INSTALLATION, OPERATION AND MAINTENANCE

INSTRUCTIONS

AREVA T&D

PURCHASE ORDER NO: 3414-4500298719

WORKS ORDER NO: 20090050/5

CONVERTER TEST TRANSFORMERS

5.0/8.333MVA

FOR

VSC HVDC DEVELOPMENT

MANUAL NUMBER: MM 0376

Rev 1 Modified as Built

Rev 0 Original

INTERNATIONAL TRANSFORMERS
a division of IST POWER PRODUCTS LTD
LONGLEY LANE
WYTHENSHAWE
MANCHESTER M22 4RU
 LIST OF CONTENTS

SECTION TITLE

1.0 Description
1.1 Introduction
1.2 Technical Description
1.3 Detailed Description

2.0 Installation Instructions

2.1 Introduction
2.2 Method of Despatch
2.3 Unpacking and Examinations
2.4 Handling
2.5 Storage
2.6 Location
2.7 Foundation
2.8 Schedules of Erection Drawings

3.0 Maintenance Instructions

3.1 General
3.2 Pre-commissioning Checks
3.3 Paintwork
3.4 Buchholz Relay
3.5 Pressure Relief Valve
3.6 Heat Exchanger
3.7 Surge Diverter

4.0 Maintenance Instructions

4.1 Transformer
4.2 Pressure Relief Valve
4.3 Buchholz Relay
5.4 General

5.0 List of Drawings

2
6.0 Fittings List

7.0 Appendix A - Cooling Liquid

8.0 Appendix B - Buchholz Relay

9.0 Appendix C - Pressure Relief Valve

10.0 Appendix D - Magnetic Oil Gauge

11.0 Appendix E - TES Heat Exchanger

12.0 Appendix F – Surge Diverter

13.0 Appendix G - Oil Temperature Indicator (OTI)

Winding Temperature Indicator (WTI)

14.0 Appendix H - Paint Specification

15.0 Appendix I - Guide to Maintenance of Oil Immersed

Transformers WI0007

16.0 Appendix J - Current Transformers

17.0 Appendix K - Test Certificates

18.0 Appendix L - Core Characteristics

3
SECTION 1
DESCRIPTION

1.1 Introduction

The transformer unit manufactured by International Transformers, a division of

IST Power Products Limited, is supplied as follows:-

The Converter Transformer is a single phase, outdoor, oil forced, water forced,
cooled transformer for a 12.1kVolts 50Hz supply.

1.2 Technical Description

CUSTOMER : AREVA

PURCHASE ORDER NUMBER : 3414-4500298719

WORKS ORDER NUMBER : 20090050/5

ELECTRICAL SPECIFICATION : T4728

VOLTAGE RATIO : 6350/6350 – 11000V

TYPE : Single Phase Free Standing ‘OFWF’

Transformer

DUTY CYCLE : 8.33 MVA for 30 minutes in any 24 hour

period.

5.0 MVA continuous.

AMBIENT TEMPERATURE : -5ºC to + 30ºC.

H.V. TERMINATION : 36kV 2 Pole air filled cable boxes

Bushings Webster Wilkinson type B4289

L.V. TERMINATION : 36kV 2 Pole air filled cable boxes

Bushings Webster Wilkinson type B4289

FITTINGS : Name and Rating Plate

Earthing Terminal
De-hydrating Breather
Oil drain valve
Magnetic Oil Level gauge
TES Thermal Engineering heat
exchanger Ref A010848
1 off Oil Temperature Indicator
2 off Winding Temperature Indicators
Qualitrol Pressure Relief Device type
206
4
 Buchholz Relay Comem type 2DE
ABB Input Surge Diverter Type
MWD12
Internal Current Transformers
Input 1500/1A Class TPY qty 2 off
Output 1500/1A Class TPY qty 4 off

SPECIFICATION : Generally to Areva Specification

P0013/07012/EQUIP Iss.E

COOLING OIL : In accordance with BSEN60296 OFWF

APPROX WEIGHT : 11000kg

1.3 Detailed Description

The transformer consists of a 2-limb single phase coil assembly mounted on

a core assembly.

The coils are wound from copper conductor wound as spiral winding with
ducts for cooling. The coils have been dried out prior to immersion in oil.

The core is built up from laminations of cold rolled silicon steel.The

laminations are interleaved and clamped with fabricated steel frames.
The core is fitted with gaps along the leg length

The transformer is contained within a fully welded steel tank with a bolted
on lid. The tank is complete with heat exchanger, pressure relief device,
drain valves, conservator, Buchholz relay, OTI, WTI and silica gel breather.

The input and output leads from the coils are made onto bushings.

The unit is filled with transformer oil. See Appendix A for data sheets.

1.3.1 Transformer Tank Termination Boxes

The transformer tank is of sheet steel welded construction. The 2 HV

bushings are suitable for single open line connection from below.

36kV 2 Pole air filled cable boxes

Bushings Webster Wilkinson type B4289

The Input Cablebox is fitted with an ABB Input Surge Diverter Type MWD12

1.3.2 Auxiliary Equipment

The transformers are fitted with the following equipment :-

1) A pressure relief valve with alarm/trip changeover contact mounted

on the side of the tank.

5
2) Buchholz Relay with alarm and trip contacts.

3) A TES heat exchanger

4) Magnetic Oil Level Gauge with alarm and trip contacts

5) Winding Temperature Indicator (Input and Output)

6) Oil Temperature Indicator

7) Surge Diverter

Other fittings include removable cable gland plates, oil filler and
drain valves. A loose silica gel breather to be fitted on site is
included.

6
SECTION 2

INSTALLATION INSTRUCTIONS

2.1 Introduction

These instructions are intended to give guidance and assistance in the

installation and maintenance of the oil filled single phase convertor
transformers.

2.2 Method of Despatch

Every precaution is taken to ensure that the equipment will arrive at its
destination in perfect condition.

