= t oe NATIONAL ELECTRIC POWER AUTHORITY LAGOS THERMAL STATION-EGBIN MAINTENANCE MANUAL 270MVA GENERATOR TRANSFORMER FOR EGBIN THERMAL STATION CONTRACT NO. NEP/0078/LTS-4 (2. MITSUBISHI ELECTRIC CORPORATION270MVA GENERATOR TRANSFORMER (MAINTENANCE MANUAL) 1, INSTALLATION MANUAL FOR TRANSFORMER 2. MAINTENANCE 3, SPECIAL TOOLS, SPARE *PARTS AND CONSUMABLES, 4.DRAWINGS AND CATALOGUES FOR GENERATOR TRANSFORMER “NATIONAL BLECTRIG POWER AUTHORITY, NIGERTA LAGOS THERMAL STATION, ECBIN" CONTRACT NEP 0078 / LTS —4 ENGINEER _SHAWNONT LTD. WORK ORDER NO. = SYSTEM NO. SERIAL NO. SHAWMONT LTD 93 [yoi2/4o}o1 014) —Usreuape'gep = ve| Subject:Test Report of Transformer Oil for NEPA National Lagos Thermal Electric Power Authority Station-Egbin Contract NEP 0078/LTS-4 The measured values are as follows: Property | Power |Interfacial |Neutrali- factor|tension zation at 100C)at. 25¢ number Sample Oi? (% Y| C ayne/em ) | (mskOH/s) Generator Tr NO. 5 0. 28 41.1 0. 005 @535840101 Generator Tr NO. 6 0. 25 41.5 0. 006 8535850101 Inter bus Tr NO. 1 0. 25 42.0 0. 006 8335860101 Inter bus Tr NO. 2 0: 20 42.1 0. 005 8335860102 2 ‘ASTM p 924 | vo971 D 974 Test Method Type 1| Below Above | Below Limit 0. 30 40 0.03 value|Type 2| Below Above Below 0. 30 40 0. 03 Conclusion: The measured values of the above transformers meet the ASTM limit value. 4 MITSUBISHI Yours truly, Stsned by: (7//7iStaal) Manager of QA section AKO WORKS ELECTRIC CORPORATION SNK -304 48270MVA GENERATOR TRANSFORMER (MAINTENANCE MANUAL) INSTALLATION MANUAL FOR TRANSFORMER 4 1.1 INSTALLATION MANUAL FOR TRANSFORMER SBA-E30121 i 1.2 SITE COMMISSIONING TEST AND CHECK LIST 70-4303 1.3 RECOMMENDED SETTING OF PROTECTIVE DEVICES s10-3652 STC4286 (2/6)* ‘uetonaL, BueTRIe POWER [AVIORTTY NIGERIA LAGOS THERWAL STATION . EGBIN" g INSTALLATION MANUAL FoR THREE PHAGE OBNERATOR TRANSFORMER (346.5/16 KV 270 MVA) Date Apr, 10. 1785 perce ne NA res riannea by +_2fi Sugrhona — MITSUBISHI ELECTRIC CORPORATION, AKO WORKS (sBA-230121) 4 (01/29) cl aiia a INSTALLATION PROCEDURE Following table shows the installation of the transformer at the sit : PREPARATION OF INSTALLATION RECEIVING INSPECTION AND STORAGE TIGTALLATION OF MATN BODY ON FOUNDATION OTD RECEIVING AND FILTERING REPLACING DRY GAS WITH OTL PRECAUTIONS OF OT, PIPING - ATEACHING BUSHING ADAPTOR ATTACHING RADIATOR EQUIPMENT ATTACHING CONGERVATOR AND PRESSURE RELTEF DEVICE ATTACHING BUSHING ATTCHING ACCESSORIES IWTERNAL LEADS CONNECTION WIRING FOR CONTROL OTL LEAKAGE TEST OTL, PILLING UNDER VACUUM Es ‘TEST AND GENERAL INSPECTION (02/29) & Page 03 - 05 06 - 07 08 - 09 10 a 2 3 4m -45 16 - 17 18-19 20 - 21 22 - 23 Bs 25 - 26 27 - 28 a341A PREPARATION OF INSTALLATION ‘SBB-P12001, 82-12-28 1, Determining location for installation of transformer ‘The location in which the transformer is to be installed must be accurately determined and preparations for which, such as the concrete foundation, base, anchor,etc. should be completed prior to the arrival of the transformer. 1-1, The foundation must be laid-as to maintain a correct horizontal level. For this reason, it is highly advisable that the base, rails and other things which are to be embedded in the foundation have been wedged in the concrete in advance. 3 mm or less is required for flatter base. 1-2, In the case of a transformer with wheels, the rail gauge is made accord= ing to the foundation drawing. 1-3. Anchors for the earthquake-proof and other anchors for installing accessory must be so arranged as to permit a smooth bring-in of the transformer body. 1-4, Gonsider the transformer weight and placement and then adjust the hook. 1-5, It is necessary to secure the storage space of parts and equipment. 2, Equipsents, tools and parts needed for installation ‘The necessary equipments, tools and parts to be installed the transformer are ehowa in LIST OF ERECTION EQUIPMENTS & TOOLS. The followings are required to satisfy the specification described below. 2e1, Mobile crane ‘A mobile crane is used to Fig-1 Mobile crane lift up the external parts, the top tank section, the tap changer tank section, ete. It is necessary to use about 15 ton crane for lifting general parts such fas connecting pipes, pressure relief vent, radiators,etc. For the heavy weights, such the top tank sections, XN bushings, ete. the mobile Fig-2 oil storage tank crane lifting capacity should be decided by the pave Pelee) weight and the setting height of the parts. Also a skilled mobile crane operator should be engaged. Breather 2-2. O11 storage tank It is necessary to provide an ole oil storage tank which has a on eamplin vain capacity with enough oil for Vale one transformer. (03/29)The of storage tank should be equipped with valves (filling, draining and sampling), a manhole, a breather, an air release plug and oil level gauge, and then should be painted on the inside with ofl-proof paint. Before filling, the inside of oil storage tank should be cleaned. 2-3, O41 Filter The ofl filter ie used for pouring of] nto the oil storage tank from a drum or tank lorry and for taking oil in / out between the of} storage tank and transformer. The ofl filter must be capable of removing dirt and moisture. A press type or a cartridge type filter is generally used, If a filter press type is used, filter paper dryer is required. 200 L/min.oil filter is recommended, 2-4, O11 treatment equipment The oil treatment equipment is used for removing the gases and moisture from oil while feeding ofl into the transformer. It is desirable for the equipment to have the specifications shown in Table-l. 2-5. Vacuum pump The vacuum pup is used for evacuating the transformer at the final oil filling. It is desirable for the vacuum pump to have the specifications shown in Table-2. 2-6. Dry gas Fig-3 Oil filter 1 t (x) Cuangeover wave ©) Table-1 O41 treatment equipment ‘Treating capacity] more than 4000 L/h] OL moisture content characteristic | 15 ppm or less gas content 1.0 % or less Filling oft temperature 40 - 60% ‘Table-2 Vacuum pump Ultimate vacuum value 0.01 torr oF less Exhausting capactt 2500 = 4000 L/min Dey gas with a dew point of -40%c should be used. The cylinder is equipped vith’a regulator and a pressure gauge. As the cylinder is a high tension vessel, special care must be taken in handling. 