69kV and Above Oil Immersed Transformer Instruction Manual

Power Transformer Instruction Manual
Version 1.0 Page 1 of 30

Oil Filled Power Transformer
Instruction Manual

66 kV and above

JSHP Transformer Co., Ltd.


Table of Contents

1. General

2. Receiving

3. Moving and Handling

4. Storage

5. Assembly and Installation

6. Processing and Vacuuming

7. Field Testing

8. Energization

9. Maintenance

10. Attachments

1. General

This manual applies to J iangSu HuaPengs (J SHP) modern liquid filled power
transformers with high voltage rating of 69 kV and above. It is developed to assist
in transformer receiving, installation, test and maintenance procedures.

1.1 Safety

The installation, operation and maintenance of power transformers present
many potentially dangerous situations such as falling, asphyxiation, high
pressure and high voltage. Always observe safety precautions and follow all
applicable safety procedures such as OSHA requirements, local safety
requirements and safe working practices. Good judgment must be used when
installing, operating and maintaining power transformers.

1.2 Contact information

In the event of shipping damage, or any information that is not covered in this
manual, contact J SHPs Service Department.

J SHP Transformer Co., Ltd.
68 Kunlun Development Zone
Liyang City, J iangsu Province, P.R. China
Phone: +86-519-87319099
Fax: +86-519-87319215
Email: rui_yin@jshp.com

2. Receiving

It is important that shipping damage be detected before the transformer is off-
loaded. A though inspection of the unit and its accessories should be made as
soon as possible to identify any shipping damage. J SHPs transformers are
covered by warranty against defective materials and workmanship. This warranty
does not cover shipping damage and therefore does not relieve the user of the
responsibility of accepting damaged transformer and/or it accessories from the
carrier.

2.1 Inspection on receipt

Representatives from both J SHP and the carrier should be present during the
inspection. Any evidence of damage should be noted on the Bill of Landing.
Before removing the unit from rail car or truck, perform the following
inspections to identify any damage that may have occurred during shipment.

2.1.1 Impact recorder

Impact recorders are provided on all rails and some truck shipment. The
impact recorder used by J SHP is a three way device capable of
measuring shocks in the longitudinal, vertical and transverse directions.

On shipments where impact recorders are provided, remove the tape in
the presence of J SHP and carriers representative. If the tape recorder
stopped or jammed before the transformer reached its destination,
indicate this on the tape. Also write down the tape removal time and date
on the tape. Have a representative sign the tape.

To analyze the tape, it is best to do it indoor or in an area sheltered form
wind. Traces in longitudinal, vertical and transverse directions which are
less than 3G, 2G and 2G are considered acceptable. Impact higher than
those figures is considered rough handling and might cause shipping
damage. In this case, authorization is needed from J SHP to inspect the
unit further. If the traces indicate no probable shipping damage, the
receiving inspection may proceed.

Replace tape in the recorders, seal and ship back to J SHP at the
following address within one week:

J iangSu HuaPeng Transformer Co., Ltd.
No. 68 Kunlun Development Zone
LiYang City, J iangSu Province
PR China 213300
Attn: Shipping Dept.

2.1.2 External inspection

A damaged tank assembly may mean a faulty or damaged transformer. It
is important that the transformer be inspected before it is off-loaded. A
thorough inspection at this point saves time and cost of off-loading a
damaged transformer. In addition, proper claims can be filed if damage
is found or hidden damage is suspected.

i. Transformer tank

Visually inspect transformer tank, cover, drain valve, radiator valves
and other external accessories mounted on the tank. Note any
external damage.

All welds or bolted-on flanges and covers should be in place and
secure, all valves and cabinet doors should be tightly sealed.

Check attached radiators for bent or dented fins.

Look for signs of oil leakage along weld seams on the exterior of
small power transformers which are normally shipped oil filled.

Check gas pressure in the tank for dry air or N2 filled units. These
units should have a positive or negative gas pressure in the tank if
there is no leak. Zero gauge pressure is a good indication of a leak.
Refer to section 2.4 for test for moisture entry if a leak is suspected.

ii. Bracing, blocking and tie down

Inspect bracing, blocking, etc. Note all damage, shifting and
movement, etc. Take photos as well to substantiate possible claims.

Depressed steel platform cars usually have steels blocks welded to
the deck and placed tightly against the transformer base at each end.
Excessive impact could show up as dents in the base of the unit or
results in block movement. Side blocks are normally placed tight
against the base and tank movement will result in as scratched paint.

Flat car or truck loads normally use wood braces and blocking
timbers. Some movement is expected, however, broken blocks or
crashed timbers indicate rough handling.

Anchoring or spring loaded tie down rods should be straight and
tight. All nuts should be tight as well. Any bent or looseness
indicates movement of the unit.

iii. Accessories inspection

Check the packing list against the materials received. Look for
missing creates or containers.

Check radiators or coolers for dented or broken fins, loose or
missing fans, etc.

Check bushings and lightning arresters for cracked or broken
porcelains, oil leaks, porcelain shifts, etc.

Check conservator tanks for dents, cracks and leaks.

2.2 Internal inspection and tests

When required, follow the procedures listed below to conductor internal
inspection.