The units are despatched completely assembled, finished and tested.

2.3 Unpacking and Examination Upon Arrival

Immediately upon arrival the equipment should be thoroughly examined

externally. Any damage should be reported at once to the Carrier and to
International Transformers quoting the Advice Note details to enable a
claim to be lodged with the responsible party. Any deficiencies of material
should also be notified to the Carrier and to International Transformers
immediately.

2.4 Handling

When lifting the equipment use the four lifting points provided with the
correct lifting slings and sling through each lifting point. Great care must
be taken not to knock or damage the equipment. Lifting weight of complete
unit is 11000kg.

2.5 Storage

The unit should be stored indoors or in a covered area until commissioned.

2.6 Location

As this equipment is a static unit the location is of course fixed. Care must
be taken to protect the unit from severe environments ie, pollution from
active chemicals, hot air blasting unit or any elements not deemed normal.
The unit is despatched full of oil to operating level sealed for use outdoors
with heavy duty paint finish.

7
2.7 Foundation and Connections

1) The equipment must be mounted on the floor/plinth. Ensure that the

plinth is securely fastened to the ground. Ensure that the skid base
of the transformer is bolted securely to the plinth.

2) The Input and Output line connections are to be made directly onto
the HV bushings. The bushings are Webster Wilkinson type B4289.
Palm terminals are supplied (50 x 16mm with 2 sets of 4 x 10mm
holes)

Sufficient clearances must be maintained. Approved cable

terminations should be used.

Ensure that the leads are connected to the terminals marked A1, A2,
and a1 and a2 as shown in rating and diagram drawings listed below

3) Ensure that an efficient earth connection is made to the earth

terminals on the tank.

2.8 Schedule of Erection Drawings

General Arrangement A2349G

Rating/Diagram Plate C3793D

8
SECTION 3

COMMISSIONING INSTRUCTION

3.1 General

Check the equipment for any obvious signs of damage, loose items and
contamination by water or other substances. Site tests and checks are not
carried out by International Transformers. The site test results and checks
are not part of our contract.

3.2 Equipment Pre-Commissioning Checks

The following electrical tests should be carried out on the equipment.

3.2.1 Ratio Measurement

With the transformer isolated from the supply the input bushings with 1% of
the rated input voltage as a reduced single phase, 50Hz supply. Measure the
output voltage of the secondary windings of the transformer. Compare the
results with the values given in the test certificate.

3.2.2 Resistance Measurement

With the transformer isolated measure the resistance of the windings

compare with results in test certificate.

3.2.3 Insulation Resistance Measurement

With the transformer isolated the insulation resistance should be measured.

3.2.3.1 Measured with a 2500 volt megger the following are minimum insulation
resistance values.

a) Transformer Windings to Earth 200Meg ohms.

b) Primary winding to secondary windings 500Meg ohms.

3.2.3.2 With a 500 volt megger check the LV wiring to earth. The minimum value
of resistance should be 25Mohms.

3.2.3.3 Reconnect all leads.

3.2.4 Voltage Withstand

9
 A separate source ac voltage (flash test) at 80% of 38kV, ie 31kV, should be
applied to the Input windings and Output + earth for 1 minute.
A separate source ac voltage (flash test) at 80% of 50kV, ie 40kV, should be
applied to the Output windings and Input + earth for 1 minute.

3.3 Paintwork

The exterior paintwork should be inspected and any damage caused through
transport, installation or commissioning should be made good
immediately.

The final colour is Dark Admiralty Grey to BS381C shade 632 semi gloss.
The general paint specification is detailed in specification PC2/1.

3.4 Buchholz Relay

A Buchholz relay type BS50LA is fitted in the pipework between the

conservator and the main tank. This gas detection device is fitted with
normally open mercury switches factory set.

See Appendix B for manufacturing details.

3.5 Pressure Relief Valve

An auto re-setting pressure relief valve is mounted on the main tank lid. It
is set to release any pressure built up above 11.6 psi (0.85 atmospheres). A
change-over contact indicates operation.

Operation of this device is usually an indication of major failure with the

tank.

See appendix C for manufactures details.

3.6 TES Heat Exchanger

Refer to Appendix E for manufacturers details.

3.7 Surge Diverter

Refer to Appendix F for manufacturers details.

10
SECTION 4

OPERATING INSTRUCTIONS

4.1 Unit Isolation

The transformer has no inherent means of input isolation. The supply to the
transformer of 11,000 Volts 1 phase must therefore be isolated and locked
off at the supply breaker located remote to the transformers before any work
is attempted on the equipment.

ISOLATE ALL SUPPLIES PRIOR TO WORKING ON THIS

EQUIPMENT.

11
SECTION 5

MAINTENANCE INSTRUCTIONS

MAINTENANCE MUST ONLY BE CARRIED OUT WHEN THE EQUIPMENT HAS

BEEN TOTALLY ISOLATED.

5.1 Transformer

Maintenance of the transformer is covered in standard Works Instruction

WI0007 attached to the rear of this manual. The insulating liquid is
transformer oil classified non hazardous. See Appendix A for the safety
data sheet. Oil samples should be taken every 12 months via sampling
valve provided and as detailed in WI0007 and BS 5730.

The oil level should be checked at the same time. Re-process or replace the
oil if it becomes discoloured or fails to meet the withstand requirements.

If it is required to replace the oil, filling must be done with the tank under a
vacuum of <20mbar to ensure complete filling of the heat exchanger
pipework.

5.2 Pressure Relief Valve

The rating of the operating micro switch is such that no maintenance of the
contacts is foreseen. However it is advisable that the contacts be checked
every twelve months for correct switching by manual operation of the
switch only. See Appendix C for manufacturer’s data.

5.3 Buchholz Relay

The Buchholz relay type BS50LA is fitted with factory set alarm and trip
relays. (See section 3.4). The contacts of the relay should be checked every
twelve months for correct operation. See Appendix B for manufacturer’s
data.

