Site Training Manual For Power Transformer

POWER TRANSFORMER
SITE TRAINING MANUAL

FOR POWER TR. AND N.E.R.
NAME OF CLIENT : ABU DHABI OIL REFINING COMPANY

PROJECT : GREEN DIESEL PROJECT
ITEM : POWER TRASNFORMER AND N.E.R.
CONTENTS
1. OPERATION GUIDANCE
2. APPROVED VENDOR PRINT
2013917-OWPE
1. OPERATION GUIDANCE
2013917-OWPE
EXTRA HIGH VOLTAGE POWER TRANSFORMER
OPERATION GUIDANCE
Page 1
Contents
1. Introduction of Transformer
2. Transformer Installation Procedure
3. Transformer Protective Device And

Otherwise Device
4. Operation & Maintenance
Page 2
1. Introduction of Transformer
Page 3
Introduction of Transformer
1.1 Location of Transformer  Steam Turbines

Power Plant  Gas Turbine
 Hydropower
 Nuclear
 etc.
Power Transformer(GSU)
Increases voltage for transmission
Transmission
Substation
Reduces voltage
Distribution Substation
Reduces voltage
Page 4
1.2 Transformer Theory
Transformer
Input
from
Load
Power
Line
Input Output
I1 I2 H1
H1 X2 X1
Secondary
Primary
N1 N2
E1~ E2 ~ Load E1 P E2
X1 X2
H2
Magnetic H2
Flux Iron Core
Page 5
1.3 Sort of Transformers
Core-Form
Core-Form Shell-Form
Shell-Form
Page 6
2. Transformer Installation Procedure
Page 7
Transformer Installation Procedure
2.1 Transformer Installation Flow
Receivng
Receivng Inspection
Inspection Site
SiteTest
Test
Preparation
Preparation
Setting Vacuum
Vacuum and
and Oil
Oil Filling
Filling
Setting on
on Foundation
Foundation
under
under vacuum
vacuum
External
External Assembly
Assembly
Coolers,Radiators Internal
Internal Inspection
Inspection
Coolers,Radiators
Conservator And
And Bushing
Bushing Lead
Lead
Conservator
Or Connection
Connection
OrAccessories
Accessories
Page 8
2.2 Reciving Inspection Preparation
· The Impact Recorder Check

Point
- Longitudinal : Under ±3.0G
- Vertical : Under ±3.0G
- Lateral : Under ±3.0G
* G : Acceleration of Gravity
· When Lifting Transformer,

Check Lift Clamp Condition.
· Use The Proper Crane For
Transformer Weight
· Prepare Admission Passage
Page 9
· Insulation Resistance Test

(Megger Test)
① Standard : Oil Temperature-

Insulation Resistance Curve
Page 10
· External Assembly Parts

Condition Check
① Parts Quantity Check

② Check Damaged Parts
Quantity
- Bushings, Radiators
Page 11
2.3 External Assembly

Check
Check Point
Point
• Before Assembly, Compare
Parts with Packing List
• Assembly Conservator, Radiator,
Pipe ,Etc.
• Assembly equally on Drawing
Notice
Notice
• When opening Transformer,
Tank internal Pressure higher
than Air Pressure for Assembly
• When assembling Bushing,
Caution for Damaged Insulator
and Gasket
Page 12
2.4 Internal Inspection

Check
Check Point
Point
• Internal Worker Must Wear
Protective dust Clothes
• Tight again The Bushing Lead
Connection Bolts that
have already tighten from the
plant
Notice
Notice
• Before The Worker enter

the Transformer, Check Oxygen
content 19.5% over
• Keep the Exterior Supporter
• Check Internal/ External
Equipment
Page 13
2.5 Vaccum work

Check
Check Point
Point
• 154kV : Maintain under 1 Torr

for 12 hours
• 345kV : Maintain under 1 Torr
for 24 hours
• When 2 Torr reach, Perform
Pressure Test
Notice
Notice
• Record Vacuum Pressure

once an hour
• Keep Equipment Watcher
Page 14
2.6 Oil Filling under Vacuum

Check
Check Point
Point
• Before filling Oil, Perform

Oil dielectric Breakdown Test
: 50kV Over, Water
under 30ppm
• Circulation Filtering Times:
3th over include filling
Notice
Notice
• Keep Searcher for Fillng Oil
Page 15
2.7 Site Test

Check
Check Point
Point
• Voltage Ratio test

• BCT polarity / Ratio test
• Insulation resistance test
• Function test for all protective
devices
Notice
Notice
Attention electric shock
Page 16
3. Transformer Protective Device
And
Otherwise Device
Page 17
Transformer Protective Device
3.1 Buchholz Relay For Main Tank