2-7. Pressure gauge The pressure gauge usually is used for measuring the gas pressure while an oil leakage test is being carried out Measuring range : 0 - 1.0 kg/en? 2-8. Vacuum gauge. The vacuum gauge is used for measuring the degree of vacuum at the final oi} filling. Measuring range : 1 Torr or less (For example McLeod, Pirani gauge.) 2-9. Are welding machine & Gas welding equipment ‘The are welding machine and gas welding equipment are used for welding and gas cutting of the connecting tube that is between the conservator and the main body. And the gas welding equipment is used for welding and annealing of the copper tube for the breather and gas sampling valve. a (04/29)2-10. Electric power supply ‘The electric power supply should have sufficient capacity for using the ofl filter, the of1 treatment equipment and welding machine. The cable should have enough capacity and length for each piece of equipment. 2-11. Hoses. The hoses should Hoss have enough length Caliber Remarks for using. Oi hose %0_/50na_| O21 proof ‘Vacuum hose | 40-~50ea | Vacuum proot Vinyl hose | 10/-16me_[-For supplying dry gaa (05/29)hia SBB-P 13001 82-12-28A 1, Inspection. 1-1, Main boay. When the transformer has arrived at the site, check the appearance for any damage caused during transportation, RECEIVING INSPECTION AND STORAGE and also check the dry gas pressure in the transformer and the top tank section. If there is any damage or rust, you will be able to repair easily. Tn case the damage is serious, effective treatment can not be made at site. So please inmediately inform the representatives of MELCO about the damage in-detail. The transformer is pressurized at the factory to about 0.2 ke/em? gauge pressure at 25 °C. Fig-1 ‘This pressure changes according to Relationchip between nitrogen the temperature, so refer to the gas pressure and temperature Telations as shown in Fig-1. If the pressure comes down to the atmospheric pressure, air will enter the inside of trensformer. & § | Pressure (kg/cm?) $ E010 2030 20 Fem 0) ‘The checking and controlling of sealed gas pressure is made as follows: * If the sealed gas pressure is positive, the tank is free of leaks. But, if the pressure is close to 0 kg/cm@ or decreasing, add the nitrogen gas immediately and check for leaks. Please contact MELCO if the nitrogen gas escapes in apite of the above ‘treatment. In ease the pressure gets to 0 kg/em?, the insulation material vill absorb moisture. If this occurs, please contact MELCO inmediately with details. 1-2. Measure and record the shock value of the impact recorder before unloading. ‘The value should be less than 36. 1-3. Parts. Check for any shortage of parts by confirming number of packages, parts name and quantity compared to packing list. Check for any damaged packing case or parts. If there are any damages, repair the damaged parts and report any damage to the representatives of MEZCO, 2. After arrival of the transformer to the site, the transformer is stored until the installation is started. ‘he transformer and ite parts should he stored as follows. 2-1. Main body. ‘The transformer tank should be stored dry gas sealed, Check the ary gas (06/29)pressure periodically with pressure gauge and check for any leaks. As for dry gas inspection method, refer to item 1 "inspection" If the transformer is stored for more than 6 months, please contact MELCO. 2-2. Parts 4s some parts are affected by wind and rain, it is necessary to store indoor or to cover with waterproof sheet. Caution symbols for handling are printed on the packing cases. Parts should be stored according te the symbole which are shown in table 1. Package Place the wooden blocks under the-packege to avoid rainwater, as shown in Fig-2. Fig? tana | pontahock | Keep dry Graney point Sing point vod socks rracite | xecrony | TOP UP . ae { eaten oF | sua om re {6666 : ° ws Table 1 Precaution marks (Symbols) Note; Arrange the parts in assembling procedure for more efficient installation. (07/29)34c INSTALLATION OF MAIN BODY ON FOUNDATION SBB-P14002 83-08-29 A This manual applies to the job after arrival of the main body to the site by the trailer. 1, Preparation. I=L. Apply the parking brake perfectly to the trailer. 1-2, When removing the lashing wire ropes, do not hit the main body, valves ete. 2. Unloading from trailer and main body on foundation m 2-2, When using the rollers. (See Fig-1) (1) Support the main body by the jacks or the timber underneath the frames of the trailer. (2) The level of the temporary platform should coincide with the height of the trailer surface. (3) The coefficients of friction when rolling are as follows. (a) Starting...0.15 (b) Moving...0. 10° ‘The pulling capacity should be more than 6 tons. (2x3Tons=6tons.) Use 2 parallel wire ropes with the pulley. Pulley & Wire rope We Roller _ Hook Roller a5 = lf SSE i Winch } S (AGI) Sree L 00 0 ‘Timber Plank’ bes Fig-l Unloading by rollers. Trailer | —Wain body ‘Timber 2-3 In case of greasing on rail. (See Fig-2) nat body sii Fie Rees Pulley & Wire rope = : E— ohfnned i a A is e * Rail ast TT FE sumer Fig-2 Unloading by ratle = (08/29) ;y (1) Support the frame of the trailer by the timber or the jack. (2) The level of temporary platform should coineide with the level of the trailer surface. (3). The coefficients of friction when greasing are as follows. (a) Starting---0.20 ~ 0.30 (0) Moving-=-0.10 ~ 0.15 (4) Two rails should be run in par- allel. The degree of the parallel should be within 3am, (See Fig-3.) 3. Centering. 3-1. Confirm the direction of the installation of the main body on the foundation and decide the pulling method. 3-2, Clean the floor of the founds tion. 3-3, Check the level, foundation cen- ter line, the position of the house etc. The horizontal level should be within 3mm, When over 3mm, adjust the bottom of the main body by using the liners. 