Oil-Cooled Transformers Manual 4000 kVA
Oil-Cooled Transformers Manual 4000 kVA
OIL-COOLED TRANSFORMERS
UP TO 4000 kVA
TABLE OF CONTENTS
1. INTRODUCTION ...................................................................................................... 5
2. BASIC INSTRUCTIONS ...........................................................................................6
2.1. GENERAL INTRUCTIONS ......................................................................................... 6
2.2. AS SUPPLIED CONDITION ....................................................................................... 6
2.2.1. Reception Place ................................................................................................................. 6
2.2.2. Inspection upon Receipt ..................................................................................................... 7
2.2.3. Unloading and Handling Procedures .................................................................................. 7
2.2.4. Checking and Testing Procedures upon Receipt ................................................................ 7
2.3. STORAGE .................................................................................................................. 8
3. INSTALLING POWER TRANSFORMERS > 300 kVA ............................................ 9
3.1. GENERAL CONSIDERATIONS .................................................................................. 9
3.2. PLATFORM TYPE TRANSFORMER .......................................................................... 9
3.3. ALTITUDES .............................................................................................................. 10
3.4. CONNECTIONS ....................................................................................................... 12
3.5. TANK GROUNDING ................................................................................................. 12
3.6. PROTECTION AND MANEUVERING EQUIPMENT ................................................. 13
4. ASSEMBLING THE TRANSFORMER................................................................... 14
4.1. RECOMMENDED CARES DURING AND AFTER ASSEMBLY ................................ 14
4.1.1. Thermometer ....................................................................................................................14
4.1.1.1. Application................................................................................................................14
4.1.1.2. Instruction .................................................................................................................15
4.1.2. Pressure Relief Device .....................................................................................................15
4.1.2.1. Membrane type “explosion pipe” ...............................................................................15
4.1.2.2. Valve type pressure relief device ..............................................................................15
4.1.3. Pressure Surge Relay .......................................................................................................17
4.1.3.1. Generalities ..............................................................................................................17
4.1.3.2. Construction and working principle............................................................................18
4.1.3.3. Installation procedure ...............................................................................................19
4.1.4. Expansion Tank ................................................................................................................19
4.1.4.1 Silica gel air dryer: generalities .................................................................................19
4.1.4.2. Construction .............................................................................................................20
4.1.4.3. Drying agent .............................................................................................................20
4.1.4.4. Regeneration of the silica gel ....................................................................................20
4.1.4.5. Procedures for the installation of the air dryer ...........................................................21
4.1.5. Buchholz Type Gas Relay .................................................................................................21
4.1.5.1. Generalities ..............................................................................................................21
This manual is intended to provide the user with all necessary information about
reception, installation and maintenance of distribution and power transformers up to
4000 kVA. Compliance with these instructions will allow for a better performance of the
transformer and will extend its useful life.
All of WEG transformers are designed and built in strict accordance with the last
editions of the Brazilian ABNT and the IEC 60076 standards. Therefore, the information
contained herein remains subject to changes without previous notice.
For further information about the applicable standards, we recommend you to
read the following standards:
NBR 7036 – Reception, installation and maintenance of distribution
transformers submerged in insulating liquid.
NBR 7037 – Reception, installation and maintenance of power transformers
submerged in insulating mineral oil.
NBR 5416 – Applying loads to power transformers.
IEC 60076 – 7 – Loading guide for oil submerged power transformers.
IEC 60076 – 8 – Power transformers – Application guide.
Also very important is to keep in hands all publications about installation of
transformers that are issued by the network power suppliers of your region, since many
of them have a normative character. For further clarifications, call our Technical
Assistance Department.
All transformers are factory tested before shipment in order to assure their
perfect working condition. Depending on the transformer size or on its shipment
conditions, it can be shipped either assembled or disassembled. Further details are
described hereinafter. Upon receipt, we recommend a careful inspection in order to
check the transformer for any damages occurred during the transport. In case damages
have occurred, please notify immediately your local WEG representative and the
freight carrier so that insurance indemnification can be claimed without problems.
Before unloading the transformer, specially assigned personnel should carry out
a preliminary inspection in order to check its outside shape, accessories and
components for any deformity, oil leakage and its painting condition. Also, all
components and accessories should be checked against the provided packing list.
In case of any evident damage, missing accessories or components or any
indication of improper treatment during shipment, the manufacturer and the freight
carrier should be notified.
All of the transformer unloading and moving work should be carried out and
supervised by specialized personnel according to all applicable safety rules and using
all indicated support and lifting points.
The transformer should be hoisted or dragged by the points as indicated in the
drawings. Do not use any other points, otherwise severe damages can occur to the
transformer.
