2 ELECTRICA Y COM, FREE NO.DE TEL : atexsase00 6 AER, 2006 94:37M PL ELECTRICA Y COMERCIALIZADORA FREE, S.A DE CN. OIL CONSERVATION SYSTEM MANUAL MODEL: NP-095 ELECTRICA Y COMERCIALIZADORA FREE, S.A DE C.V. BOGOTA # 232 VALLE DEL NOGALAR: ‘SAN NICOLAS DE LOS GARZA, NL E-MAIL: comfree@Infosel.nat.mxtinh digit HET Hil) ety lig | ; Pe Ha Hae [a i jal Ha | a | al ae a iil Ha ay i iat Ae it ‘i : si i ith til _ Ha a ME i Pale a Aa Ae HET UG a Ie i i li ie a i i ieee ntl TELA he Ul fit iil wail ahaDE: ELECTRICA Y COM, FREE 11 Terminal block with clear cover: This 12 point terminal block enables customer's Connection to the twee alarm switches (Empty Cylinder Alarm, High Pressure Alarm, and Low Bresaure Alarm). See wiring diagram in figure 9. Wiring is 14 AWG wit insulated sword terminals. The Block is rated 30 amps and has #10-52 serews for securing terminals, 12 Outlet Valve and Bulkhead Adapter: The outboard side of this valve is intended for Gonnection to a 14 inch NPT male fing and tubing leading to the transformer ges space. in the closed position, this valve isolates the Free ‘System from the transformer gas space. This positon is used when evacuating the transformer, ‘nd when testing the pressure relief unit. In the ‘Open position the vole connects the Free System to the transformer gas space. This position is used inthe standard “Operating Configuration", and for purging and pressure testing the entire system. 13. Sampling Valve: This valve is intended for ‘connection to the transformer gas space through ‘an Independent fiting and length of tubing. The barbed hese connector for 1/4 ID tubing atows. gas samples lo be obtained from the transformer for testing and analysis. This may also be used as ‘an exhaust port when purging the gas space with ‘resh nitrogen. During normal operation this. valve remains dosed. 14 Outlet hose: This hose is appronmately 24 inches (610 mm) long and connects the ‘sump(6) tothe outlet vaive (12). 15 High Pressure Hose: The standard hose fs approximately 24 inches (610mm) long and is used to connect the high pressure regulator (3) to the nitrogen cylinder. The cylinder end of each hose has @ CGA (Compressed Gas Association) ‘880 male connector with an integral check valve wich prevents gas escaping from the Free System, 16 Check valve: The Check Valve prevents gas escaping from the Free System when the Firogen cylinder is changed. (Figure 2). . 2. Installation 2. Safety information. Keep this Instruction Leaflet available to those responsible for the installation, maintenance and the operation ofthe Free System. NO.DE TEL = axeasaseaa ‘The installation, operation and maintenance of @ Free System present potentially unsafe ‘conditions, including, but nat kmited to. the following: + High pressures + Lethal voltages © Heavy components Specialized procedures and instructions are required and must be adhered to when working ‘on such apparatus. Failure to follow instructions ‘could fesut in severe personal injury, death ‘andlor product or property damage. ‘Adétionally all applicable safety procedures such ‘38 OSHA requirements, regional and local safety requirements, safe working practices, and good jedgment must be used by personnel when instaling, operating, andlor maintaining such equipment. Important Notice: Faure to observe the requirements of OSHA standard 1910269 can cause death or severe bums and disfigurement ‘That standard specially prohibits the wearing ot polyester, acetate, nylon, of rayon dothing by employees working with exposure to electric arcs orflames. Safety notations defined in this instruction leafte, involve two possible conditions: 1. Personal injury or death. 