TBE/I ifS ST

d
’

I BEA
'
SHENYANG TRANSFORMER GROUP CO. , LTD
.
NO.18 BEIER ZHONG ROAD TIEXI DISTRICT,SHENYANG 110025 CHINA
 tdEaffcr
i sygsK Installation & operation manual of 500KV transformer

1. GENARAL DESCRIPTION

2. LIFTING AND TRANSPORTATION OF MAIN BODY

3. ACCEPTANCE AND STORE

4 . INSPECTION BEFORE FINAL REASSEMBLY

5. FINAL REASSEMBLY OF SUBASSEMBLY

r
(
6 . OIL FILLING UNDER VACUUM

7. INSPECTION AND TEST BEFORE OPERATION

8. OPERATION AND MAINTENANCE

9 . ELSE

10. F INSTALLATION PROCEDURE

11. TOOL AND FIXTURE FOR INSTALLATION AND SCHEDULE AT SITE

/ -* \
•

f b
 TSE/I mmmiL Installation & operation manual of 500KV transformer
f
1. General Description

Type of transformer: Power Auto-transformer with Single Phase and OLTC (off-circuit
tap-changer)
Range: Out door, HV 500kV
Tiptop work voltage: HV 500 / V 3 ± 8 X 1. 25%kV, LV 220/ V 3kV, Tertiary 22 kV
Height: < 1000m
Environment temperature: -10 °C ~ 50 °C
Cooling: ONAN/ONAF1/ONAF2 (62.5%/80%/100%)
Coolers number: 20units (2 sets for standby)
Structure description: ( 500 kV series winding terminal is OLTC , rated frequency 50Hz.
Core type , cylindrical tank , 500 kV is leading at the middle. The HV terminal should
be wrapped at insulation cylindrical for meliorate the electric field and insurance the
insulation strength. The instruction contains the transportation, acceptance,
installation, maintenance and other technical requires. Please refer to the drawings to
check the outline instruction and installation dimension.

2. Lifting and transportation of main body

2.1 The transformer is cylindrical type tank , the outline drawing shows the upper part
of tank and lifting of the main body. Lift main body with all the main lifting lugs.
Each sling shall bear equal force to prevent the main body overturn. The bearing
plate for jacks should be used to withstand the main body, all jacks should be
used when sling the main body, jacks should operate at the same and even
v speed to prevent main body inclining and rolling.
2.2 The main body transported with nitrogen, the large discreteness which should be
dismantled are: HV bushing, LV bushing, tertiary bushing, natural bushing,
coolers and connected oil ducts, tuber connecter of gas, control box
i

pressure-relief valve, conservator and ascending flanged base. The main body
transport without oil, only a little rudimental oil at the bottom of tank, fill with dry
nitrogen with air pressure is 19.6-29.4kpa , hallmark>99.99%, dew point < -40 °C .
The nitrogen pressure can’t less than 9.8kpa on the transport, and fill the
qualified nitrogen above at any moment.
2.3 Transportation requirements
2.3.1 For transformer loading, unloading, driving on road and pulling to the
foundation, the vibration and bumpiness shall not exceed 3g in longitudinal 2.5 g
in perpendicularity; the inclination angle along long axis shouldn’t exceed 15 ,
and 10 0 along short axis.
°

