Numero doc. / Doc number:
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING
s
C07064/05/59 Foglio/Sheet :
1/38 Edizione Edition
00 Data 10 10/11/08 Date
Redatto Odorizzi Edited
Controllato De Paoli Approvato Cecked Approved
TRANSFOR TRANSFORMER MER HANDLI HANDLING, NG, INSTALLA INSTALLATION TION AND ASSEMBLING ASSEMBLING
CUSTOMER:
Bekhma Company Company for Construction Contract
INSTALLATION:
NO. 1 Transformer Tr ansformer SS ERBIL PARK (EP)SUMEIL SS
ORDER:
S/S STAGE STAGE 3 - B1 - 16/10/20 16/10/2007 07
DESCRIPTION:
Three-phase transformer
Serial number
0706405/01
Type:
PO
Rated power:
44,1 / 35 35 / 28 ONAN 63 / 50 / 40 ONAF NAF
Cooling type:
ONAN / ONAF
Voltage:
132 ± 8 x 1,25 % / 33 ± 2 x 2,5 % / 11,5
Quantity:
1
MVA
Frequency: 50
Hz
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
2/38
INDEX 1 TRANSFORMER HANDLING..............................................................................................3 1.1 TRANSFORME TRANSFORMER R LIFTING, LIFTING, ANCHORING ANCHORING AND TRAILING TRAILING ................................ ................................................ ................................ ...................4 ...4 1.1.1 Lifting.................................. Lifting................................................................. .............................................................. .............................................................. ............................................................ ............................. 4 1.1.2 Anchoring Anchoring ........................................................... ......................................................................................... ............................................................. ............................................................ ............................. 6 1.1.3 Trailing ............................................................... .............................................................................................. ............................................................. ........................................................... ............................. 6 1.1.4 Precautio Precautions ns during the handling handling .............................................................. ............................................................................................ ...................................................... ........................ 7
1.2 TRANSFORMER TRANSFORMER BEARING.............. BEARING.............................. ................................ ................................ ................................ ................................ ............................... .....................8 ......8 1.2.1 Assembly Assembly of sliding rollers rollers mounted on forks whitout whitout insulation insulation (with/whitout (with/whitout border): border): ................................... ................................... 8 1.2.2 Bearing Bearing points............................................................... points.............................................................................................. ............................................................. ................................................. ................... 9
2 TRANSFORMER INSTALLATION ......................... ............ ............................ ............................ ........................... ............................ .................10 ...10 2.1 TRANSFORMER TRANSFORMER RECEPTION....................... RECEPTION...................................... ............................... ................................ ................................ ............................... ......................11 .......11 2.2 TRANSFORMER TRANSFORMER INSTALLATION INSTALLATION ............................... ............................................... ................................ ............................... ............................... .........................11 .........11
3 TRANSFOR TRANSFORMER MER ASSEMBLY AND PREPARATION PREPARATION .......................... ............. ........................... ............................ ...............12 .12 3.1 ASSEMBLY.................. ASSEMBLY.................................. ................................ ............................... ................................ ................................ ............................... ................................ .........................13 .........13 3.1.1 Introductio Introduction.............................................. n............................................................................. ............................................................. ............................................................. .......................................13 ........13 3.1.2 Dismountin Dismounting g of the nitrogen maintaining maintaining system .............................................................. ..........................................................................................1 ............................14 4 3.1.3 Pressure Pressure restore... restore................................. ............................................................. ............................................................... ............................................................... ...........................................14 ............14 3.1.4 Transform Transformer er assembly assembly and preparat preparation ion sequence sequence:: ........................................................... .......................................................................................1 ............................15 5 3.1.5 Tighten Tighten torques............................................. torques............................................................................ ............................................................. ............................................................. ..................................16 ...16 3.1.6 Radiator Radiator assembly assembly ............................................................. ............................................................................................ ............................................................. ...........................................17 .............17 3.1.7 Fan assembly assembly ............................................................... .............................................................................................. ............................................................. ................................................1 ..................18 8 3.1.8 Conservat Conservator or assembly assembly ............................................................ ........................................................................................... ............................................................. ......................................19 ........19 3.1.9 Piping Piping Assembly Assembly ........................................................... .......................................................................................... ............................................................. ................................................2 ..................20 0 3.1.10 3.1.10 HV bushi bushing ng assem assembly bly – type P&V – PSO–PNO PSO–PNO 52÷245 52÷245 kV 800÷125 800÷1250 0 A..................................................21 A..................................................21 3.1.11 3.1.11 MV bushing bushing assembly assembly – type CENELEC CENELEC 12-24-36 12-24-36 kV / 1250-20 1250-2000-3 00-3150 150 A .................................................2 .................................................23 3 3.1.12 3.1.12 MV bushing bushing assembly– assembly– type DIN 12-24-36 12-24-36 kV / 1000-20 1000-2000-3 00-3150 150 A ............................................................2 ............................................................27 7 3.1.13 3.1.13 Assemble Assemble the drive shaft shaft - off-circuit tap-change tap-changer............................. r........................................................... ..........................................................3 ............................31 1