2. Product of property damage (includes. damage lo this product or other property). Safety notations are intended fo alert personnel of possible personal injury, death, or property Gamage. ‘The have been inserted in the instructional text prior to the step in which the condition is cited. ‘The safety notations are headed to alert personal by one of three hazard intensity levels which are defined as follows: DANGER - immediate hazard which will result in ‘severe personal injury, death or property damage. WARNING + hazard or unsafe practice which could resuit in severe personal injury, death or property damage. CAUTION - hazard or unsafe practice which could result in minor personal injury, death or property damage. 2.2 Installation MP-095 Free System. 26 ABR. 2006 04:36" PSDE + ELECTRICA Y COM. FREE 22. A. Mount the enclosure onto the transformer. Three mounting holes are provided in the brackets on the rear of each enclosure. The Free systems brackets should rest on the transformer's Supports and be connected by a bolt, fat washers, lock washer and nut as shown in figure 5 IW there is a gap between the transformer bracket ‘and the enclosure brackel one or more washers ‘Should be used to shim as necessary to distribute the enclosure’s weight between the upper and ower brackets. 2.2. B. Connect the low-pressure tubing from the enclosure to the transformer gas space. ‘While the instructions that follow can be used a6 ‘general guidelines, please refer to the assembly instructions provided by the supplier of tubing and ‘tings. ‘The customer must weld the two 1H inch NPT female couplings to the transformer wall to provide access tothe transformer gas space. ‘Some transformer designs locale the couplings side by side, whereas other place the couplings at diagonally opposite comers near the top of the transformer for 2 cross flow gas. Cut tubing to length, deburr and bend as required Verify that tne tubing is ree of debs Using a light coating of thread cement or Teflon ‘tape, attach two elbows jn to the female 14 inch NPT female bulkhead ftings on the right wall of the Free system enclosure. When tight, these elbows should point, upward at an angle of about 30° from vertical toward in the transformer wall, Using a similar process, attach the other two elbows to the transformer gas space couplings. ‘The tubing ends should point downward. ‘The tube fitings come preassembled finger-tght. Inert the tube into the fiting. Make sure that the tubing rests firmly on the shoulder of the fiting ‘and that the nut is finger ight. Soribe the nut at the 6 o-clock position. Whie supporting the body ff the fiting with a back-up wrench, tighten the ‘nut 1.25 tums, watching the scribe mark make ‘one complete revolution and continue to the 9 0 ‘lock position. Repeat this process for-each tour tube connections. Secure te tubing along ts path with supports and hardware. Led ia 2.2. G. Connect electrical leads and run wiring. NO.DE TEL : atessa5e00 Consult transformer controls wiring diagram for specific connections in the wansformer's contro! ‘scheme. A schematic diagram of the standard Free System alarms and other electrical equipment is show in figure 4. 1. Cut one mare holes in the enclosure to ‘accommodate the cable or conduit fiting(s) required. Refer Lo figures 5 for suggested location 2. Install iting (8) (not included) into the hole (8) and instal wing, 3. Connect leads to the appropriate terminals on the 12-point terminal biock ‘Two 0.25 inch (8.4mm) diameter holes along the lower edge of the "Active Part* can be used lo ‘secure wiring with wire tes. CAUTION Do not use a ow voltage bell ringer when checking the alarm circuits; this could exceed the interrupting ratings of the contacts and may damage the contacts. An indicating ight device Is best for checking the crcults. Figure lists the interrupting ratings of the alarm contacts. 3. Operation 3.1 Replacing/eonnecting a nitrogen Cylinder. ‘When the pressure in the cylinder in below 100 psi (689 kPa) it should be replaced with @ full tyinder of trogen, The nitrogen used should ‘comply with de requirements of the transformer manufacturer, however the following guidelines are provided for reference: Cylinder dimensions: Capacity 200 ft? (5.66m") (2200 psi @ 70°F) (15,168 kPa @ 21°C) Height: 55 in (1397 mm) Diameter. 