-2-
 TBEJI mmmx Installation & operation manual of 500KV transformer

requirement of Clause 3.2.3 , t

3.2.2.2 Requirement of nitrogen storage for pressure of main body and fill up
nitrogen, according to the instruction of 2.2.
3.2.2.3 Check nitrogen pressure more than 2 times everyday. Record the
pressure in the tank and fill up nitrogen. If nitrogen pressure decreases rapidly,
nitrogen wastage is large, there is leakage, Check immediately to prevent moistened.
3.2. 3 For transformer stored with oil
Stored more than 3 months or not satisfied clause 3.2.2.1, the transformer shall
be filled up with oil for storage .
3.2.3.1 Check according to 3.2.1.1 before fill up oil and remove nitrogen, remove
waste oil and dirt inside tank . Waste oil can’t be used in transformer once more.
3.2 . 3.2 Fill up oil and remove nitrogen: open up the DN100 copper butterfly valve
r
on tank cover (prevent dust from entering the tank) to remove nitrogen, transformer
oil should be filled from the DN100 copper butterfly valve at the tank bottom and any
flange hole installing cooler, oil should accord to the requirement below:
nitrogen pressure: 60KV(Standard Oil Vase Test)
water content:
^
gas content:
^ 10ppm .
<2 %
tg 6 (90 °C ): <0.5%
3.2.3.3 Check further if the transformer is moistened after leaving the factory.
The standard indicates the transformer is not moistened (test with oil) is , winding
to winding and winding to earth:
insulation resistance R6o ,
^ 70% of factory routine test (2500V megger )
absorptance” R 60/Ri 5 “ : T* 70% of factory routine test, and on less than 1.5(2500V
{ megger )
dissipation factor (tan5): <130% of factory routine test , (the same temperature )
(If not satisfied the standard above , "it indicates the transformer is moistened, the
product can ’t be run, it shall be drying treated and communicate with the
manufactory.)
3.2.3.4 Setting the temporary conservator system, adding oil spiccato, adjust the
oil level to little higher of the conservator normal oil level, and release the gas of the
conservator according to the instruction of the conservator.
3.2.3.5 Check the cover of the conservator usually while storage, if lower the
lowest level of the conservator, fill qualified oil accord with clause3.2. 3.2 to prevent
moistened .
3.2.4 Be well arranged the cannibalize fittings, prevent from rust and dirt, the
cannibalize fittings transported with oil must be stored in oil.
[

-4-
 THEM mmmix Installation & operation manual of 500KV transformer

c) Check whether leads are properly clamped , bundled and supported;

d) Check whether compressing pin, localizer pin and setscrew are clamped.
e) Measure insulation resistance between core and clamps (with 2500V
megger) . Check if core is earthed by one point.
f) Check if the contacts of the tap-changer and the leading are in good
condition.
g) Finally, remove waste oil, wastepaper and dirt inside tank .
h) Bushing s can be mounted during inspection inside the tank.

5. Final reassembly of subassembly

5.1 Complete general final reassembly of subassembly (e . g. cooler, conservator,
pressure relief valve, air tube connector) before vacuum oil filling.
1.
5.2 Each final reassembly of subassembly shall be required as the installation &
operation specification, outline drawing and installation drawing. All tube
connector assembly shall be required as marking on tuber at factory. Dustproof
method shall be provided for the insulating parts waiting for installation and
open cover of the main body.
5.3 The lead draught shall not be too tight in order to prevent the insulation of the
rooted part of the leads when bushing installation . The tapered part of the
insulating leads shall enter into equipotential shielding for bushing as drawing
required . The equipotential shielding for bushing and molded insulating parts
shall be in accurate position, not to touch each other.
5.4 Inspection of tap changer
5.4.1 Manual operation two circuits (from max. tap to min. tap, and then returning
the max. tap, calling one circuit) .
5.4.2 Measuring whether the indicating tap position of the tap changer is correct
(generally ratio test used) .
5.4.3 It shall not have difference for measuring the DC resistance of the winding
when tap changer is at each tapping position, compared with the factory value.
5.4.4 Installation and other test shall be as tap changer specification.
5.4. 5 After completing the test of installing tap changer, it shall be at rated tap.
5.5 Cooler shall be cleanout with eligible transformer oil, which flux is no less than
318m3/h and which temperature is (90+5) °C , before installation.).

6, oil filling under vacuum

6.1 Preparation
6.1.1 The oil must be dehydrated , by vacuum colander and filtrated, required
/ i
v. qualified as follow:

-6-
 nse#a mmmT. Installation & operation manual of 500KV transformer
f
connecting to the vacuum pump, then open the butterfly valve which connect the
main body and the conservator, keep filling qualified oil accord with clause 6.1.1
by Vacuum Hot Line Oil Purifiers, the conservator oil level should be little higher
the normal level under the oil-curve.
6.4.2 Tightness test will be done after oil filling under vacuum
6.4.2.1 Test with static oil method, the oil is 8m-8.5m high, Keep internal static oil
pressure for 12 hours for leakage test.
6.4.2.2 Or test by oil pump: fill oil with Vacuum Hot Line Oil Purifiers , Keep
internal pressure of tank being 24-29kPa for 12 hours for leakage test.
6.4.2.3 All the two methods above should close the vacuum butterfly valves
connected the conservator, conservator can’t be test. (Keep conservator
nitrogen pressure of 0.02- 0.03MPa for 12 hours for leakage test .)
]
6.4. 3 Open the vacuum butterfly valves connected the conservator and main body
of transformer, transformer shall be placed quietly for 72 hours without leakage.
Then open all the butterfly valves to release gas, conservator operated accord
with the instruction.
6.4 .4 Transformer mustn’t be imposed voltage until placed quietly for more
than72hours.

