Power Transformer Assembly PROCEDURE
Power Transformer Assembly PROCEDURE
VERSION: TO
min iDiD PAGES 11
This procedure is applicable for assembly work on power transformers greater than
60kV.
2. OBJECTIVE:
This procedure aims to describe and responsibilities for the reception, installation
and assembly of power transformers, transported filled or partially with nitrogen,
applying controls in the development of all activities, controlling risks and
preventing accidents. Protecting the equipment found in the work area and
preserving the area and the environment.
3. SCOPE:
This procedure has been designed to help improve the quality and safety of work
in the reception and installation of transformers.
These instructions are not intended to cover all accessories and variations of the
equipment, or foresee any possible contingency that may
arise during your
installation, operation and maintenance.
4. RESPONSIBILITIES:
5. RESOURCES :
5.1 STAFF
To carry out this type of work, qualified and expert personnel must be employed,
which is why the following personnel must be available:
• 1 Field supervisor.
• 1 Security supervisor.
• 1 Qualified technician.
• 4 Qualified operators.
The equipment, tools and consumable materials described below are the
minimum required for the activity of this procedure:
EQUIPMENT:
-Spinterometer.
-Tensiometer (only when Regeneration processes are being carried out).
-Truck crane
TOOLS:
-Telescopic ladder
-Nipples and couplings
-Electrical extensions
-Torquimeter.
-Basic mechanical tool kit.
-Slings
6. SECURITY MEASURES:
a) The OHS plans and coordinates the security requirements for the entry of
personnel to carry out any operational work at the client's facilities, such as induction
talk, environmental talk, medical examination, etc.
b) The Service Supervisor, advised by OHS, prepares the AST Workplace Safety
Analysis in the ABB format. If the client has another format that has the same
function as this one, then this will be done in the client's format.
c) The Service Supervisor verifies that the personnel has all their safety equipment
according to the activity to be carried out.
d) The Service Supervisor inspects all the tools and instruments involved in the
work.
e) The Service Supervisor inspects, before use, the harnesses for work at height.
The OHS verifies this activity.
f) The Service Supervisor inspects the ladders to be used, whether from ABB or the
Customer, using the ABB format. The OHS verifies this activity.
g) The Operator marks the work area with meshes, to alert and prevent the client or
person unrelated to the work from suffering an accident by entering the demarcated
area.
h) The Service Supervisor and Operators check the proper functioning of electrical,
mechanical, etc. equipment. to use in each process.
i) The Service Supervisor verifies energized areas and draws safety distances to
avoid induction, and identifies energized lines and systems.
j) The Service Supervisor and Operators must ensure that all chemicals to be used
have their MSDS Sheet. It must be ensured that the staff knows the main risks of the
product as well as the safety measures, first aid, emergency, etc.
k) The Service Supervisor and Operators verify that all containers containing any
chemical product are properly labeled and labeled.
l) The Service Supervisor and Operators verify that the customer has made the
power cut, following the following 7 steps (seven steps).
ASSEMBLY OF POWER TRANSFORMERS Page 5 / 20
A Use your senses – vision, hearing, smell – and your common sense – to verify that
the workplace is free of unsafe conditions.
2. Lock all disconnect points. Equipment must be disconnected from all possible power
points and then protected by the Personal Lock Card and padlock, to ensure that it
cannot be accidentally re-energized.
A Failure to lock could cause power backflow to occur and cause an incident.
Protection may be in the form of warning signs posted on /!\ all adjacent panels
that are not being worked, or protective barriers over exposed energized conductors.
5. Perform the Voltage Reveal in the equipment, installation, and system on which you
are going to work.
First test the developer on an element with tension, then check for the absence of
tension in the equipment, installation, system on which you are going to work.
then retest the developer on a live item.
6. Grounding and short circuiting, if the client does it then verify that it has been done
correctly.
A First connect the temporary ground line to the installation ground system, then
attach the temporary ground line to the line to be grounded and shorted.
m) The Service Supervisor and Operators verify that all electrical equipment is
grounded in order to minimize induction since working in energized areas.
n) The Service Supervisor and Operators verify that there is a PQS type fire
extinguisher in the work area to deal with a possible fire.
a) Service Supervisor and Operators ensure that they have adequate containers (in
good condition and properly labeled) for the temporary storage of different types of
waste and subsequently proceed to their final disposal in the waste deposits located
at the client's facilities.
b) If any type of chemical substance is used to clean the equipment to be tested, the
Service Supervisor must have a deposit for hazardous waste.
c) At the end of the work day, the Operator will proceed to clean the area. Under no
circumstances will waste end up in waterways.
d) The Service Supervisor must ensure that they have a containment mechanism for
the potential spill of chemical substances; for this, trays will be used on which the
chemical inputs are placed. If generating sets are used, it is necessary to have trays
to minimize the risk of spilling the fuel used.