9 in (229 mm) ‘Weight: approx. 1401b (63 Kg). Valve connection: CGA 680 Female. Purity: max impurities 0.20% by volume. Moisture: Dew Point of55* C (-67°F) or lower. (Oxygen Content: Maximum 0.20 % (2000 ppm) by volume, 6 ABR. 2006 94:39 PaELECTRIOR Y COM. FREE Warning Abways follow this sequence of steps when replacing a nitrogen cylinder. Failure to do so may ‘cause equipment damage or severe personal Injury This procedure covers the complete process of replacing a nitrogen cylinder, forthe instalation of the inal cylinder begin on step 5 4. Close the valve on top of the installed nigger der by ng elociowise 2. Close the Free System's Outlet Valve (CW) to the limit to isolate the transformer ‘gas space from the reguiator system. 3. Siowly loosen the connection between the ritrogen cylinder and the Free System's High Pressure, Hose by tuming the union rut counter clockwise (CCW). & small ‘amount of gas should escape from the fiting, Proceed lo detach the hose fiting from the cyfinder and secure the hose out cof the way. If the hose will be left disconnected for more than a few minutes, stall a dust cap to prevent enisy of dit or moisture into the system nti the new cylinder is ready to instal, 4. Release the cylinder strap, swing it out of the way, and remove the cylinder, Install the cylinder valve’s protective cap. 5. Verily that the bypass valve is closed (CW). So that gas will be directed trough the low pressure regulator. 6. Remove the protective cap trom the full nitrogen cylinder, and position the cylinder in place. Secure the cylinder withthe strap and store the cylinders protection cap in a safe, convenient location 7. Be sure that the cylinder valve is free of it. A good procedure is to briefly open the cylinder Valve siightly (CCW) to allow any contamination lodged in the vaive to be blown out CAUTION Point the opening of the valve away from personnel in the area to avoid injury from a high pressure gas stream or for blowing particles. 8, Connect the nigh pressure hose othe cylinder tightening the union nut only hand sgh Sowly open the cllndar valve sighy and alow the NOLDE TEL ¢ a1essess20 ga leaking out of the connection to blow off any fine din. Tighten the union nut with a 1-1/8 inch wrench until the gas leaks stops: then open the cylinder valve (CCW) tothe fully open postion. CAUTION ‘Opening the cylinder valve should be done very ‘slowly to avold damage to the valve seat ‘Always back seat the open valve with the same force that would be use to close the valve, Failure to observe the se precautions may cause ‘equipment damage or personal injury. ‘9. Briety open the drain cock on the bettom Free ‘System's sump by tuming the wings counter- ‘lockwise (CCW). When only dry gas exis the ‘sump, close the drain cock (CW), 40. Open the open valve (COW) lo its limit. The system may operate to stabilize the gas space preseure within ts range. Monitor the Preseure/vacuum gauge to sec than acceptable level is reached. ‘The unit is now in “Operating Configuration”. 3.2 Adjusting the 2 Stage Output Pressure ‘and Testing the Pressure Relief Unit. ‘This Procedure may be performed 28 part of routine maintenance to very proper operation of the equipment. The instuctions assume that the system in set in the "Operating configuration” os defined in section 3.1, 1, Read the nameplate inside the Free ‘System to determine the preset value for the pressure Relief Unit (standard setting is + 6.5 psi (44.8 KPa) ) 2. Chose the outlet valve (CW to limit). 3. Open the bypass valve (CCW to limit). 