operation instruction of power transformer

First. Application area

As a general technical document of 150kV power transformer with OLTC, this
instruction doesnt include the specific parts determined by product particular
configuration (shown in products complementary installation and operation
instruction), nor does the installation and operation instruction of subassembly (shown
in installation and operation instruction of subassembly).
Second. Main body of transformers haul
According to the final assembly drawing, the main body of transformers haul
should use the lifting lug set in the middle part of upper part of tank and all the lifting
lug of bottom part of tank, and the angle of steel cable and upright line shouldnt
exceed 30 , the haul height is shown in the final assembly drawing, jack frame is set
either on the upper part of tank or on the bottom part of tank, when using, all the
jacking lug must be forced equally to make them be lifted simultaneously.
Third. Transportation
3.1 Transportation of main body of transformer from the factory to the
installation spot adopt railway or highway transportation in accordance with Chinas
standard gauge, standard transportation limit, and should stand by relational
regulations of railway department, followed by sea transportation then short distance
highway transportation or transportation with manpower, in the transportation, the
incline angle of transformers shouldnt exceed 15, and should stand by the following
regulations:
3.1.1 In the railway transportation and manual roll, the jolt of main body of
transformers shouldnt exceed the natural instance of railway transportation.
3.1.2 The speed of highway transportation shouldnt exceed 10km/h.
3.1.3 In the transportation with manpower, if the traction is along the long
shaft, use the drawing board set on the bottom part of tank, if the traction is along the
short shaft, use the jacking lug. The traction speed shouldnt exceed 2m/min.
3.1.4 When the trailer set in the bottom of transformer fill its shoes in the
railway track or exit, it should be lubricated in advance, the traction speed shouldnt
exceed 2m/min.
3.2 The transportation dimension of main body of transformer by the railway
transportation limit can be seen in the transportation dimension drawing. All the
assembly parts, component parts and accessories which cant be linked with main
body of transformer to transport as a whole, should transport independently
according to the dismountable parts list. All the spare parts prescribed in contract and
additional equipments should transport according to correlative regulations prescribed
in spare parts, additional equipments lists.
3.2.1 Be careful when transport bushing, the bushing package cant endure
large impact.
3.3 According to the transportation dimension drawing, main body of
transformer should be transported with nitrogen filling or transported with oil filling.
3.3.1 When transported with nitrogen filling, before shipping, release the oil

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from the transformer tank to make 100mm or so is left. At the same time, inject high
pure nitrogen (99.9%), dew point (-40 C), pressure 20-30kpa, in the transportation,
watch the nitrogen pressure in the tank, and inject eligible nitrogen when needed to
ensure the pressure inside tank to be 20-30kpa.
3.3.2 When transported with oil filling, inject eligible transformer oil into the
tank, and the oil surface should be under the tank cover 200mm. All the airproof cover
plate should airproof very well and dont leak oil.
3.4 All the disassembled tube connector, turrets, conservator, cooler, bushing-
type current transformer, down-lead transport boxand insulation canister transport
box should be transported with airproof, the above component parts with insulation
parts should be transported with oil filling, according as actual case, make the oil
immerge the insulation parts.
3.5 The assembly parts and spare parts shouldnt be rolled and uncoupled with
slipping in the installation and transportation.
3.6 In water transportation, the incline angle of main body shouldnt exceed 15
(ocean transportation is not included).
Fourth. Check and accept
After receiving the transformer, the consumer should firstly check if the product
rating plate and quality certificate are consistent with the specification prescribed in
the order contract, then make the universal examination and record.
4.1 If crude transportation evidence is discovered (see the equipment), stop the
unloading, and inform the transportation department.
4.2 According as the catalog of technical documents for product, check if the
technical documents for product provided by factory is perfect.
4.3 According as the dismountable parts list, check if the disassembled parts are
consistent with the packing list, the number prescribed in the dismountable parts list,
and if the disassembled parts are damaged.
4.4 If there is spare parts according to the contract, check if these spare parts are
perfect according as the spare parts, additional equipments lists, and if the product
packing list is consistent with the list.
4.5 after transformer and accessories are transported to user department,
installation and user department should check the amount and put them into storage
inform the factory in 5 days if factory is necessary in check and accept.If after 15
days, nothing is done with checking the amount, the factory will not responsible for
the coming losing.
4.6 For transformers transported with nitrogen filling, check if the nitrogen
pressure inside the main body is at 20-30kpa, for transformers transported with oil
filling, check if there is oil leaking, if there is displacement between main body and
transportation car, if the steel cable used for fixing has been snapped., if there is
apparent impact damage and other damage.
Make a careful record of the damaged component parts discovered in above
checking and other abnormal phenomenon, take pictures on the spot, and offer the
factory and transportation department photos, nonconformity list and copy of
inspection record within the time prescribed in 4.5, to find the cause in time, carry the