2.2.1 Safety precautions

Do not allow anyone to enter the tank unless the oxygen content of gas
at the tank bottom is measured and considered acceptable. The oxygen
content should be at between 19.5% and 30%. For units shipped with
nitrogen, purge air space with dry air first.

Always have a person stationed at the opening outside the tank
whenever anyone is in the tank.

Before removing any covers and fittings, Make sure that there is no
gauge pressure in the tank and the oil level is under that particular
opening.

Fire extinguishers should be provided and smoking should not be
allowed.

Ground transformer tank, all windings and all oil handling and
processing equipment.

Do not perform electrical tests while the unit is under vacuum.

Do not walk on the cover while the unit is under vacuum.

2.2.2 Internal inspection preparation

Extreme care must be taken to protect the transformer, especially its
insulation system from damage. Care should also be taken to prevent
foreign materials form entering the tank during inspection.

All personnel working on the top of the tank, while its open, should
empty all pockets and remove all watches and jewelry. Wear protective
clothing and shoe covers.

All tools, hardware and any other foreign objects that will be used
during the inspection should be accounted for. If anything is dropped
into to the tank and cannot be retrieved, notify J SHPs representive
immediately.

Have provisions for closing the tank in case of rain or sudden weather
change.

For transformers shipped dry, follow the steps below to perform internal
inspection.

Adjust the internal pressure to zero PSI before opening the tank.
Record the time tank is opened to determine total exposure time.
Do not open the tank if the transformer temperature is below 0C.
Circulate dry air. When transformer is opened and exposed to the
environment, dry air (dew point of -40C) should be purged
through the tank to prevent moisture entrance. Clear plastic sheets
may be placed over the manhole openings to reduce the air volume
required.

For transformers shipped oil filled, follow the steps below to perform
internal inspection.

Adjust the internal pressure to zero PSI before opening the tank.
Lower the oil level to allow for a limited internal inspection.
Record the time tank is opened to determine total exposure time.

2.3 Perform internal inspections

For transformers shipped dry, the internal inspection should include, but not
limited to, the following:

Access the overall condition of the active parts and all components.
Check internal parts for tightness and damage.
Inspect coils and insulation. Look for misaligned spacers or loose blocks.
Look for loose insulation between the core and core clamps and any signs
of lamination shifting. Make sure core ground lead is not loose.
Conduct core megger at 500 volts. A minimum of 200 volts megohms is
acceptable.
Check lead/cable for insulation abrasions, frayed strands at bushing
connecting stud. Look for broken lead supports.
Check contact alignment and tap leads of the off load tap changer. Make
sure operating mechanism is free of damage.
Check the support of current transformers. Verify that all leads from the
CTs to the terminal blocks are secure and free of damage.
Look for debris at the bottom of the tank.
Look for signs of moisture such as rust or free water.

For transformers shipped oil filled, the internal inspection should include, but
not limited to, the following:

Access the overall condition of the active parts and all components.
Look for signs of moisture such as rust or free water.
Make sure core ground lead is not loose.
A visual inspection, through the oil, should be made to look for evidence
of damage or loose parts.

The oil should be drained completely to allow a thorough inspection if there
are any indications of damage or if the impact recorders indicate excessive
impact.

2.4 Test for moisture

If moisture entrance is suspected, pressurize the tank to 6 PSI gauge pressure
with dry air and look for leaks with soap and bubbles. Check welded and
gasketed joints. If the leaks are found, repair leaks and re-pressurize the tank
to 6 PSI. Let the unit sit for at least 24 hours and perform a dew point
measurement.

The dew point inside a transformer can be related to the partial pressure of
water vapour at the surface of the insulation material. This is called the vapour
pressure and it is measured in micrometers of mercury.

Once known, the vapour pressure and the temperature of the insulation
material determine the moisture content (percent by weight) at the surface of
the insulation material assuming that all the partial pressure of gases in the gas
space and in the insulation have come to equilibrium.

The attached chart, Figure 1, converts the measured dew point into the vapour
pressure. The chart for determining moisture content from vapour pressure is
called the moisture equilibrium chart, Figure 2. using the two charts, the
moisture content can be determined.

To make good judgment of moisture content, the actual temperature of the
insulation materials must be known as accurate as possible. The best way to
accomplish this is to make the dew point measurements in early morning
hours when the insulation temperature, the tank pressure and the ambient
temperature are all still relatively equal. In addition, the vapour pressure must
be adjusted for any overpressure in the transformer tank.

Results which occur in the unacceptable range should be referred to J SHPs
service department.

2.5 Damage claims

All shipping damage, both obvious and hidden, will be filed by J SHP. When
obvious damage is observed, contact J SHP customer service immediately. A
damage report must be completed by the carrier. Under no circumstance is a
damaged shipment to be removed from the rail car or truck without written
authorization from J SHP.

All hidden damage claims should be filed if:

The impact recorders indicate transit impact has exceed 3G, 2G and 2G in
the longitudinal, vertical and lateral direction.
Prolonged period of 2-3 hours or more of vertical ribbon effect is recorded.
The impact recorders did not run full time.
Excessively rough handling is evident.

Contact J SHP customer service immediately if hidden damage is suspected.
The bill of landing should be signed with a statement Unit received with
possible hidden damage.