3.2 TRANSFORME TRANSFORMER R FILLING FILLING ................................ ................................................ ................................ ................................ ................................ ............................... ...................35 ....35 3.2.1 Filling Filling of the tank and of the transformer transformer conservator conservator (with rubber rubber bag) .......................................................3 .......................................................35 5 3.2.2 Filling Filling of the conservator conservator of the On-Load On-Load Tap Changer Changer................................ ............................................................... ................................................3 .................36 6 3.2.3 Oil level adjusting adjusting .............................................................. ............................................................................................. ............................................................. ...........................................36 .............36 3.2.4 After the filling up........................................................................ up....................................................................................................... .............................................................. ..................................36 ...36 3.2.5 Dehydrat Dehydrating ing breather breather assembly................ assembly............................................... ............................................................. ............................................................. .......................................37 ........37 3.2.6 Other Other external external accessorie accessories s mounting mounting ........................................................... ......................................................................................... ................................................3 ..................38 8 3.2.7 Auxiliary Auxiliary circuit connections................................ connections............................................................... ............................................................. ..........................................................3 ............................38 8
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
2/38
INDEX 1 TRANSFORMER HANDLING..............................................................................................3 1.1 TRANSFORME TRANSFORMER R LIFTING, LIFTING, ANCHORING ANCHORING AND TRAILING TRAILING ................................ ................................................ ................................ ...................4 ...4 1.1.1 Lifting.................................. Lifting................................................................. .............................................................. .............................................................. ............................................................ ............................. 4 1.1.2 Anchoring Anchoring ........................................................... ......................................................................................... ............................................................. ............................................................ ............................. 6 1.1.3 Trailing ............................................................... .............................................................................................. ............................................................. ........................................................... ............................. 6 1.1.4 Precautio Precautions ns during the handling handling .............................................................. ............................................................................................ ...................................................... ........................ 7
1.2 TRANSFORMER TRANSFORMER BEARING.............. BEARING.............................. ................................ ................................ ................................ ................................ ............................... .....................8 ......8 1.2.1 Assembly Assembly of sliding rollers rollers mounted on forks whitout whitout insulation insulation (with/whitout (with/whitout border): border): ................................... ................................... 8 1.2.2 Bearing Bearing points............................................................... points.............................................................................................. ............................................................. ................................................. ................... 9
2 TRANSFORMER INSTALLATION ......................... ............ ............................ ............................ ........................... ............................ .................10 ...10 2.1 TRANSFORMER TRANSFORMER RECEPTION....................... RECEPTION...................................... ............................... ................................ ................................ ............................... ......................11 .......11 2.2 TRANSFORMER TRANSFORMER INSTALLATION INSTALLATION ............................... ............................................... ................................ ............................... ............................... .........................11 .........11