A. Function
: Make Alarm & Trip Signal
to Internal Fault
B. Operating Values
a. Alarm
- Gas Volume
: 350cc
b. Trip
- Oil Surge
: 100~150 cm/sec
C. Mounting Position
Main Tank Cover to
Main Conservator
Page 18
3.2 Oil Level Gauge For Main Tank

A. Function
: Make a Alarm Signal
: Check to
Main Tank/OLTC Oil level
B. Operating Value
a. Alarm
- 0 (Zero) Position
b. Compare to Oil Level
and Oil Temp. Curve.
To attached in front
of MK.
Main conservator side
Page 19
3.3 Gas Accumulation Indicator

A. Function
: Make a Alarm Signal
to Internal Fault
B. Operating Value
a. Alarm
- 200 cc
Top of
Main Conservator
Page 20
3.4 Pressure Relief Device For Main Tank

A. Function
: Make a Trip Signal
to Internal Fault
B. Operating Value
a. 10psi ± 10%
b. 0.7kg/㎠ ± 10%
a. Tr Upper Cover : 2ea
b. OLTC Head Cover
: 1ea
Page 21
3.5 OLTC Protective Relay

A. Function
to OLTC Diverter
Switch Fault
B. Operating Value
a. Oil Surge :
1.2m/sec ± 0.2
: OLTC Diverter Switch
Head Cover to OLTC
Conservator
Page 22
3.6 OLTC Motor Drive Unit

A. Function
a. OLTC Operating
b. Step by Step operation
c. Lower and Raise operation
B. Designation
a. Tap position Indicator
- Tap change indicator, counter
b. OLTC Motor protective Switch
c. Oil Filter Unit Operating Switch
for Manual switch
d. Operating for Local or Remote
Position switch
e. Raise/Lower Control Switch
f. Oil Filter Motor protective switch
g. Hand crank
Page 23
3.7 Rapid Pressure Rise Relay

A. Function
to Internal Fault
B. Operating Value
a. Pressure Rate
1.0 ~ 200 psi-sec
b. Various Response
Time Chart
Side On the Main Tank
Page 24
3.8 Oil & Winding Temperature Indicator

A. Function
a. Make Alarm & Trip Signal
to internal fault
b. Fan Motor Operation
B. Operating Values
a. O.T.I
- 90℃ : Alarm
- 95℃ : Trip
b. W.T.I
- 85℃ : Fan Motor
Operating
- 115℃ : Alarm
- 120℃ : Trip
Page 25
Otherwise Device
3.9 Silicagel Breather For Conservator

A. Function
: To Protect the dust
and moisture come into
conservator
B. Mounting Position
End position of
Conservator pipe line
Page 26
Otherwise Device
3.10 Surge Counter with Leakage Current
A. Function
a. Recording the number of discharges
experienced by a Surge Arrester
b. To permit the leakage current

monitoring
B. Mounting Position
Surge Arrester to Ground
Page 27
Otherwise Device
3.11 Radiator with Fan Motor

A. Radiator
a. Highly efficient cooling unit
b. Re-painting or touch-up, to
keep the surface free from
dust .
c. Periodically cleaning by
air or water
B. Fan Motor
a. Rating : 3P 50Hz ac 415V 0.8kW
b. Starting current : 5.6A
c. Running current : 0.95A
d. MCCB set value
= 0.95 × 120% = 1.14A
Page 28
Otherwise Device
3.12 Valves
A. 1 & 2-inch gate vave B. 4-inch Butterfly valve for Radiator
C. 1 & 2-inch gate vave with oil sampling
Page 29
4. Operation & Maintenance
Page 30
Operation & Maintenance
4.1 Necessity of Inspection and maintenance
 Getting larger capacity to meet increasing power demand

 Prevent from emergency or unexpected power outages
 Better efficiency than the others
 Easy to maintain
 Very important instrument in electrical facilities.
 If you do proper maintenance, you can prevent almost fault.
 Kind of Inspection
[Routine inspection] [Periodical inspection] [Additional inspection]
Page 31
4.2 Routine Inspection
Inspect daily on operating transformer

- OTI, WTI, Atmosphere temperature, Oil level, Oil Leak
Maintenance Externally Transformer by visual or hearing

1) Transformer body – Oil temperature, Oil level, Wrong sound, vibration,
Leak oil
2) Cooling device – Cooling fan, Oil pump, Oil flow indicator, valve,
Radiator
3) Breather – Breath Condition
4) Bushing terminal – Leak oil, Over heat, Crack, Stain
5) Pressure relief device (P.R.D) – Leak oil, Destroy the P.R.D Cover
enough attention is prevent Other fault
Page 32
4.2 Routine Inspection