7. GENERAL CONSIDERATIONS
Power transformers are transported without insulating oil, with separate accessories and
in some cases in modular sections. To preserve the insulation and prevent the entry of
moisture, during transportation the tank is filled with nitrogen or dry air.
The personnel in charge of receiving the transformer for installation must carry out a
thorough exterior inspection in order to verify that there are no signs of external damage.
The pressure conditions, oxygen content and dew point of nitrogen or dry air will be
reviewed according to the case.
The transformer will be checked internally to verify and/or confirm if it has no damage;
This review will be carried out only in applicable cases and will consist of the following:
Before starting the internal review, precautions will be taken to avoid risks of suffocation
or gas contamination, for which it must be evacuated with a vacuum pump and replaced
with dry air; If the gas pressure is “ZERO” or “NEGATIVE”, and the oxygen content and
dew point are higher than expected, there is a possibility that the transformer insulation
is contaminated with air and moisture from the atmosphere, so It will be necessary to
subject the transformer to a rigorous drying process after assembly.
The transformer should not be opened in circumstances that allow the entry of humidity
(rainy days), it should not be left open for a long time but only for the time strictly
necessary, for which a maximum of two hours is considered sufficient.
To prevent the entry of moisture when opening the transformer, oil will be filled to cover
the coils. The oil must be degassed and dehydrated at a temperature of 30º C, heating
the core or coils to reduce the possibility of moisture condensation. For greater safety of
this preliminary filling, it can be done using the high vacuum method.
Foreign objects must be prevented from falling or remaining inside the transformer; the
tools used must be tied to the tank with cotton straps while they are assembling or
verifying the connections.
Thorough verification of the fastening of the core and coils, as well as possible
displacement.
Verification of the number of core grounds; checking your connection and testing its
resistance to ground.
Review of the lead changers, verifying their contacts and pressure in each position.
Verification of current transformers and bushing terminals, checking their parts and
connections.
The personnel in charge of receiving the transformer for installation must carry out a
thorough exterior inspection in order to verify that there are no signs of external damage.
The pressure conditions, oxygen content and dew point of nitrogen or dry air will be
reviewed according to the case.
The transformer will be checked internally to verify and/or confirm if it has no damage;
This review will be carried out only in applicable cases and will consist of the following:
The service supervisor must request the information from the client or the transformer
manufacturer, depending on the contract (this information includes plans, dimension
sketches, nameplate, terminal box, assembly, etc.)
The service supervisor checks the nitrogen pressure in the transformer tank.
The service supervisor measures the dew point only in cases where the nitrogen
pressure is zero, in order to verify that no moisture has entered the transformer.
If the transformer is equipped with an impact recorder, the service supervisor verifies
and analyzes the record sheet to rule out internal damage due to poor maneuvers during
transportation.
The packaging and the areas where they will be located must be clean. The
radiators must be located according to the plan issued by the factory.
This will always be done in a vertical position and they must be clean and dry
externally and internally. Special precautions will be taken during assembly to
avoid breakage and damage to the porcelain.
The “Cork” gaskets used for mounting accessories and in flat areas (that do not
have stops) must be clean, as well as the housing surfaces; Their assembly will
be done carefully, compressing them evenly to guarantee a perfect seal.
8.3 Transformer oil treatment process
—Extraction of initial oil samples from the transformer, for physicochemical and
chromatographic analysis, which will be called “before service”.
ASSEMBLY OF POWER TRANSFORMERS Page9 / twenty
— Installation and energization of the thermovacuum equipment.
— Check the oil level.
— Check the air dehumidifier (silica gel).
— Place valves on the connections of the inlet and outlet hoses of the
thermovacuum equipment on the transformer as indicated in the following
graph:
PROCESS DIAGRAM FOR VACUUM TERM OF INSULATING OIL IN
— Start oil circulation through the closed circuit. If there are oil leaks at the
connections, correct them before continuing.
— Check the inlet and outlet temperature in the thermovacuum equipment and
pressure in the vacuum chamber.
To eliminate the probable humidity that has been absorbed during the internal
inspection and assembly maneuvers; To carry out the high vacuum, the
conservator tank, radiators, pipes and accessories must be insulated and sealed.