3 TRANSFOR TRANSFORMER MER ASSEMBLY AND PREPARATION PREPARATION .......................... ............. ........................... ............................ ...............12 .12 3.1 ASSEMBLY.................. ASSEMBLY.................................. ................................ ............................... ................................ ................................ ............................... ................................ .........................13 .........13 3.1.1 Introductio Introduction.............................................. n............................................................................. ............................................................. ............................................................. .......................................13 ........13 3.1.2 Dismountin Dismounting g of the nitrogen maintaining maintaining system .............................................................. ..........................................................................................1 ............................14 4 3.1.3 Pressure Pressure restore... restore................................. ............................................................. ............................................................... ............................................................... ...........................................14 ............14 3.1.4 Transform Transformer er assembly assembly and preparat preparation ion sequence sequence:: ........................................................... .......................................................................................1 ............................15 5 3.1.5 Tighten Tighten torques............................................. torques............................................................................ ............................................................. ............................................................. ..................................16 ...16 3.1.6 Radiator Radiator assembly assembly ............................................................. ............................................................................................ ............................................................. ...........................................17 .............17 3.1.7 Fan assembly assembly ............................................................... .............................................................................................. ............................................................. ................................................1 ..................18 8 3.1.8 Conservat Conservator or assembly assembly ............................................................ ........................................................................................... ............................................................. ......................................19 ........19 3.1.9 Piping Piping Assembly Assembly ........................................................... .......................................................................................... ............................................................. ................................................2 ..................20 0 3.1.10 3.1.10 HV bushi bushing ng assem assembly bly – type P&V – PSO–PNO PSO–PNO 52÷245 52÷245 kV 800÷125 800÷1250 0 A..................................................21 A..................................................21 3.1.11 3.1.11 MV bushing bushing assembly assembly – type CENELEC CENELEC 12-24-36 12-24-36 kV / 1250-20 1250-2000-3 00-3150 150 A .................................................2 .................................................23 3 3.1.12 3.1.12 MV bushing bushing assembly– assembly– type DIN 12-24-36 12-24-36 kV / 1000-20 1000-2000-3 00-3150 150 A ............................................................2 ............................................................27 7 3.1.13 3.1.13 Assemble Assemble the drive shaft shaft - off-circuit tap-change tap-changer............................. r........................................................... ..........................................................3 ............................31 1
3.2 TRANSFORME TRANSFORMER R FILLING FILLING ................................ ................................................ ................................ ................................ ................................ ............................... ...................35 ....35 3.2.1 Filling Filling of the tank and of the transformer transformer conservator conservator (with rubber rubber bag) .......................................................3 .......................................................35 5 3.2.2 Filling Filling of the conservator conservator of the On-Load On-Load Tap Changer Changer................................ ............................................................... ................................................3 .................36 6 3.2.3 Oil level adjusting adjusting .............................................................. ............................................................................................. ............................................................. ...........................................36 .............36 3.2.4 After the filling up........................................................................ up....................................................................................................... .............................................................. ..................................36 ...36 3.2.5 Dehydrat Dehydrating ing breather breather assembly................ assembly............................................... ............................................................. ............................................................. .......................................37 ........37 3.2.6 Other Other external external accessorie accessories s mounting mounting ........................................................... ......................................................................................... ................................................3 ..................38 8 3.2.7 Auxiliary Auxiliary circuit connections................................ connections............................................................... ............................................................. ..........................................................3 ............................38 8
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
1 TRANSFORMER TRANSFORMER
HANDLING
Numero Numero doc. / Doc number: number:
C07064/05/59 Foglio/Sheet :
3/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
4/38
1.1 TRANSFORMER LIFTING, ANCHORING AND TRAILING 1.1.1 Lifting NOTE: the position and the shape of the hitching points shown in the pictures of this section are just an indication; for a more detailed and real representation refer to the Assembly drawing and to other drawings referred in each paragraph.
The transformer is provided with four hitching points for the lifting (transformer lifting lugs), the only points dimensioned for its weight (both in shipping and in operating arrangement); This points are shown on the Assembly drawing. The lifting of the whole transformer by means of the lifting eyes on the cover (designed only for internal core&coils lifting) is strictly prohibited; the illegitimate use of this eyes could cause heavy damage of the transformer itself, of the neighbouring goods and represent a danger for the life of the people.
While lifting, the transformer should be kept as horizontal as possible. Ropes with adequate lifting capacity must be used, hitched to the points provided for this purpose; the angle formed by the ropes on each plane should be less than 30°. Lifting lugs: type
MAX 30°
type B
MAX 30°
MAX 30°
MAX 30°
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
5/38
The on site lifting, for little displacements (for example for rollers mounting) can be carried out by means of hydraulic jacks, placed under the proper points, marked on the Assembly drawing.
