oils
and precautions to avoid adverse health effects. The legal requirements and local rules for different
countries must be followed for each specific case of handling mineral based oils. It is emphasized
that the supplier must forward specific advice on individual products.
The specific product information is recommended to include:
Transportation classification
Information on composition
Biological, properties
Labelling
Health hazard
Fire and explosion hazard
Preventive measures
Personal protective equipment
First aid
Emergency action in case of fire
Spillage and decontamination
10.10.2 LABELLING
The labelling has to be done in accordance to the rules and guidelines issued by the various central and
state government bodies from time to time.
10.10.3 SAFE HANDLING
Most insulating oils have a low level of toxicity but the range of exposures can be very wide. To
prevent adverse effects, the extent of possible exposure in any situation needs to be assessed and
appropriate precautions established to control that exposure is at an acceptable level
In all cases it is desirable to minimize exposure.
The main contact areas from exposure to oils are the skin and eyes. Some processes also create oil mist
which is fine enough to enter the upper and lower respiratory tract and cause contamination of body
surface.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 88 -
10.10.4 PREVENTIVE MEASURES
The main preventive measures can be summarized as follows:
Avoid inhalation of any mist, fumes or vapour generated during use.
Avoid contact with the skin.
Avoid contact with the eyes.
10.10.5 PERSONAL PROTECTIVE EQUIPMENT
The personal hygiene is of big importance.
Therefore:
- Wash hands carefully before eating and drinking.
Ms -i - Change heavily contaminated clothing.
10.10.6 FIRST AID ,
First Aid due to inhalation is unlikely to be needed under normal use
For skin contact, the first aid is to wash " with soap and water”.
For eye contact, wash out eyes thoroughly with water.
Better consult a doctor if there is risk of swallowing
10.10.7 SPILLAGE AND DECONTAMINATION
Take up spills with dry chemical absorbent. The spill should be disposed by normal disposal
methods based on state and local codes.
10.10.8
DESTRUCTION
Insulating mineral oil can be destructed by burning or can be reused for other purposes than as
insulating oil. Before choosing the way of destruction the oil has to be classified regarding the
degree of contamination
10.10.9
1.
2.
3.
4.
USED OIL CAN BE SEPARATED IN FOUR GROUPS:
Non contaminated and also free of water.
Contaminated oil and free of water.
Oil containing water.
Spilled oil
10.10.10 NON CONTAMINATED OIL
Non, contaminated oil is free of particles free of water and free of PCB (Polychlorinated Biphenyles).
Prior to destruction the oil has to be tested for PCB. The non-contaminated water free oil is
destructed by burning.
10.10.11 CONTAMINATED OIL FREE FROM WATER
Contaminated oil free from water is an oil with particles and/or containing PCB. It shall be filled in drums,
approximately 209 litres of size, and sent to the local authority for disposal.
10.10.12 OIL BLENDED WITH WATER
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 89 -
Oil blended with water should be sucked up and collected in a tank and delivered to the local
authorities. There the water is separated from the blend and the oil can thereafter be used for asphalt
production.
10.10.13 SPILLED OIL
Oil spills is taken up with a dry chemical absorbent. It should be assembled and put on a platform
and passed on to a container made of concrete. After the sedimentation of the absorbent the oil can
be used for asphalt Production.
10.11 OIL FILLING
10.11.1
OIL FILLING: RECEIVING AND HANDLING OF TRANSFORMER OIL ON SITE
PRODUCT INFORMATION 1ZBA 4601-213 ENCLOSED [THREE PAGES]
10.11.2 FINAL FILLING ON SITE -ATMOSPHERIC PRESSURE PRODUCT
INFORMATION 1ZBA-4601-214 ENCLOSED, 3 PAGES
10.11.3 OIL CONSERVATORS WITHOUT AIR CELL [PRODUCT INFORMATION 1ZBA 4601-218] 2
PAGES
10.12.0
VACUUM OIL FILLING ON SITE
PRODUCT INFORMATION 1ZBA 4601-215 ENCLOSED [13 PAGES].
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 90 -
PART 11
ERECTION AND ASSEMBLY
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 91 -
11
ERECTION AND ASSEMBLY
11.1 GENERAL
11.2 MOUNTING OF ACCESSORIES
11.3 BOLTING/ SCREWING CONNECTIONS
11.4 PAINT
11.5 CONSERVATOR AND BRACKETS
11.6 COOLING EQUIPMENT
11.7 BUSHINGS
11.8 PIPES AND FITTINGS
11.9 OTHER ACCESSORIES
11.10 ELECTRICAL CONNECTIONS
11.11 OIL FILLING
TABLES
T 11.1 A MAXIMUM RECOMMENDED TORQUE
T 11.1 B MAXIMUM RECOMMENDED TORQUE
T 11.1 C TORQUE FOR GAKETETTED JOINTS
FIGURE
F11.1 ARRANGEMENTS FOR OIL FILLING - SCHEMATIC PICTURE
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 92 -
11
ERECTION AND ASSEMBLY
11.1 GENERAL
Commissioning of a transformer should, as a rule, be carried out by the manufacturer's experts.
Should this not be possible or the user decides to have the commissioning carried out by his own
personnel, the following instructions should prove as useful guidelines.
However, the assembly of transformers must only be carried out by well-trained staff who is familiar with the
relevant safety regulations. Also refer parts EARLIER DESCRIBED regarding arrival on site, unpacking and
checking of the consignment, installation, checklist for the consignment on arrival.
11.2 MOUNTING OF ACCESSORIES
The transformer should be assembled when the weather is dry. In order to minimize the penetration
of humidity and dust into the inside of the tank during assembly, all openings must be re-closed as
soon as possible.
Caution!
Blank flanges must only be removed from tank and accessories if this is
necessary for the assembly and immediately before starting with the mounting procedure
Separately supplied parts must be checked for cleanliness, humidity and damages before the
assembly. The inside of conservator, radiator, pipes, etc. must be clean and dry. The inner coating
must not be damaged. If parts are soiled, they must be cleaned thoroughly. Only those kind of
cleaning agents are to be used, which do not leave any residues. Humidity can be removed by
flushing with hot air or with hot transformer oil.
Accessories like cooling fans, pumps, OLTC and components for supervision and control, oil level indicator,
flow indicators, gauges, buchholz relay, PRV, thermometers etc. are assembled according to leaflet/
description valid for the components. After assembling locking strip/card /pin shall be removed for correct
functioning of Oil Flow Indicator.
11.3 BOLTING/SCREWING CONNECTIONS
All oil tight and / or vacuum tight screwing connections must be made with special care. Only the gaskets
supplied by ABB or gaskets of the same quality must be used.
Sealing surfaces must be checked for damages of any kind. They must also be free of rust, paint, oil and
grease.
Caution
Roughness on surfaces resulting from transport handling must be evened.
Contaminations must be removed.
After the gasket and the connection parts have been fitted, the screws must only be turned a little,
one by one (about 1-2 turns). This shall be repeated until all screws around the gasket are tightened.
This procedure guarantees, that the pressure on the gasket is applied evenly.
When remounting blanking plates, connection flanges etc., the gasketting surface shall be cleaned well and
new gaskets fitted.