5.4 TES Heat Exchanger

Refer to Appendix E for details.

5.5 Surge Diverter

Refer to Appendix F for details.

12
5.6 General

The housing of the pressure relief valve, and marshalling equipment should
be vacuumed out every 12 months.

The paintwork should be touched up where required. Refer to paint

specification works instruction WI0096 section.

13
SECTION 6

Fittings List
The transformers are fitted with the following equipment :-

1) A Qualitrol pressure relief valve with alarm/trip changeover contact

mounted on the side of the tank.

2) Buchholz Relay Comem with alarm and trip contacts.

3) A TES heat exchanger

4) Qualitrol Magnetic Oil Level Gauge with alarm and trip contacts

5) Surge Diverter ABB

6) Qualitrol (AKM) Winding Temperature Indicator (Input and Output)

7) Qualitrol (AKM) Oil Temperature Indicator

SECTION 7

Appendix A

Cooling Liquid
SECTION 8

Appendix B

Buchholz Relay Gas Relay

BS50LA
SECTION 9

Appendix C

Pressure Relief Valve

Qualitrol type 208

SECTION 10

Appendix D

Magnetic Oil Gauge

Qualitrol Ref LLG032

SECTION 11

Appendix E

Heat Exchanger

TES Ref A010848

SECTION 12

Appendix F

Surge Diverter

ABB Type MWD 12

SECTION 13.0

Appendix G

Oil Temperature Indicator (OTI)

&

Winding Temperature Indicator (WTI)

Qualitrol (AKM) Ref AKM35

 MANUAL
TD34

Oil Temperature Indicator OTI Series 34

Winding Temperature Indicator WTI Series 35

AB Qualitrol AKM
FLYGFÄLTSGATAN 6 C SE - 128 30 SKARPNÄCK , SWEDEN
Phone +46 8 447 54 50 Email: [email protected]
Fax +46 8 604 68 10 Website: www.qualitrolcorp.com

2007
 MANUAL
Oil Temperature Indicator OTI Series 34
Winding Temperature Indicator WTI Series 35

1. General
AKM Oil Temperature Indicators Series 34 and AKM Winding Temperature Indicators
Series 35 are robust weather proof instruments. They are designed and manufactured for
long and trouble free outdoor operation under all conditions. To secure maintenance free
operation, the installation on the transformer must be made with care. However, some
executions might require control and possibly some maintenance – please see below.

2. Installation
2.1 Before installation, check for possible damage from transport handling
2.2 Do not carry the instrument by the capillary. Do not twist the capillary when unwinding it, or
bend too sharply – min radius 25mm. Clamp it along its entire length at approx 400 mm
intervals. Excess capillary can be wound in a spiral with minimum diameter 100 mm.
2.3 Leave at least 15 % thermal expansion space in oil filled pockets (see page 6).
2.4 The non-vibration mountings included must be used to prevent mechanical wear out
caused by transformer vibrations.
2.5 Installation shall prevent instrument casing temperatures over 70 °C for standard types

3. Calibration check
3.1 Each instrument is factory calibrated and no further calibration is required.
3.2 To check calibration put the bulb in boiling water (100°C) or in a well stirred bath with a
control thermometer. Read the thermometer after 15 minutes. If necessary adjust the
pointer by carefully turning the screw on the pointer. If error is larger than +/-5ºC we
recommend you contact your local agent or the manufacturer.

4. Switch setting
4.1 Switches are factory calibrated.
4.2 Each switch is individually adjustable and provided with a scale.
4.2.1 Loosen the knurled-head screw on the red pointer
4.2.2 Hold the screw in position and rotate the scale drum until the red pointer under the knurled
screw points at the desired contact point on the scale.
4.2.3 Tighten the screw in this position
4.3 Check that contact is obtained slowly turning the shaft of the drum so that the pointer of
the temperature gauge moves towards higher values on the scale. The shaft of the drum
must not be turned in the other direction since the calibration of the instrument may
change. When checking, the instrument must be in a vertical position.

5. Wiring diagram
See last pages.

6. Technical data
Please refer to general OTI/WTI bulletin 345.

7. Maintenance
7.1 Models built in protection class IP65 are provided with two desiccant capsules inside the
instrument in order to eliminate the risk for condensation. These capsules can get
saturated after time in operation and a replacement could become necessary. The colour
of the gel will change from pink (older versions blue) when new, into white after having
been saturated. At this time, or if it seems that condensation occurring inside the
instrument is not disappearing, a replacement of the capsules are necessary.
7.2 Models which are equipped with rubber dampers, type AKM 47737, AKM 47760 or AKM
47000 need to have observation for material ageing. The vibration dampers on these
mountings are made of Natural Rubber, NR (also called Isoprene). The expected life time
of these parts is estimated to minimum eight years. Since natural Rubber is ageing faster
when exposed to direct sunlight and high ambient temperatures we recommend a regular
check of these parts in climates where this is occurring. When rubber parts become old
they should be replaced. Please also note that it is important to mount these parts without
any torsional stress.
 MANUAL
Winding Temperature Indicator WTI Series 35

Gradient

Bulb in oil filled well. Approximate

temperature rise above oil temperature.

Imax = 2,3 A continuously

Imax = 10 A, 5 s
Thermal time constant (63,2% value) ca.9
min.

Heating Current

Guideline for adjustment of heating current

Keep cover mounted, feed a stable current and wait 45 minutes
before reading the winding temperature.

Gradient ºC for bulb type 11, 12, 15 and 18

10 12 14 16 18 20 22 24 26 28 30
Oil temp. 30ºC 0,72 0,79 0,86 0,92 0,99 1,04 1,10 1,15 1,21 1,26 1,31
Oil temp. 60ºC 0,71 0,78 0,85 0,91 0,97 1,03 1,08 1,14 1,19 1,24 1,29
Heating Current Amp. I2 ±5%
 MANUAL
Oil Temperature Indicator OTI Series 34
Winding Temperature Indicator WTI Series 35

Weight 4 kg

Cable gland PG16: 5 – 12,5 mm All dimensions are subject to change without notice.