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obligation, research and make a disposal.
Fifth. Storage
After the transformer is sent to the locate, if not install and launch into operation
immediately, consider feasible storage ways according to the actual case, that is keep
on storing with nitrogen filling or discharge nitrogen and store with oil filling.
5.1 Product is transported with nitrogen filling, the inspection of inside pressure.
5.1.1 For product transported with nitrogen filling, check immediately after he
transformer is sent to the locate, after transporting, the nitrogen pressure inside the
main body shouldnt less then 4.9kpa under circumstance temperature.
If the nitrogen pressure doesnt accord with the above condition, the product
shouldnt be stored with nitrogen filling. Besides, decide if the product is affected
with damp according to 5.3.3.
5.2 Storage with nitrogen filling less then 2 months
5.2.1 If 5.5.1 is satisfied, Storage with nitrogen filling is permitted, but the
storage shouldnt exceed 2 months, otherwise, store with oil filling according to 5.3.
5.2.2 When storing with nitrogen filling, the nitrogen pressure requirement
inside the main body is the same as 3.3.1.
5.2.3 In the storage with nitrogen filling, check at least 2 times every day,
make a record of the pressure inside the trunk and the additional nitrogen amount, if
the nitrogen pressure drop very fast, the wastage is large, there is nitrogen leaking,
check and make a disposal in time, prevent the transformer surface from being
affected with damp.
5.3 Storage with oil filling
Product transported with nitrogen filling and stored with nitrogen filling over 2
months or product which cant be stored according as 5.1 should store with oil filling,
usually the storage time doesnt exceed 6 months.
5.3.1 Firstly discharge the oil in the bottom of the tank
5.3.2 inject oil and discharge nitrogen
Open the butterfly valve on the tank cover to discharge nitrogen (adopt effective
measure, prevent the damp air, water and other objects from entering the tank), at the
same time, inject transformer oil according to the following requirements from the
gate valve in the bottom of the tank or any of the valve installed with condenser.
Voltage withstand50kV/2.5mm
Moisture content15ppm
gas content2%
tg0.5% (90)
5.3.3 Check and decide if the product is affected with damp more after leaving
the factory. If the product isnt affected with damp (measure after the oil is injected),
all the windings and grounding should meet the following requirement: (at the same
temperature)
insulation resistance R60 70% of routine value (2500v Mmeter)
absorption ratio R60/R15 70% of routine value
dielectric loss factor tg130% of routine value
If the above requirements are not met, it shows that the transformer surface is

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affected with damp, the product cant be installed or put into operation, make dryness
disposal of the surface over again, contact with the factory, up to fulfill the above
requirements.
5.3.4 Install the conservator system (including dehydrating breather) temporarily
and keep on injecting oil, adjust the oil surface to be higher than the normal oil
surface position of the conservator, and discharge the air inside the conservator
according to the installation and operation instruction.
5.3.5 In injecting oil and storage, check the transformer appearance every other
10 days, make a disposal in time if there is oil leaking. Take out oil muster from the
main body of transformer and test, its performance should meet the following
requirements:
Voltage withstand45kV/2.5mm
Moisture content15ppm
For product transported with oil, take out oil muster from the main body of
transformer and test after being sent to the spot, its performance should meet the
following requirements:
Voltage withstand45kV/2.5mm
Moisture content15ppm
Under this circumstance, only after assembling according to 5.3.4 can storage with
oil be carried out. And check and test according to 5.3.5. If the oil muster doesnt
meet the above requirements, inform the factory decide if the product is affected with
damp more, make a disposal, if all the requirements are met, store with oil.
5.4 Storage and keeping of dismountable parts
Keep the dismountable parts carefully in its storage period, prevent them from
rainwater, dust and being polluted, rust and dirtiness is not allowed, and the open air
storage is not allowed, prevent the inside insulation parts from being affected with
damp.
Sixth. Main equipments and tools needing preparing before
reinstallation in the spot
(1) oil tank 50t a suit
(2) vacuum machine 6000L/h vacuum degree 13.3Pa a suit
(3) pinch oil-filter 2000L/h a suit
(4) vacuum pump 3stere/h vacuum degree 13.3Pa a suit
(5) filter paper drying box a suit