Assemble the control cables according to the drawing of wiring system and connect the cable ends to
terminal blocks in instruments, terminal boxes, junction boxes and control cabinets according to valid
connection diagram.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 93 -
11.3.1 SPECIFICATION OF TORQUES FOR BOLTS AND NUTS
11.3.2 GENERAL
The maximum recommended torque can be calculated on the basis of the material properties and 70% of the
proof stress can be considered as limit value for tightening torque. The general classification can be made
as follows. For all inspection covers, pin screws are used.
11.3.3 BOLTS AND NUTS
Bolts and Nuts should conform to property class of 4.6 of IS 1367 having UTS of 4200 kg/sq mm and
yield stress of 2400 kg/sqcm.
EXAMPLE FOR PIPE CONNECTIONS: [HIGHLIGHTED BOLD IN TABLE 11.1A]
TABLE T 11.1 A MAXIMUM RECOMMENDED TORQUE N -m
BOLT SIZE
UNPLATED: TORQUE N -m
ZN PLATED GALVANISED
M 10
M 12
M 16
M 20
M 24
M 30
M 36
20
36
90
175
300
600
1050
25
40
110
210
360
720
1260
11.3.4 Bolts and nuts should conform to property class of 8.8 of IS 1367 having UTS of 7000 kg/sqcm and
yield stress of 4200 kg/sqcm
EXAMPLE: FOR TANK- COVER CURB
TABLE T 11.1 B: MAXIMUM RECOMMENDED TORQUE N-m
BOLT SIZE
UNPLATED: TORQUE N-m
M 10
M 12
M 16
M 20
M 24
M 30
M 36
35
60
145
280
490
970
1700
ZN PLATED
GALVANISED
40
70
170
340
590
1160
2040
11.3.5 Recommended torque for bolts/studs only for GASKETED JOINTS. Based on maximum pitch
generally used for that class of bolt, for example: radiator valves, valves.
TABLE T 11.1 C: TORQUE FOR GAKETETTED JOINTS
BOLT SIZE
TORQUE N -m
M 10
M 12
M 16
M 20
M 24
20
30
50
70
100
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 94 -
11.4 PAINT
Damaged paint coatings must be repaired. Only the paint supplied by ABB or equivalent must be
used for this purpose. The damaged spot on the inside or outside must be smoothened to provide an
even transition to the undamaged paint. The surface must then cleaned from dust, grease and other
contaminations by using a chemical-cleaning agent. Commercial paint removers are suitable as
chemical cleaning agents.
The procedure described in the following is to be repeated at least three times, in order to obtain a
protective, multiple -layer coat of paint:
-
The paint shall be applied in a thin and even layer.
The paint must dry out completely (on the average over a period of approx.8
hours).
Afterwards the repainted area must be smoothened carefully and all dust shall be
removed.
When the third coating has dried out completely, the repaired component can be assembled.
11.5 CONSERVATOR AND BRACKETS
The conservator must be assembled ready for operating before mounting the bushings and / or other
components which must be filled with oil. This guarantees that oil filling of the transformer can be
started immediately and without further delay after the assembly has been completed.
Conservator and brackets must be mounted to the transformer as shown in the outline drawing. The distance
in height between transformer tank and conservator as indicated on the outline drawing must be strictly
observed.
The conservator is mounted on separate A- frame assembly as shown in the general assembly
drawing.
The conservator is in two compartments: one for the main transformer separated by other compartment
for OLTC connection.
Flxi separator bag is mounted inside main conservator compartment. Magnetic oil level gauge with its
float is suitable for FLXI separator mounting.
Before the conservator is assembled it shall be checked that belonging equipment, example oil level
indicator- functions satisfactorily. The breather is connected to the oil conservator and it is very important
that joints and couplings in the pipe between breather and conservator are airtight.
11.6 COOLING EQUIPMENT
Valves which are not dismantled like shut off valves for radiators, coolers and possible headers are
provided with blanking plates during transport. Check that valves are closed and remove blanking
plates before assembling the coolers
11.6.1 SEPARATELY STANDING RADIATOR ASSEMBLY
The radiator battery is supplied separately. The radiators are mounted to the frame along with oil
pumps, oil flow indicators ,non- return device and suitable valves. Openings at the radiator frame, at
the transformer and at the radiators are closed by blind flanges. They must be removed before the
assembly.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 95-
Caution:
Desiccant bags inside the radiators, if provided, must be taken out.
The gasket between radiator flange and butterfly valve must be centered. The radiator battery
including all accessories (piping, valves and extension joints etc.) is erected and assembled as
shown in the outline drawing.
Fans must be mounted to the attachments provided for this purpose on radiators as shown in the
general assembly.
11.7 BUSHINGS
The bushings are mounted as described earlier. Please refer supplier‘s catalogue.
11.8 PIPES AND FITTINGS
The assembly is done as shown in the outline drawing and the piping scheme. The venting pipes
between the transformer tank and the Buchholz relay and between the tap changer, Buchholz relay
and the protective relay rise by about 3 -7 degrees to ensure an unhindered excape of any gas from
the transformer.
Caution
The sealing surfaces of pipes and fittings must not be subjected to any kind of mechanical stress.
There is sufficient space/clearance between pipes and live parts. These spaces/ clearances must be
strictly observed.
Breather pipe, conservator pipes, equalizing pipes, cooler pipes etc. should all be assembled
properly as per the general assembly drawing. The pipes shall preferably placed 3 to 7 degrees
upward from the transformer. Internal surfaces of pipes should have been treated with oil resistant
paint and external surfaces as per the specification required.
11.9 OTHER ACCESSORIES
All other accessories disassembled for transport and not mentioned above must be mounted now. The
assembly position is shown in the outline drawing.
11.10 ELECTRICAL CONNECTIONS
All electrical connections for current transformers, supervisory equipment etc. shall be made as
indicated in the Circuit Diagram of Transformer supervision. For the fans, attention must be paid to the
direction of rotation.
Caution
Cables shall not be layed over sharp edges
After the cables have been connected the compression glands at control cabinet and devices must be
tightened and protected against the penetration of dust and humidity by means of a permanently elastic
sealing substance.
In the case of steel-armored cables, the armoring is to be earthed on one side (usually inside the
control cabinet).
The tank must be connected with the functional grounding of the system at two diagonally opposite
points. The location of the earthing pads is shown in the outline drawing.