When the transformer is shipped without oil, check the pressure of the dry gas
inside the transformer’s tank and inside the gas bottles, if supplied.
When the transformer is shipped with oil at atmospheric pressure, the pressure
gauge should indicate a “zero” level. Check for its dielectric stiffness and water
contents in the oil in order to obtain conclusions about the absorption of humidity by the
insulation.
2.3. STORAGE
a) The unit should be preferably assembled and filled with insulating oil at its
operation place and be inspected as soon as it is received, no matter if the
transformer is not supposed to be started up right after it’s reception. In case the
transformer is to be stored for short time periods (maximum 3 months), this can be
done without filling it with oil, as long as it is filled with pressurized dry gas. In such
case, the gas pressure should be inspected on a daily basis in order to detect any
leakages in due time and to prevent the penetration of humidity.
b) When the transformer is not installed immediately, it should be stored preferably in
a sheltered and dry place, free of dust and corrosive gases, and it should be placed
always in its normal position and set apart from any areas with too much traffic or
subject to collisions.
c) Components and accessories, when removed from the transformer for shipment or
storage purposes, should meet the following:
All accessories should be stored in suitable places.
Radiators should be stored next to the transformer, and they should not remain
in contact with the ground.
Bushings should be stored, if possible, in suitable and dry places.
The insulating oil should be stored in drums, which should remain in a horizontal
position with their lids aligned, if possible, covered with canvas and should not
remain in contact with the ground.
A transformer fitted with auxiliary circuit panels should be kept with its heating
resistors switched on, controlled by a thermostat and adjusted for the
recommended temperature of 30ºC.
Before starting any installation work, make sure that qualified personnel as well
as suitable installation equipment and tools will be available.
a) Transformers should not be installed on rainy days.
b) Before starting the installation of the transformer, the following procedures should
be carried out:
Visual inspection, particularly for a proper level of its base;
Check the transformer’s anchor devices for proper fastening;
Visual inspection on the outside of the transformer tank for any damages
occurred during the handling procedures;
Make sure the name plate ratings are compatible with the equipment technical
specification;
In case of re-starting transformers, make sure the shipped connection meets the
specified details;
In case of transformers shipped without oil, check the gas pressure;
In case of transformers shipped with oil, whenever possible, collect a sample of
the insulating oil for lab analysis;
Check the transformer’s grounding connections.
Therefore, all air inlet openings should be located next to the floor and be
distributed in the most effective manner, preferably bellow the transformer level, and
should not be bigger than the transformer dimensions.
The air exit openings should be located as high as the building allows. The
number and size of exit openings will depend on their distance above the transformer
height, on their performance and their loading cycle. Usually, the air exit openings
should have 5,50 m2 per 1.000 kVA of installed capacity.
3.3. ALTITUDES
Our transformers are designed in compliance with ABNT and IEC standards, i.e.,
they will perform optimally at altitudes up to 1.000 m above the sea level.
When installed at altitudes above 1.000 m, the transformer will have a reduced
performance or will require a more effective cooling system. The transformers are
designed to withstand a safe temperature increase in altitudes up to 1.000 meters.
Should a transformer work in altitudes above 1.000 meters, the limits specified on table
1 should not be exceeded.
Hot-spot winding 68
Note: The power rate reduction for altitudes above 1.000 m occurs according to the following equation:
H 1000
Pr Pn 1 k
100
Where:
Pr = Reduced power rate in kVA
Pn = Rated power in kVA
H = Altitude in meters (Always rounded up to the next centesimal meter value)
k = Reduction factor (Table 2)
3.4. CONNECTIONS
4.1.1. Thermometer
4.1.1.1. Application
The thermometer (See figure 1) is designed to capture the temperature from the
hottest point of the oil, right bellow the transformer lid, and can be preset to trigger an
alarm and to shut off the transformer at given distinct temperatures. It has four hands
that are connected to four contacts, which features are the following:
Actual temperature hand: Indicates the actual temperature level.
Alarm hand: An alarm is triggered when the temperature exceeds a preset
level.
Shut off hand: The transformer is completely shut off when the temperature
exceeds a preset level.
Max. Temp. hand: It indicates the maximum temperature that has been
reached within a given time period. This red hand moves only forward, driven
by the “actual temperature hand”, and does not return when the temperature
decreases.
4.1.1.2. Instruction
The three “b, c and d” hands can be preset to any position of the thermometer
scale. Recommended temperature setting: For an increase of 55º in the winding vf =
75º, a= 85º, d = 95º.
After each periodic inspection of the thermometer, return the red hand to the
same position as the actual temperature hand.