3-4, Align up three marks on the main body to the base lines from the reverse side (Fig-4) " 3-5 The centering method is as Fig-5. The clearance should be about Sum. Note : The capacity of the hydraulic Jack should be more than half capacity of the main body weight. (09/29) Difference of these distances should be less than 3 mm Main body ve Fig-3. Rail, Base Line mark |— Foundation base line Fig-4 Centering O) ee [oP ie I-y About 5 Roller Fig-5 Centering34ic OIL RECEIVING AND FILTERING SBB-P15001 82-12-28 The quality of insulating of1 should be checked before replacing the nitrogen gas with oil in the transformer. 1, Measure the breakdown voltage of the oil from all the drums or tank lorries. If from the drums, a composite sample should be made from 5 different ofl druns. Note; The sample should be taken from the bottom of all drums, the method 4s shown in Fig-1. O11 sampling Sampling eu} a = JFL os. If the breakdown voltage of ofl is above 30kV/2,5mm gop (stendard "JIS"), store the o11 in the storage tank through the esl NG filter as shown in Fig-2. Lf the breakdown voltage of ofl is unsatisfactory, treat the oil by the oil treatment equipment and after confirming that the breakdown voltage of oil is satisfactory, my then store the oil in the storage tank. = 3. O11 treatment should be avoided on a rainy day. ‘he the insulating of1 4s inflammable, the fire extinguishers mist be kept ready. Fig-2 Oi] receiving i ‘ip release plug Ly Storage Ean 3 Filter Ss press Drums 6 a = I Note; For further information, refer to 1B-66297 "MITSUBISRI TRANSFORMER INSULATION OIL", (10/29)3a1c REPLACING DRY GAS WITH OIL SBB-P 16003 83-06-21 After installing the transformer on the foundation, the dry gas in the tank should be replaced with treated oil after confirming that the breakdown voltage of the stored oil is above 40 KV/2.5 mm gap. (Standard "JIS") 1. Preparation. 1-1, Make sure hose and pipe interiors are cleaned in advance. 1-2. Connect the ofl pipes to the lover filter valve as shown in Fig-1. 1-3. Attach a transparent vinyl hose for oil level gauge as shown in Fig-1. tol, sAbtach the valve to the top of main body as shown in Fig-1. Dry gas release valve preseure Bat “3, | ‘transparent Va ievet gauge) 012 storage tank ‘op end of insulating washer Filter press Fig-l Replacement of dry gas with oil 2. O11 filling. 2-1, Open the filter valve at the top of the tank for releasing the dry gas ‘and open the lower filter valve for oil filling. 2 . At this time, the oil storage tank air release plug should be opened. 2-3, The oil should be filled in up to above the top of insulation washer in ‘the transformer leaving a small space for gas above. ‘The of1 level of the tank is monitored by the oil level gauge attached to above iten "1-3". If the filter press ceases working due to electric failure, etc, close the upper filter valve immediately, as it ie possible that the air will get into the transformer tank. 2-4, After replacing, seal the dry gas on the oil surface with a pressure of 0.1 - 0.2 kg/em2. Maintain this condition for more than 48 hours, 2-5. Remove the dry gas release valve from the top of main body as shown in Pig-1. (yea)aac PRECAUTIONS OF OIL PIPING ‘SBB-P21001 83-01-06 This manual applies to the ofl piping of " ATTACHING COOLER EQUIPMENT" and "ATTACHING CONSERVATOR AND PRESSURE RELIEF VENT" I 1, Remove the blind cover of the pipes — ‘and clean the surface of the flange and the gasket grooves with a clean S and dry cloth. a Do not use water. Make sure that there are no other 2 things, dirt and silicagel in the dpe. sh Gasket ooove Fig-l Setting of gasket 2. After cleaning, apply varnish to the gasket groove on the flange as shown in Fig-1 and set the gasket in the groove. : dip D ‘dentea number mtching number] 3. The pipes should be attached align- ing to the fitting mark and matching identical numbers as shown in Fig-2. relies 4. Tighten the bolts gradually and q ‘indformly as shown in fig-3. ail ip | Aina me 5. Make ure that the gasket does Fig-2 Connection of pipes not slip from the groove and is not damaged when tightening. 6, When the jobs cannot be completed at. one time, the open portions should be covered by the blind covers because ofl leakage can not be stopped per- fectly by closing of the radsator valve. Mumbers in tightening order } (2/29) * Fig-3 Tightening of bolts3uic ATTACHING BUSHING ADAPTOR SBB-P20002 83-07-074 1, Preparation. Isl. Remove the blind cover on the flange of the main body and clean the flange surface with dry and clean cloth. (See Fig-1) 1-2. Confirm that the insulating washers are immersed in the inoulat~ ing oil. 1-3, Cover the flange of the main body with clean sheet as shown in Fig-l. 2. Attaching. 2-1, Remove the bottom side blind cover of the bushing adaptor and clean the inside surface and flange surface of it after lifting up with mobile crane. 2-2, Apply varnish to the gasket and set the gasket on the flange surface of the main body. 2-3. Lower the bushing adaptor gradu- ally onto the flange of the main body by mobile crane. \At this time, it is important to confirm the matching numbers and fitting marke are aligned as shown in Fig-2. 2-4, Set the bushing adaptor to the flange of the main body by bolts. (13/29) Clean sheet Flange of Pig-1. Covering Fig-2. Aligning marksahic ‘SBB-P22008 ATTACHING RADIATOR EQUIPMENT 8h-Oh-19A, Preparation. i-1, Remove the blind iron pletes from the headers and connecting tubes. And before sttaching clean the inside of the headers and connecting tubes. 1-2. Remove the blind iron plates for the transportation from the connecting portions of the main body, and cover with clean sheets to protect from Gust and other particles from entering the inside of the transformer. 1-3. Remove the blind iron plate and the moisture proof silicagel from the radiator. (The moisture proof silicagel is attached the blind iron plate). Assembly. 2-1. Attach the lover supporters to the main body. See Fig-1. 