All metal parts are to be connected to the earthing pads by means of flexible conductors.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 96 -
11.11 OIL FILLING
PLEASE REFER PART 10
FIG. F11.1 ARRANGEMENTS FOR OIL FILLING - SCHEMATIC PICTURE
1 -Transformer
2 -oil treatments plant
3 -vacuum hose
4 -oil hose
5 -oil filling connection
6 -gate valve for oil treatment plant
7 -air vent valve
8 -manometer
9 -lower shut-off gate valve
10 -vac. Flange with
sight glass
11 -connection full vacuum Gauge
connection f. vac. Gauge
12 -oil inlet slide valve
oil inlet slide valve
13 -inlet pump
inlet pump
14 -filter
15 -heating heating
16 -degassing chamber degassing chamber
17 -discharge pump discharge pump
18 -oil outlet gate valve
oil outlet slide valve
19 -vacuum pump vacuum pump
20 -gas ballast valve
gas ballast valve
21 -vacuum valve
vacuum valve
22 -vacuum gauge vacuum gauge
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 97 -
PART 12
ACCEPTANCE TEST AND
ENERGIZATION
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 98 -
12.0 ACCEPTANCE TESTING AND ENERGIZATION
12.1 PRODUCT INFORMATION 1ZBA 4601-216 [11 PAGES]
12.2 STANDING TIMES + TABLE T 12.1
12.3 CHECKING
12.3.1 GENERAL
12.3.2 ELECTRICAL TESTS,
12.3.2.1 PROTECTIVE DEVICES
12.3.2.2 WINDING RESISTANCE
12.3.2.3 MEGGER TEST
12.3.2.4 OIL SAMPLES
12.4 RECOMMENDATIONS FOR ENERGISING
12.5 SOAKING TIME VS. MAX. OPERATING VOLTAGE OF TRANSFORMERS
12.6
RECOMMENDED REQUIREMENTS OF INSTRUMENTS USED
TESTS + T 12.2
12.7 OVER LOAD PROTECTION FOR ENERGISING UNLOADED
FOR
PRE-COMMISSIONING
TRANSFORMER + T12.3
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 99 -
12.0
ACCEPTANCE TEST AND ENERGIZATION
12.1 PRODUCT INFORMATION 1ZBA 4601-216
[ 11 PAGES]
12.2 STANDING TIMES
Since it is almost impossible to remove all gas inclusions from the insulation during evacuation and, on the
other hand, small quantities of residual gas can cause internal discharges, it is necessary that the residual gas
in the insulation is dissolved in the insulating oil. This is a slow process which is
accelerated with rising temperature of the oil penetrating into the insulation. However, residual gases can
only be dissolved in oil, if the oil itself is highly de-gassed.
The following soaking periods are valid for oil temperatures of appr. 20 °C starting from the time
insulating material is covered by oil until putting into service.
when all
TABLE T 12.1: SOAKING TIME VS. MAX. OPERATING VOLTAGE OF TRANSFORMERS
Highest operating voltage (k V)
72,5
> 72,5 - 123
> 123 - 170
Standing time(days)
1
> 170 - 245
> 245 - 420
> 420
5
7
7
3
3
12.3 CHECKING
12.3.1 GENERAL
Before the transformer is put into service, various checkings must be performed.
12.3.2 ELECTRICAL TESTS
We recommend to perform the following checks before energizing the transformer.
12.3.2.1PROTECTIVE DEVICES
A functional test has to be performed on all protective devices of the transformer.
12.3.2.2WINDING RESISTANCE
Winding resistances depend on the temperatures. The measured data should be converted to the same
reference (say 75 deg. C) operating temperature and compared to the data mentioned in the
transformer test certificate.
12.3.2.3 MEGGER TEST
Check the insulation resistance beween the windings as well as each winding to ground
with a 5 kV
Megger-Tester. Insulation resistance of core to ground and secondary wiring to ground are to be tested
with a Megger-Tester of 1 kV only.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 100 -
12.3.2.4 OIL SAMPLES
Sample has to be taken and the dielectric strength must be tested. If the results of
test do not comply
to the requirements, the oil must be dried and de-gassed by circulating through an oil purifying plant.
12.4 RECOMMENDATIONS FOR ENERGISING
When energising an unloaded transformer, overvoltages occur on the energised as well on the notloaded
side. Inner flashovers can occur even when an unloaded transformer is energized. On the energised side,
overvoltages occur as a consequence of reflections. On the no-loaded side capacitive and inductive
voltages can interfere with voltages which are caused by vibrations of the windings. The following
recommendations should be observed while energizing an unloaded transformer in order to exclude
possible dangers:
1
A transformer should always be connected to the main power supply on the HV
side. If the HV-winding is provided with an on-load tap-changer, the latter
should be adjusted to the tap position with the maximum number of windings
( TAP 1).
2.
When energizing 3-phase-transformers, the synchronism of the circuit-breakers has
proved to be important with respect to formation of switching surges.
Measurements have shown that the smaller the time delay between the third
pole and the second one, the smaller the over voltage level. Therefore, an
examination of the synchronism of the circuit breakers should be made
during the first commissioning of transformers with a voltage rating 245 kV
and above.. If necessary adjustment of the synchronism must be performed.
3.
Lightning arresters are the best protection against switching surges for all terminals
which are not grounded. To prevent capacity transmitted voltage peaks, the
low voltage terminals of generator transformers and the tertiary terminals of
system transformers should be connected to capacitors installed between
terminal and ground. Protection with capacitors is not necessary if the
capacity to the ground of the connected busbars or cables is approximately
0.05 µF/phase.
4.
Before energizing an unloaded transformer ensure that all short-circuit connections
are removed from the secondary terminals. If there is a short-circuit, it must be
eliminated before energising the transformer.
The following TABLE T 12.3 gives recommendations for over voltage protection for energising
unloaded transformers with regard to the voltage ratio.
12.5
TABLE T 12.2
RECOMMENDED REQUIREMENTS OF INSTRUMENTS USED FOR PRE-COMMISSIONING
TESTS
SL
NO.
1
TEST
Ratio, polarity and
phase relationship
MEASURING
INSTRUMENT
Voltmeter
INSTRUMENT
RANGE
0-500 V
REQUIRED
ACCURACY
+/- 2 %
LEAST
COUNT
5V
-6
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 101 -
12.6
2
Resistance
Bridge
0 - 100 ohms
+/- 2 %
1 x10
ohms
3
Insulation
resistance
Meggar
0-50,000
M -ohms
+/- 5 %
4
5
Excitation current
Oil BDV
Ammeter
BDV meter 2.5 mm
gauge
0-200 m A
0-100 k V
2.5 mm
+/- 0.5 %
+/-2%
+/- 0.1mm
5 Mohms
at the
lowest
scale
1mA
kV
GONO-GO
6
Moisture in oil
Moisture meter
0-100 ppm
1 ppm
1 ppm
TABLE T 12.3
OVER LOAD PROTECTION FOR ENERGISING UNLOADED TRANSFORMER
Voltage ratio of the
transformer
HV/LV or HV/LV/TV
Putting in
circuit on
the HV-side
Lightning
arrestors on all
not earthed terminals> 30kV
Protection
capacitors on
the LV-or
TV-side
kV
110/30
110/6,3...30
X
X
X
110/6,3...30/10
X
X
110...245/15...27
X
245/110...132/10
X
345...525/15...27
X
345...525/110...245/10...20 X
750/15...27
X
750/245...525/30
X
X
X
X
X
X
X
X
X
X
X
X
X
Examination of
the
synchronism of
the circuit
breakers in case
of a 3 -phase
transformer
X
X
X
X
X
X = is recommended
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 102 -
PART 13
FIELD TEST RECORD
AND
FIELD QUALITY PLAN
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 103 -
FIELD TEST RECORD GENERAL CONTENT [REF:1ZBA 4601-217]
13.1 RATIO TEST
13.2
CHECK OF VECTOR GROUP INSULATION TEST CHECK OF POTENTIAL CONNECTION
BETWEEN TANK AND TURRET
13.5 POLARITY CHECK OF CURRENT TRANSFORMERS
13.6.
13.7.
CHECK OF WINDING TEMPERATURE CIRCUITS
OIL TEST
13.8.
OPERATIONAL TEST OF SUPERVISORY EQUIPMENT
13.9.