The lifting with hydraulic jacks must be carried out very carefully; during the lifting the transformer must be levelled as much as possible, both to avoid any instability both to avoid dangerous stresses on the tank. All four bearing points must be used, by alternating the action of the jacks with a circular sequence. An incorrect use of the lifting jacks could cause a damage of the tank, of the neighbouring goods and represent a danger for the life of the people.
Supporting point for jacks Type A
Type B
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
6/38
1.1.2 Anchoring For the anchoring during the transportation, only the points marked on the shipment drawing can be used (and if necessary the transformer lifting lugs); the use of other points not suitable for this purpose could damage the transformer tank. The haulage of the transformer can be done by means of the rollers, if any, or by a trolley with adequate loading capacity. Sliding guides with suitable shape and capacity must be used (rails for railway type rollers, U type channels for flat rollers). The hitching points for the trailing ropes can be only those marked on the Assembly drawing. The transformer must never be hauled with its base directly on the ground, even if it is equipped with skids.
1.1.3 Trailing The trailing eyes are placed on the four sides of the tank, in the lower part; their number and position vary depending on the size and the arrangement of the transformer. Some typical layouts are shown in the following pictures. In general, all the provided trailing eyes (on one side) must be used for the haulage. Trailing eyes: Type 1
Type 2
Type 3
Type 4
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59
1.1.4 Precautions during the handling During all the transportation and handling operations, impacts, pulls, wide oscillations, strong vibrations must be avoided. The lifting and the putting down of the transformer must be done smoothly and gradually. In any case, the accelerations applied to the transformer must be less than 2.5 g, in any direction.
Foglio/Sheet :
7/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
8/38
1.2 TRANSFORMER BEARING 1.2.1 Assembly of sliding rollers mounted on forks whitout insulation (with/whitout border): For mounting the sliding rollers: - Unpack the transformer of the possible packing; - lift the transformer following one of the two possibilities: o by means of a crane and the provided lifting hooks. In this case the angle formed by the ropes on each plane should be less than 30° by means of jacks, applied to the provided plates on the bottom tank. o During this operations, all the necessary safety precautions (according the laws) must be adopted to avoid any injury to the people or damage to the goods. Depending on the situation, proceed according to the relevant following procedures.
- Place the sliding rollers with the fork 1 in the correct position. - Fix the forks on the transformer base by means of the bolts 2, after placing properly the washer 3 and the spring washer 4.
2
3
4
1
In case of roller with border , mount the roller so that the border is inside the rails.
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
9/38
1.2.2 Bearing points The transformer is provided with bearing zones, dimensioned to carry its weight (both in shipping and in operating arrangement), marked on the Assembly drawing or on the Shipment drawing; if the transformer is intended for a mounting on sliding rollers or transformer support, these zones correspond to the fixing zones of the rollers or transformer support. During the transportation or in case of putting down for handling (when the rollers are not mounted), the bearing of the transformer must be done only by means of the proper zones; the bearing of the transformer on other zones than those provided for the purpose is not admitted even for a short time. The bearing surface shall be level, horizontal, steady and designed to support the mechanical stresses due to the transformer weight.
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
2 TRANSFORMER
INSTALLATION
Numero doc. / Doc number:
C07046/01/59 Foglio/Sheet :
10/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07046/01/59 Foglio/Sheet :
11/38
2.1 TRANSFORMER RECEPTION On delivery, check carefully the transformer and its accessory components for any damage suffered during transport. Any claims must be made immediately to the carrier, also informing the manufacturer. The transformer should be positioned in dry, covered areas, equipped for overhaul. In case of exposition to inclemency of the weather during the transport, when removing packing, make sure that any water in the packing does not contaminate the components which will lat er be immersed in the transformer oil. Check carefully the condition of the insulators and of the accessories. Pay particular attention to the state of the outer casing which contains the live parts of the transformer (core & windings).
2.2 TRANSFORMER INSTALLATION The transformer is designed with an inclination sufficient to permit the water evacuation on the outside and the gas evacuation on the inside. The surface on which the transformer lays must be horizontal. The transformer seat must be designed and built to support the weight and the mechanical stresses transmitted by the transformer. In the case the rollers are not used (or no rollers are provided), the bearing zones must have a level surface, with size not less than the bearing zones of the transformer. Once that the transformer is placed on its final position, the protections fitted for transportation reason can be removed and, if the transformer has been delivered partially dismantled, the assembly operations can be started.