2-2. Attach the lower headers to the lower connecting portions of the main body fand the lover supporters. See Fig-1. Lower header 2-3. Attach the upper supporters to the main body. Attach the upper connecting ‘tubes to the upper connecting portions of the min body. See Fig-2. Attach the upper headers to the upper connecting tubes and upper supporters. See Fig-2. - Fig-1, Attaching lower header. Upper header, Connecting pipe Support Fig-2. Attaching upper header. (14/29)2-5. Lift up the radiators carefully as shown in Fig-3 and Fig-» sand attach the radiators. Note: When attaching the radiators with fans, check the attaching position according to the outline drawing. Fig-3. Lifting up l Sa Fig-l. Attaching radiator equipment (15/29)341d ATTACHING CONSERVATOR AKD PRESSURE RELIEF DEVICE ‘SBB-P2304 83-08-25, 1. Attaching conservator. 1-1. Assemble end attach the oil level gauge to the conservator for the transformer. 0 ring Leek nut (1) Connect the float, the arm and the oil level gauge vith the lock nuts as shown in Fig-1. (2) After confirming the alarm contact operation, attach the oil level gauge to the conservator. Fig-l 0f1 level gauge 1-2. Attach the valves to the conservator = oe 2 according to the drawing of trans- former outline. Pressure relief device Lift up end attach the conservator to the main body with a mobile crane. The bolts should be tightened slightly. Blind iron plate << Gsket essure relief vent 2. Attaching pressure relief device. - oe H.V. Bushing adsptor 2-1, Assemble the blind iron plate against pressure, and pressure relief device of pressure relief vent as shom in Fig-2. 2-2, The pressure relief vents assembled Wig-2) Preneurs:relset dsiice: per item 2-1 above should be attached ‘to the main body using the mobile crane according to the draving. Conservator 3. Attaching connecting tube and protec~ tive reley. (Rlefer to drawing of transformer outline and Fig-3.) Buchholz's relay 3-1, Before attaching the Buchholz's relay, the oil filled inside the Buchholz's relay should be drawn out and then the elarm contacts #1 and #2 should be checked in the horizontal position. 3-2. Attach the connecting tube and the Buchhol2's relay to the main body. Fig-3. Buchholz's relay (16/29)3-3, Attach the comecting tubes to the conservator, These connecting tubes are between the Buchholz's relay and the conservator. 3k, Mighten perfectly the bolts of conservator. (See above item 1-3.) The fitting holes of the Buchholn's relay should coincide vith the holes of ‘the connect.ing tubes on the conservator. 3-5. Connect the Buchholz's relay and the connecting tubes from the conservator. (17/29)3a1D ATTACHING BUSHING SBB~P24004 83-10-05, As the bushing is made of porcelain, care should be taken when handling. aL ‘There are many lifting methods of bushing depending on different lengths oe apeporeinn oft secon van 5S P = Thread of ae female screw 1, General caution. Fig-l Cleaning I-1. Lay out the mobile cranes and the bushings so that the bushings can be easily attached. Upper terminal 7 Newer Wire 1-2. Unpack the bushing package on the assembling floor. 1-3. Before attaching, clean the vise porcelain surface on of] innersed eee side with a clean and dry cloth is acai or with solvent. ‘The thread of fenale screw of the attaching po rtion of the lover terminal should’ be cleaned after removal of the Fig-2 lover terminal as shown in Fig-1. Measurement insulation resistance 1-4. After cleaning, measure the in Sulation resistance of the bushing and uake sure the insulation re~ sistance is more than 1000 Meg ohm ‘Bushing flange by 1000 V Megger as shown in Fig-2. Clean sheet ‘2 1-5. After removal of the blind cover, clean the bushing flange String with clean cloth just before at— tachment of bushing. Cover with clean sheet as shown in Fig-3. Fig-3 Covering 1-6. When the bushing is attached aslant, make sure of the direction Ll of the bushing oil level gauge according to the outline draving before lifting up. Bashing Nets Avice! thal Gusting) 4a) 1ifced ey, flange pesclel ryetohveeaies ache bushing flange. Apply varnish co the B.c.m RSE groove’ owe the;tlenge” aad (Binhing fet the gaster in the groora, ren % i Transformer) ‘Bushing 1-8, The bushing is lovered gradual~ ly. Take care not to hit the Lower porcelain lower porcelain tube against the ‘tube bushing flange and B.C.T. (See Fig-4) Fig-4 Inserting bushing (18/29), 1-9, After the lower porcelain is Protector 2. How to Lift up RVL bushing. cq 2-1. Connect the bushing with the - wire rope from the mobile crane — and the guide rope as shown in Fig-5 Guide rope Fig-5 & Fig-6. Crane Upper porcelain ‘tube crane Guide rope Main wire rope poe de Guide rope Protector Shackle [al ‘Timber ‘Timber porcelain tube Fig-6 How to 1i£t up HVL bushing 2-2, Take out the lover terminal as shown in Fig-l end rest on a piece of timber as shown in Fig-6. 2-3. Raise the bushing up gradually keeping the bottom of the bushing on the timber. 2-4, After lifting up the bushing about 1M in height, attach the lover terminal. (Above item 2-2) (The LV bushings are already attached in factory) (19/29)3418: ATTACHING ACCESSORIES ‘SBB-P26005 85-03-06, 1, Thermal relay. (gor ofl and H.V winding) Note : As the conduit and conduit protecting flexible tube of the thermal relay is broken easily, the therual relay should be handled carefully. While welding works are carried out near the thermal relay, cover it with asbestos sheet to protect from sparks. 1-1, After attachment of the instrument co- ‘mpartuent of the relay on the floor, bring the heat sensitive element up on the main body through the attachment route of the conduit. 1-2, After attachment of the protective casing of the heat sensitive element, f111 at with insulating oil and then attach the heat sensitive element. (See Pig-1) 1-3, Fix the conduit and conduit protecting tube with cushion and supporter(See Fig-2) go as not to damage them with radical bending and pulling. 2, Dehydrating breather. 2-1, Remove the cap on the top of the dehydrating chamber of the breather and fill che chamber with silicagel. 