(6) oiliness test equipment (withstand voltage, tiny water, airiness, tg , etc) a suit
(7) dry air occurring machine a suit
(8) oxygen content meter a suit
(9) pipeline for oil-filling appropriate amount
(10) vacuum soft pipe appropriate amount
(11) sling equipment (including sling tool) 15t a suit
(12) lead chain 1t 3t each one
(13) ladder 3m 5m each one
(14) plastic cloth appropriate amount
(15) fire extinguisher appropriate amount

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 (16) illuminating equipment a suit
(17) empty oil box total capacity 5000L a suit
(18) psychrometer a suit
(19) megger 2500V 5000M, 500V 2000 M a suit
(20) vacuum meter 133.3Pa a suit
(21) air shear, welding equipment a suit
(22) withstand oil rubber board appropriate amount
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(23) boult 30item per cm a suit
(24) silica gel 5kg
(25) plain cotton tape electrician crepe paper (drying) each 3 plate
(26) insulating pressboard (drying) appropriate amount
(27) plastic outer wear ( without clasp) 4 suit
(28) high canister withstand oil rubber boot 4 suit
(29) electric torch (4.5V~6V) 4 suit
(30) high grade cotton white cloth hypo-cotton cloth without sinning cloth
each 4 suit
(31) insulation lacquer (varnish immersed with polyvinyl acetate) 2kg
(32) hair brush 2 suit
(33) emery cloth 300200mm 20 sheets
(34) nylon rope 8mm 20m 3 suit
Seventh. Inside inspection before transformer final assembly
Under normal circumstances, there is no need for transformer lifting cap or lifting
core inspection, but should enter tank from the manhole to inspect. If impact has
happened during the transportation, or the tank body has been part damaged and
distorted, or the transportation incline angle has exceeded 15 , or the user has the
requirement for lifting check and can offer all the spot requirements for lifting
checkthe transformer should be inspected lifting cap.
7.1 Requirements and announcements in lifting cap inspection:
7.1.1 Before lifting capinject dry air to discharge nitrogen, then decide if the
transformer surface has been affected with damp according to 5.3.3.
7.1.2 The lifting cap inspection should carry out in sunshine, and the relative
humidity shouldnt exceed 75%, the ground should be clean, prevent snow and
rainwater, dust from being entered into.
7.1.3 The core temperature measured through upper yoke should be higher than
circumstance temperature 10 15 , in case that moisture in the air coagulate on the
transformer surface.
7.1.4 The time interval that transformer surface stay on the air should shorten to
the best, count the time from starting discharge oil or disentangling cover plate to
vacuumize (or inject oil), the time interval that the transformer surface stay on the air
shouldnt isolate the following regulations:
a The relative air humidity shouldnt exceed 65% of dry weather16h
b The relative air humidity shouldnt exceed 75% of dry weather12h
7.1.5 The backout of upper orientation equipment is shown in final assembly
7.1.6 The actual request for on-load regulating-changer. disassembly and