The automatic closing pressure relief valve has a spring, which is fitted with a
system that instantly amplifies the actuation force.
Figure 3
The figure 3 above shows a view of the valve mounted on the transformer by
means of screws fixing it to the flange (1) and sealed with a gasket (2).
The valve disc (3) is compressed by the springs (7) and sealed by means of the
gaskets (4 and 5). The valve operates when the pressure actuating on the area defined
by the gasket diameter (4) exceeds the opening counter pressure caused by the
springs (7).
As soon as the disc (3) slightly lifts from the gasket (4), the pressure inside the
transformer immediately starts to act over the disc entire area, which is limited by the
gasket diameter (5), thus resulting in a force much higher that moves the disc upwards
4.1.3.1. Generalities
The pressure surge relay (See figure 4) is a protective device for sealed type
transformers. It is installed above the maximum level of the liquid, in the space
containing gas between the liquid and the transformer’s lid.
The relay is designed to actuate when failures occur inside the transformer
producing abnormal internal pressure. Therefore, its operation is triggered only by
quick changes in internal pressure, regardless of the transformer’s operating pressure.
In case of pressure gradients above 0.2 atm/sec, the valve operates instantly.
On the other hand, the relay does not operate as a result of slow pressure changes that
are typical during the transformer´s normal operation, not due to disturbances to the
system (lightning, maneuvering over voltage or short-circuit), unless such disturbances
may result in damage to the transformer.
Typically, the pressure surge relay is mounted on one of the transformer’s tank
sidewalls, between the maximum insulating liquid level and the lid. Nevertheless, it can
be also mounted horizontally on the top of the transformer’s lid.
When the transformer is shipped filled with insulating liquid or vacuum is applied
to it in the field, it is important to make sure that insulating liquid will not penetrate into
the pressure equalizing orifice or inside of the relay.
The flange to which the relay is applied is usually supplied with a blank sealing
flange. The relay is supplied separately and should be mounted after the transformer
installation is completed and its tank filled up with insulating liquid.
Make sure the inside of the expansion tank is dry and clean. If necessary, wash
it with clean and preferably hot oil (Maximum 50ºC).
Figure 6
The expansion tank consists of a metallic casing containing the air drying agent
and one oil chamber, located in front of the casing containing the air drying agent,
isolating it from the atmosphere. During normal operation, the oil becomes hot and
expands, thus expelling the air from the expansion tank through the air drying agent. If
the transformer load or the room temperature decreases, so will the oil temperature
decrease, followed by the corresponding volume reduction.
As a result, the air volume inside the expansion tank decreases and fresh air
from the atmosphere is sucked in through the chamber and through the drying agent,
which absorbs humidity from the air.
The drying agent named silica gel is vitreous and hard, chemically almost
neutral and highly hygroscopic. It is silicon impregnated with cobalt chloride, and when
it is active, it has a sky blue color and a crystalline aspect. It is capable to absorb 40%
more water than its own weight.
Due to water absorption, its color changes to a rose shade, which indicates it
must be replaced. It has a long useful life and can be regenerated and reused after a
drying process, which can be applied many times.
Remove the plug located on the top of the expansion tank (It is not
necessary to remove the oil from the tank).
Remove the upper lid from the air dryer and fill it with silica gel.
Fit the lid back on the air dryer.
Fix the air dryer to the bottom of the expansion tank with the glass facing
downward.
Remove the bottom glass of the air dryer and fill it with the same
transformer oil until the available red indication.
Carefully re-install the glass in the air dryer.
Make sure it will be perfectly fixed in order to prevent the penetration of
any humidity into the transformer.
Figure 7
4.1.5.1. Generalities
The Buchholz Relay (Figure 8) has the purpose of protecting the electrical
appliances working in insulating liquid, particularly transformers.
While overloads and over currents are phenomena’s that can be controlled by
means of maximum current intensity relays, failures like loss of oil, internal discharges,
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defective winding insulation, from iron or even to the earth, occurred on transformers
equipped with maximum current relays, can cause great damage if the failure remains
unnoticed by the operator for some time.
Therefore a Buchholz Relay is installed on transformers in order to indicate, by
means of an alarm or by switching off the transformer, failures like the above
mentioned ones and prevent them from developing any further.
Figure 8
The Buchholz relay is usually mounted between the transformer main tank and
the expansion tank. The relay’s casing is cast iron, having two flanged openings and
also two sight glasses having a graduated scale to indicate the volume of gas. There
are two floats mounted one over the other on the inside. When a certain amount of gas
accumulates inside the relay, the upper float is forced to move down. If, in turn, an
excessive production of gas causes a circulation of oil inside the relay, it is the lower
float that responds, even before the formed gas reaches the relay. In both cases when
the floats touch each other, an electrical contact will be made.