2-2, After attachment of the dehydrating breather, the copper tube should be co nnected between the top of the breather and the conservator. The copper tube should be annealed and bent. (The model is made by 5 mm diameter iron bar, the copper tube should be bent to coincide with the iron bar.) Never spoil the copper tube when bending it and the connecting portion should be welded air tight, (See Fig-3) 2-3. Fix the copper tube with supporter. (See Fig-2) 2-4. Remove the oil pot of the bottom of the breather and £11] with insulating oi] to the level mark. (20/29) —> Indicating section Conduit and conduit protectin, Meziefe ibe 4 p—1] --transforner [Heat sensitive KR elenent Protective caging Insulating oi1 Fig-1 Heat sensitive element Conduit. and aj gondust protecting cushion ‘tube Supporter Main body Copper tube ‘Supporter Fig-2 Supporter Gas weldis portion (coop) Fig-3 Copper tube.ey Se 3-1, Attach the insulating supporter of the earthing conductor. i [PSweutren bushing 3-2. Attach and connect the conductor to the == | f= insulating supporters and neutral bushing Main body terminal. | 3-3. While electrical test of transformer is \ carried out, this connection should be \ ee Fenoved at neutral bushing position. neulat ing BP zl ‘supporter 4. Pressure relief device. Fig-4 Earthing conductor Attach all the pressure relief devices on their positions with gaskets and bolts. = 5. Other accessories. ; Attach the following accessories according to the OUTLINE DRAWING. (1) artnguake protective device. (2) ladder vith barrier and padlocking. (3) Cooler control cabinet. (4) Core grounding connecting box. (5) Nene plate. (21/29)3u1e INTERNAL LEADS CONNECTION ‘SBB-P28001 83-1-24 1, Preparation. I+1. During :the internal leads con- nection, the insulation materials are exposed to the open air. There- fore it is essential to do this work on a fine day. 1-2. Provide a cover of tarpaulin or waterproof sheet to protect from a sudden weather change. 1-3. Never allow anyone to enter the transformer tank unless an analysis of the air in the tank shows at Least 18oxygen. 1-4. The oil level is lowered until the upper surface of insulation, 1-5. Mame and quantity of tools used internal leads connections should be recorded before starting the work and checked after the work as shown in Fig-l. 1-6. All tools must be accounted for. The tools should be attached to lines made from clean cotton tape 80 that they can not be lost. (See Fig-2) 7. Clothes and shoes should be clean and oll-proof. Before entering the tank, brush work clothes off and eupty all pockets. 1-8. A lamp with a safety cover as shown in Fig-3 should be used for internal jobs. 1-9, Glean around the manhole before entering the tank. 1-10. A Second person--shoula be stationed outside the manhole in order to com~ municate with the worker in the tank. I-11. All the top sides of coils should be covered completely with a clean cotton or vinyl sheet as shovn in Fig-4 so that foreign matter never enters the coils, (22/29) Fig-4 Leads connectionInterns) leads connection. 2-1. Connect the line lead to the lower terminal of the bushing as shown in Figs5. Lead Fig-5 Leads connection = _ (1). Pass the line lead through the shield. (2)! Attach the lead to the bushing terminal. G); Attach the shield. 5 (23/29)341e WIRING FOR CONTROL SBB-P29001 27-10-82 Attaching armored cable. 1-1, The armored cable is guided with the support from the terminal box to each cooling and protective device ac- cording to the wiring diagram and the drawing. 1-2, After measuring the length of the wire for the each device on the trans— former and confirming the details of the each wires by the drawing, cut the armored cables to about one (1) meter longer. 1-3, Attach the armored cable terminal, marks as shown in Fig-l. 1-4, Attach the armored cables from the side of the terminal box to leach of the devices. 1-5. The armored cables should be pro~ tected by protector at the supporting portion as shown in Fig-2. 2. Wiring. 2-1, Ground the metal sheath at ‘the terminal box as shown in Fig-3 and wrap vinyl tape round the metal sheath. lb Note ; The earthing lead should be soldered to the metal sheath. 2-2. After wiring, check the connection of the wire and measure the insulation resistance of wire. (2h/29) Armored cable Wrap transparent tape ‘Terminal mark Fig-l Terminal marks Supporter Protecter ‘Armored cable Fig-2 Supporting portion Fig-3 Eecting los Ee Barthing of armored cable35310001 ont, pares esr 82-10-09A "The Leakage test is made after attaching the oil pipea, bushings, radiators, conservator, instruments and the pressure relief device. 40 9. 10. Insert the blind iron plate on the oi1 side of the pressure relief device as shown in Fif=1. ‘Take out the dehydrating breather for the main body, and attach the blina iron plate to the flange of the copper tube for the main body.as shovn in Fig-2. Make sure the connected portions are fastened completely. Carefully clean the velded and the con~ nected portions before testing. So ofl leak will be easily aiscernible. FALL the oil to the transformer to mark 6 or 7 on the ofl level gauge through the filter press from the lover filter valve. Apply pressure to the transformer at O.5kg/em? with dry gas as chown in Fig-3. Check the transformer for air leaks with soapy water and oil leake after 2\ hours from the time the pressure was applied. Jot down the gas pressure and the oil. temperature before and after the leakage test. Check the pressure drop. If any leaks are found on the welded portion, repair by welding, and if on ‘the connected portion, tighten more or change the gasket. Repeat the same test again. Remove the pressure after checking of oil leakage and remove the blind iron plate that vas inserted above item 1. And fasten the pressure relief device completely. (25/29) Pressure relict =. device SW Blind iron plate Gasket. Fig - 1, Blind iron plate Connecting copper tube Gasket _ \_Blind iron plate Fig - 2. Blind iron platePressure gauge —~ Witrogen gas Filter press 041 storage re ae ‘tank nwt] Fig - 3. Oi1 leakage test » (26/29)3uiT OIL FILLING UNDER VACUUM SEB-P31031 85-04-10 1, Preparation. 