OPERATIONAL TEST OF OTHER EQUIPMENT
13.10 FIELD QUALITY PLAN
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 104 -
13.0 FIELD TEST RECORD : GENERAL CONTENT
[ REFERENCE: PRODUCT INFORMATION 1ZBA 4601-217]
Order No
Transformer type
Tap-changer type
Motor-drive
Mechanism type
Serial No
Serial No
Serial No
CONTENT
NOTE: MARK X for the respective test, which are carried out under Yes.
Yes
13.1.
No
Ratio test
13.1.1 Windings
13.2. Check of vector group
13.3.
Insulation test
13.3.1 Windings
13.3.2 Current Transformers
13.3.3 ... .............................................................................. ... Control-circuit cabling and auxiliary power cabling
... _________________________
13.3.4 Core
13.4
Check of potential connection between tank and turret _______________________
13.5.
Polarity check of Current Transformers
13.6.
Check of winding temperature circuits
13.7. Oil test
13.8.
Operational test of supervisory equipment
13.9.
Operational Test of other equipment
13.9.1 Coolers
13.9.2
On-load tap-changer with motor drive mechanism
Customer represented at test
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 105 -
13.1 RATIO TEST
13.1.1 WINDINGS
Tap
changer
Position
Magnetizing
on __-kV side
Volt
No
load
current
measured on ___kV side
Calculate
d voltage
Volt
u-v
Volt
u-v-w
Volt
u-w
Volt v-w
measured on
___kV side
Volt
u-v
Volt
u-w
Volt
v-w
Calcula
ted
voltage
Volt
u-v-w
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Voltage between phase - 0 checked?
Yes
No
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 106 -
13.2 CHECK FOR VECTOR GROUP
Connect 1U with 2u
Magnetized on
kV side
Measured voltage U between
Vv
Ww
Connect 1U with
Magnetized on
Uv
Vw
Wv
Connection
UV
Vw
Wv
Connection
2u
kV side
Measured voltage U between
Vv
Ww
The vector group corresponds with connection diagram No
Remarks
13.3 INSULATION TEST
13.3.1WINDINGS
Megger
kV
Note Maximum 5kV megger
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
to earth
to earth
to earth
to earth
to terminal
to terminal
M ohm
M ohm
M ohm
M ohm
M ohm
M ohm
Terminal
to terminal
M ohm
Weather conditions:
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 107 -
13.3.2 CURRENT TRANSFORMERS
Note Maximum 1kV MEGGER
Location:
Location:
Location:
Location:
Location:
Location:
Location:
Weather conditions:
Megger
Terminal:
Terminal:
Terminal:
Terminal:
Terminal:
Terminal:
Terminal:
KV
to earth
to earth
to earth
to earth
to earth
to earth
to earth
M-ohm
M-ohm
M-ohm
M-ohm
M-ohm
M-ohm
M-ohm
13.3.3 CONTROL-CIRCUIT CABLING AND AUXILIARY POWER CABLING
Megger
V
Note Maximum 1kV megger
Cables to earth (min value)
M ohm
13.3.4 CORE
Megger___________ V
Note Maximum 1kV megger
The Megger must be of an of ABB Transformer approved type
Core - earth
________________M ohm
Yoke beams -earth ________________Mohm
Weather conditions_____________________________________________________________
REMARKS:___________________________________________________________________
13.4
CHECK OF POTENTIAL CONNECTION BETWEEN TANK AND
TURRET
The potential connection between tank and turret has been checked with buzzer
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 108 -
13.5
POLARITY CHECK OF CURRENT TRANSFORMERS
Check of Current Transformers according to diagram No
Location/terminal
Location/terminal
Location/terminal
Location/terminal
Location/terminal
Location/terminal
13.6 CHECK OF WINDING TEMPERATURE CIRCUITS
CURRENT TRANSFORMER FOR
Location
Location
Location
Measured resistance for:
Current transformer
ohm
ohm
ohm
Instrument
ohm
ohm
ohm
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 109 -
13.7 OIL TEST
The oil level checked in
Transformer
Tap-changer/diverter switch
Other separate compartments
The oil system has been de aired
Date
Oil samples are taken from
Oil conservator
Transformer/reactor tank
Cooling group No
Cooling group No
Cooling group No
Breakdown voltage
kV
Breakdown voltage
Breakdown voltage
Breakdown voltage
Breakdown voltage
kV
kV
kV
KV
Cooling group No
Breakdown voltage
kV
Oil test equipment type
Electrode distance
with
electrodes
mm
Oil samples for dissolved gas analysis
have been taken
REMARKS
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 110 -
13.8 OPERATIONAL TEST OF SUPERVISORY EQUIPMENT
Alarm circuit tested to
Control
Control
circuit
room
Cabinet
No/OK
No/OK
Trip circuit tested to
Control
Breaker
circuit
Cabinet
No/OK
No/OK
No/OK
No/OK
Gas detector relay transformer
Gas detector relay tap changer
Oil level indicator tap changer High
Low
Oil level indicator transformer High
Low
Pressure relief valve for transformer
Pressure relay for transformer
Pressure relay for tap changer
Flow indicators for coolers
Cooler group 1
min oil flow
max. oil flow
Cooler group 2
min oil flow
max. oil flow
Manometers for
coolers
Cooler group 1
min oil
pressure
Max. oil
pressure
Cooler group 2
min oil
pressure
max. oil
pressure
No/OK
Thermometer for top oil
Set for alarm
Deg
Set for trip
Deg
Set for start of
Cooler group 1
Deg
Cooler group 2
Deg
Thermometer for
kV winding
Set for alarm
Deg
Set for trip
Deg
Set for start of
Cooler group 1
Deg
Cooler group 2
Deg
Thermometer for
kV winding
Set for alarm
Deg
Set for trip
Deg
Set for start of
Cooler group 1
Cooler group 2
No/OK
Deg
Deg
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 111 -
13.9 OPERATIONAL TEST OF OTHER EQUIPMENT
13.9.1 COOLERS
1.
2.
3.
Pump rotation direction checked
Fans rotation direction checked
Over current protection tipped at 2 -phase connection:
Fan No
After
(sec.)
Current setting
(A)
Pump No
After
(sec)
Current setting
(A)
1
2
3
4
5
7
8
9
Alarm obtained for tipped current protection at terminals _______ in the control cabinet.
13.9.2 ON-LOAD T AP-CHANGER WITH MOTOR DRIVE MECHANISM
The position indicators in motor drive mechanism and tap changer
indicate the same position
Shaft coupling lubricated with grease
Gear box filled with lubricant to correct level
Motor drive mechanism checked and test runned
lubricated
end position contacts
local/remote control
interlocking switch manually and with the crank assembled
setting of motor protection
tripping time for blocked motor
pressure relay tested
heating element connected and In operation
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 112 -
13.10 FIELD QUALITY PLAN
SL
NO
CHARACTERISTICS/
ITEMS
1
1.1
CHECK ON RECEIPT
MAIN EQUIPMENT
TEMPORARY STORE
IF THE PERMANENT
LOCATION IS NOT
READY ,ENSURE THAT
TEMPORARY STORAGE
IS DONE IN A SUITABLE
LOCATION
CHECK THAT THE
EQUIPMENT IS NEVER
STORED IN A
POLLUTED AREA
CHECK THAT THE
EQUIPMENT IS KEPT
ON SLEEPERS/ ROLLER
MOUNTED
FACILITATING FREE
FLOW OF AIR
UNDERNEATH.