4.1.6.1. Generalities
The magnetic level gauges are intended to indicate with accuracy the insulating
liquid level and, in addition, when they are fitted with contacts for alarm or trip, they are
intended to operate as protective devices for the transformer.
The magnetic level gauges (Figure 9) have a cast aluminum casing. The level
indication is carried out by a hand coupled to a highly sensitive permanent magnet,
which makes it very accurate.
The display case of the magnetic level gauges has three indications, i.e., MIN,
which corresponds to the minimum level; 25ºC, which corresponds to the marked room
temperature and MAX, which corresponds to the maximum level. Trip occurs at the
minimum level.
Figure 9
4.1.7. Radiators
4.1.8. Bushings
Before the assembly, all bushings should be perfectly cleaned up with benzene
and dried up.
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The sealing gaskets should be carefully fitted and their fixing elements should
be carefully tightened in order to achieve a good tightness. The bushings should be
mounted one at a time in order to prevent the penetration of air from the atmosphere.
The bushing should be fitted in a safe manner, using suitable lifting and handling
devices.
Figure 10
4.2.1. Definitions
Insulating liquids are fluids having dielectric features, made of mineral oils or
synthetic products, which are used in transformers in order to promote the dissipation
of heat produced by the coils of the equipment.
a) Sampling flask
a) Collect the samples, preferably under dry weather in order to avoid any external
contamination; if the weather is rainy, the following precautions should be taken:
b) If possible, the liquid should be at least at the same temperature as the room
atmosphere.
c) If the equipment is operating, make note of the liquid temperature when collecting
the sample.
NOTES: This requirement is particularly necessary when checking the water
contents or features depending on it.
a) Transformer provided with dry gas and a non vacuum resistant air dryer.
After the vacuum process (The manufacturer determines how long and how
much), fill up the transformer with oil under vacuum until approx. 20 kPa (150
mmHg) bellow the lid. Interrupt the vacuum between the oil level and the level
using dry gas. Disassemble the vacuum pump hose. Fit the valves and gas relay
to the pipeline and open the installed valves. Open the plug B (Figure 13) or
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install an air dryer without silica gel. Continue filling, now preferably through the
upper valve of the transformer. Fill up the expansion tank to the level that is
compatible with the oil temperature (Detectable level by the “I” indicator). Close
the plug B. Check the oil preserving system (bag or membrane), if applicable, for
proper working.
Note: The pressure x temperature relationship must be as per NBR 10576.
(Table 2)
b) Transformer provided with dry gas and a vacuum resistant air dryer.
After the vacuum process (The manufacturer determines how long and how
much), fill up the transformer with oil under vacuum through one of the tank
valves. Fill up the expansion tank to the level that is compatible with the oil
temperature. Switch off the vacuum pump, interrupt the vacuum between the oil
level in the expansion tank and the top of the expansion tank with dry gas.
Disconnect the vacuum hose. Close the flange. Install the air dryer. Check the
oil preserving system (bag or membrane), if applicable, (See figure 14) for
proper working.
Note: The pressure x temperature relationship must be as per NBR 10576.
(Table 2)
c) Transformer with a lowered oil level
Open the valves installed on the gas relay. Open the plug B or install an air
dryer. Fill up the expansion tank to the level that is compatible with the oil
temperature (Detectable level by the “I” indicator). Close the plug B. Check the
oil preserving system (bag or membrane), if applicable (See Figure 15), for
proper working.
Note 1: The pressure x temperature relationship must be as per NBR 10576.
(Table 2), as follows:
Note 2: The temperature inside the vacuum chamber should be as a function of
the quantity of vacuum that is applied in order to avoid any distillations of the oil
and/or oxidation inhibitor fractions. The Table 2 showed bellow serves as a
guideline for choosing the ratio of vacuum and temperature.
Figure 13
Tg at 90ºC(%) or
FP at 100ºC (%)
Water TIF > 20 mN/m at
(Factor of Stiffness Acidity Recommendations
contents 25 ºC
dielectric loses at
90ºC or at 100ºC)
M None
Oil regeneration or
M M M N
change
Oil regeneration or
N - change and cleaning of
the oil filter
M
Oil regeneration or
M M M N
change
Oil regeneration or
N -
change
N M M AP and oil drying
AP drying and Oil
N
regeneration or change
AP drying and Oil
N N -
regeneration or change
Oil regeneration or
N - - - -
change
Notes:
Oil regeneration or change (whatever is more costs saving).