CONTACT RATING
Breaking capacity
Rated current A
Switch type Rated voltage V
Resistive load Inductive load
DC 30 10 10
110 0,6 0,1
Standard switch
220 0,3 0,05
AC 110 15 15
220 15 15
AC/ DC 30 10 10
M.B.O. switch 110 10 6
220 3 1,5

Service life: Std. type min 500 000 operations.

M.B.O. type min 100 000 operations
Ambient temperature range: - 40 to + 70 ºC.
Note: 1. inductive load means that power
factor is 0,4 for AC and time
constant L/R = 7 ms max for DC.
2. M.B.O. = Magnetic blow out.
 MANUAL
Oil Temperature Indicator OTI Series 34
Winding Temperature Indicator WTI Series 35

OIL TEMPERATURE INDICATOR WINDING TEMPERATURE INDICATOR

Series 34 Series 35

Indicator Micro switches "Thermal image" heating element

Options

Output acc. to TD66 Output acc. to TD111 "Thermal image" heating element
with matching resistance TD 50/76
 MANUAL
Oil Temperature Indicator OTI Series 34
Winding Temperature Indicator WTI Series 35

Example of installation of bulb in well with M27 thread:

Other bulb and connection versions please see AKM 345 bulletin.

Please remind to leave at least 15 % thermal expansion space in oil filled pockets
SECTION 14

Appendix H

Paint Specification
SECTION 14

The paint specification is to International Transformers specification WI0096. The final

colour is Dark Admiralty Grey shade 632 to BS381C.
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0096
PAGE 1 OF 1
SPECIFICATION FOR PAINTING

SCOPE

This specification covers the cleaning, preparation, painting and preservation of ONAN
steel tanks for outdoor use in extreme weather conditions and salt laden atmospheres.

SURFACE PREPARATION

Exterior
A full shot blast to Sa3 is to be given to all surfaces, any excess of shot or grit to be
vacuumed away. After grit blasting it is important that the first coat of paint be applied as
soon as possible, less than 4 hours and before the onset of rusting, to prevent surface
oxidisation.

Interior
All surfaces are to be rubbed down, wire brushed or mechanically abraded to obtain a clean
sound surface. All surfaces are to be cleaned and degreased using HMG S.N. thinner.

PRIMER

Exterior
One coat of HMG Zinc Phosphate Epi-prime. MDFT 50 microns. Drying time 2-2½
hours.

Interior
One coat of HMG 2 pack Zinc Chromate Etch Primer. MDFT 5 microns average
Drying/curing time 15-30 minutes.

UNDERCOAT

Exterior
One coat of HMG Epi-primer PRIEPI 2 pack epoxy. MDFT 60 microns. Drying time 1
hour between coats, 24 hours before overcoating.

FINISH COAT

Exterior
One coat of HMG Epilife TOPEPI 2 pack epoxy. MDFT 50 microns. Drying time 1 hour
(touch), 3 days hard dry.

Interior
One coat of HMG Type K single pack Polyurethane oil proof paint.

Note: 1. Minimum external dry film thickness is 160 microns.

2. All paints are manufactured by H Marcel Guest.
SECTION 15

Appendix I

Guide to Maintenance of Oil Immersed Transformers WI0007

INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 1 OF 13

OIL IMMERSED TRANSFORMERS

INSTALLATION, COMMISSIONING

AND

MAINTENANCE INSTRUCTIONS

ISSUE A ISSUE B ISSUE C

MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 2 OF 13

CONTENTS

SECTION 1 - GENERAL INSTRUCTIONS

1.1 INTRODUCTION
1.2 CAUTION
1.3 METHOD OF DESPATCH
1.4 UNPACKING AND EXAMINATION UPON ARRIVAL
1.5 HANDLING
1.6 STORAGE

SECTION 2 - INSTALLATION

2.1 LOCATION
2.2 OUTDOOR TRANSFORMERS
2.3 TRANSFORMERS DESPATCHED FILLED WITH OIL TO
CORRECT WORKING LEVEL
2.4 TRANSFORMERS DESPATCHED WITH OIL COVERING
CORE AND WINDINGS ONLY
2.5 TRANSFORMERS DESPATCHED WITH CORE AND
WINDINGS IN TANK FILLED WITH DRY AIR OR INERT GAS
UNDER PRESSURE
2.6 REMOVAL OF TRANSFORMER COVERS
2.7 OFF-CIRCUIT TAPPING SWITCH

SECTION 3 - PRE-COMMISSIONING CHECKS

3.1 GENERAL
3.2 SPECIAL INSTRUCTIONS

SECTION 4 - MAINTENANCE

4.1 PAINTWORK
4.2 INSULATION
4.3 OIL
4.4 DEHYDRATING BREATHER

LIST OF REFERENCES

ISSUE A ISSUE B ISSUE C

MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 3 OF 13

SECTION ONE

GENERAL INFORMATION

1.1 INTRODUCTION

These instructions are intended to give guidance and assistance in the

installation and maintenance of standard transformers and accessories.
International Transformers should be consulted in connection with
transformers of special, or unusual design and construction. In general, the
instructions apply to transformers up to and including 2,000 kVA and
33,000 volts.

These instructions also apply to spare windings.

1.2 CAUTION

Great care must be taken in the handling, installation and maintenance of

transformers, particularly of those wound for high voltages.

1.3 METHOD OF DESPATCH

The method of despatch adopted depends upon the size and type of the
transformer, and whether any special requirements have to be met in
transport and installation. Generally the transformer is despatched in one of
the following ways :-

(a) The tank is filled with the full amount of oil to the correct working
level, i.e. ready for service.