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
3 TRANSFORMER
Numero doc. / Doc number:
C07064/05/59
ASSEMBLY AND PREPARATION
Foglio/Sheet :
12/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
13/38
3.1 ASSEMBLY 3.1.1 Introduction When the overall dimensions of the transformer and its weight fit the transportation limits, it is possible to ship the transformer completed assembled. In this case, if the transformer is sent without oil but filled by nitrogen, proceed with the oil filling according to the procedure later in this manual. If the transformer dimensions and weight do not fit the transportation limits, some parts of the transformer are dismantled and then re-assembled on site according to the instructions that refer to one of the following possible arrangements: 1. The main body (tank containing core and windings) is filled with treated insulating oil, whose level in the tank is lowered to allow thermal expansion; the upper side of the tank is filled with nitrogen (to avoid the contact between oil and humid air). 2. The main body (tank containing core and windings) ) is filled with nitrogen.
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
14/38
3.1.2 Dismounting of the nitrogen maintaining system If the transformer has been equipped with a system for maintaining the nitrogen pressure during the shipment, dismount this system before starting the assembling. Valve on the cover
Joint
Safety valve
Pipe
bottle valve
pressure reducer (1° stage) pressure reducer (2° stage)
regulating knob (2° stage) "DO NOT TOUCH" 2° stage gauge shows the pressure inside the transformer
nitrogen bottle
-
1° stage gauge shows the pressure inside the bottle
Close the bottle valve Close the valve to which the bottle is connected on the transformer cover. Remove the connection tube between the bottle and the valve on the cover. Remove the bottle and the joint on the valve (with the safety valve)
3.1.3 Pressure restore Before starting the assembling of the transformer, according to the order and the instructions reported in the following sections of this manual, is important to restore the internal pressure of the tank to the normal level (atmospheric pressure). To do this, open the vacuum pump valve or the pressure gauge valve positioned on the transformer cover (see Assembly Drawing) to let out the nitrogen, then close the valve again The opening of the valve must be done slowly and taking a great care because the nitrogen could be in overpressure.
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
3.1.4 Transformer assembly and preparation sequence: The steps outlined below should be carried out in the sequence indicated (as far as they are applicable): Surge arrester supports mounting (on the tank wall) Radiator assembly Radiator support assembly Conservator assembly M.V. bushing assembly M.V. busbars and surge arresters assembly H.V. bushing assembly Assemble the drive shaft - off-circuit tap-changer Filling up of the transformer Dehydrating breather assembly Other external accessories mounting Auxiliary circuit connections
15/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
3.1.5 Tighten torques (generic table: refer to the mounted components)
Joint type Tank/Cover
Torque [Nm] 150
Bolt size M16
Tank/Conservator
120
M20
Surge arrester support
60
M12
Air cooling support
120
M20
Air cooling piping
60
M12
Radiator
100
M16
Buchholz relay
100
M12
Valves
40
M10
MT cable box
60
M12
MV bushing
40
M12
HV bushing P&V PSO ; Trench COT Flange
70
M12
60
M12
Control cubicle
60
M8
NOTE: the above torque values are given as a reference and can vary.
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
16/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
17/38
3.1.6 Radiator assembly Some radiators may already be fitted with fans, auxiliary circuit cubicles, rating/item plates or other supports. Particular attention must be taken in case that thermometer pockets are installed on the radiator collectors. These radiators must be positioned as shown on the Assembly Drawing. 1. Make sure the radiator intercepting valves are closed. 2. Remove the blank flanges and the plastic caps from the valves themselves, bearing in mind that the valve fixing bolts are used to fix the radiators. Suggestion: the intercepting valves are not completely oil-tight and consequently some leakage of the insulating liquid may occur. It is therefore best to remove the blank flanges one at a time as you install each radiator.
3. Remove the blank flanges which are bolted to the radiator flanges (one at a time), making sure that no extraneous matter enters the radiators and that the seal seats are thoroughly clean.
4. Raise the radiators one at a time, by first positioning them horizontally on two blocks of wood. Then, taking care not damage the radiator through violent jerks or blows, hook it up to the crane by the upper eyebolt and raise to a vertical position.
5. Fix the radiator to the tank, taking care to fit the corresponding seals between the flanges.
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
18/38
3.1.7 Fan assembly Sometimes the fans are sent on site not mounted on the radiators: usually this happens with the horizontal application. In this case, follow the assembling configuration shown in the figure below:
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
19/38
3.1.8 Conservator assembly 1. Make sure that the valves of the Buchholz relay, on the conservator connection piping and the transformer connection piping are closed, then remove the blank flanges. 2. Make sure that the valves of the O.L.T.C protection relay, on the conservator connection piping and the transformer connection piping are closed, then remove the blank flanges. 3. Remove the by-pass link between two valves on the OLTC head (this connection is provided to equalize the pressure inside the OLTC vessel during the transportation). 4. Mount (if not already mounted) the Buchholz relay and the O.L.T.C. protection relay on the transformer as shown on the Assembly drawing, making sure that the arrow always is pointing towards the conservator. 5. Make sure the seal seats are thoroughly clean. 6. Lift the empty conservator by means of the proper eyes. If the conservator is not completely empty, the ropes must be fitted around the conservator cylinder Check carefully the rope lifting capacity before. The hitching eyes fitted on the conservator must only be used to lift the conservator when it is empty. The illegitimate use of this eyes could cause heavy damage of the component itself, of the neighbouring goods and represent a danger for the life of the people. 7. Position the conservator as shown on the Assembly drawing, taking care to fit the corresponding seals between the flanges on the piping and on the Buchholz relay. Take care that the Buchholz relay doesn’t suffer any damage. 8. Insert all the conservator fixing bolts, but do not tighten them down. 9. Interpose the gasket between the Buchholz relay and the flange on the conservator connection piping . 10.Insert the Buchholz relay fixing bolts in the tank and conservator, but do not tighten them down. 11.Mount (if not mounted already) the piping between the O.L.T.C. protection relay and the O.L.T.C. 12.Interpose the gasket between the O.L.T.C. protection relay and the flange on the conservator connection piping . 13.Insert the O.L.T.C. protection relay fixing bolts in the tank and conservator, but do not tighten them down.
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
20/38
14.Tighten down the bolts in the conservator supports, alternating between the bolts fixing the Buchholz relay and the O.L.T.C. protection relay so that they are locked at the same time. 15.Make sure that all the bolts are duly tightened down (for an indication about the tightening torques, refer to the table in the Transformer Operating Instructions and Maintenance Manual). 16.Connect the copper pipe coming from the gas collecting box, to the proper cock of the Buchholz (Buchholz instructions, see the Transformer Operating Instructions and Maintenance Manual).
3.1.9 Piping Assembly 1. Remove blind flanges, if present, from pipes sent unmounted; 2. Clean all the gasket seats; 3. Mount the piping as shown in the Outline Drawing and in the "Valves and Piping sketch" in TRANSFORMER OPERATING INSTRUCTIONS & MAINTENANCE MANUAL (section1).
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
21/38
3.1.10 HV bushing assembly – type P&V – PSO–PNO 52÷245 kV 800÷1250 A Install the bushing in the position shown on the Assembly drawing, according the following procedure. NOTE: The items reported below are referred to the attached drawing. 1. Unscrew the lock nuts of blank flange on the cover, take care that the lock nuts don’t fall inside the tank. 2. Pull the terminal pin (2) out from the tank; the terminal pin is connected to the winding end by means of a flexible cable and is hung on the internal side of the blank flange during transport. 3. Fit the gasket on the cover, making sure that its seat is thoroughly clean. 4. Lift the bushing by means of a crane, slinging it as shown in the drawing, using the eyes provided on the base flange of bushing. Use if possible hempen or nylon ropes having sufficient section. If metallic ropes are used, interpose wipers or similar between the ropes and the bushing porcelain, to avoid any damage of porcelain. 5. Place the bushing exactly above the hole on the cover. 6. Run a string with a threaded pin M12 through the bushing, starting from the top (until the string comes out from the bottom); Suggestion: if it’s possible use a pin made of insulating material, that could be left inside in case of falling down. 7. Screw the threaded pin in the hole M12 of the lug. 8. Pull softly the upper end of the string. 9. When the flexible cable is arranged inside the bushing, lower gently the bushing maintaining the cable tight. 10.When the bushing is close to the cover, check the alignment of the flange holes with the stud on the cover; check also that the bushing is correctly oriented 11.Lower the bushing on the cover. 12.Fix the bushing by tighten the nuts on the studs gently and thoroughly 13.Check that the terminal pin stands out from the cap. 14.Place the terminal pin (3) in the hole. 15.Place the gasket on the top terminal (1) and fix its on the bushing.