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sequence is shown in operation instruction of on-load tap-changer. Then lug the upper
part of tank using the lifting lug set in the upper part of tank and can inspect the
transformer surface.
7.1.7 When inspecting transformer surface, see the core compaction, the
support and clip of leadthe insulation enswathement, the fixing of all the bolt and
nut around the transformer surface, the contacts contiguity and switching on or off of
on-load tap-changer.
Besides, inspect if there is abnormal objects existing on the transformer surface, upper part
of tank and bottom part of tank.
7.1.8 After inspecting the transformer surface, make a good disposal of the
fault and make a record for future examination, for convenience, adjust the tap-changer
to the rated tapping position.
7.1.9 Make the following measurement for transformer surface:
a the insulation resistance between clamping frame and core;
b the shield between core leg and side pillar should connect with clamping frame;
c the insulation resistance among drawstring, core and clamping frame;
d the voltage rate in each tapping position of switch and connection symbol of
transformer;
e winding direct current resistance in each tapping position of switch;
f measurement of insulation resistance of each winding and absorptance;
7.2 If the transformer wont be inspected lifting cap (lifting core), enter the tank from
manhole to inspect (for short inside inspection hereinafter), requirements and
announcements are as follows:
7.2.1 If there is rainwater, snow, wind (above 4 grade), and if the relative
humidity exceed 75%, the interior check is forbidden,
7.2.2 For transformers transported with nitrogen filling, before the main body
discharging nitrogen, nobody are permitted to enter the tank, in case asphyxia;
7.2.3 Commonly the number of people entering the tank to interior check
doesnt exceed three, the interior check personnel should read the instruction and
supplementary installation and operation instruction of actual products, understand the
content, requirement and announcement.
7.2.4 Main content and technical requirement:
a Open all the hole on the tank, the interior check personnel should put on
clean clothes, shoes and caps, metal and other goods which are foreign to the work are
forbidden to carry, prevent strictly dust, other goods from entering the tank, all the
tools should be registered and assigned a number.
b Check one by one according to the interior check item and technical
requirement in 7.1.7,7.1.8 and 7.1.9, fill in the inspection result in detail.
c Install transformer accessories when interior check, the actual installation
technical requirement is shown in the 10 item of the instruction.
d In interior check, keep on injecting dry air into the tank to avoid personnel
asphyxia.
e The entrance should have dustproof measure in interior check, people are
required to stay there so that to contact with interior check personnel.

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 f After inspection, the personnel should clean the bottom of the tank, prevent
tools from leaving behind the tank, close the entrance cover plate after the interior
check personnel leave the tank.
7.2.5 During the interior check, be careful not to harm and pollute assembly
parts, component parts and structure parts of the inside part and exterior part of
transformer.
7.2.6 The permitted working time of interior check is the same as 7.1.4.
Eighth. Desiccation on the spot
8.1 If the transformer has the following problems, make a desiccation disposal on
the spot:
8.1.1 Transformer transported with nitrogen filling cant satisfy 5.3.3.
8.1.2 The time interval that the transformer surface stay on the air has isolated
the regulations in 7.1.4 and the surface has been affected with damp.
8.1.3 The desiccation should be carried out according to the insulation
appraisal result when installing transformer or after comprehensive consideration.
Going along insulation appraisal according to 5.3.3.
8.2 According to operation regulations of transformer", use corresponding ways
to make a desiccation disposal in accordance with the equipment conditions and the
products degree that are affected with damp.
Ninth. Collectivity reinstallation
9.1 Before collectivity reinstall the upper part of tank, clean the transformer
surface and tank again.
9.2 Details and component parts which have installation signs must be reinstalled
according to the indication position (such as high voltage, mid-voltage turret and
pressure relief equipmentthe relative position and angle between turret and tank).
9.3 The root part of transformer leads shouldnt be dragged, wringed and bended.
9.4 For 60kV leads and above, the insulation pin which bind up the leads should
enter the jaws of the equipotential shielding which locate on the bottom of the
bushing.
9.5 When reinstall assembly parts, do according to installation and operation
instruction of the corresponding assembly part.
9.6 If there is upper orientation parts on the top of the tank, go along orientation
and airproof according to final assembly drawing and technical requirement.
9.7 There is no need for transformer to incline if it is installed flatly on the base,
the tank cover and tube connector have 1-1.5% pitch.
9.8 Each thermometer socket should be full of transformer oil.
9.9 Reinstall each disassembly assembly parts, component parts and details (not
including gas relay, airproof both tube flange using cover) according to transformer
final assembly drawing. The installation requirement and announcement is shown in
installation and operation instruction of each assembly parts. Install the gas relay
after the transformer vacuum oil-filling.
9.10 For assembly parts which have air exhausting plug on the top (such as low
voltage bushing, gas relay, conservator, cooler tube, etc), open the air exhausting plug
to discharge the collective air after oil-filling, close when there is oil leaking (note: the