(b) The tank is filled with sufficient oil to cover the core and windings,
the remainder of the oil being supplied in sealed drums.

(c) The tank is filled with either dry air or inert gas to a pressure slightly
above atmospheric, and the whole of the oil is supplied separately.

(d) On transformers fitted with conservator vessels, the conservator

vessel and/or bushings are sometimes removed for transport and
packed separately.

Sufficient topping-up oil is despatched in sealed drums.

ISSUE A ISSUE B ISSUE C
MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 4 OF 13

(e) Spare windings are despatched in oil in a sheet steel tank, or

enclosed in a polythene bag housed in a sealed case.

When oil is shipped, it is despatched in sealed drums and is perfectly dry

when it leaves the Works.

Every precaution is taken to ensure that the transformer will arrive at its
destination in perfect condition.

1.4 UNPACKING AND EXAMINATION UPON ARRIVAL

Immediately upon arrival, transformers should be unpacked and thoroughly

examined externally. Any damage found should be reported at once to the
Carrier, and to International Transformers, quoting the advice not details, to
enable a claim to be lodged with the responsible party. Any deficiencies of
materials should also be notified to the Carrier and International
Transformers immediately.

Oil drum seals should be checked to ascertain that the seal is unbroken.
Any damage should be reported to International Transformers immediately.

Ascertain whether there is any indication of the entrance of moisture. If

there is any reason to suspect this, samples of oil taken from the bottom of
the tank should be tested.

1.5 HANDLING

When lifting the transformer, use the lifting lugs provided for this
purpose. Avoid placing the slings under the oil valve, cooling tubes,
radiators or other projections or attachments.

If there are no means of lifting the transformer, it may be rolled or skidded

into position, taking care not to cause damage to the underbase. The
cooling tubes or radiators must not be used for leverage. The rollers are
usually provided with holes which facilitate barring of the transformer
into position.

ISSUE A ISSUE B ISSUE C

MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 5 OF 13

1.6 STORAGE

Where indoor type transformers filled with oil cannot be commissioned on

receipt, they should be stored in a warm, dry place, as free as possible from
ambient temperature variations. On transformers fitted with oil seal
dehydrating breathers, the breathers should be commissioned and the oil
seal and the dehydrating agent continuously maintained in working
condition. Instructions are given on a label tied to the breather. Plain
breathers, where fitted, should be commissioned as detailed in the
instructions attached to the breather. The plain breather will have been
sealed for transport.

Indoor type transformers stored in the open air must be thoroughly sheeted
or protected in some way to keep out moisture.

Where outdoor type transformers cannot be commissioned on receipt, they

may be stored in any reasonable outdoor location, and the oil seal
dehydrating breather, where fitted, continuously maintained. Where
outdoor units are fitted with plain breathers, it would be beneficial to
energise the transformer at rated volts and frequency on no-load, with the
breather commissioned as detailed in the instructions attached thereto. The
plain breather will have been sealed for transport.

In general, the transformer windings should never be exposed to the

atmosphere, either in or out of their tanks, unless their temperature is at
least 10°C higher than the surrounding ambient temperature. Where
exposure to atmosphere is unavoidable it should be for the shortest possible
time.

Where oil from drums is not to be used immediately, the drums should be
placed under cover in a dry warm place, horizontally, with seals downwards
so that there is a head of oil on the seal or plug to prevent the entry of water
during storage. The drum should not be stood on end, since water could
collect on the dished ends of the drum. Drum seals should not be broken
until the oil is required for filling the transformer tank and until the oil has
reached the temperature of the room in which it is placed. Any condensed
moisture on the surface of the drum should be allowed to dry before
breaking the drum seal. Drums should, in general, stand undisturbed under
cover for twenty-four hours, before withdrawing a test sample.

Failure to observe these instructions may involve prolonged drying out of

both transformer windings and oil before the final commissioning.

ISSUE A ISSUE B ISSUE C

MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 6 OF 13

SECTION TWO

INSTALLATION

2.1 LOCATION

The location of a transformer has a definite effect upon its loading

capabilities and life, and should provide maximum accessibility and ease of
inspection.

2.2 OUTDOOR TRANSFORMERS

Adequate facilities for erection, maintenance and removal should be

available. Sufficient headroom must be provided for removing tank covers
for inspection.

In order to allow free air circulation, self-cooled transformers should be

adequately spaced from one another, from walls etc.

Guidance as to the permissible loading associated with particular ambient

temperatures, loading cycles and top oil temperatures is given in B.S. Code
of Practice CP.1010.

2.3 TRANSFORMERS DESPATCHED FILLED WITH OIL TO CORRECT

WORKING LEVEL

On these transformers, a sample of oil drawn from the valve or plug at the
bottom of the tank should be tested for moisture content before
commissioning the transformer.

The recommended sampling and testing procedure for the oil is as outlined
in British Standard Code of Practice BS5730, entitled "Maintenance of
Insulating Oil". This is especially important where transformers have been
stored for a long period. The crackle test for moisture content described in
BS5730, is a simple and useful test for presence of suspended moisture in
oil. Oil which does not pass this test should be suitably treated as
described in BS5730.

Other tests as recommended in BS5730 may be carried out if facilities

permit, but not all the tests are necessary on every sample. If the crackle
test for moisture indicates only a small proportion of moisture, the oil only
should be treated. If, however, a large proportion of moisture is indicated
it may be advisable to dry out the transformer itself before commissioning.
Instructions on 'Drying-out Procedures' can be obtained on request from
International Transformers.

ISSUE A ISSUE B ISSUE C

MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 7 OF 13

2.4 TRANSFORMERS DESPATCHED WITH OIL COVERING CORE AND

WINDINGS ONLY

Where transformers are despatched with oil covering the core and windings
but not to the correct working level, oil from drums must be added. In the
case of a transformer despatched without the conservator vessel and/or
bushings, these must be fitted and the transformer filled with oil to the
correct working level.