FOR GAS FILLED
STORAGE ,
PERIODICALLY CHECK
THE GAS PRESSURE
AND ENSURE THE
READING OF
PRESSURE AND
TEMPERATURE AS
LOGGED
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
THERMOMETER , FLOW
INDICATORS ETC.
CHECK THAT THESE
ARE STORED WITHOUT
DAMAGE TO FRAGILE
PARTS.
OIL DRUMS , CHECK
THAT THE DRUMS ARE
STORED IN PROTECTD
AREA AND ARE NOT
PLACED ON THEIR SIDE
FACE
OIL LEVEL GAUGE ,
BUCHHOLZ RELAY,
SILICA GEL BREATHER
ETC. CHECK THAT
THESE ARE STORED
WITHOUT DAMAGE TO
FRAGILE PARTS
TYPES OF
CHECK
QUANTUM/
FREQUENCY
OF CHECK
ACCEPTANCE
CRITERIA
REMARKS
PHYSICAL
AT THE TIME
OF STORAGE
HARD LEVEL
GROUND
--
AT THE TIME
OF STORAGE
UNPOLLUTED
--
PHYSICAL
PHYSICAL
READING OF
PRESSURE
GAUGE AND
RECORD
PHYSICAL
PHYSICAL
PHYSICAL
AT THE TIME
OF STORAGE
DAILY
AT THE TIME
OF STORAGE
AT THE
TIME OF
STORAGE
100 %
AT THE
TIME OF
STORAGE
100 %
NORMAL AIR
DIRECTION
SHALL BE
CONSIDERED
--
MAINTAIN GAS
PRESSURE OF
0.1 TO 0.2
Kg/Sqcm
USE
PRESSURE
GAUGE
AND
RECORD
ON LOG
SHEET
NO PHYSICAL
DAMAGE
--
SEALS
INTACT , NO
LEAKAGES
--
NO PHYSICAL
DAMAGE
--
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 113 -
SL.
NO
CHARACTERISTICS/
ITEMS
1.1.8
COOLING SYSTEM,
CHECK THAT ITEMS
CONNECTED AS PUMP
MOTOR ARE STORED
INDOOR
CHECK THAT
SUPPORTS AND
FABRICATED PARTS
ARE NOT PLACED
DIRECTLY ON GROUND
BUT KEPT ON WOODEN
BATTONS/PLANKS
BUSHINGS- CHECK
THAT BUSHINGS ARE
STORED IN
RESPECTIVE CASES IN
CLOSED PLACE
MARSHALLING BOXESCHECK THAT THE
MARSHALLING BOXES
ARE STORED IN
CLOSED PLACE IN THE
CASES
LOOSE ITEMS-CHECK
THAT LOOSE ITEMS
ARE STORED IN
CLOSED PLACE
COMPLETE
RECEIPT/STORAGE
CHECK LIST
ERECTION CHECK
DOCUMENT CHECK
FOR AVAILABILITY OF
ALL RELEVANT
DRAWINGS AND
DOCUMENTS
SITE PREPARATION CHECK THAT THE
TRANSFORMER YARD
IS PROPERLY LEVELED
1.1.9
1.1.10
1.1.11
1.1.12
1.1.13
2.0
2.1
2.2
2.3
2.4
CHECK THAT RAILS
ARE LEVELLED AND
EXACT LOCATION OF
ROLLER ASSEMBLY IS
MARKED IN
PERMANENT LOCATION
OF THE TRANSFORMER
WHERE APPLICABLE.
OIL FILTERATION
PLANT- CHECK FOR
AVAILABILITY OF OIL
FILTERATION PLANT OF
ADEQUATE CAPACITY
TYPES OF
CHECK
PHYSICAL
PHYSICAL
PHYSICAL
PHYSICAL
QUANTUM
FREQUENCY OF
CHECK
AT THE
TIME OF
STORAGE 100%
AT THE
TIME OF
STORAGE 100%
AT THE
TIME OF
STORAGE
AT THE
TIME OF
STORAGE
ACCEPTANCE
CRITERIA
REMARKS
NO PHYSICAL
DAMAGE
--0
NO PHYSICAL
DAMAGE
COVERED
STORE
--
COVERED
STORE
PHYSICAL
AT THE
TIME OF
STORAGE
NO PHYSICAL
DAMAGE
AS LISTED
AS LISTED
INSTRUCTION
MANUAL
PHYSICAL
VERIFICATI
ON
ONCE BEFORE
ERECTION
VISUAL
ONCE BEFORE
ERECTION
COMPLETE SET
OF ERECTION
DRAWINGS,
INSTRUCTIONS,
TEST
CERTIFICATES
FOUNDATION
DRAWING
PHYSICAL
ONCE BEFORE
ERECTION
FOUNDATION
DRAWING
USE LOG
SHEET
ONCE BEFORE
ERECTION
OPERATION
MANUAL FOR
FILTERING
MACHINE
USE LOG
SHEET
PHYSICAL
USE
CHECK
LIST
CHECK
LIST
USE
LOGSHEET
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 114 -
SL.
NO
2.5
2.6
CHARACTERISTICS/
ITEMS
CHECK FOR FACILITIES
FOR OPERATION OF
FILTER MACHINE SUCH
AS:
-PROPER POWER
SOURCE
-CABLE OF ADEQUATE
CAPACITY AND LENGTH
-HOSE PIPE OF
ADEQUATE CAPACITY
AND SUITABLE ENDS
ERECTION CHECK
CHECK FOR
AVAILABILITY OF
SUITABLE AND
ADEQUATE QUANTITY
OF OIL
TYPES OF
CHECK
QUANTUM
FREQUENCY OF
CHECK
ACCEPTANCE
CRITERIA
PHYSICAL
ONCE BEFORE
ERECTIONAT THE
TIME OF
STORAGE
PHYSICAL
VERIFICAT
ION
QUANTITY
CHECK
ONCE BEFORE
ERECTION
RATING AND
DIAGRAM
PLATE AND
GA.DRAWING
OPERATINN
MANUAL FOR
FILTERING
MACHINE
2.7
CHECK THAT ALL
ITEMS AND
ACCESSORIES ARE
INSPECTED FOR
DAMAGE
PHYSICAL
100% BEFORE
ERECTION
PACKING LIST
NO DAMAGE
2.8
CHECK THAT THE PRE-
PHYSICAL
100% BEFORE
ERECTION
FOUNDATION
DRAWING,
LAYOUT DRG.
IN LINE WITH
SPECIFICATION
S
ERECTION SURVEY HAS
BEEN CARRIED OUT TO
ENSURE THAT
TRANSFORMER YARD IS
READY IN ALL RESPECTS
AND TO VERIFY AND
ACHIEVE THE POSITION
OF VARIOUS
EQUIPMENTS TO BE
CONNECTED, LEVEL OF
FLOOR/RAILS, POSITION
OF FOUNDATION BOLTS,
POCKETS AND
CUTOUTS, ALIGNMENT
OF CABLE TRENCHES
ETC.