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oil-filling and gas discharging of air cooler is shown in installation and operation
instruction of air cooler in detail).
9.11Before the sealed washer is put on the slot or flange, keep the metal surface clean,
sealed washer should be in proper position of the slot, let the flange around be forced
equably when fixing with bolt.
9.12 Pay attention to the installation of horizontal shaft and vertical shaft in
the installation of on-load tap-changer, ensure that the handle turn flexibly and
reliably and the tapping indication is correct (it is shown in detail in operation
instruction of on-load tap-changer).
9.13 When installing oil filter, pay attention to the installation method and quality
of wire netting, prevent the silica gel granule from entering the tank and the interior of
transformer body, dont use those wire netting which has been rusted or have bug (it is
shown in detail in installation and operation instruction of oil filter)
9.14 After vacuum oil-filling, the additive oil should inject slowly from the top of
the tank, dont inject from the gate valve located on the bottom of the tank or from the
valve (except using the degassing oil), see the operation instruction of rubber
diaphlagm type conservator when injecting oil from the conservator, the oiliness
should accord with regulations in 5.3.2.
9.15 After injecting oil, watch closely all the seal and ensure there is no oil
leaking, watch at least 72h, then discharge air according to 9.10.
9.16 The transformer installation also should implement relative regulations in
operation regulations of transformer.
Tenth. Vacuum oil-filling: Vacuum oil-filling should be performed
after transformer final assembly
10.1 Preparation before vacuum oil-filling.
10.1.1 Remove gas relay, install temporary cover on the siphon of main body,
install U type tube which connect the switch and tank (it is shown in detail in
operation instruction of switch).
10.1.2 Open the butterfly valve on the main body of transformer and tube
among cooler, open the butterfly valve between oil filter and tank.
10.2 The transformer oil should accord with the requirement of 5.3.2.
10.3 Before oil-filling, improve the vacuum degree inside the main body of
transformer to 101.2kpa (left voltage 133.3pa), keep the vacuum degree 6h and then
inject oil, vacuumize using the 80 butterfly valve located on the tank cover.
10.4 Oil temperature 45-55 C, inject oil calmly (2-5t/h), keep the above vacuum
degree when oil-filling.
10.5 The oil had better is injected both from the valve located on the bottom of the
tank and from the butterfly valve located on the cooler tube at the same time (that is
injecting from body interior and tank at the same time), if the spot condition isnt
satisfied, inject from 80 valve and 150 butterfly valve.
10.6 The oil should immerge the winding and yoke insulation at least, and stop
injecting oil if people cant draw out oil from vacuum pump.
10.7 Close valve immediately after oil-filling, remove oil-filling tube and airproof
oil-filling opening, keep on vacuumizing and maintain 8h under the prescriptive