1 Arrange all required egiupnent such es the oil treatment equipment, oil storage tank, oil filter, vacuum pump, vacuum gauge, vacuum hose and oil hose as shova in Fig-1, The connections from the transformer to the vacuum pump should be short and large in diameter as possible. 4-2. Check the oil for the vacuum pumps of the oil treatment equipment: and ‘the vacuum pump set. (1) 082 level of the vacuum pump. (2) No weter in the vacuum pump. 1-3, Make @ trial operation of the oil treatment equipment and vacuum pump set in advance. 2, Evacuate. 2-1, Byacuate the transformer after the valve "Vi", "V5", "V6" and "V7" are opened. 2-2. Evacuate the transformer until a vacuum pressure of 1 (one) torr or less is reached and stop the vacuum pump for at least 30 iin after closing the valve "V7" to check for vacuum leakage. After checking, evacuate the transformer after opening the valve "V7" further for ! hours. - 3. 0i1 filling. 3-1. Open the valve "V1" and "v2", and circulate the oil in the oil treatment equipment until the oil temperature reaches 40 °c. 3-2. Fill the oil into the transformer after opening the valve ‘mark 8 on the oil level gauge is reached, 3" until the 3-3. The evacuation should be continued further for 1 (one) hour after finishing the of filling. 3-4, Break vacuum with dry gas. 3-5. Take out the blind iron plate that was attached above item 2 Oil leakage test, and reattach the dehydrating breather. 3-6. Let the transformer sit for over 2k hours after vacuum breaking and adjust the ofl level referring to the oil temperature - oil level curves. (27/29)O41 storage ‘tank Vacuum gauge 081 treatment equipment, vi [vacuum punp v3 9. Fig - 1. 0i1 filling under vacuum (26/29)Ls 341F TEST AND GENERAL ‘$BB-P33001 82-10-18 1, Electrical test. A nunber of tests can be used to deter- mine the condition of the transforner. The most typical teste are as follows. I-L, Insulation resistance. The inulation resistance of each winding to ground and the other wind- ings are measured by the megger above o00v. As the insulation resistance changes according to the temperature and hu- nidity, it is necessary to neasure ‘and jot down the oil temperature at that time, (Refer to Fig-l ) 1-2. Winding ratio test. ‘As. for winding ratio test, there are three measuring methods: A volt meter, a ratio tester and a resistance poten- tometer. ‘The measuring method using the volt- meters is shown in Fig-2. 1-3. Polarity, phase relationship test. A low, three-phase voltage is applied to the leads A, B and C as shown in Fig-3. With lead A and a connected together, measure voltage between C and b, C and c, Band b, B and c. ‘Be sure that the relation of measured voltages is as follows. B-b=C-b=C-c ral oiLimmersed transformers being subjected to abnormal compression due to mechanical load besides the. gasket clamping force, it is necessary 10 control the force of compression Le LI tale G Litt : Conk aber Mixture of cork and rubber Fig, 1 Compan of detector by eampresin The 1 Gate Mavi nese ee Gok] bemiy | Hares | demle |__Comprenion eS be ween si] a/omt | stores | alent | Raio | (Ee j Fr sin a Reale ai ea eee as Conkprene " .~0.70| sinto | Abo 29] neo | a0 vate ‘For mineral oll. eal neta rw pa =| = [mee [eee] ae | ae sTC 4290 easeagainst the gasket (by adopting a semi-confined gasket with a slot in the flange). In this case, cikproof synthetic rubber (nitrile rubber) hhaving large restitution is generally used, Table 1 shows the properties of these gasket materials. In actual use of above cork- rene, synthetic rubber (nitrile rubber) for gaskets, adhesive varnish is applied to both surfaces of the gasket to make the sealing more complete. GASKET FITTING STRUCTURES Fig. 2A and Fig. 2B show Mitsubishi standard gasket fitting structures, Fig, 2A shows a structure to clamp flange through a corkprene gasket. (flat flanges) Although this structure unsuitable to high-pressure units and to places of large loads, in view of the clamping, pressure limit, the pressure working on the gas- kket due to the internal pressure shown in Fig.2A and also of the load on the flange surface, Preteens! Pressure to Bange surlace fu 2 rm ap fo it is suitable for places with a low internal pressure and with not much load imposed. On the other hand, the gasket shown in Fig, 2B is of a structure with flange surfaces designed in mutual contact (called confined type), suited to synthetic rubber (nitrile rubber) which has large restitution, and this structure can provide higher flange clam- ping pressure while keeping the gasket clamping. pressure uniform and constant, At the same time, it is a better structure against pressure to the gasket and the flange surface. When excessive pressure is given between the flanges, this structure can restricts compressive power to be added to the gasket, This is because the fatigue limit of the gasket is maintained by the “gasket stop”, due to the mutual contact of flange surfaces, and gasket properties are indefinitely preserved ‘The gasket is inserted into a gasket slot having a depth and width determined accord- ing to relations shown in Table 2 and normally clamped under a constant pressure. For adop- tion of structure Fig. 2A, the dimension X and the dimention Y in the figure should be set at least three times and twice the thickness of the gasket before clamping, respectively. be i paket slot Gasket thickness Gasket Material —- (Nile suber) Gasket width ‘Synthetic rubber] | Stor widths | 1.58 Soo | St de 28 3. FORMS OF GASKETS Forms of gaskets to be used for trasfor- mers are as shown in Fig. 3. sTc4290 SoBeGa (3B) Note: 3A, Bw wsaUsed for @anhole, on-losd MAKING AND FITTING OF GASKETS 4.1 Marking of Gaskets Gaskets to be used as standard items are manufactured chiefly by punching out of large strips, producing uniform products in large quantities and with fine qualities. As for special ones, if they can be taken from large strips, they are manufactured by cutiing thereform with cutting tools. For a gasket which cannot be taken from a single large corkprene strip, such as that for clamping the tank cover, an actual-size pa- tiem of the gasket is prepared, and, using this Paper pattern, several segments of the gasket are cut out. These gasket segments should be connected according to the procedure shown “in the following Item, 4.2, In cutting the gasket segments, it is necessary to cut them 50 mm longer than the required dimension for the connection. 