The vacuum must reach a negative pressure, in these conditions it will be
maintained for 12 hours, plus 1 additional hour, for every 8 hours that the
transformer has remained open and exposed to the environment during its
inspection and assembly. The vacuum will be broken by introducing air or dry
nitrogen into the transformer until zero pressure is achieved.
Until the core and winding are covered, if for any reason the process is
interrupted, the transformer must be emptied and filling restarted. The insulating
oil that will be used for the final filling of the transformer must be a previously
dehydrated and degassed oil.
For transformers with nitrogen oil provision systems, filling will continue up to the
level indicated as standard and for conservator tank system as high as possible.
Once the filling of the transformer over the free space is completed, the vacuum
conditions will be maintained for 3 more hours before breaking
the vacuum with dry air or nitrogen, in order to expel to the outside, through the
vacuum pump, the water or gas bubbles caused by the vacuum itself obtained
during filling.
Finally, the oil will be forced to recirculate through the treatment plant for 8
continuous hours, or an equivalent to twice the total volume of the transformer oil;
In order to eliminate residual moisture and loose gases, during this process the oil
pumps will be operated. Upon completion of this operation, the transformer will be
ASSEMBLY OF POWER TRANSFORMERS Page11 / twenty
left at rest for a minimum of 24 hours to carry out tests and verifications.
7.1 Disconnection and connection of the HV and BT bus system, includes removal
of the trunk lid.
—Turn on the equipment and the controller by pressing the equipment switch, then
configure the data required by the controller, series, brand, power of the
transformer to be tested.
—Set the test voltage, check the data, press the two safety switches and perform
the test, the equipment gradually raises the test voltage and automatically
performs the tests at the voltage value set by the person in charge of testing.
—The equipment automatically sends to ground once the safety switches are
deactivated, de-energizing the Transformer.
—Reverse the high and low voltage cables and continue testing on the low voltage
side.
—The standard procedure for Overall tests is summarized in the following table.
CH: Refers to all insulation between HV conductors and grounded parts that include
bushings, winding insulation, structural insulating members and oil.
CHL: Referring to all winding insulation, separators and oil between the high and
low voltage windings.
AC
cg
DC
Co
EC
EC
cg
c
C,
cj
Ck
—— TAP ELECTRODE
° GROUNDED
1 LAYER/F LANGE
GROUNDED
LAYER/F LANGE
For the vast majority of transformers, the measurement pattern is that the
two extreme phases have a greater measurement than the central phase.
Recommended initial tests are with the switch taps to the center tap, the
neutral position and a step in the opposite direction.
ASSEMBLY OF POWER TRANSFORMERS Page15 / twenty
The transformer core may take into account residual magnetism resulting
from previous disconnection of the power supply or as a result of winding
resistance measurements.
Procedure:
— Carry out the tests in accordance with the voltage indicated in the
manufacturer's manual, do not exceed the phase-to-neutral voltage of the
high winding.
— After taking the current and voltage readings, the team will de-energize
the transformer and proceed to change to the next phase; We will
proceed in the same way and move on to the next phase.
— The values will be verified, and the test cables will be collected.
— Using the Omicron CPC 100 primary test module, connect the cables of
said equipment between the terminals on the HV and Neutral side of the
transformer (L) and the secondary terminals (H) of all the CTs, with their
terminals free. in the Terminal boxes, according to their layout and
installation in the transformer.
— Repeat the same procedure for the LV side and its secondary terminals in
the transformer terminal box.
— Record all measured values in the Test Protocols and consider the
polarity of said values according to the sign of the result.
ASSEMBLY OF POWER TRANSFORMERS Page16 / twenty
Connection of the terminals of the coil under test for the winding
resistance.
— Connection of the terminals of the coil under test and the terminals of the
other open coils.
Figure 1.
— Connection of the terminals of the coil under test and the terminals of the
other short-circuited coils.
ASSEMBLY OF POWER TRANSFORMERS Page18 / twenty
Figure No. 2
Figure No. 3
— Test connection criteria for two and three winding power transformers
according to Doble Engineering procedure
A. Two-winding transformer.
- The customer must provide the respective electrical drawings of the grouping box.
- HE mechanically checks the alarm and relay trip
Buchholz, its drive is verified in the grouping box.
- The setting of each AKM, both thermal image and oil, is mechanically checked; its
activation is verified in the grouping box.
- Verification of the safety valve actuation contacts (if applicable).
8.7Tolerances
9. ANNEXES
DATE
NAME
PREPARED BY: Luis Gonzales / Herson
22-12-2011
Parhuana
REVIEWED BY:
APPROVED BY: