ASSEMBLY INSTRUCTIONS

(This manual should be read in conjunction with Voltamps Service Manual)

1. Purpose:
The purpose of this document is to define the procedures for re-assembling the 10MVA power
transformers equipment or accessories which are removed for shipment. All items removed for
shipment will be noted on the Bill of Landing. These items should be reassembled at the site in
the following order:
<M/s Voltamp to recommend the order of mounting arrangement of accessories for easy
Installation >
S.no
Description
1
Radiators
2
H.V Condenser bushings
3
HV Bimetallic Connectors
4
H.V Neutral bushing
5
Conservator Supports
6
Conservator Supports angle
7
Conservator tank with MOG & 2 Nos Valves, 2 Nos Breather Pipe fitted on
tank
8
Conservator Connection Pipe
9
Breather pipe for Main tank
10
Breather pipe for OLTC
11
OLTC connecting pipe
12
OLTC connection pipe support & breather pipe support with clamp
13
Silica Gel Breather Main tank
14
Silica Gel Breather OLTC
15
Erection Gasket
16
Main tank Buchholz relay with 2 Nos valve
17
OLTC Buchholz relay with 2 Nos valve
18
Marshalling Box
19
Gas sampling pipe with petcock valve
20
Air tripping pipe
21
Flange Type Rollers
22
LV Cable box with 6 Nos bus bar and 3 Nos Jumper with Al. gland plate
23
MS Support for LV Cable Box
24
Earthing strips
25
HV N copper earthing bar
*Refer Packing List & Drawing No.3GA-22192 to see the dismantled accessories for shipping.

2. ASSEMBLING RADIATORS:
(Also Refer Volt amp manual pg.no:11, 39 & 41)
a) After unpacking the radiator package carefully, lift the radiator out from the package and
place it in a convenient place for mounting. Inspect all radiator panels and flange
mating surfaces for shipping damage.
b) Check that all valves on tank flanges are closed and remove blank shipping plates,
gaskets from the mounting flanges of the radiator.
c) Remove blank shipping plates on radiator flanges and inspect for moisture or
contamination inside radiator headers. If the radiators are contaminated,
flushing will be necessary.
d) After removing the blanking plates and gaskets from the upper and lower radiator valves,
confirm that the gaskets are not damaged during transportation and set the gaskets to the
gasket grooves of the radiator valves after applying the varnish.
e) Lift the radiators by means of the lifting eye at the top. Install the radiators with
matching numbers on tank flanges. Bolts should be drawn up evenly, alternating
across corners, top and bottom, until spring washers are fully compressed.
f) Lift the radiator up carefully about one-meter from ground and incline the radiator to
drain the residual insulating oil.

g) Flush radiators if they are contaminated. DO NOT OPEN the tank flange valves prior
to flushing the radiators. Remove the top and bottom pipe plugs from the radiator
headers and circulate clean insulating fluid through the radiators using a filter press.
Reverse the flushing procedures, so that the radiators are flushed top to bottom and
then bottom to top. Reinstall the pipe plugs after flushing, using Teflon thread sealing
tape.
h) Relieve the tank pressure or vacuum, and vent the tank by removing a hand hole
cover, shipping plate, or plug, whichever is most convenient. (This opening must be
above the oil level.)
i) Open first the bottom, and then the top, flange valve on each radiator in succession,
until all valves are open.

CAUTION: Do not remove radiator drain plugs unless replacing them

with valves.
Install conservator base, then conservator, then conservator pipe to main tank, including
valves and Buchholz relay.
Torque Values:
All nuts on the flanges should be torqued to the following values:
Nut Size: To be provided by M/s Voltamp
Torque Value: To be provided by M/s Voltamp
Tools Required: To be provided by M/s Voltamp

Before fixing the radiators:

Shut off Valve

Blanking Plate

After fixing the radiators:

3. ASSEMBLING BUSHINGS:

a) Unpack the package of bushings by the assembly floor. And confirm that the
bushings are not broken.
b) Before attaching, clean the porcelain surface and the terminal portion on oil
immersed side should be cleaned carefully with a clean and dry cloth or with
solvent.
c) Bushings should be absolutely clean and dry when installed.
d) Gaskets and gasket recesses should be carefully cleaned.
e) Gaskets should be carefully placed and uniformly clamped so that tight seals are
formed.
f) Current-carrying connections should be thoroughly cleaned.
g) The bushing central cavity should be swabbed to remove particulate contaminants.
(Also refer pg.no:4, 33 & 34 in M/s Voltamp manual)

Sample Picture:

3.1 DRAW OUT LEAD CONNECTION TO BUSHINGS:

(Refer pg.no:4 M/s Voltamp manual)

< M/s Voltamp to insert & brief the step by step installation with pictures of internal lead
connection, preferably from any of their ongoing jobs for both the condenser bushings &
neutral bushings>
Sample Picture: (This picture must be replaced)

Torque Values:
All nuts on the
should be torqued
values:
Bolts & Nuts Size: To be provided by M/s Voltamp
Torque Value: To be provided by M/s Voltamp
Tools Required: To be provided by M/s Voltamp

4. ASSEMBLING CONSERVATOR:

bushing flanges
to the following

a) Complete the installation of the bushings and other accessories on the main tank of the
unit.
b) Do not assemble the pipe connection between conservator and the tank before
installing the conservator.
c) Install the support structure to install the conservator on the tank.
d) Lift the conservator with the help of lifting eyes/lugs on the top, and place it in
position on the support structure.
e) Connect the pipe circuit between the conservator and the tank.
f) Mount the conservator supports and their reinforcements on the position.
< M/s Voltamp to insert Pictures >
Sample Pictures: (Replace it from pictures from your works)

Sample Picture:

Torque Values:
All nuts on the flanges should be torqued to the following values:
Bolts & Nuts Size: To be provided by M/s Voltamp
Torque Value: To be provided by M/s Voltamp
Tools Required: To be provided by M/s Voltamp

5. PIPING CIRCUIT BETWEEN CONSERVATOR AND MAIN TANK:

(Valves, Flanges, Buchholz relay)

< M/s Voltamp to insert Pictures >

Torque Values:
All nuts on the flanges should be torqued to the following values:
Bolts & Nuts Size: To be provided by M/s Voltamp
Torque Value: To be provided by M/s Voltamp
Tools Required: To be provided by M/s Voltamp

6. PIPING CIRCUIT BETWEEN CONSERVATOR AND OLTC:

(Valves, Flanges, Oil Surge Relay)

< M/s Voltamp to insert Pictures >

Torque Values:
All nuts on the flanges should be torqued to the following values:
Bolts & Nuts Size: To be provided by M/s Voltamp
Torque Value: To be provided by M/s Voltamp
Tools Required: To be provided by M/s Voltamp

7. PIPING CIRCUIT BETWEEN CONSERVATOR AND BREATHER:

< M/s Voltamp to insert Pictures >

Torque Values:
All nuts on the flanges should be torqued to the following values:
Bolts & Nuts Size: To be provided by M/s Voltamp
Torque Value: To be provided by M/s Voltamp
Tools Required: To be provided by M/s Voltamp

8. PIPING CIRCUIT BETWEEN CONSERVATOR AND OLTC

BREATHER:

< M/s Voltamp to insert Pictures >

Torque Values:
All nuts on the flanges should be torqued to the following values:
Bolts & Nuts Size: To be provided by M/s Voltamp
Torque Value: To be provided by M/s Voltamp
Tools Required: To be provided by M/s Voltamp

9. MOUNTING LV CABLE BOX:

< M/s Voltamp to insert Pictures >

Torque Values:
All nuts on the flanges should be torqued to the following values:
Bolts & Nuts Size: To be provided by M/s Voltamp
Torque Value: To be provided by M/s Voltamp
Tools Required: To be provided by M/s Voltamp

10.MOUNTING WHEEL ROLLERS:

< M/s Voltamp to insert Pictures >

Torque Values:
All nuts on the flanges should be torqued to the following values:
Bolts & Nuts Size: To be provided by M/s Voltamp
Torque Value: To be provided by M/s Voltamp
Tools Required: To be provided by M/s Voltamp