3. Moving and Handling

When no shipping damage is detected, the customer should remove the
transformer from the rail car or truck and move it to the installation or storage site.

Extreme caution must be used in moving a transformer. Unsafe practices may
result in serious injury or even death. Unsafe practices may also result in major
damage to the transformer, substation equipment or moving equipment.

3.1 Before the move

The outline drawing of each transformer included with this manual has
information on the weight of the unit, clearances required, and the locations of
lifting eyes, jacking pads and mounting pads.

The new location should have been prepared and certified as ready, and the
pathway along which the transformer will be moved should have been cleared
of all obstacles.

Before positioning the transformer on a permanent or temporary pad, the
foundation and surroundings should be checked carefully. Because of the
weight of a power transformer is normally heavy and the weight is
concentrated in a relatively small area, there is considerable stress on both the
transformer and its foundation.

In addition to the strength required to support the unit, the mounting must
provide for maintenance and service access to the transformer.

3.2 Move preparation

3.2.1 Newly received transformer should be inspected in accordance with the
procedures described in the Receiving section of this manual.

3.2.2 For transformers that are to be moved from storage, pre-move inspection
and processing should be performed.

Follow the steps below to prepare the move.

List all accessories and equipment that must be disconnected before
moving.
Relieve pressure in the tank.
Match mark, disconnect and remove all accessories that must be
removed.
Clean and seal all tank openings created by the removal or
disconnection immediately.
Wrap, identify and store all removed items in a dry location pending
reinstallation.
Inspect the tank exterior for damage or deterioration.
Release and remove and bolts or nuts fastening the transformer to its
foundation.
Order, if necessary, damaged components during disassembly.

3.3 Actual move

The outline drawing of each transformer included with this manual has
information on the various weights of the transformer and the precise location
of the various lifting, pulling eyes, skid noses and jack bosses, etc.

When making a decision on the moving technique, take into consideration the
size and weight of the transformer, the job site condition and the type and
capacity of the lifting and moving equipment.

3.3.1 Lifting and moving transformer by crane

Whenever possible, the transformer should be lifted and positioned by
crane. Moving by swing crane should not be attempted if working space
is inadequate or overhead obstacles do not permit the crane boom to be
raised or moved effectively.

When a crane is used to lift the unit, lift hooks or hitches should be
attached only to the lifting eyes built into the tank and the cables must be
held apart by a spreader to prevent bending the lifting lugs or putting too
much strain on other parts of the tank. Safety ropes or guide lines should
be attached only to the towing eyes at the tank base and the load should
be carefully controlled during the lift operation. The load should never
be permitted to swing freely.

Before the transformer can be lifted, the internal pressure should be less
3 PSI.

3.3.2 Moving transformer by rolling or skidding

When lifting a transformer by crane becomes impractical, the
transformer can be moved along the ground by rolling or skidding.

Although the actual moving procedures will vary with the size and
weight of the transformer, the condition of the ground over which it
must be moved, and the travel distance. To ensure a successful move,
the following precautions should be observed.

i. The work surfaces including truck bed, railcar deck, skid way or
rollway and foundations must be as level as possible and absolutely
firm.

ii. Use jack bosses to raise the unit when necessary. Do not attempt to
raise the unit by placing jacks under the base, drain valves, pipe
connections or other attachments. Use the outline drawing for any
special instructions. Generally there are four jack bosses, one at each
corner. When lifting a transformer completely, use all the jacking
pads provided. To avoid springing the base, all jacks should be
loaded evenly. Interlocked hydraulic jacks are recommended for this
purpose.

iii. When the transformer is to be moved on rollers, all rollers used must
be of the same diameter and evenly and closely spaced. The use of
sound hardwood rollers greater than 6 in diameter or steel rollers
greater than 4 in diameter spaced on centers with less than 12
separation must be used. Rollers must extend at least 2 beyond the
tank base.

iv. Movement of the transformer should be controlled at all times. A
tow and drag winching system is recommended with one winch
pulling in the direction of movement and a second acting as a brake.

v. Towing cables must be attached only to the jack pads or
towing/pulling eyes provided. The tow cables should never be
looped around the tank or attached to the radiators/coolers, pipes, etc.
spreading yokes should be used if the hitch configuration will place
undue strain on the towing/pulling eyes on the tank.

vi. When turning a transformer, it is a good practice to place the
plywood or lubricated steel sheets under the base to minimize
turning resistance. Use pulling eyes only to attach the cable. As for
lateral movement, it should be accomplished by the use of the
towing/pulling eyes provided for the purpose.

vii. Keep the transformer level at all times. The transformer must never
be tilted more than 15 from the vertical in any direction.

4. Storage

Generally a transformer should be set up in a permanent location, assembled and
processed for operation as quickly as possible after receiving inspection is
complete. However, if the transformer needs to be stored before installation, the
following rules should be followed.

4.1 Storage location

The foundation should be firm and relatively level. If a transformer is to be
stored on a timber platform, support timbers should be closely and evenly
spaced. Transformers should never be stored on rollers, blocks or jacks. When
transformers are to be partially or fully activated during storage, the
conditions of access and ventilation appropriate to permanent location should
apply.

All transformers stored in temporary locations should be grounded as though
the installation was permanent. Ground connections to both the tank and
installed accessories should be checked carefully. Heaters should be
connected and energized to prevent condensation in closed compartments.