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
22/38
2 1
3
7 5
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
23/38
3.1.11 MV bushing assembly – type CENELEC 12-24-36 kV / 1250-2000-3150 A For shipment reason, the bushing is assemble before packing. Before to proceed with the mounting of the bushing on the transformer cover, remove the porcelain from the rod (pos.2) referring to the following procedure: 1. Loose the nut (pos.14) 2. Remove all the washer (pos.4), the gasket (pos.5), the contact ring (pos.17), the cap (pos.3), the gasket (pos.7). 3. Remove the porcelain from the rod (pos.2) Mount the bushing referring to the following procedure: 1. Remove the hole protection on the transformer cover (2N-2U-2V-2W) 2. Connect the rod (pos.2) with the internal connections (make use of the suitable screw) 3. Check that the gasket (pos. 8) is fitted in the correct position on the cover hole 4. Insert the pressing bits (pos. 18) and the clamping ring (pos. 16) 5. Insert the porcelain on the threaded rod (pos. 2) and bring the rod in position by pulling the string. Check that the rod fins enter in their set in the porcelain. 6. Screw the fixing nuts at the base of the porcelain (pos. 15-19) and lift the clamping ring and fix it by means of the pressing bits by screwing the nuts alternately ensure a sufficient pressure on the gasket. 7. Insert on the porcelain all the parts gasket (pos.7), the cap (pos.3), the contact ring (pos.17), the gasket (pos.5), the washer (pos.4) 8. Screw (ensure a sufficient pressure on the gasket but pay attention not to damage the porcelain) the nut (pos. 11)
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
24/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
25/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
26/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
27/38
3.1.12 MV bushing assembly– type DIN 12-24-36 kV / 1000-2000-3150 A For shipment reason, the bushing is assemble before packing. Before to proceed with the mounting of the bushing on the transformer cover, remove the porcelain from the rod (pos.2) referring to the following procedure: 1. Remove the upper connecting flags (pos.11) 2. Loose the nut (pos.14) 3. Remove all the washer (pos.4), the gasket (pos.7), the contact ring (pos.23), the cap (pos.3), the gasket (pos.9). 4. Remove the porcelain from the rod (pos.2) Mount the bushing referring to the following procedure: 1. Remove the hole protection on the transformer cover (2N-2U-2V-2W) 2. Connect the rod (pos.2) with the internal connections (make use of the suitable screw) 3. Check that the gasket (pos. 10) is fitted in the correct position on the cover hole 4. Insert the pressing bits (pos.24) and the clamping ring (pos.25) 5. Insert the porcelain on the threaded rod (pos. 2) and bring the rod in position by pulling the string. Check that the rod fins enter in their set in the porcelain. 6. Screw the fixing nuts at the base of the porcelain (pos. 21-22) and lift the clamping ring and fix it by means of the pressing bits by screwing the nuts alternately; ensure a sufficient pressure on the gasket. 7. Insert on the porcelain all the parts gasket (pos.9), the cap (pos.3), the contact ring (pos.23), the gasket (pos.7), the washer (pos.4) 8. Screw (ensure a sufficient pressure on the gasket but pay attention not to damage the porcelain) the nut (pos. 14) 9. Mount the upper connecting flag (pos.11) 10.If arcing horns are present, check they are in the correct position.
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
28/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
29/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
30/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
31/38
3.1.13 Assemble the drive shaft - off-circuit tap-changer -Keep the bevel gear 1.12.204 blocked in position 3 -Place the control box drive 1.12.201 in the same position 3 -Block the Drive 1.12.201 in position 3 -Place the bevel gear 1.12.203 -Assemble the drive shaft pipes 25x25 mm, vertical and horizontal, like indicated on ISTR08-0001 -Check the complete position range, passing from position 3 to pos. 1 and from 1 to 5; after pos. 1 and after pos. 5 you should be able to rotate, more or less, for the same degrees.