7 > Inspection and test before operation

7 , 1 Inspection before operation (Check all the components according to their
instructions.)
a) Whether all the butterfly valves are in right condition, whether the terminal
of bushing thermometer are filled with transformer oil.
b) Whether all the components are correctly installed, whether there is
leakage somewhere .
c) Whether main body and core are earthed well, whether by only one point.
d) Whether oil in conservator and in bushings is in required level.
e) Check the wiring of all kinds of protective, alarming and controlling devices
of the gas relay, pressure-relief valve, fan, oil meter, and CT.
f) Whether the breaker in good condition, whether three-phase open
periodicity is right.
g) Test the final oil, it should accord with clause 6.1.1, Compare the windings
dielectric dissipation factor tg5 with factory routine test .
7.2 Test before operation
7.2.1 No-load test slowness (cooler motor doesn’t run)
7.2 .1.1 Connect the signal contact of gas relay to the trip circuit of transformer.
i Over current protection shall react instantaneously.

-8-
TBEJI mmmi: Installation & operation manual of 500KV transformer

as to find the problem in operation.

8.5.1.2 During operation, transformer oil shall conform to the following
requirements at least :
Withstand voltage >50KV (Standard Oil Vase Test)
Water content <20ppm
Gas content < 3%
If the oiliness draws faster during the early operation, we should analysis the
reason and take some measures.
8.6 Internal inspection during operation
8.6.1 When the transformer is running, if the oil didn’t as worse as the minimum
standard (item 7.7.1.2) or there didn ’t severe leakage, internal inspection is
unnecessary.
8.6 . 2 If the oil is as worse as the minimum standard , the oil must be filtrated in
time. The gaskets must be changed if the gasket lost the elasticity and severe
leakage happened. The internal inspection must be done at the same time of
filtrating the oil or changing the gaskets.
8.6. 3 The internal inspection should be obey the item 3.2 and item 3.3 of the
instruction, be care for if the pinch device is fastness when doing the internal
inspection.
8.6 .4 When finished the internal inspection, work as the item 5 of the instruction.
9. Others
Attention paid to transformer installation
9.1 In order to lift the tank cover, the disconnection shall be made between all
bushings and leads. Remove the bolts for the locating device on the cover to
dismantle the strip connecting the cover with the lower part of tank. And
disconnect OLTC with the cover. For the lifting dimensions see the overall
dimension drawing.
9.2 The winding thermometer, resistance thermometer and appropriate auxiliaries
shall be accommodated in the control cabinet. The control conductors for some
components (such as resistance thermometer, pressure relief valves, gas relays,
oil gauges, CT line terminals for bushings , ect) shall be connected to the cabinet.
See wiring diagram of measuring and protective facilities for transformer. The
length of cables used for connection shall be according to the practical condition .
9.3 For the radiator connecting wires , see wiring diagram for fan and motor
assembly. The length of cables shall meet the practical condition.
9.4 For radiator installation , see its installation drawing.
9.5 For the installation of conservator connecting pipes, see the fabrication drawing
of connecting pipes .

- 10 -
 TBEA mmmJL Installation & operation manual of 500KV transformer
\
. {. J

10.5 During normal operation, insulation plate shall be located between the two
bushings of tertiary winding. Insulating plate assembly is shown in Fig. 2.
10.6 The installation position of surge arrestors for spare transformer and LOT1
transformer is shown in Fig.3. When the spare transformer is used for
replacement, a transition supporting frame shall be added between the surge
arrestor and the base plate. The arrestor shall be insulated according to
Fig 1.
10.7 During installation, lifting and handling, the force imposed on the connecting
aluminum pipe shall be uniform and avoid any crash, bending and insulation
failure.