4.2 Storage duration

It is important to know the duration of the storage so proper procedures can be
followed. Generally speaking, the storage duration can be classified as less
than 3 months, between 3 and 18 months and over 18 months.

The storage period should be considered as beginning on the date of shipment
from the factory. All in-transit time and all time consumed in the receiving
process should be included in determining which storage classification is
applicable. An internal inspection is recommended if a transformer is shipped
without oil and will be stored for more than 3 months.

4.2.1 For units to be stored for less than 3 months, the storage procedures
are intended to preserve the as-delivered condition of the transformer.
Where practical, transformers not immediately energized should be
positioned in a permanent location and placed in a semi-active storage
condition. Where storage in a temporary location is necessary, inactive
storage is acceptable, however, the control cabinet and LTC control
cabinet heaters should be energized to prevent condensation.

i. When the transformer is stored in a semi-active mode on a
permanent pad, the transformer should be assembled, fitted with all
the accessories, processed for installation, filled with oil and have
all control cabinets and heaters energized.

ii. When the transformer is stored in an inactive mode on a temporary
pad, the transformer should be kept either in dry air (or nitrogen)
or oil filled.

When transformers are received filled with factory oil, they can be
stored for up to 3 months in the as received condition without
further attention.

To store the transformers in dry air, a positive pressure of 2-3 PSI
should be maintained at all times. A reserve air supply controlled
by a pressure regulator should be connected to the tank. The air
supply should be coupled to the tank via the pressure vacuum
regulator. Both the reserve air supply and tank pressure should be
monitored daily during the first 7 days of the storage period. Gauge
readings should be taken approximately the same time each day
and recorded carefully. If supply and tank pressure remain stable
during this period, the interval between readings may be extended.

To store the transformers in nitrogen, a positive pressure of 0.5-5
PSI should be maintained at all times. For normal pressurization, 2
PSI is recommended. If the tank is pressurized during warm
weather (above 25C), a 3 PSI reading is recommended.
Connections to the tank, installation of gauges or regulators and
monitoring procedures should be the same as described above for
dry air.

4.2.2 For units to be stored between 3 and 18 months, the transformers
should be filled with oil to the proper level. Transformers with
conservators should be filled to about 20 below the cover. The space
above the oil should be pressurized by dry air or nitrogen to 3 PSI.
Control cabinet and LTC control cabinet heaters must be energized to
prevent condensation.

4.2.3 For units to be stored more than 18 months, the transformer should be
completely assembled and fully functional. All accessories should be
installed and connected. All heaters, fans and pumps, etc. should be
connected and operational. Stored equipment should be tested and
maintained as though operational.

4.2.4 Accessories storage. Accessories not mounted on the transformer tank
at the factory or not installed immediately after receiving must be
protected from damage or deterioration during storage. Carefully
reseal shipping boxes opened for inspection and store inside to prevent
damage. All items stored outdoors should be covered and protected
from the weather.

Accessories stored outdoors and are not protected properly from the
weather are susceptible to rust and other moisture related damage.

4.2.5 Removal from storage. During long storage, moisture may accumulate
in transformer insulation if the transformer is not properly stored.
Excessive moisture in the insulation lowers its dielectric strength and
may cause failure

For transformer stored dry, a dew point measurement should be made
before relieving the storage pressure in the tank. When making a dew
point measurement, follow the instructions provided with the dew
point tester. The dew point of the gas sampled should be below the
acceptable limits shown on the moisture equilibrium chart, Figure 1.
1% moisture in the insulation system is considered acceptable.

For transformers stored oil filled, an oil sample should be measured for
moisture content. An acceptable limit is 15 ppm.

5. Assembly and Installation

Assembly and installation methods vary with the size and type of the transformer,
and facilities for handling transformers and their components. J SHPs Parts List
and Shipping Instructions should be used for items that are detached for shipment.
These items should be reassembled on the transformer as instructed below.

5.1 Ground the tank

Before assembling the transformer, the tank should be permanently grounded
by means of the grounding connection provided at the bottom of the tank. The
ground cable must be of correct size and must be 4/O or larger.

5.2 Contamination prevention

Carefully plan for control of all tools, hardware and other objects that are
going to be used in the assembly process.

5.3 Bushing installation

Remove bushings from their crates with care using rope or nylon slings. Make
sure not to damage or chip any of the porcelain skirts on the bushings. If the
porcelain is chipped or cracked, or if there is any other damage to the bushing,
contact J SHP for further instructions. Always make sure that the top end of
the bushing is higher than the lower end when handling bushings.

Place the bushing on a suitable surface for cleaning. The cover removed from
the crate can be used as a base with rugs to cushion the bottom threads. Never
rest the porcelain section on the bushing on anything. Use bushing flange for
support as necessary.

Clean the bushing well using a rag dampened with a fast drying solution such
as denatured alcohol. Check MADS prior to using any solvent. All bushing
surfaces which will be inside the tank should be wiped clean and tried to
prevent contamination of the oil in the tank.

Bushings with draw lead leave the factory with the conductor ends loosely
sealed. Dirt and moisture may accumulate in the conductor tube. To clean this,
draw a cloth saturated with cleaning solvent through the hollow conductor.
Make several passes until the cloth comes out clean. If the bushing comes
with a corona shield, make sure not to make any dent on the shield.

To install bushings, first relieve tank pressure to 0 PSI by loosening a manhole
cover, a shipping cover or a plug, whichever is most convenient to vent the
transformer.

If the transformer is shipped without oil, start flowing dry air through the
transformer. Record the time to determine how long to hold vacuum on the
unit before filling.

For draw lead bushing installation, follow the steps listed below.

i. Remove the bushing shipping plate. Inspect the gasket and make sure
there is no damage. Clean the bushing mounting boss and install the
gasket.

ii. Pass a pull wire down through the center tube of the bushing and
attach it to the small hole in the top of the cable terminal stud. Lower
the bushing into the transformer opening. Do not allow slack in the
pull wire as it may allow the lead to become kinked below the end of
the bushing.

iii. Install the locking pin at the top of the bushing and remove the pull
wire. Thread the terminal cap in to position. Make sure the gasket is in
place. Tighten the terminal cap to seal against the gasket. Torque the
stud nut and cap as directed by the bushing manufacturers installation
instructions.

iv. Install and tighten the bushing flange hardware to apply even pressure
to the flange. Hardware should be tightened alternating across the
flange.

v. Check all leads to maximize clearance to ground or to other electrical
parts.

For bottom connected bushings, follow the steps listed below.

i. Lower the oil level when the transformer is shipped oil filled. Do not
drain oil below the top clamping ring.

ii. If the transformer is shipped dry, start flowing dry air through the
transformer and record the time.

iii. Remove the bushing cover plate. Inspect the gasket to make sure there
is no damage. Clean the bushing mounting boss with a solvent.

iv. Place the bushing into the right position on top of the transformer.
Install the internal transformer connectors to the bottom of the bushing
studs and tighten the bolts alternately and evenly with a wrench.
Secure the bushing on the transformer cover by tightening all the bolts
evenly in several steps. Do not attempt to pull the bolts down to the
final setting on the first tightening. Allow time between each
tightening to allow the gasket to seat properly.

v. Connect the internal bushing cables to the internal bushing spades.

vi. Check all leads to maximize clearances to ground or to other electrical
parts.

5.4 Radiator installation

Do not remove the shipping cover until ready to install radiators. Verify that
all radiator valves on the tank are closed before removing the shipping covers
on the radiator flanges. Use care to prevent gasket and paint damage. It is
recommended that the radiators be lifted from the crate with manila rope with
sling spreaders and be placed across suitable supports while preparing for
mounting to the tank.

Inspect for moisture or contamination inside the radiators headers. Contact
J SHP is contamination is found. Make sure the flange face is free of paint or
other material. Clean gasket groove and flange face and install gaskets.

Lift the radiator by lifting eye in the top header and swing it into position over
the valves. Bolt the radiator header to the valves with the bolts provided and
pull down evenly all the way around. Attach radiators with mounted fans first
and then attach the remaining radiators. Leave the radiator valves closed.
Touch up the paint when necessary.

For transformer shipped or stored with oil, do not allow oil level to fall below
the top of the top coil clamping ring. If there is insufficient oil in the tank, stop
the radiator filling process and add oil before completing radiator filling. If the
unit was shipped or stored over-filled with oil, the radiator valves should be
opened at this time to lower the oil level. Loosen the top radiator header plug
and slowly open the bottom radiator valves one at a time. This will allow the
radiators to be filled from the bottom, avoiding trapping of gases or air
pockets in the radiator. As the oil becomes visible around the header plug or
when all of the gas is purged from the radiators, tighten the header plug and
open the top valve. After all radiators have been filled with oil and the oil
adjusted to the 25C level, remove the top header plug, then reinstall using
Teflon pipe thread tape on the plug to prevent future leaks.

For transformer shipped or stored dry, leave the radiator valves closed until
the unit is ready for oil filling.

5.5 Cooler installation

Coolers should be placed plat on suitable support with fans on the top side.
Remove the shipping covers and make sure there is no internal contamination.
The gasket groove and flange faces should be clean.

5.6 Conservator installation

Install the conservator per outline drawing. Make sure flow pipe is correctly
aligned before tightening the tank down.

Following the mounting of all accessories, a final internal inspection should be
performed if any work has taken place inside the tank. Electrical connections
should be checked for tightness. Bushing gasket sealing and the draw lead
connections should be checked as well. Also check all leads for maximum
clearances. In addition, check the liquid float and operation of the indicator for
free movement.

Finally, verify all tools and foreign materials that have been used inside the tank
have been removed.

Reinstall all manhole and hand hole covers and other covers where a device has
not been installed.

Ground bushings to protect personnel and the transformer.

Record the time that the transformer is closed to determine total exposure time.


6. Processing and Vacuuming

Tests to be performed after final processing (24 hours):

Leak test. Apply 6 PSI of dry air on the unit. Log readings until pressure
levels off indicating no leak.
Core ground test. Hold a steady voltage for 3 minutes with a megger. The
minimum reading should be 200 volts megohms.
Ratio test. Complete readings on all taps and compare with test report
from factory.
Check all current transformers including hot spot heating coil circuit for
open circuit using an ohmmeter.

Oil quality check

Oil samples from the transformer should be taken from the oil sampling valve
at the bottom of the tank. Oil samples from tankers or drums should be taken
from the bottom as well.

Before the oil can be pumped into the transformer, it should have the
following characteristics:

Moisture content <15 ppm
Gas content <0.5%
Dielectric strength: >35 kV (ASTM 877), >60 kV (ASTM 1816, 0.08
gap)
Oil power factor. The maximum allowed is 0.5% at 90C

Processing for transformers shipped or stored oil filled

If any oil must be removed or added for any reason, the oil may be replaced
by one of the following methods.

i. If oil must be removed below the top of the core or below the top of a
350 kV BIL or above terminal board, the oil must be complete removed
and vacuum processed per section 6.4 below.

iii. If limited amount of oil, such as make up oil, is removed, it may be
allowed to add the oil through the manhole by laying the hose on top of
the core and directing the oil along the top of the core. Adding additional
amount of oil entails a greater risk of aeration of the oil and the
possibility of entrapping air bubbles in the windings. This method is
therefore not preferred and should only b used when there is no other
alternative.

If this method is used, a minimum of 24 hour sit time must be observed.

Vacuum filling procedure

Equipment needed for vacuum filling:

Vacuum pump, approximately 150 CFM capable of 200 microns in the
blank-off condition.
Filter press, approximately 30 gallons per minute.
Extra set of filters.
Vacuum gauge.
Vacuum pipes or flexible hoses (2 diameter minimum).
Oil supply lines and connections.
Vacuum valve.
Dry air supply.

The principal function of vacuum treatment is to remove trapped air and
moisture from the insulation. Small gas bubbles have much lower dielectric
strength than the solid and liquid insulation and may cause dielectric failure if
located in high stressed areas.

The transformer should be oil filled on relatively clear days when the
humidity is less the 70%. The oil temperature must be 0C or higher.

Before setting up the vacuum filling procedure the conservator and the air bag
should be checked carefully for any defects and contamination.

Follow the procedures below for vacuum filling:

i. Pressurize the air bag with 0.5 PSIG so that the air bag will be flat and
straight prior to oil filling. This work can be done on the ground before
the conservator is installed on the mounting bracket.

ii. Connect the vacuum line and vacuum gauges in preparation for pulling
a vacuum. An oil sight gauge (or tube) should be installed as well.

iii. Check all radiators or coolers to make sure that all the valves are open
and bolted to the open position.

iv. All transformers should be filled through bottom filling valve.
v. Make sure equalization is achieved between main tank and LTC and
between conservator tank and its bladder.

vi. Pull a vacuum to 1 torr.

vii. Hold a vacuum of at least 1 mm for a minimum of 4 hours, plus an
additional hour for each hour the transformer was open for inspection
and assembly. The vacuum must be held for a minimum of 8 hours at
1 torr. or lower for transformers rated up to 350 kV BIL, 12 hours for
450-550 kV BIL, 24 hours for 650-750 kV BIL and 48 hours ??for
825-1050 kV BIL. During this period, the vacuum level should be
recorded at least once every hour.

viii. At the end of vacuum hold cycle, the oil filling process can then be
started. An oil temperature of 50-75C is recommended as higher
temperature oil will speed up the impregnation of solid insulation.

ix. During oil filling, the vacuum level should be maintained at 5 torr. or
less. The operator should observe the oil sight gauge. When oil level
reaches approximately 10-12 inches form the top of the cover, the oil
filling process should be stopped by closing the top filling valve.

x. Break the vacuum with dry air or nitrogen. The main transformer
should then be pressurized to approximately 0.5 to 1 PSIG. The
vacuum fittings should also be removed at this time and the vent
sealed.

xi. Open the top filling valve. Fill the conservator tank until the oil level
gauge on the conservator register 25C or higher depending on oil
temperature. As the oil is being pumped into the conservator the
pressure in the bag should be observed and air bled off as the oil level
rises. The pressure in the bag should not exceed 2 PSIG during filling.
The vent valves on the conservator tank should be open to relieve the
air pressure in the conservator that will build as the oil is pumped into
the conservator.

xii. Inject 1 PSIG into the bladder. Oil should discharge from the
conservator tank filling valve. Install the male plug on the valve right
after. Adjust oil level so the gauge corresponds to the oil temperature.
Level correction with temperature should be considered.

xiii. Close top filling valve and remove fill line.

xiv. Air that is entrapped in various locations should be bled off as follows:

Normally the air entrapped in the top of the main transformer can
be bled off through the gas monitor.
Some transformers are designed with bushing wells or turrets.
There will be vent valves through which the air must be bled off.
There are some designs in which the top cover will be crowned.
These will have piping with vent valves through which this air
must be bled off.
In other cases there are vent valves on the conservator from which
the air must be bled off.

xv. Check thoroughly that all vent valves are closed so that oil will not be
forced out of them.

xvi. Check the gas monitor to make sure that all air has been purged from
the piping leading to the gas monitor. If this is not done, the gas
monitor will trip and show gas in the transformer.

xvii. It is recommended that the gas monitor be checked one week after the
transformer has been oil filled to confirm that it is reading in the
normal range. If it is not, more than likely there is air entrapped wither
in the gas monitor or the line that must be bled off.

Oil Filling When Core and Coil Assembly Are Below 0C

i. Pull a vacuum of 5 torr. for 4 hours.

ii. Following this, spray hot oil through the cover of the transformer. The
oil should be sprayed so that the stream is broken up into droplets for
more efficient heating of the core and coils. Maintain a vacuum of
10mm or better on the transformer during the oil spraying operation in
order to prevent oxidation of the oil and to aid in the removal of gas
from the insulation.

It will probably be necessary to maintain some oil in the bottom of the
unit to feed the output pump. Usually 12 to 24 inches of oil level in the
bottom will be sufficient. Do not allow the oil level in the bottom to
exceed 36 inches. A clear plastic hose can be used as an oil level
indicator. Pump the oil from the bottom of the transformer through
filters, through degasification and dehumidification equipment,
through the heat exchanger, and finally back to the cover of the
transformer.

The oil temperature entering the tip of the transformer should be as
high as possible but should not exceed 90C. Continue spraying the
hot oil under vacuum until the temperature of the core and coils is well
above 0C. The temperature of the core and the coils will be at
equilibrium conditions when the output oil temperature becomes
constant, and will be within 5C of the temperature of the input oil.

The heating rate can be increased by closing the bottom valves to the
coolers or radiators and by blanketing the outside of the tank to restrict
heat loss.

iii. After the temperature of the core and coils has been elevated above
0C, drain all oil from the tank and coolers or radiators. It will be
necessary to break the vacuum in order to drain the oil. The vacuum
must be broken with dry air (-60C dew point) to prevent condensation
in the tank.

iv. As soon as the oil is drained from the tank, immediately start the
vacuum treatment.

Open all valves to all radiators, pumps, coolers, or other cooling equipment.
Pull vacuum to 1 torr. and hold for 8 hours prior to filling. Then admit oil
(60C) into the top filter press valve while holding the vacuum level at 5 torr.
until oil reaches the normal level as shown by the liquid-level gauge. Then
proceed as explained on Section 6.4.

Safety precautions

Never leave a transformer that is under vacuum unattended.
Never walk or stand on a transformer cover when the unit is under vacuum.
Never apply any voltage to a transformer that is under vacuum.

7. Field Testing

The following tests must be performed before the transformer can be energized.

Oil dielectric strength. The minimum value should be over 40 kV (ASTM
D-877) or 35 kV (ASTM D-1816, 0.04 gap)

Oil power factor. The maximum allowed is 0.05% at 25C or 0.3% at
100C

Oil water content. The maximum 15 ppm

Ratio test. The maximum allowed is within 0.5% of calculated value. The
tested value should also be very close to the factory test results.

Insulation power factor and capacitance including bushings. The
maximum allowed power factor is 0.5% corrected to 20C. Capacitance
should not vary for more than 5% compared with factory test results.

Core ground test. The core ground should have been tested during the
internal inspection. If the internal inspection is not done, the core ground
should be tested at this time.

Winding resistance. The resistance of transformer windings can be
measured using either the resistance bridge method or the Drop in
Potential method. The values reported on the factory test report are
corrected to either 75 or 85C. Correct the measured value to the same
temperature base for comparison.

Current transformers. All current transformers must either have their
secondary windings short circuited or connected to a load before a voltage
is applied. Never open the secondary circuit of a current transformer while
the primary is carrying current. A high voltage might develop which can
be harmful to personnel or equipment.

Accessories test. For transformers furnished with thermometers for
measuring oil and winding temperatures, the settings for the signaling
should be made per customer standard. In addition, all indicators such as
fault pressure relays, pressure relief devices, etc. should be tested. Follow
instructions provided and check that all signals, trappings, etc., are going
through.

Fan motors. The direction of fan motors rotation should be checked to
ensure correct fan cooling.

8. Energization

8.1 Check the following before energization.

Transformer tank and neutral bushing(s) are properly grounded.
The connections to lines, bus bars and ground are secure.
No bushings and arresters are strained.
All bolts and gaskets are sufficiently tightened.
All relays are adjusted to specifications.
No tools or equipment are left on the transformer.
The off load tap changer is in the desired position and is locked in place
with a padlock.
All insulating oil is at its proper position.
Valves from the conservator to the main tank should be in open position.
All radiator/cooler valves should be open and bolted.
All paint damage is repaired.
Silica gel in conservator tank breather should be blue.
Terminal connections in control cabinet are tight.
Place shorting straps across the full CT winding for all CT are not
connected to load. All CT secondary circuit must be grounded, whether
the CT is in use or not, either in the transformer control cabinet or at the
load.
Shorting straps on winding temperature indicator CT terminal block and
line drop compensator CT terminal block should be removed. Similarly,
shorting straps on all other CTs that connected to loads should be
removed.
Make sure heaters in control cabinet are in working condition.
Bleed gas detect relay.
Remove all temporary shipping plugs.
Reset all drag hands on alarm gauges and the LTC position indicator.

8.2 Sitting time

To guarantee complete oil penetration and dissolving of any gas bubbles in the
insulation, the transformer should not be energized until sufficient time has
passed to allow oil to dissolve any gas bubbles which were formed in the
vacuum filling process. The following table sows the recommended sit time
based on units BIL rating.