Item Method Action
OTI & WTI Read indications and compare Check indication is correct or not.
Load current, with data.
Atmosphere When temperature are higher, If not, exchange with new one.
Temperature inspect the thermometers.
Be recorded at the same time. If OTI is too high due to dust, clean up them.
Oil Level Read indication. When indication is constant, inspect the dial
Gauge gauge and check the actual oil level.
Oil leaks Check radiator, flanges, pipes, Cause gasket, tighten bolts or exchange them.
tank Cause welded parts, apply adhesive material or
weld again.
Abnormal From fan motors, should be Exchange the bearings with new one.
noise listened. Vibrating due to loose bolt, tighten them.
And vibration Check easily by hand.
Appearance Bolt connection. Tighten them.
Dust. Clean up.
Rust. Re-painting.
Dew. Dry it out.
Page 33
4.3 Periodical Inspection

Item Method Action
Breather Check the discoloration of silica If the color of silica gel has turned pink by
(once every gel due to moisture. more than two thirds, dry out or exchange it.
six months)
Insulating oil Measure oil test, it is more than If measured values are not satisfactory, filtering
dielectric 40kV/2.5mm gap. or degassing
strength
Moisture Measure Karl-Fischer method,

content it is less than 25 ppm.(154kV over
case)
Acid value Measure acid value and judge it
(once every with the standard.
three years)
Fan motor Measure insulation resistance of If insulation resistance is less than 2MΩ, check
(once every fan motors with a 500V megger. balancing of load currents of three phase.
three years)
Page 34
4.3 Periodical Inspection

Item Method Action
Control panel 1) Check the tightness of all Tighten the loose bolt.
and terminal control wiring connections.
box (once
every three 2) Operate all switches. If any part mal-operates, adjust or exchange
years) them.
3) Check any crack on cable If any crack is found, put tape on it or
insulation. exchange it with new one.
Protective 1) Check function and Circuit Power off and Check function.
relays (Oil level 2) Check destroied part If any crack is found, put tape on it or
gauge, Rapid exchange it with new one.
P.R.D,
Buchholtz
Relay etc.)
Insulation Measure insulation resistance of When the insulation resistance is less than 2MΩ,
resistance protective relay with a 500V check dews in the terminal box.
(once every megger.
three years)
Operation Operation tests should be done. The cause of a mal-operation should be
investigated by operation tests.
Page 35
4.4 Additional Inspection

Item Method Action
Insulating oil Analyze every one or two years. When the combustible gases are obtained,
analysis of gas Using an appropriate air-tight evaluations can be made to probable location
dissolved in oil. containers. and type of trouble.
The dissolved gas should be
extracted. If there is an indication of moisture, sludge
formation, low dielectric strength and low
Dielectric Measure Dielectric Breakdown of
resistivity, an inspection should be made on
Breakdown insulating oil when the oil is bed
the inside of the tank.
condition.
Insulation Measure between a pair of The matter is wide variation with temperature,
resistance of windings, humidity and cleanness of bushing porcelains.
winding And ground with a 1000 volt
megger.
The megger test should be made It may be low due to the leakage current
to check if the transformer is in through the weakest point of inferior insulation.
suitable conditions.
Ratio test Measure by voltmeter method or Compare the test results with those in the test
with a ratio tester. report.
The test voltage may be between
100 and 200V at the rated
frequency.
Page 36
4.4 Additional Inspection

Item Method Action
Winding Measure by bridge method or If the winding resistance, corrected to a
resistance drop-of-potential method. specified. Temperature, is different from the
If oil pump are provided, they data obtained previously, more detailed
should be operated. investigation should be made.
The oil temperature should be
also recorded.
Exciting current Measure the exciting current at If the measured exciting current or impedance
at low voltage low voltage(100-200V) voltage is much larger than original data at
The voltage wave shape should installation, recommend inter Inspection.
be sine wave.
Impedance Measure the impedance voltage
voltage at low current(5-10A)
Bushing current Exciting current and winding If the measured exciting current or impedance
transformer resistance should be measured in voltage is much larger than original data at
the same way installation, power off and disassemble bushing,
Perform Independence bushing test again
Page 37
4.5 Maintenance
Material and part Maintenance frequency Remarks
Grease of fan motors Grease them up once a Use grease gun.

year.
Porcelain insulator Cleaning should be done With compressed air or water.
such as bushing, periodically. Interval
lightning arrester, depends on actual
supporting insulator circumstance condition at
site.
Radiator Recommended cleaning
period is once every two
years.
Paint Repainting should be done After cleaning the painted surface.
once every five years.
Bearing of fan motors Expected life is ten years. Exchange with new ones, if a motor becomes
noisy due to broken bearings.
Gasket (cork- Expected life is ten years. Exchange with new gaskets, if oil leaks from
neoprene) for gasket are serious.
temperature indicator
(0il, winding)
Page 38
4.6 Standard for gas dissolved Insulated Oil