Regeneration = Treatment with Fuller earth = A chemical treatment with a basic middle (e.g., meta-silicates)
and/or treatment with a solid absorbing middle (e.g., clays, bauxite or activated carbon). The oil treated this way
should be mixed with a mass of 0,3% of DBPC (Tertiary dibutyl paracresol).
AP = Active part.
M = Meets; N = Does not meet.
5.2. NAMEPLATE
Make sure the nameplate data is coherent with the system where the transformer
is being installed. Make sure the tapping panel connections or the position of the
changeover switch with regards to the connection diagram is correct.
The fastening system should be in compliance with the ABNT standard. Pole
type transformers are fitted with two fastening straps having a support for direct
mounting on the pole.
5.4. LIFTING
The transformer should be lifted with ropes or cables, which should be fixed to
the straps, hooks or eyebolts available for this purpose. The transformer should not
suffer any damages. Before lifting the transformer, it is convenient to fix the strap
5.5. CONNECTIONS
5.6. PROTECTION
5.7. GROUNDING
5.8. MEASUREMENT
7. POWERING UP
Before powering up a transformer fitted with capacitive bushings, gas relay, on load
tap changer, radiators, etc., it is recommended to carry out an air bleeding on all
provided points.
Inspect all of the transformer’s protective and signaling devices.
It is important to observe that the transformer should be powered up at least 24
hours after it is filled with oil.
Adjust and lock the position of the manual tap changer as recommended by the
system’s operation procedures.
All the assembly, essays and powering up procedures should be supervised by a
manufacturer’s technician.
The transformer should be powered up initially without load. If the transformer is
fitted with an on load tap changer, it should be changed over to all of it´s taps.
It is recommended to carry out a chromatographic analysis of the insulating oil
before powering up (as a reference), 24 h to 36 h after powering up and 10 days
and 30 days after powering up for the detection of incipient failures.
Such inspections should be carried out on a periodic basis at the power plant,
particularly in order to detect any abnormal heating of the connectors.
Samples are collected periodically and essays are carried out according to
tables in 4.2.6 and 4.3.2.
Since they put the equipment and the installations in imminent danger:
Abnormal internal noise;
Significant oil leakage;
Excessive connector heating by taking in account the established thermo
vision criteria;
Actuated gas relay;
Overheating of the oil or the windings, detected by means of the
thermometers / thermal images.
Such occurrences do not offer imminent dangers. The shutting down operations
should be carried out as soon as possible in case of the following system’s operating
conditions:
Oil leakage that offers no imminent risk of dangerous level dropping;
Heating on the connectors, observing the established thermo-vision criteria;
Unleveled base;
Anomalies verified in the oil essays, following the limits established in NBR
5356;
8.3.2. Yearly
The following essays and inspections should be carried out, as per Attachment
A, with the transformer shut down.
a) Power factor of the transformer and power factor and capacitance of the
bushings, if capacitive taps are available;
b) The transformer’s insulation with continuous current;
c) Transforming relationship;
Notes:
a) After changing from one tap of the no load tap changer and/or when holding the
tap changer under load.
b) Considering the equipment performance, the periodicity for inspections and
essays can be changed.
c) Treatment and painting should be carried out on all of the transformer’s points
requiring them.
This attachment provides for all procedures that should be carried out in the actions
listed in A-1 to A-13.
A-4. Thermometers for oil and/or windings: the following items should be checked:
Fans for heating, vibration, noise, weatherproof sealing, fastening, painting and
oxidation (S);
Manual actuation (S);
Supply circuits (S);
Fins and protective grids (S).
A-12. Terminal box for the control and protection wiring: the following items should be
checked:
Notes:
¹For the case in which the transformer is supplied with impact recorder, the impact recorder shall be
removed and sent to the responsible person at WEG in a period of maximum (five) 5 days after the
transformer delivery. Only after receipt confirmation of the impact recorder data by WEG, the warranty
period will enter into force.
²After carrying out the commissioning of the transformer at site, the electrical test results measured
during such procedures shall be sent to WEG within maximum 15 days before the Startup date. Only
after receiving these electrical test data and approval by WEG, the warranty period can come into force.
Blumenau
Gravataí
Rua Dr. Pedro Zimmermann, 6751
Rodovia RS20 - km 6,5
Bairro Itoupava Central
Rio Grande do Sul – Brasil
89068-001 - Blumenau
Tel.: +55 (51) 3489-2500
Santa Catarina – Brasil
Tel.: +55 (51) 2131-2500
Tel.: +55 (47) 3337-1000
Fax: +55 (51) 3489-2501
Fax: +55 (47) 3337-1090
Email: wtd@weg.net
www.weg.net