BIL (kV) Sit time (hours)
350 or less 12
450 to 550 16
650 to 750 24
825 to 1050 48

8.3 Energizing the transformer

Applying full voltage and allow the transformer to operate for at least 2 hours
without load. Listen for abnormal noises. Check for excessive vibrations.

After applying full voltage, the transformer can be loaded. The transformer
should be closely observed during the first few hours of operation under load.
Check gauges to see if specified limits are exceeded.

After several days of operation, check the oil moisture content and dissolved
gas level.


9. Maintenance

Proper maintenance is essential in ensuring trouble free transformer operation.
Power transformers in service are often subjected to various electrical, mechanical
and thermal stresses. In order to avoid faults, it is important to carefully inspect
and maintain the transformers.

Certain items on a transformer must be inspected regularly to ensure proper
operation and long service life. The frequency of these inspections is determined
by the size and type of the transformer, the operating environment and the
importance of the unit.

Internal inspections should be only conducted when there is a suspicion of trouble,
when oil is removed from the tank. In the event a transformer is opened for
inspection, follow the same procedures and precautions as for an initial
installation.

Spare transformer should be inspected and maintained in the same manner as
transformers in operation.

9.1 External maintenance

i. Regular annual inspection is required on transformer tank, tank cover,
gaskets and valves.

ii. Cleaning is another part of external maintenance. Use solvent to
thoroughly remove any oil that is on the tank or the gasket.

The bushing porcelain must be kept clean and inspected yearly. Abnormal
conditions such as sand and dust, salt deposits, chemical fumes, etc.
require more frequent cleaning to avoid accumulations on the surface.
Acceptable methods are hot line washing and washing with solvent.

Keep the heat radiating surface of the transformer clean. External surfaces
of coolers should be periodically cleaned. Transformers near the sea coast
or in highly corrosive environment should be painted regularly to prevent
corroding or rusting of metal parts.

All breathers and small openings in pressure relief valves and pressure-
vacuum bleeders must be kept clean and in good operating condition.

All ground buses and wiring leads to ground must be kept in good
condition.

9.2 Cooling systems

Cooling fan motors use pre-lubricated sealed ball bearings that do not require
lubrication maintenance. During extended periods of reduced capacity not
requiring fan operation, it is suggested that fans be run periodically to ensure
proper operation.

External cooling surfaces should be cleaned annually to remove any
accumulation of dirt or debris that may block external air passages of radiators
or coolers so that free air flow can be maintained.

9.3 Temperature

Transformer temperature, oil and/or winding, is one of the major factors that
determine the life of a transformer. Therefore it is important to monitor the
transformer temperature on a regular basis.

If the temperature of a transformer rises without load increase, it is possible
that some of the cooling is impaired. This situation should be carefully
investigated.

9.4 Oil

Transformer oil is hygroscopic thus easily absorbs moisture from the air. The
absorption of moisture is minimized by the conservator system with a silica
gel breather. The gel should be properly renewed or regenerated as soon as its
ability to absorb moisture begins to diminish. A change of gel colour from
blue to pink indicates saturation with moisture.

If the transformer oil has been exposed to air while work has been carried
out on the transformer, the oil should be checked for moisture content and
dielectric strength. A similar check of the oil should be made on all
transformers at regular intervals. IEC standards provide guidance for the
acceptance, maintenance, continued use and reclamation of insulating oil.

In addition to oil quality checks, oil levels in the tank and LTC mechanism
compartment should be checked weekly during the first month of operation
and annually afterwards.

In addition, dissolved gas analysis should be performed to provide early
warning of evolving problems within the transformer and to allow preventive
actions to be taken before serious damage occurs.

9.5 External circuit and control equipment

The following should be inspected 30 days after installation and once per year
afterwards.

Control circuit voltage.
Excessive heating of parts as evidenced by discoloration of metal parts,
charred insulation or odor.
Freedom of moving parts.
Excessive noise in relay coils.
Excessive arcing in opening circuit.
Evidence of water or oil in the control cabinet.
Proper functioning of timing devices, sequencing of devices, relief device
alarm contacts and thermometer contacts.

9.6 Accessories

All accessories should be tested once a year. Inspect all apparatus, electrical
cables and conductors, signaling and operating devices to the control room or
control board.

9.7 Paint

The paint of the transformer should be free of damage when the unit is put
into service or storage. In order to ensure maximum corrosion protection, all
damage, such as chipped paint or scratches through to the bare metal, should
be fixed and the paint thickness should be restored to its minimum value as
soon as possible.

If bare metal is exposed, the area must be sanded down to blend the damaged
area into the undamaged paint surface. Wipe the sanded area clean with
denatured alcohol or a solvent to remove dust or oil. The area must then be
brush or spray painted with primer, intermediate coat and finish coat. If the
primer is not damaged, lightly sand the damaged paint surface to smooth
rough edges. Brush or spray on the intermediate coat and then the finish coat
to restore or exceed the original finish thickness.


10. Attachments

Figure 1. Dew Point to vapour Pressure Conversion Chart


Figure 2. Moisture Equilibrium Chart

69kV and Above Oil Immersed Transformer Instruction Manual

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Power Transformer Instruction Manual

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