2.9
CHECK THAT PROPER
TOOLS AND TACKLES
ARE USED FOR
TRANSPORTING
VARIOUS ITEMS TO
ERECTION SITE
PHYSICA
L
100% BEFORE
COMMENCEMENT OF
ERECTION
INSTRUCTION
MANUAL
REMARKS
USE LOG
SHEET
ALSO
OIL SPEC.
--
--
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 115 -
SL.
NO
CHARACTERISTICS/
ITEMS
2.10
CHECK THAT
TRANSFORMER IS
JACKED UP USING
ONLY THE JACKING
LUGS PROVIDED FOR
THE PURPOSE AND
THAT NO OTHER
PARTS ARE USED FOR
THIS PURPOSE
PHYSICAL
VERIFICA
TION
2.11
CHECK THAT
ROLLERS (WHEREVER
APPLICABLE) ARE
GREASED PROPERLY
BEFORE ASSEMBLING
UNDER THE
TRANSFORMER TANK.
PHYSICAL
100% BEFORE
ERECTION
ROLLER
ASSEMBLY
DRAWING AND
FREE
MOVEMENT OF
ROLLERS.
2.12
CHECK THAT ITEMS
TO BE MOUNTED ARE
CLEANED WITHOUT
LEAVING ANY LOOSE
FIBRES WITH DRY
CLOTH.
CHECK THAT OIL
FILLING IS DONE
UNDER VACUUM
STRICTLY AS PER
INSTRUCTION
CHECK THAT
BUCHHOLZ RELAY
AND CONSERVATOR
ARE NOT SUBJECTED
TO FULL VACUUM
PHYSICAL
100% BEFORE
ERECTION
NONFLURRY
DRY CLOTH
2.13
2.14
2.15
CHECK THAT THE
TRANSFORMER HAS
BEEN PROPERLY
DRIED BY TESTING OIL
SAMPLE FROM TANK
AND OLTC DIVERTER
SWITCH FOR -BDV OF
OIL
-MOISTURE
CONTENT
TYPES OF
CHECK
QUANTUM
FREQUENCY OF
CHECK
100% BEFORE
ERECTION
ACCEPTANCE
CRITERIA
REMARKS
NO CRACKS
SHOULD
APPEAR NEAR
JACKING LUGS
--
OPERATIO
NAL
ONCE DURING
OIL FILLING
BDV AND
MOISTURE PPM
AS PER OIL
SPEC.
USE
VACUUM
GAUGE
OPERATIO
NAL
DURING
PROCESS-ING
REFER
INSTRUCTI-ON
MANUAL
OPERATIO
NAL
AFTER
COMPLETION OF
OIL CIRCULATION
IN TANK
RELEVANT
VALVES TO BE
CLOSED AS
PER VALVE
DIAGRAM
PLATE
AS PER
INSTRUCTIONA
L MANUAL.
USING
OIL
TESTING
SET FOR
BDV AND
PPM KIT
FOR
MOISTURE
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 116 -
SL.
NO
CHARACTERISTICS/
ITEMS
2.16
ENSURE THAT THE OIL
FILLING IN THE
CONSERVATOR (AIRCELL TYPE)IS DONE
AS PER THE OIL
FILLING INSTRUCTION
GIVEN AT SPECIFIED
RATE AND CHECK THE
WORKING OF
PRESSURE RELIEF
VALVES.
CHECK FOR ANY
DAMAGE TO CT S AND
CHECK CLEANINESS
CHECK THAT CT
SECONDARY LEADS
ARE ALL IN TACT AND
KEPT SHORTED UNTIL
RESPECTIVE LEADS
ARE CONNECTED
COMPLETE ERECTION
CHECK LIST
2.17
2.18
2.19
2.20
3.
3.1
3.2
3.3
COMPLETE
PRECOMMISSIONING
CHECK LIST
COMMISSIONING
CHECKS
SILICA GEL COLOUR
OIL LEVEL IN
CONSERVATOR
BUSHING , BREATHER
HOUSING, OLTC
DIVERTER EACH
CHECK THAT THE
MARSHALLING BOXES
ARE PROVIDED WITH
GASKET AND BOXES
ARE MADE DUST
PROOF
TYPES OF
CHECK
PHYSICAL
QUANTUM
FREQUENCY OF
CHECK
100% BEFORE
ERECTION
ACCEPTANCE
CRITERIA
REMARKS
INSTRUCTION
MANUAL
USE LOG
SHEET
PHYSICAL
100% BEFORE
COMMISSI-ONING
NO DAMAGE
LOG SHEET
PHYSICAL
100% BEFORE
COMMISSIONING
NO DAMAGE
USE LOG
SHEET
AS LISTED
AS LISTED
INSTRUCTION
MANUAL
USE
CHECK
LIST
AS LISTED
AS LISTED
INSTRUCTION
MANUAL
USE
CHECK
LIST
PHYSICAL
100 %
BLUE
USE LOG
SHEET
PHYSICAL
100%
UPTO THE
MARKING ON
GAUGE
PHYSICAL
100 %
PROPER
CLOSING
PHYSICAL
100%
WIRING
DRAWING
USE LOG
SHEET
USE LOG
SHEET
3.4
CHECK THE
CORRECTNESS OF
THE WIRING FOR
CONNECTION TO OTI
COOLERS, FANS
USE
LOGSHEET
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 117 -
3.5
3.6
3.7
CORRECTNESS OF
WTI, OTI, MOG,
BUCHHOLZ RELAY,
COOLER CONTROL
CONTACTS
OIL SAMPLE FROM
TRANSFORMER
BEFORE ENERGISING
SHOULD BE TESTED
FOR BDV AND
MOISTURE CONTENT
IR VALUES
3.8
MAGNETISING
CURRENT AT 400
VOLTS FROM HV SIDE
3.9
CHECK THAT FOR
PURPOSE OF
VARIOUS
PROTECTION AND
ALARM ARE CARRIED
OUT AS PER
INSTRUCTION MANUAL
AND RECORDED IN
LOG SHEET
COMPLETE
COMMISSIONING
CHECKLIST
TRIAL OPERATION
FOR 24 HOURS AND
CHECK FOR ANY
ABNORMAL NOISE /
TEMPERATURE RISE
3.10
3.11
OPERATIO
NAL
100%
LOG SHEET
OPERATIO
NAL
BEFORE
ENERGISING
AS PER
INSTRUCTION
MANUAL
OPERATIO
NAL
USING
MOTORISE
D
2500VOLTS
MEGGAR
OPERATIO
NAL
100%
TEST
CERTIFICATE
VALUE FOR
GENERAL
COMPARISON
100%
OIL TEST
SET FOR
BDV, PPM
KIT FOR
MOISTURE
USE MILLI
AMMETER
OPERATIO
NAL
100%
INSTRUCTION
MAUAL
CONTACTS
SHOULD
CLOSE
USE LOG
SHEET
AS LISTED
AS LISTED
INSTRUCTION
MANUAL
USE
CHECKLIST
OPERATIO
NAL
100%
SATISFACTORY
OPERATION
FOR 24 HOURS
USE LOG
SHEET
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 118 -
PART 14
TROUBLE SHOOTING
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 119 -
14
TROUBLE SHOOTING
14.1 MAINTENANCE AND REVISION
14.1.1 GENERAL
14.1.2 CHECK LIST - MAINTENANCE
14.1.3 TROUBLE SHOOTING
14.2 STORAGE
14.2.1 TRANSFORMER DISASSEMBLED TRANSFORMER WITH LOWERED OIL LEVEL
TRANSFORMER WITH DRY-GAS FILLING
14.2.2 TRANSFORMER READY FOR OPERATING
14.2.3 ACCESSORIES
14.2.4 CHECKING LIST STORAGE
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 120 -
14
TROUBLE SHOOTING
14.1 MAINTENANCE AND REVISION
14.1.1
GENERAL
ABB transformers are designed to reduce maintenance to a minimum.