Before topping-up, a sample of oil from the transformer should be tested as

above, and samples from the drums should be tested for moisture content, as
described in BS5730. Care should be taken in transferring oil from the
drums to the tank to ensure that no foreign matter or moisture is introduced
in the main tank oil. After filling with oil to the correct working level, the
transformer should be allowed to stand for about one hour before being
energised.

2.5 TRANSFORMERS DESPATCHED WITH CORE AND WINDINGS IN TANK

FILLED WITH DRY AIR OR INERT GAS UNDER PRESSURE

On such transformers, check that there is evidence of pressure in the tank

when the tank seal is broken. Usually a small valve or plug is fitted on the
tank cover or tank side. This should be opened slowly and signs of
escaping gas should be detected if the sealing has not deteriorated since
leaving the Works. The tank sealing should not be broken unless the
transformer can be filled with clean dry oil immediately. Where no
evidence of escaping gas is observed, it should be reported to International
Transformers immediately. A suitable drying-out procedure may be
necessary on site and recommendations will be given on request.

The dry core and windings should never be exposed to the atmosphere for
any length of time and should be at a temperature of at least 10°C above the
ambient temperature before such short exposures.

After checking the efficiency of the tank seal, an insulation resistance test
should be carried out between windings and earth (core and tank), to check
the transformer insulation as follows:-

1) Insulation Resistance H.V. Winding/L.V. Winding

2) Insulation Resistance H.V. Winding/Earth
3) Insulation Resistance L.V. Winding/Earth

ISSUE A ISSUE B ISSUE C

MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 8 OF 13

It is essential that all transformers be free of moisture before being

commissioned, since the presence of moisture results in a lowering of the
insulation resistance. If the insulation resistance readings obtained agree
approximately with the values recorded on the Test Certificate, the tank
may be filled with clean dry oil. If low readings are obtained, it may be
necessary to carry out a Site drying-out operation.

Oil filling should be carried out with the least possible splashing, as detailed
in BS5730.

Filling from the top of the tank can be done by removing the tank cover or
inspection cover, where provided, care being taken to ensure that no
foreign matter or moisture can fall into the tank during such filling.

The oil introduced into the tank should be at the same temperature as the
core and windings. Oil core and windings should preferably be at a
temperature of at least 10°C above that of the surrounding air.

An intermediate insulation resistance check should now be carried out as

described above, and the results should agree approximately with the values
on the Test Certificate.

2.6 REMOVAL OF TRANSFORMER LIDS

The cover of a transformer should only be removed under conditions which

ensure no moisture or other foreign matter can find its way into the tank.
When the cover is replaced, it is essential to ensure that the gasket is
properly fitted and the cover is securely bolted to the tank.

2.7 OFF-CIRCUIT TAPPING SWITCHES

When off-circuit tapping switches are fitted, the correct relative position of
switch and operating handle is fixed before the transformer leaves the
Works.

If, for any reason, it is necessary to remove the switch operating handle and
shaft, it is essential that they are reassembled in their correct relative
position.

ISSUE A ISSUE B ISSUE C

MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 9 OF 13

SECTION THREE

PRE-COMMISSIONING CHECKS

3.1 GENERAL

The connecting leads should be arranged so that the impedance drop in each
lead is the same.

A diagram of connections is despatched with each transformer and the

instructions given should be carefully followed.

Phase-out the circuits before finally connecting the transformer and set the
tapping switch or links for the required voltage, in accordance with the table
on the terminal marking plate attached to the transformer.

On dual ratio transformers, the ratio for which the transformer was
connected on despatch is indicated on the terminal marking plates.

Connect the earth terminal of the tank to an efficient earth. The neutral of
the L.V. Winding, where available, should also be earthed to comply with
the Supply Regulations.

Check the oil level of the oil level indicator.

Commission the dehydrating breather or the plain breather. Check the oil
seal and the condition of the dehydrating agent in the breather. Instructions
are attached to the breather. Ensure that the sealing plug, fitted to the base
of the breather before despatch, is removed.

Where Buchholz relay is fitted, follow the detailed installation and

maintenance instructions.

Check all other fittings.

Whether transformers are being operated in parallel, it is particularly

important to correctly phase-out all circuits before finally connecting.
Connections suitable for parallel operations are described in Appendix E of
BS171 : 1978.

On all transformers, however despatched, it is advisable wherever possible,

either :-

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MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 10 OF 13

(a) To run for a short time with one winding short circuited and with
power equal to full load and fixed losses supplied to the other
winding. This will require a supply voltage slightly greater than the
transformer impedance voltage.

The short circuiting connections should be removed, and where

practicable, the supply voltage raised slowly to the full rated
transformer voltage. Any incorrect connections will become
obvious before any serious damage occurs.

OR

(b) To energise at full rated voltage and frequency with one winding on
open circuit, supplying only the transformer fixed losses.

The transformer is thus warmed by the heat of the fixed losses and
any trapped air in the oil is dispelled by convection currents. This
procedure also helps to prevent the gas actuated elements of a
Buchholz relay, where fitted, operating and tripping the supply
breaker or sounding an alarm unnecessarily. Switching in or out
of a transformer should be kept to an absolute minimum to avoid
steep fronted voltage waves and current inrush surges
unnecessarily stressing the winding insulation, electrically and
mechanically.

3.2 SPECIAL INSTRUCTIONS

Any special instructions attached to the transformer or issued separately

should be carefully followed.

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MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 11 OF 13

SECTION FOUR

MAINTENANCE

4.1 PAINTWORK

The exterior paintwork should be inspected periodically. Any damage

caused during transport or movement to final location should be made
good immediately. The standard 3 coat paint system applied in the Works
will give a high degree of protection against all normal atmospheric
corrosion. It is not possible to generalise on the amount of maintenance
work which will be necessary on any particular site. A general inspection
and overhaul, say once a year is recommended.