- 12 -
 Installation I operation manual of 500EV transformer i ITT.. 710.30099.4 SM
I
- i
>W» >tWlV« tW»
^V V>W%VWyW«ilv » »>*>%»yWteWW\<VWW y» MT4WWVm<H »W\WWMI
^ * *

I Total 1? ! Page 13

Fire fighting wall Coxmectiag cable 1

Supporter
i
r
p
\
x
;

;
/
CiiDtcitor iif© : fin
lArreBior
Line terminal for aluminum bus bar # X (i ;•

*~r >
;c c H5
Earthing tarmisai for copper shield -^
C s
Capacitor »:o earth J ... . '"
•••• tapper)shield to earth
X? O
X
N
#
\
V
;
Connection cable 2/ Arrestor to earth
£ JA .
« , i. ,v. A,
A

A A. i fLS 1- Ul

w2 f1/ * Insulating padll§g

I
i
/ £ hV
/ /coppe
\
r ...sniel
.. _ _
d
.. ,
to earth
..
. £2&
X TL X
'
o

As Filing suppo rter for arres-tor/f Plili Arrestor to earth

Connecting strip i n
^VAVWVS«WWWM^iCA« » ,
^ \
*»
A*\VI .\ «»«»V \ V« 'A W » l<»« V<l»VA» WM»1 «WVVW»
* * * W«WW\WWV WWVSVW\ /

ts s?
!
r
$
t
;
Fig, 1 firing diagram for tertiary winding(transformer used for replacement)
Notes:
connecti ng cable 1: between bushing and gorge arrestor connecting cable- 2: between arrestor mi capacitor
arrestor to ground: when the eartiling cable led oat through the hole h the bos cover, the arrestor am the fixing supporte
r on the tank cover
5
ahsII be kmkled. the insulating parts are sbo»n in Fig,2
!

: Front view Plan view

Fixing plate for box wall
>
A Fixing plate for box wall Insulating plate >

\ ;

X / i

Bf - j ;
ii
Fixing if ; te for box wall I
$
:
l
Insulating plate
m 5 |

AL A r
t isg part 2 for base plate

XIbase plate
] w2 \w
Fixing part 1 for base plater
Fixing part 1 for base plate
\ base plate
Fixing part 2 for base plate

Fig. 211 lustralive diagram for insulation assembly along bushings of tertiary bushing
i

For LOT 1
Location for Used for replacement
i
T
Location for
surge arrestor
Loca tion for surge arres tor
 TBE/I mmmjL Installation & operation manual of 500KV transformer

10 , REFERENCE TABLE OF ASSEMBLY PRODUCE

Eligibility and leave factory

I
Transportation ( main body with nitrogen) according to iteml

I
Acceptance (according to item 2.1 ) Check
if moisten in the transportation (according to Moist
item 2.2.1.1)
Un-moist
1r
i7

Storage with nitrogen not Main body

More Storage with oil
more than two months ( drying
than 2 (according to item Moist treated
: According to item 2.2.2 ) months 2.2. 3)
> renewedly
Check if moist in
transportation
(According to item
Store
2.2.3.3)
renewedly
Main body reassembly
1 Check if moisten
(according to item 2.3. 1 )
Internal
2fill oil release nitrogen Main body Internal
inspection (according to item 2.2.3.1
and Reassembly reassembly inspection
and item 2.2.3.2) 1. if moisten in
Install Accord and
< 3 if moisten in storage storage
bushing
(according to item
with * Install
Instruction (according to bushing
2.2.3.3 ) item 2.2.3.3 ) >
and item 4
4 Internal inspection 2. Internal
and installation inspection
(According to item 3 and and installation
item 4) (According to
y
5 Others (according to item 3and item4)
item 8) 3 Others
(According to
item 8)
Moist in storage
w
Oil filling under vacuum
J
Main body drying hot oil circulation
Treated renewed ( according to item 5 )
Main body drying
Treated renewed

Connect control and Test and inspection

Signal circuit cable * before operation i
> Patch paint on surface
(According to item 6)

Operation ( monitor frequently at the beginning, according to item

7.7)
(According to item 7 and relation standard, rules and regulation)