In order to ensure trouble-free operation, maintenance works must be
carried out in regular intervals. Checking list "Maintenance" shows the
recommended time intervals for maintenance.
Detailed instructions concerning maintenance works of various accessories
can be found in the catalogues of the respective manufacturers, which are
included in this manual. ( PART 4)
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 121 -
CHECKING LIST - MAINTENANCE
SUBJECT
CHECK
TIME PERIOD
YEAR
Insulating oil
Oil tightness
Oil level
Venting devices
Earthing devices
Shut-off devices
Buchholz relay
Dielectric strength
Moisture content
Neutralisation value
Interfacial surface tension
Water content
Sludge content
Gas analysis
Tank
Conservator
Cooling equipment
Piping
Bushings
Cable sealing ends
Cable boxes
Buchholz relay
Gate valves
Valves
Tank
Conservator
Bushings
Cable sealing ends
Cable boxes
Thermometer pockets
Tank
Cooling equipment
Intermediate piping
Bushings
Piping
Buchholz relay
cable sealing ends
All metal parts
Tank
Motors
Star points
Surge arresters
Control cabinet
Steel armoured cabling
In position "service"
Direction of oil flow
Float Contacts
gas sampling device
Functional test
MONTH
S
3
3
3
3
3
3
3
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
6
6
6
6
6
6
REMARKS
if applicable
if applicable
if applicable
if applicable
Release vent screws
until oil emerges.
Afterwards
screw plugs tight
if applicable
1
6
6
6
6
6
6
6
as
required
if applicable
if applicable
see plan "Position of
shut-off devices"
(if provided)
1
1
1
1
1
if applicable
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 122 -
14.1.2
CHECKING LIST
MAINTENANCE
CONTD…
SUBJECT
CHECK
TIME PERIOD
REMARKS
year
Dial-type
Thermometers
transformers
Oil level
indicators
Breathers
Internal wiring
Corrosion
Protection
Cleanliness
Terminal box
On-load tap
Changer
Protective relay
for OLTC
Thermostat
Resistance
thermometer
Pressure relief
device
months
Contact setting
Position of maximum pointer
Functional test
1
1
1
Polarity
Ratio
Short-circuit connection
Contact setting
Float
Functional test
Silicagel
Oil level
Venting pipes
Insulation resistance
Correct wiring connections
Paint
Blank steel parts
3
3
3
1
1
1
Bushings
Fittings
Indicating devices
Tank cover
Fans
Connections
[as per EASUN-MR
CATALOGUES]
Setting see Technical
data
1
1
1
3
3
1
1
With 1000 V Megger
Tester,
Touch-up
Grease
1
1
1
1
Remove loose parts,
if applicable
1
See instructions of the
manufacturer
Functional test
Functional test
1
1
Functional test
1
See instructions of
manufacturer
NOT PROVIDED
SEE
MANUFACTURERS
CATALOGUE
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 123 -
14.1.3 TROUBLE SHOOTING CONTINUED
Protective&
FAULT
Possible cause
supervisory
instruments,
components
Buchholz relay Buchholz
Oil loss
relay
Violent oil surge
tripping
due to inside
flashover.
Violent gas
generation due to
inside failure.
Violent vibration
Fault tripping
Protective
Tripping
EASUN-MR
device for
due to
CATALOGUE
OLTC
strong oil
surge
Resistance
thermo meter
Oil
temperat-ure too
high
Thermostat
Dial type
thermometer
for oil or
winding temp.
Winding
or oil
temp. too
high
Transformer
overloaded or
inadequate
cooling.
Incorrect
temperature
adjustment
Remedial measure
Detailed
description
Maintain the shutdown status.
Carry out tests and measurements
as described above.
Vent the transformer and put it
back into operation when faults
cannot be found or faults have
been eliminated
Maintain the shutdown status.
Check the tripping mechanism.
Remove and check the diverter
switch.Reset the tripping
mechanism and put the
transformer into operation
Reduce load of the transformer
Put fans or cooling equipment in
service
Clean the cooling equipment
Check the position of butterfly
valves
Adjust incorrect temperature
setting. Check the thermometer by
comparative measurements
Check the electrical connections
and the tripping mechanism
Check control devices for cooling
equipment
Check current transformers and
thermometers
Operating
Instructions
of
OLTC
Operating.
instructions
of thermometer manufacturer
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 124 -
14.1.3
TROUBLE SHOOTING (CONTINUED)
Protective and
supervisory
instruments
Various
components
Oil level
indicator
FAULT
Possible cause
Remedial measure
Detailed
description
Oil level too
low
Not enough oil
(low
temperature or
oil loss)
Gate valve
closed , pipe
clogged,, pipe
leaky,oil
circulation pump
faulted(no
voltage or
voltage too low,
defective
winding,incorrec
t direction of
rotation, bearing
damage)
Conservator
pipe shut-off or
clogged.
Electric
flashover inside
the tank
Check for tightness
Top-up oil
Operating
instructions
of
manufacturer.
Operating
instructions.
Oil flow monitor
No
Oil
flow
Pressure relief
device
Internal
tank
pressure
too high
Top-up cooling water to the
required level
Check the electrical
connections
Check the pipes and shut-off
devices
Check the transformer as
described in "Buchholz relay
Above.
Operating
instructions.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 125 -
14.1.3
TROUBLE SHOOTING (CONTINUED)
Protective &
supervisory
instruments,
components
Motor drive for
OLTC
Fault
Possible cause
Remedial measure
Drive cannot be
operated electrically
No voltage supply at motorprotective switch
Motor protective switch not in
operating position.
Open circuit on one or more
motor phases
Brake contactor stuck
Check supply feeders.
See operating instructions of
OLTC
Close motor protective switch
Correct it.
Emergency stop button is on
or stuck.
Motor current excessive due
to overload or phase failure
Repair or replace emergency
stop button
Check drive for stiffness with
crank handle. Request a
factory engineer, if a
mechanical fault in the tapchanger is suspected
Adjusting device defective
Repair adjusting device;
operate multiple the tap
changer once a year over all
positions (extraction
points).Check the transformer
as described for the Buchholz
relay
Replace dehydrating agent.
Replace glass cylinder or seal
properly.
seal pipe leaks, check the oil
for
moisture content.
Flush the conservator with
dry air
Drive keeps on
running
Motor protective
switch trips during
operation of motor
drive
Off-circuit tap
changer
Operation not possible
Gas in Buchholz relay
Carbon formation on contacts
Dehydrating
breather
The drying crystals
turn from blue to pink
and then to white
from below
from the top
in general
High atmospheric humidity,
glass cylinder leaky.
Moisture in conservator, pipe
leaky, glass cylinder
leaky.Moisture in conservator,
pipe leaky, glass cylinder
leaky.