4.2 INSULATION

The working life of a transformer is dependant on the life of its insulation,

the rate of deterioration of which increases with increase of temperature.

It is not feasible to give accurate data for all conditions of loading and
variations in transformer design but the British Standard Code of Practice
CP.1010 entitled "Guide to Loading of Oil-Immersed Transformers to
BS171", represents a standard of good practice and takes the form of
recommendations.

4.3 OIL

The British Standard Code of Practice BS5730, entitled "Maintenance of

Insulating Oil", describes the nature of likely deterioration in service,
storage or handling, recommends routine Site methods of testing and
sampling and also covers the required frequency of such sampling and
testing. A thorough reading of this publication will amply repay the
reader. It covers the maintenance of all oil supplied to British Standard 148,
including inhibited oils. BS 5730 deals with the treatment and handling of
oil on-site.

Oil evaporates in service, and the oil level should be periodically checked
on the oil level indicator and topped up when necessary with clean dry oil.

When sampling oil, the sample should be allowed to reach the temperature
of the test room before being exposed to air. The room air temperature
should not be below 15°C and for reference purposes, not above 25°C.

ISSUE A ISSUE B ISSUE C

MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 12 OF 13

4.4 DEHYDRATING BREATHER

The air drying agent should be checked regularly for quantity and colour
and replaced or re-activated where necessary. The frequency of such
inspection is entirely dependent on site climatic conditions. It is
recommended that the breather be inspected at least every three weeks and
more often in a moist climate.

The conditions of the Silica Gel may be observed through the inspection
window. The Silica Gel provided is impregnated with the Cobalt Chloride
and when dry is deep blue in colour, and changes to pink as moisture is
absorbed.

When an indication of pink is seen the Silica Gel should be removed and
dried slowly, preferably in an oven, until the crystals become blue again.

The oil seal at the base of the breather prevents air entering the Silica Gel
except while the transformer is heating and cooling. The oil seal should be
cleaned out periodically and refilled with new transformer oil. The correct
level of the oil is half an inch above the end of the sealing tube.

Before commissioning the transformer, it is important to inspect the

breather and associated pipework to ensure that there is a free passage
through the breather into the transformer tank, or into the conservator, if
this is supplied.

ISSUE A ISSUE B ISSUE C

MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
INTERNATIONAL TRANSFORMERS
WORKS INSTRUCTION NUMBER: 0007
PAGE 13 OF 13

LIST OF REFERENCES

(1) British Standard Specification BS 5730 (1979)

Entitled "Maintenance of Insulating Oil"
Issued by :-
British Standards Institution,
British Standards House,
2 Park Street,
London, W1.

(2) British Standard Code of Practice CP.1010 (1979)

Entitled "Guide to Loading of Oil Immersed
Transformers to BS.171"
Issued by :-
The Council for Codes of Practice,
British Standards Institution,
British Standards House,
2 Park Street,
London, W1.

(3) British Standard Specification 148 : 1972

Entitled "Insulating Oil for Transformers and
Switchgear"
Issued by :-
British Standards Institution,
British Standards House,
2 Park Street,
London, W1.

(4) British Standard Specification 171 : 1978 and 1987

Entitled "Power Transformers"
Issued by :-
British Standards Institution,
British Standards House,
2 Park Street,
London, W1.

ISSUE A ISSUE B ISSUE C

MAY 76 FEB 90 NOV 92
B K HARDINGE B K HARDINGE B K HARDINGE
SECTION 16

Appendix J

Current Transformers
SECTION 17

Appendix K

Drawings and Test Certificates

DRAWING LIST

General Arrangement A2349G

Rating/Diagram Plate C3793D

Wiring Diagram C3828D

Test Certificates
 REFS 01 - INPUT CABLEBOX ( 1:10 ) REMOVABLE FRONT
COVER
AND GLAND PLATE
a1 b2

598.9
35
80
35

25
BUSHING PALMS : 50 X
16
WITH HOLES 10 DIA

SURGE DIVERTER : TYPE

MWD12

100 X 50
RECTANGULAR
HOLLOW SECTION

8 - 16DIA HOLES IN ANGLE CLEATS

TO SUIT HILTI FOUNDATION STUD A1 A2
TYPE
ANCHOR FIXINGS.
REFS : HST-HCR M16/25
REMOVED FOR AXLE AND ROLLER FOR TRANSPORT ONLY
TRANSPORT - TO BE REMOVED ONCE TRANSFORMER IS IN POSITION
-
NOTE : AXLE LENGTH = 1270LG

REMOVED FOR
TRANSPORT

A1 A2
3531
2600 MAX HEIGHT ACCESS

2590 MAX HEIGHT

1950

PROPOSED HEAT
894

EXCHANGER
WATER OUTLET FLANGE 360 BUSHING CTRS

PROPOSED HEAT
EXCHANGER
WATER INLET FLANGE
775

258

455 CTRS 455 CTRS

185 185
352 50
1000 FIXING CTRS 1000 FIXING CTRS
80 585 585

1459
3300 WIDE ACCESS
1486 1165

T4728
A1

M.S - RADIATORS REMOVED REPLACED BY HEAT EXCHANGER , CABLEBOXES NOW TOP ENTRY , 16/11/09
M.S - HEAT EXCHANGER ADDED TO DRAWING 07/12/09
M.S - FOUNDATION FIXING CENTERS WAS 995 AND 580 - CHANGED TO 1000 AND 585 23/12/09
M.S - DRAWING BROUGHT UP TO DATE INCLUDES FINAL ASSEMBLY OF HEAT EXCHANGER 05/01/10
M.S - MARSHALLING BOXES AND HEAT EXCHANGER CUBICLE ARE NOW TOP ENTRY 12/01/10
M.S - DRAWING UPDATED TO SHOW CORRECT TYPE BREATHER 14/04/10 M.SANDHU 1:15 27/06/09