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
32/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
33/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
34/38
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
35/38
3.2 TRANSFORMER FILLING 3.2.1 Filling of the tank and of the transformer conservator (with rubber bag) These instructions apply to a transformer delivered with lowered oil in the tank; the operation consists in completing of the filling of the upper tank and of the conservator with rubber bag. Before starting, check that the valves are as indicated on the Transformer Operating Instructions and Maintenance Manual (section “OPERATING INSTRUCTIONS”, chapter “Final revision”, table “State of the valves”) 1. Open all the lower intercepting valves of the radiators. 2. Open all the upper intercepting valves of the radiators. 3. Connect the vacuum pump to the transformer dehydrating breather pipe (pos. 49). 4. Open the rubber bag compensation valve (pos. 60). 5. Connect the oil filling pipe to the tank drain valve (pos. 34). 6. Evacuate the transformer; filling can be started. 7. Open the drain valve (pos. 34) to make the oil flow in the tank. 8. Fill the conservator up to the maximum indication of the oil level. 9. Close the rubber bag compensation valve (pos. 60). 10. Maintain the vacuum in the rubber bag. 11. Continue with the conservator filling up to the upper part of them. 12. Vent the conservator by open the air vent plug (open gas release cock of electrical alarm pos 74). 13. Break down vacuum. 14. When the oil arrives in the rubber bag damage detector (pos. 74), vent them by open its screw. 15. Break down the filling and close the drain valve (pos. 34). 16. Remove the vacuum pipe and mount the dehydrating breather to allow the air access into the rubber bag. 17. Open the conservator drain valve (pos. 46) for to drain the excessive oil (if necessary). Drain the oil to restore the correct level, corresponding to the temperature indicated on the oil thermometer.
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
36/38
3.2.2 Filling of the conservator of the On-Load Tap Changer Before starting, check that the valves are as indicated on the Transformer Operating Instructions and Maintenance Manual (section “OPERATING INSTRUCTIONS”, chapter “Final revision”, table “State of the valves”) Check that the its dehydrating breather pipe end is free Connect the filling hose and the pump to the lower drain valve to the oil outlet valve on the OLTC head (note the “outlet” and “inlet” indications are referred to the oil treatment operation; use the outlet valve for the oil filling). Start the filling and check the insulating liquid level on the level gauge of the conservator (OLTC compartment); the oil level is correct when the level gauge reading corresponds to the temperature indicated on the oil thermometer. Vent the O.L.T.C. by opening the air vent plug on the top of the head. Then close the plug again.
3.2.3 Oil level adjusting To restore the oil level (that could be lower due to the venting operations), put in again oil in the conservator (both for the transformer and for the OLTC compartment ) from the conservator drain valves.
3.2.4 After the filling up After the filling operation, positioned all the valve open-closed device as shown on the "State of valve” table chapter of the Transformer Operating Instructions and Maintenance Manual. Disconnect the filling plug from the barrel.
Before energizing the transformer await two or three days to calm-down the oil (rest period) and repeat the vent operations.
s
TRANSFORMER HANDLING, INSTALLATION AND ASSEMBLING Section 3
Numero doc. / Doc number:
C07064/05/59 Foglio/Sheet :
37/38
3.2.5 Dehydrating breather assembly NOTE: the following instructions apply to all the dehydrating breathers mounted on the transformer.
If the piping is not disassembled for the transport, skip to point 4:
1. Remove the flange from the lower piping of the conservator, placed a vessel down the conservator piping for collect the eventually oil converged in the piping during the transport. 2. Remove the flange from the piping. 3. Mount the connection piping, interposed the gasket between the flanges. 4. Remove the upper and lower plugs from the dehydrating breather. 5. Check the colour of the salt, with the label on the dehydrating breather. If the salt is saturated, refer to the instructions given in the "Preventive maintenance" chapter of the Transformer Operating Instructions and Maintenance Manual. 6. Mount the dehydrating breather: - If threaded connection, screwing it on the proper pipe after binding the thread with Teflon® tape. - If flanged connection, mount the dehydrating breather interposed the gasket, between the flanges 7. For dehydrating breathers with hydraulic closure, pour oil in the lower sump until the oil level covers the bottom half of the inspection glass. 8. The dehydrating breathers and piping must be positioned as shown on the Assembly drawing.