Decision ( Caution ) ( Abnormal ) ( Danger )
Voltage
(kV) 154kV 345kV 154kV 345kV 154kV 345kV
Section
H2 400～800 801～1,200
C2H2 25～80 20～60 81～150 61～120 Over 150 Over 120
CO 400～700 350～600 701～1,000 601～800 -
C2H4 300～750 751～1,000 -
CH4 250～750 751～1,000 -
C2H6 250～750 751～1,000 -
T.C.G 1,000～2,500 2,501～4,000 Over 4,000
Over 300/month
Quantity of increasing T.C.G Over 200/month in normal state Over 200/month in caution state
in abnormal state
Follow up survey Follow up survey Internal inspect after

Action
Once every three month Once every one month Stopped movement
If factor is over lowest limit 50% on the standard, applies it.

First maintenance on New transformer
C2H2 gas is never detected.
CO2 Gas
Decision Action Remark
(ppm)
Under
○ No action
5,000
Normal ○ Change the maintenance

1. Down the oil temperature
5,000 - 7,000 CO2 gas analysis is user furious flame of insulation
2. Inspect the Dielectric Breakdown Voltage
paper than internal abnormal state of transfomer.
3. Analysis insulation oil.
○ Inspect furious flame on insulating material

Over 7,000 Caution 1. Insulation oil : Analysis CO2, CO Gas and Furfural
2. Insulation paper : Analysis intensity
Page 39
4.6 Standard for gas dissolved Insulated Oil

Abnormal case Genesis gas
Low ( Over 300℃) C2H6, CH4, C2H4
Heating of
Medium ( 300 - 700℃ ) CH4, C2H4, C2H6
insulation oil
High ( Over 700℃) C2H4, CH4, C2H6
Heating of solid insulation materials

CO, CO2, CH4
( Over 200℃)
ARC on insulation ( Over 1,000℃) C2H2, H2, C2H4, CH4
CORONA on Insulation ( Over 1,000℃) H2, C2H2, C2H4, CH4
Heating of insulation oil and materials CO2, CO
Page 40
2. APPROVED VENDOR PRINT
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POWER TRANSFORMER

SITE TRAINING MANUAL

NAME OF CLIENT : ABU DHABI OIL REFINING COMPANY

2. APPROVED VENDOR PRINT

2. Transformer Installation Procedure

3. Transformer Protective Device And

4. Operation & Maintenance

1.1 Location of Transformer  Steam Turbines

1.2 Transformer Theory

1.3 Sort of Transformers

2.1 Transformer Installation Flow

2.2 Reciving Inspection Preparation

· The Impact Recorder Check

· When Lifting Transformer,

2.2 Reciving Inspection Preparation

· Insulation Resistance Test

① Standard : Oil Temperature-

2.2 Reciving Inspection Preparation

· External Assembly Parts

① Parts Quantity Check

2.3 External Assembly

2.4 Internal Inspection

• Before The Worker enter

2.5 Vaccum work

• 154kV : Maintain under 1 Torr

• Record Vacuum Pressure

2.6 Oil Filling under Vacuum

• Before filling Oil, Perform

2.7 Site Test

• Voltage Ratio test

Attention electric shock

3.1 Buchholz Relay For Main Tank

3.2 Oil Level Gauge For Main Tank

3.3 Gas Accumulation Indicator

3.4 Pressure Relief Device For Main Tank

3.5 OLTC Protective Relay

3.6 OLTC Motor Drive Unit

3.7 Rapid Pressure Rise Relay

3.8 Oil & Winding Temperature Indicator

3.9 Silicagel Breather For Conservator

3.10 Surge Counter with Leakage Current

b. To permit the leakage current

3.11 Radiator with Fan Motor

A. 1 & 2-inch gate vave B. 4-inch Butterfly valve for Radiator

C. 1 & 2-inch gate vave with oil sampling

4.1 Necessity of Inspection and maintenance

 Getting larger capacity to meet increasing power demand

4.2 Routine Inspection

Inspect daily on operating transformer

Maintenance Externally Transformer by visual or hearing

enough attention is prevent Other fault

4.2 Routine Inspection

4.3 Periodical Inspection

Moisture Measure Karl-Fischer method,

4.3 Periodical Inspection

4.4 Additional Inspection

4.4 Additional Inspection

Grease of fan motors Grease them up once a Use grease gun.

4.6 Standard for gas dissolved Insulated Oil

C2H2 25～80 20～60 81～150 61～120 Over 150 Over 120

CO 400～700 350～600 701～1,000 601～800 -

C2H4 300～750 751～1,000 -