A2349G 1
 F
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A

D
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1
0
ISSUE
BY

M.S
-

1
1

WHERE USED

ECN
CONVERTER TRANSFORMER
TO BS EN 60076 AND

NEW
T4728
CUSTOMER SPECIFICATION NUMBER : P0013/07012/ELQUIP
RATED CONT. POWER MVA 5 COOLING L/ OFWF
SHORT TIME POWER - 30MIN MVA 8.33 COOLING WATER FLOW RATE MIN 110
RATED INPUT 6350 CONNECTION SYMBOL SINGLE PHASE
VOLTS OUTPUT 6350 -11000 IMPEDANCE AT 5MVA %
CONT.RATED INPUT 788 IMPEDANCE AT 8.33MVA %

2
2

CURRENT OUTPUT 788 - 455 CORE & WINDINGS kg 5670

INPUT 1312 OIL kg 2885
SHORT TIME RATED
CURRENT OUTPUT 1312 - 758 TOTAL WEIGHT kg 11565
PHASES 1 OIL QTY. Ltrs 3370
FREQUENCY Hz 50 SERIAL No.
YEAR MADE

DESCRIPTION
INSUL. LEVELS INPUT 38AC / 95LI

OIL QTY WAS 2710LTRS AND WIEIGHT WAS 2320KG

INSUL. LEVELS OUTPUT 50AC / 125LI DIAGRAM DRG. No. C3793D

OUTPUT - 6350 / 11000VOLTS

VOLTAGE RATIO LINK BOARD
UNDER ACCESS COVER.
3

3
3S1 P1
11kV 11kV
3S2
4S1
CT'S RATIO :
4S2
1500/1A 5S1
CLASS : TPY
5S2 6.35KV 6.35KV P1
6S1 8S1
W.T.I CT RATIO :
6S2 P2 8S2 1312/2.5A
P2
CLASS : 5
a1 a2

A1 A2

DATE
4

4
02/02/10
P2
2S2 P2 7S2
CT'S RATIO : W.T.I CT RATIO :
2S1 7S1 1312/2.5A
1500/1A 1S2 P1
CLASS : TPY CLASS : 5
1S1 P1

TITLE
IF IN DOUBT ASK

INPUT - 6350VOLTS
5

5
6
6

RATING AND DIAGRAM PLATE

300 X 200
ALL HOLES 5 DIA
6mm FROM EDGES
WHICH IS TO BE RED

TOLERANCES UNLESS OTHERWISE STATED : NO DECIMAL PLACE ±1mm ONE DECIMAL PLACE ±0.4mm ANGULAR ±1°

DRAWN
M.SANDHU

DRAWING No.
© COPYRIGHT 2009
7

7
MATERIAL : 1.6THK STAINLESS STEEL

THIS DOCUMENT IS THE

PRODUCTS LIMITED AND

PROPERTY OF IST POWER

REPRODUCED,TRANSMITTED
NO PART OF IT MAY BE USED,

PRIOR WRITTEN PERMISSION.

AND/OR DISCLOSED WITHOUT

CHECKED

C3793D
ALL LETTERS TO BE BLACK EXCEPT "INTERNATIONAL"

SCALE
N.T.S
A3
8

8
Fax : 0161 - 428 - 0052
Tele : 0161 - 428 - 9507
MANCHESTER, M22 4RU

DATE

1
Sharston Ind.Est, Longley Lane
297 X 420

SHEET No.
a division of IST POWER PRODUCTS LTD

05/01/10
international transformers

F
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A

D
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 INTERNAL C.T'S
2.5mmSQ SINGLE 2.5mmSQ SINGLE

QUALITROL PRD
W.T.I AND AUXILIARY
MARSHALLING BOX FAB
BLACK CABLE WIRING MARSHALLING BLACK CABLE
BOX

BUCHHOLTZ RELAY

ALARM

TRIP
LIQUID LEVEL GAUGE

LEVEL
MAX
TO - W.T.I'S

WINDING TEMPERATURE WINDING TEMPERATURE OIL TEMPERATURE

LEVEL
INDICATOR - INPUT INDICATOR - OUTPUT INDICATOR

MIN
TRIP ALARM TRIP ALARM TRIP ALARM

INSTRUMENT CONTACTS OPERATION COMMENTS INSTRUMENT CONTACTS OPERATION COMMENTS

PRESSURE 1 N.O CHANGE OVER RELEASE AT WINDING 1 N.O CLOSES ON CLOSE AT
RELIEF DEVICE 1 N.C ON RELEASE 12 P.S.I. TEMPERATURE ALARM TEMP RISE °C
INDICATOR 1 N.O CLOSE AT
1 N.O CLOSES ON ALARM CLOSES ON
- INPUT - TRIP °C
ALARM EXCESS GAS TEMP RISE
BUCHHOLTZ 4-20MA REMOTE IND.
1 N.O
RELAY CLOSES ON
TRIP TRIP WINDING 1 N.O CLOSES ON CLOSE AT
OIL SURGE
TEMPERATURE ALARM TEMP RISE °C
1 N.O 11 CLOSES ON INDICATOR 1 N.O CLOSE AT
14 AND OPENS MIN LEVEL CLOSES ON
1 N.C - OUTPUT - TRIP °C
LIQUID LEVEL TEMP RISE
ON 12 4-20MA REMOTE IND.
GAUGE
1 N.O 21 CLOSES ON 1 N.O CLOSES ON CLOSE AT
MAX LEVEL OIL
1 N.C 24 AND OPENS ALARM TEMP RISE °C
TEMPERATURE
ON 22 1 N.O CLOSE AT
INDICATOR CLOSES ON
TRIP °C
TEMP RISE
4-20MA REMOTE IND.
1.5mmSQ 4 CORE PVC SWA CABLE

T4728

AUXILIARY WIRING DIAGRAM

M.SANDHU N.T.S 07/01/10

C3828D 1
SECTION 18

Appendix L

Core Characteristics