- 14 -
 V •
afcmtfjg
•

installation & operation manual of 500KV transformer

The installation progress at site and required tools and devices list for 500KV transformer
Loading
Main Working days(for reference)
Item Main Tools &
No.
Items inspection 1 2 2 2 2 3
contents Equipment 1-9 10 11 12-13 14-15 16-18
2
25-32
3
35-37 38-39 40 Remarks
items 9 0 1 2 3 4 3 4
Prepare the
Check the
installation
Preparation horizontal Installation Mi
1 for
installation
equipments,
tools, materia !
level
foundation
of equipments
level gauge
& *
and temporary
(rail)
equipments
Jack, tracking
Check the
and lifting
Put the main position of
Fix the equipment,
2 body on the main body
transformer rolling pole,
foundation, and nitrogen
pressure
pressure
indicator
See item 2.1.3
Check the
and 2.1.4 and
amount the Crowbar, saw,
Check the check if any
3 accessories and pliers , camera
boxes disfigurement
check the and etc.
on the
appearance
appearance
Mechanical
property and
alarm conditions Gas
Oil
Check the
of oil-level relay
treatment indicator of Oil container, oil must be
performance of
4 and relays, oil flow pipes line, oil m tested in
accessories,
accessories meter , filter drying air , related
oil treatment
inspection thermometer, laborato
electrical ry
performance of oil
in bushing.
Binding the Installation Jack, lifting
scaffold, install position and gourd by hand,
Installation
of
the bogie, seal crane, 6#and 8#
the
5 conservator , performance, torque wrench, &
auxiliary
cooler and oil check the electric and
parts
pipes line, position of water welding
press-relief valve auxiliary parts device

- 15 -
 I EfeflZ# l JL Installation & operation manual of 500KV transformer
Main Working days(for reference)
Item Loading Main Toois &
No.
Items inspection
contents Equipment 1-9 10 11 12-13 14-15 16-18
1 2 2 2 2 2
25-32
3
35-37 38-39 40 Remarks
items 9 0 1 2 3 4 3 4
Filling oil and Check if the exhausting
Draining oii exhausting oil pipes line is Oil container, oil nitrogen,
.
r.

and nitrogen or clean, check if pipes line, oil the oil

6 should
exhausting draining out oil the dew point filter and drying
nitrogen and fill drying air of drying air is air
satisfied
in the tank -35 °C .
~ item 2.2
and 2.3
See item 3.2,
Check active 3.3 and
part, install 3.4,check the Crane, 6# and
Internal turret, backout insulation 8# moment
inspection the Supporting resistance of torque,
7 and frame for bushing, spanner,
bushing transport, install polarity of CT, megameter,
installation bushing and installation safe-light
gas-conduit, fill position and waterproof doth
drying air seal
performance,
Open the valve on
the top of
Close the
See item 5 , valve on
conservator and
Vacuum and check the oil pipes line, the
in the oil pipe line
treatment, seal vacuum pump, connector
of cooler, open
8
vacuum oil
the butterfly valve
performance vacuum meter, ;
r
of the
filling and of oil pipe, vacuum oil filter , mmm ^
cooler
under the bottom
hot-oil check the oil test when
of press-relief
circulation quality of the instrument hot-oil
valve and the one
oil. circulatio
which connect the
conservator n
Tube

9
connector
Installation
of control
Install

lines of the
control box
the
connector and
Pliers,
screwdriver,
spanner,
m
box
Close the valve
Leakage Pump or
10 of relay See item5.4
test vacuum oil filter
connector
Oil-level
indicate
Adjust the regulate to Thermometer,
11 Fill or drain oil m
oil level more than 5°C . vacuum oil filter
of the true
temperature

- 16 -
 r \
\
/

Installation & operation manual of 500KV transformer

Main Working days(for reference)
Item Loading Main Tools &
No .
Items inspection 1 I 2 I 2 1 2 I 2 I 2
contents
items
Equipment 1-9 10 11 12-13 14-15 16-18
9 0 1 2 3 4
25 32
-
%3 l4 35-37 38 -39 40 Remarks

Testing and
Related test
Inspection
12 See item6 See Item 6 equipments and
Before
power
operation

Dismantle the
scaffold and Ejection gun
13 Patch paint
others, patch paint
paint

Reference method: Check if there are leakage on the connector when vacuumize. Make the smoke of anti-mosquito incense move slowly
around the flange. Use a plate to prevent the smoke from diffusing when check the top and make the smoke around
the flange. If the smoke enters the connector, then the flange is leakage. Or if there are some noisy, the flange is
leakage.
Reference equipment specification: Vacuum pump outlet air capacity>150L/S, the residual pressure< 3Pa.
heating temperature of vacuum filter >60 °C , oil flow capacity > (8-10)t/h, dehydration capacitydOppm,
degas capacity< 0.1%, the weight of lifting >200t, the height of lifting> 12m.
hydraulic pressure Jack 50t .

- 17 -