Glass cylinder burst,
maintenance interval
Clean or replace
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 126 -
14.1.3 TROUBLE SHOOTING (CONTINUED)
Protective and
Fault
Possible cause
supervisory
instruments
Various
components
Electrical
Breakdown voltage too low. Breather inoperable or
breakdown voltage Water content too high
transformer in service
of the oil
very low.
Leaks in water cooling
system.
Water pressure reducer
inoperable.
Protective spark
gap on bushings
Frequent operation
Electrical arcing distance
no longer correct
Terminal lugs on
bushing control
Control cabinet
Discoloration of connecting
parts
Electrical apparatus does
not operate
properly.Contacts corroded
contaminated.Appa
-ratus housing bent
Poor contact making
Earthing
connection
Earthing line interrupted
Excessive humidity in
control cabinet.
Water or dust inside the
cabinet.
Excessive high
temperature in the
cabinet
Excessive currents due
to external flashovers.
Impermissible current
loops through multiple
earthing.
Remedial measure
Put breather into operation.
Seal or repair coolers.
Contact manufacturer; dry
the oil, if necessary
Adjust the clearance
between the arcing horns
and screw them tight
Clear the contact faces.
Tighten the screws
Set the cabinet heater to a
higher temperature
Seal the cabinet door, fit a
dust filter if
necessary.Protect the
cabinet against solar
irradiation; provide for
better ventilation
Clean the contacts, tighten
the screws and check the
electrical distances. Open
up current loops. Only one
earthing with a sufficient
cross section
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 127 -
14.1.3
Protective and
supervisory
instruments
Various comp .
Presssure gauge
for HV-bushing
Pressure monitor
for HV-bushing
Air flow
monitoring
TROUBLE SHOOTING( CONTINUED)
Fault
Possible cause
Remedial measure
Oil pressure in HVbushing too high
Incorrect contact adjustment.
Bushing overloaded, oil
temperature too high due to
solar irradiation
Correct the contact adjustment
Incorrect contact adjustment
Bushing overloaded, oil
temperature too high due to
solar irradiation.
Violent vibration on
transformer
Correct the contact adjustment
Oil pressure of the
HV-bushing too high
No air flow or
reduced air flow
Protective screen iced up or
clogged.
Cooler clogged or very dirty.
Fan motor faulty (winding
defective or overheated,
bearing damage).Incorrect
direction of rotation
Check the reading.
Check the bushing; reduce the
transformer load, increase the
cooling effect
Check the pressure monitor and
reset the auxiliary switch.
Check the bushings; reduce the
transformer load; increase the
cooling
Clean protective screen, open the
frost flaps
Clean coolers
Check the supply leads
Repair fans
Oil sightpot
Traces of oil on the
water surface
Leakages in the oil circuit or
the water cooling system
Seal and repair coolers
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 128-
PART
15
STORAGE
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 129 -
15. STORAGE
15.1
TRANSFORMER DISASSEMBLED : WITH LOWERED
OIL LEVEL
15.2
TRANSFORMER WITH DRY-GAS FILLING
15.3
TRANSFORMER READY FOR OPERATION
ACCESSORIES
15.5
CHECK LIST FOR STORAGE
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 130 -
15
STORAGE
15.1 TRANSFORMER DISASSEMBLED : WITH LOWERED OIL LEVEL
A transformer with lowered oil level (i.e. the entire insulation of the core and coil assembly has to be
completely covered with oil) must be provided with a dehydrating breather during storage, in order to avoid
the ingress of humid air in the transformer tank.
In case heating elements are installed in the motor drive cabinet, and control cabinet, they must be
connected to a power supply system to prevent the formation of condensation water. The heating elements
shall be checked at regular intervals.
The silica-gel content of the dehydrating breathers is to be checked every 2 weeks . When more than 2/3 of the
blue silica-gel filling have turned light, the filling has to be exchanged. However, it can be reused after
having been dried at 120 °C (24 hrs.). At the same time the tank has to be examined for oil traces. Should
any leakage be detected, they have to be sealed immediately. Before commissioning and after a long
storage the oil is to be checked for moisture content. Motor drive cabinet and control cabinet have be
checked for Condensation of
water
15.2
TRANSFORMER WITH DRY-GAS FILLING
In case it is not possible to store the transformer completely mounted or with oil filling, the transformer is to
be filled with dry gas in order to prevent the ingress of moisture during storage.
After the transformer has been filled with dry gas/ air, one or several gas cylinder attached to the tank has to
be connected. In order to provide a constant positive pressure in the transformer tank, the gas cylinders are
connected via pressure-reducing and pressure relief valve (see also chapter on transport( PART 5 ) in this
instruction manual). The valves have been adjusted to maintain a positive pressure in the tank ie approx.
0.25 bar. The pressure is to be checked every two weeks.
Caution:
The pressure must not fall below 0.05 bar.
In case of leakages in the transformer tank have been detected or in the case of high pressure loss in the
gas cylinders, the leakage has to be sealed.
If there are heating elements provided in the motor drive cabinet and control cabinets, they have to be
connected to a power supply system, in order to avoid the formation of condensation water.
The storage with dry-gas filling should be not be longer than 6 months. If the storage exceeds 6 months, the
ABB must be contacted.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 131 -
15.3 TRANSFORMER READY FOR OPERATION
This type of storage is to be preferred over all other alternatives. After arriving at the place of installation the
transformer should be assembled completely and filled with oil. The heating elements installed in the motor
drive cabinet and control cabinet have to be connected to a power supply system, in order to prevent the
formation of condensation water. The heating elements have to be checked at regular intervals.
The condition of the silica-gel content in the dehydrating breathers has to be checked every 2 weeks. Should
more than 2/3 of the blue silica-gel filling have turned light, the filling must be exchanged. However, it can be
reused after drying at 120 °C (24 hrs.). At the same time it is necessary to check the oil level in the
conservator, and to examine the tank for oil traces. Should any leakage be detected, they have to be taken
care of immediately. Before commissioning and after long storage the oil is to be checked for humidity.
15.4 ACCESSORIES
The accessories shall be stored in compliance with the printed-on storage instructions and the hints given in
the brochures for the individual accessory parts. In principle the accessories should be stored in their
respective transport packing in dry rooms. Possibly, dessicant bags have to be enclosed in the crates.
All accessories shall be protected against damages.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 132 -
15.5
CHECK LIST FOR STORAGE
SUBJECT
Insulating oil
Oil level
Oil tightness
Earthing
Fans
Control
cabinet
Oil circulation
pumps
Silica gel
breathers
Cleanness
Corrosion
protection
Bushings
CHECK
Dielectric strength
Moisture content
Conservator
Tank
Conservator
Piping
Buchholz relay
Bushings
Tank
Test run
Heating
Time periods
YEAR
MONTH
1
1
1
1
1
1
1
6
3
1
Trial run
3
Silicagel
1
Cooler
Bushings
Tank
Final coat
1
1
1
1
During storage or at time
1
of handling the bushing
can be placed:
- either in horizontal
position
- on inclined, but with the
head
at the highest point
Please take care that the
oil level indicator always
directs to the bottom. A
respective label is fixed on
every bushing or shipping
crate.
REMARKS
1 hour
1 hour
Touch up
Before the
bushing is
assembled on
the tank, the
whole surface
should be
dried and
cleaned
thoroughly.
Observe
standing times
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA
Page - 133 -