4. Release the 1/2 inch jam out on the High Pressure Regulator’s _sorewaiver adjustment, While watching the pressurelvacuum gauge, tur the ‘Screwdriver adjustment clockwise slowly to increase the pressure. Gas should begin escaping from the Pressure Relief Valve within +/- 0.5 psi (#/- 3.4 kPa) of the setpoint vaiue. Wt the Pressure Relief Unit does not operate at the correct valve, adjust it 26 ABR. 2006 @4:39RH PSELF ELECTRICA Y OOM, FREE Luniocking puling the knob with the hand Labeling and arrows_on the unit show proper direction, Afer finishing the ‘adjustment lock the knob pushing it 5. Tum the regulator T-handle adjustment counter-clockwise (CCW) to reduce the Pressure to its setpoint (+5.0 psi (+34.5, kPa), standard). Excess pressure may be bled by briefly opening the sump's drain ‘cock and watching the pressure/vacuum ‘gauge stabilize. 6. Close the Bypass valve (CW). 7. Open the Outlet Valve (CCW). ‘The unit is now back in "Operating Configuration’. 2.3 Purging the Gas Space. ‘Some transformers are shipped with dry air in the (gas space rather than nitrogen (0 allow breathable gas be present for @ technician to ‘attach intemal leads and perform other ‘commissioning activiies. When the transformer has been prepared for operation, the Free System may be used to purge the gas space with nitrogen. Follow the instructions provided by the transformer manufacturer for fing the transformer with of! and gas, The following procedure may be use generally to purge the gas space. The instructions assume that the system inset in the “Operating Configuration as defined in section 3.1. Also verify there Is adequate nitrogen pressure in the cylinder before beginning the procedue. ‘CAUTION Use extreme care when purging the gas spaco with nitrogen from a high pressure cylinder. Do rot seal the transformer until the nitrogen in the ‘gas space has reached ambient temperature (Do ot cose the oullet valve which seals the transformer from the Free Systom’s Pressure Rolie! Valve). As high pressure (up to 2000 psi (13,789 kPa)) ntvogen is reduced to atmospheric pressure and piped fo the gas space. the gas expansion reduces its temperature. Unless the gs is free to expand as it warms to ambient temperature, the pressure within the tank may - increase to such a value as to operate me relief unit 1 de-energized before proceeding with this step. Faure to do so could result in electrical shock. 41, Close the Bypass Valve (CW). 2. Open the cylinder valve to limit (CCW), NO.DE TEL : e1essesea 1. Close the outlet Vaive (CW), 2. Open the Bypass Valve (CCW), 3. Verify the pressure within the sump is 45.0 psi (634.5 kPa). Adjust if necessary as described in section 3.2 4A. Open the Outlet Valve (COW): the Free System will work to pressurize the transformer tank to #5.0 psi (34.5 KPa). 6 Open the sampling valve (CCW) to exhaust gas from the gas space untl gas ‘analysis yields satisfactory results. Close the sampling valve securely when the purge vaive is complete. 6. Close the bypass valve (CW). “The unitis now back in “Operating Configuration” 3.4 Tank Leak Test. ‘A.5.0 psi (24.5 kPa) nitrogen pressure test can be ‘made on the transformer tank and Free Syste ‘Any small nitrogen leak should result in a change in pressure on the Free System's Pressure/Vacuum gauge. After verifying that th adjustment of the regulator T-handle adjustment is cored (83.2), perform the following procedure: ‘Open the Bypass Valve (CCW) arid allow the system 10 stablize at +5.0 psi (*34.5 kPa), See ‘Caution in section 3.3 regarding expansion of gas from cylinder. Close the nitrogen cylinder valve (CCW) and allow the system to stabilize at *5.0 psi (+345 Pa) and allaw the transformer to stand several hours under this pressure. i the pressure falls off with no change in temperature, a leak fs present ‘and should be located and corrected. ‘Check all hose connections, vaive packing glands ‘and fitings for signs of escaping gas, A solution ‘of soapy water applied to the joints wall bubble ‘where leaks are present. WARNING Be certain all current caning items have bee The unit is now in "Operating Configuration” 3.5 Sampling the Gas Space. Before beginning this procedure, verity that there | positive pressure within the transformer gas space by checking the pressure/vacuum gauge 26 ABR, 2006 04: 4PM PSDe. ELECTRICA Y COM, FREE NO.DE TEL {or a positve reading, and verify tat the nitrogen cylinder has adequate pressure remaining 41. Open the sampling valve (CCW) briefly to clear the sampling tube of any ol ‘condensate oF static gas. Connect a sampling device with 0.26 inch (6-4mm) inside diameter hose to the barbed hse connection on tre sampling valve. 