4.2. Connection of Gaskets In making @ very large gasket such as that for a tank cover, it is necessary to connect \sed for manhole, bushing, valve, connection lange, raditor, radiator valve et sp changer cover of gates ‘materials with joints, since the materials are limited in size. Each joint is cut with a knife to provide a gradient of $0 mm as shown in Fig, 4, and filed so as to make an even and proper gradient and as precise as possible before adhesive material is applied. If the gasket has bolt or other piercing holes, the joints should be kept from these holes as far as possible. thermore, the joints should be kept, at least 390 mm away from the maximum curve A or from the angle B as shown in Fig. 4. In case two gaskets are to be used, one over the other, the joints should not be overlapped but they should be kept apart at least 150 mm. 4.3. Fitting of Gaskets a, Care is needed to keep the gasket surface clean from oil, grease, and other foreign materials. b. The surface to be fitted with a gasket should be cleaned with rags or similar stuff s0 as not to leave oil and other foreign ma Fur terials on it. ¢. Both sides of the gasket should be applied with the adhesive material, and the gasket a Cy = STC 4290 21should be fitted several minutes later 4. Clamping bolts are to be tightened evenly around the circumference. For those without gasket stops, the tightening should be made {ill the gasket thickness is reduced to about 3/5. (e.g. gasket thickness of 9 mm is about 6 mm, Gasket thickness of 6 mo is about 4 mm.) ©. For the storing of gaskets, care is needed not to damage the surface (especially the tapering portion), and not to let oil or other foreign materials stick, Further, anything heavy should not be placed on the gaskets 5. LEAKAGE TEST AFTER FITTING OF GASKETS For those fitted with gaskets and made cil tight and air-tight, a test for leakage should be done after assembly. This test is to be made by filling the oil to the prescribed oil level of the trasformer, and by increasing the nitrogen gas pressure over the oil surface. (For details, please refer to Transformer Installing Instructions.) Afer applying the pressure for the pres- cribed time, connections above the oil surface should be tested with lather for leakage of nitrogen ; connections below the oil surface should be checked for an oil leak, If the test reveals any leakege of nitrogen or any lleakage of oil, the faulty parts should be repaired before conducting the same test again 6. ORDERING INSTRUCTIONS a, Sizes of large corkprene strips in stock are shown in Table 3. In ordering large strips, please specify the manufacture num- ber and ratings of your transformer and the kind, number and fitting place of gaskets required b, For any gasket ordered, requied dimensions will be cut from the abovementioned large strips for supply. ¢. Synthetic (Nitrile) rubbers will not be supplied in the form of a large strip, but they. will be supplied in the required di- mensions only. So, please specify the kind, number and the fitting place of gaskets required. Table 3. Sizes of Large Corkprene Strips Thickness (om) Width Length Gam) ‘ | sm x sw ’ | ooo x aaH0 STC 4290 =22APPENDIX WV 041 sampling method ‘When insulating oil is tested, sampling is important. Characteristic of insulating ofl is in- fluenced by a small amount of impurities, and therefore @ perticular attentiou must be paid to sampling 60 that measurement shows correct results, 1. Quantity of sample ‘The following minimum quantities are recom: mended For dielectric breakdown voltage test 2 liters For tests other than above 300 ml Note: For dielectric tests and crackle test, itis essential that the sample be taken from the Lottom of the containes (transformers, drums). One sample may be taken from each drum, or if desired, a composite sample may be made from oil of five drums, provided all of the drums are airtight. When the bung is first loosened, a hissing sound should be heard. If the test of the composite sample is not satisiactory, a sample from each of the drums represented should be tested ‘When drums have been stored exposing to the weather, a sample from each drum shall be tested, ‘The sample of oil should be examined for free water, and if any is noted, the drum of oil should be put through a filter and resampled for dielectric tests, At the sample is being taken from a storing tank, and water appears, follow the same proce: dure. 2, Sample-container For containing oilsample, a transparent or brown color glass botile is used. ‘The transparent bottle is convenient for finding stain of material for solid material. If there is not any suitable containes available, an empty can be used for substitute. Also the sample container which can be shut tight is suitable except the one to be tested. immediately after oils are sampled. In this case if natural rubber tap and others which disolve in oil are used, sulphide may get in and correct judgement cannot bé made, An air-tight bottle is suitable for carrying for a long distance. Prior to sampling oil the container must be thoroughly washed. It is ideal that the container is washed with benzine or dry lead-free gasoline, and then washed again in order of soap solution, water and distilled water and dried. Drying is preferable to heat at 105°C for 2 hours, and cool by flowing. gently with a stream of filtered air. When a dielectric strength test is given, it is sufficieit that the container is washed clean, wiped off, dried and washed again with new oil 3. Sampling oil from drums (1) Sampling tube, When oils for test are sampled from a drum, a sampling tube is need. It is as shown in Fig. 1 and is described ASTM So designed that the sample is taken from within 3mm off the bottom of the drum, and having a capa- city of at least 1/2 liter. A clear glass tube is recommended so that dirt on the tube or contamination in the oil can readily be seen. It shall be of thick glass with the lower end ground slightly oblique, and long enough to reach the bottom of the drum, A convenient internal diameter is about 25mm. The use of a metal tube is permissible; it shall be of stainless stee] or nonferrous metal, preferably plated sheet metal tube fitted at each end with an ‘open cone-shaped cap, and with three legs ‘One form consists of @ STC 4290 =eequally ‘spaced and the lower end to hold the ‘opening 3mm from the bottom of the drum. Unless the sampling tube is available a glass cor vinyl pipe can be utilized. However rubber pipe and others which disolve in oil must not be used under any circumstance. Fig. 1 Samp ‘Dimensions in mi (2) Procedure ‘The samplecontainer and sampling tube must be washed before they are used. All dust inside and outside the sampling tube must be cleaned and washed with benzine. Also the surface and inside are washed well. The drum is placed with its bung up and the cap is cleaned thoroughly so that dust dose not get in the drum. If detection of water, rust, for other insoluble contaminants is desired, let the drum remain in this position long enough to permit the contaminants to settle. Remove the bung and place it beside the bung hole with the oily side up. Close the upper end ofthe clean dry sampling tube with the thumb, and lower the tube into the liquid for ‘a depth of about 30cm. Remove the thumb, allowing liquid to flow into the tube, ~ Again close the upper end with the thumb and withdrow the tube, Rinse the tube with liquid by holding it nearly horizontal and turning it so that the liquid comes in contact ‘with that part of the inside surface which will be immersed when the sample is. taken, Avoid handling any part of the tube which will be immersed in the liquid during. the sampling operation, Discard the rinsing li- ‘quid and allow the tubeth drain tube into the liyuid again, holding the thumb against the upper end, When the tube rea ches the botiom, remove the thumb and allow the tube to fil desired insert the tube with the upper end ‘open. Replace the thumb, withdrow the tube quickly, and transfer the contents to the sample-container. Do not allow the hands to come in contact with any part of the sample. close the sample-container, leaving & small air space, replace”and tighten the bung in the drum, Insert the If an alldevels sample is 4. Sampling oil from transformer ‘When oils for testis sampled from transformers the above mentioned sampling tube can not be used. However oil checking valve for oil testing is usually attached to the transformer. If the valve is small in size oil fiter valve can substitute. First of all a glass container and a large mesh cylinder are prepared for sampling, Before they are used they should be thoroughly washed and dried In order to receive spilt oil a metal bowl, bucket and other suitable containers are placed The outlet of metal- lic valve of oil checking valve is wiped clean so Then the oil checking valve is opened a little and the outlet of the valve is opened a little and the outlet of the valve is discharged. Oil is then taken out from the oil checking valve and the sampling tube is washed under the oil checking valve. that cust does not mix in. clean. This method is repeated two or three time and oil is then thrown away. 2 sTc 4290 oe‘Then cil is discharged in order to get rid of cil in the oil checking valve and the pipe leading Approximately 2 or 3 liters (10 liters are desirable) of oil must be taken out. After the oil in the pipe is cleaned out oil is poured into the oil testing container to the valve, The oil valve is then closed and oil is moved into a prepared oil The container is sealed and This ‘method must be carefully done so that dust does testing. container. the content is ready for use as oil sample. not get in, Ina certain occasion water may stay in the bottom part of the transformer and it may come out first. In that case oil must be taken after water is completely discharged. 5. General cautions on sampling In order to obtain proper oil sample at the time of sampling it is necessary that dust and moisture do not mix in the oil sample from out side. If impurities get in the drum at the ime of sampling oil may be degenerated. Also the cil sample must be made quickly so that water does not get in the can, When oil is sampled from a number of drums, each sampling tubes are ne led, then efficient sampling will be made Sampling will be safely made in # good weather condition and it should be avoided on a rainy day When temperature of the oil-sample is lower than that for relative humidity is more than 80%, ‘of atomospherie or when the oil-sample is moved from low atomospheric temperature to high room. temperature, moisture condensate on the surface and superficial electristic becomes less. Conse. quently il sampling should not be made on such. fan occasion oF oil must he warmed up before it is sampled. Oil sampling from transformer should not be made while itis operating and oil should be taken out while the oil temperature is still high Sampling quantity of the oilsample depends on the kind of immediately after operation ceases measurement. However approximately 23 liters should be sufficient and container, sampling tube and others must be large enough, ‘The oil sample is go small in quantity that its characteristic is often changed by external cause if ts late for «ong period of time without proper care and correct judgement of the oil may be impossible soon as possible. any reason for slong. period of time the container ‘Therefore testing must be made as When it can not be tested for ‘must be sealed and placed in a dark room. sTC 4290 ake