2 Open the sampling vawe (CCW) and raw of fan adequate gas sample. The Free System will function 26 required 10 maintain the pressure above the low pressure limit, 3 Close the sampling securely valve (CW), 136 First month of operation. ‘The amount of nitrogen used by the transformer wil depend on the Integrty of the tansformer tank, the load cyele, and ambient temperature variations. In arder to be sure that the equipment is operating correctly and that there are no leaks in the system, Free, recommends the folowing Teadings be taken ‘during the frst month of ‘operation and recorded on the table on the page soc for analysis 1. During the first week take daily readings: of: ‘+ Nitrogen cylinder pressure. ‘+ Transformer tank pressure as indicated. ‘on the pressure/vacuum gauge. Transformer ol temperature. + Ambient air temperature. Weekly readings will suffice forthe remainder of the month 2. A. weekly oxygen analysis may be performed to determine whether the fansformer is operating property. ‘Aakdtional purged should he done if the oxygen content approaches 5% (this 1s ‘generally considered to be the safe upper limit to prevent explosions in the gas ‘spece). Follow specific _ instructions provided by the transformer manufacturer ‘with regard to testing and levels. . 4, Maintenance Free Systems are designed to require very ite maintenance, Replacement of nitrogen cylinders {is described in section 3.1, 44 Annual Inspection. oressaseae “The folowing checks should be performed atleast once a year 1. Drain the sump of any accumulated fuid (see 3.1 steps) 2. Check the operation of the Pressure Relief Unit (6003.2) 5, Renewal Parts IF cenewal pans are required, order them through the nearest supplier or Free S.A. representative. Please provide the item identification located in each component. Technical Support it a technical question arises regarding the product detaled in This Technical Product Uerature contact the supplier or: ‘leetrica Y Comerciaizadara Free, S.A. DE CV. Tel. (81)8350-5801 Fax. (81)8350-5800 ‘San Nicolas de los Garza, N. L. C. P. 85480. DISCLAIMER OF WARRANTTES AND LIMITATTON OF LIABILITY THERE _ARE NO UNDERSTANDINGS, AGRFEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTTRE OBLIGATION OF SELLER. THE CONTENTS OE THIS DOCUMENT SHALL NOT BECOME P ART OF OR MODIFY ANY PRIOR OR EXTSTING AGREEMENT COMMITMENT OR RELATIONSHIP. The information, recommendations, description. and safety notations in this document are based (on OUT experience and judgment with respect to Bushings. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE ALL INCLUSIVE OR COVERING ALL CONTINGENCES. If further information Is required, Free S.A. should be consulted, NO WARRANTIES, EXPRESSED. OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A 26 ABR. 2006 84:41PH P726 AER. 2006 84:41PM Pa : 183525800 NO.DE TEL DE: GLECTRICA ¥ COM, FREE 2 3andla (.9's2) usu 009 Gudeasa wows so8 Jausojsuc4y Syuanaud anyon 423U9 caiddiu % yu) 4oxDauUUO> ayo QgcH (uoH.0/30Ssy S09 passaudwoj) yO) asoy sunsaud yo (SPOIL puopucss JOU0I-ON uozjuauy) poouyy you LAN b/TNO.DE TEL + @16g5@5500NO.DE TEL + @19835@5600 26 ABR. 206 04:42 P18 108 ¥ COM, FREE ti aeyorg prepuers afeyoeg 8 aunola25 ABR. 2006 4:42M PLL eerste ee vo.ne T+ oteeaseo is CABINET DIMENSIONS 1 some | | a por eesinse ero are, (AMERICAN NATIONAL ‘STANDARD TAPER PPE. THREADS) MOUNTING HOLE Tora 7G |-~ RECOMMENDED WaRE L-T] ENTRANCE LOCATION (enter $108) qisie 1 MOUNTING HOLE (2TOTA) 916 9 Figure 5 Mounting The Enclosure On A Transformer