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vacuum degree, according to 9.14 to supplement oil.
10.8 After finishing all the oil-filling procedure, take oil sample to make an
experiment (compare with the experiment result before oil-filling), then go along the
following insulation performance measure in the temperature not under +10C:
10.8.1 The insulation resistance absorption ratio R60/R15.
10.8.2 tg of winding.
Eleventh. Check-up of transformer before being put into operation
11.1 Check carefully before the transformers are put into operation, make sure
they are under good condition, the check-up should emphasize the following items:
11.1.1 The working ground is in gear.
11.1.2 The installation of tap-changer is correct.
11.1.3 The action of all the protection equipments are in gear.
11.1.4 The grounding of tank and core is reliable, dehydrating breather system
is well.
11.1.5 Make sure the oil-way system is good, check if the butterfly valve in the
pipeline of cooler has been opened, if the butterfly valve between conservator and oil
filter tank has been opened.
11.1.6 The cooling system and control system are under good condition.
11.1.7 The switch-on and switch-off of breaker is good, the corresponding
period of three phase switching on or off should accord with relative regulations.
Twelfth. Each experiment result should be eligible before
transformers are put into operation
These experiments should emphasize the following items:
12.1 Measure insulation resistance using megger meter to make sure that there are
no fault and bug in measurement, control and assistant power supply loop.
12.2 The assay of transformer oil should accord with 5.3.2, at the same time, the
insulation resistance absorption ratio and tg shouldnt have apparent difference
with routine value.
12.3 Measure the winding connection symbol.
12.4 Check the position indication of on-load tap-changer and measure the voltage
ratio under each tap.
12.5 Measure direct current resistance of all the winding (for high voltage
winding, each tapping position is included).
12.6 When doing cooling system experiment, check if oil pump, turning of air
machine and control system are working well.
12.7 For low voltage, make exterior withstand voltage experiment, if the location
condition is good, make a one minute exterior withstand voltage experiment, the
experiment voltage shouldnt exceed 85% of routine test voltage.
12.8 No-load switching-in experiment (the cooler wont be put into operation),
make switching-in without load current impulsion experiment 3-5 times, watch the
action of relay protection equipment under the impulsion of exciting current, finish
the following items before no-load switching-in.
a Adjust the signal switch of relay switch to connect with the alarm loop, the
switching-off switch should connect with the protection switching-off loop.

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 b Adjust the overcurrent protection to scheduled point.
c The neutral point should be grounded directly.
12.9 For other experiment items prescribed according to nation standard or
technical agreement of both sides, the factory and the user consult with each other
again.
Thirteenth. Operation and maintenance
13.1 When the transformer is put into operation, the switching-in operation should
go along according to the regulations in secure operation regulation.
13.2 For forced-oil circulating air cooler transformer, pay attention to the
following items:
13.2.1 When the cooler is not put into operation, it is not permitted to operate
with load, and it is also not permitted to operate without load long time.
13.2.2 If all the cooler exit operation suddenly, the transformer is permitted to
operate 20 minutes under rated load more.
13.2.3 In the operation with small load, it is permitted to stop some cooler, the
relation of cooler number and the load of transformer is computed as the following
formula:
the permitted load when n cooler are put into operation Sn=SH (PKn /PK) (kVA)
the permitted load wastage when n cooler are put into operation PKn=nP-Po (kW)
P of each cooler when they are put into operation with full load P= (Po+P N)/(N-1)
(kW)
In the formula:
SH --- rated capacity of transformer (kVA)
Po --- no-load lossshort-circuit loss when the transformer is put into
operation with full load (kW)
P --- the cooling capacity of each cooler (kW)
N --- the total cooler number of transformer (kW)
13.3 Add oil to conservator in operation
Adhesive tape is installed in the conservator to prevent the oil from aging, oil-
filling valve is installed on the bottom of the conservator to add oil in operation, there
is air exhausting chamber on the top of the conservator, when adding oil (the oiliness
must accord with 5.3.2), firstly open the air exhausting plug, then inject oil through oil
valve, after the oil surface come to appropriate position, screw the plug and close oil-
filling valve.
13.4 In the operation of transformer, watch the grounding system periodically,
analyze and measure the gas component of the transformer oil using chromatography,
gas analysis, this is very important for finding the fallow fault and must be performed
seriously, the scout in initial stage of operation and preventive check-up should be
performed according to the following prescription:
a oil sample assay in operation:
During the first month, take oil sample to test after 3 days, ten days and 30 days.
From the second month to the fifth month, take oil sample to test every month,
change into periodical check-up if nothing is abnormal. Take oil sample to test every 3
months.

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 B The withstand voltage of transformer oil in operation shouldnt less than
40kV, in the initial stage of transformer operation, if the oiliness guideline drop very
fast, find out the reason as sooner as possible and take some measures.
C Check-up of insulation core:
On the cover of tank, there is core grounding bushing installed, in transformer
operation, people can use the bushing to check the core grounded current to determine
the insulation of core, the core should be grounded reliably.
13.5 The other check-up items should be performed according to transformer
operation regulation.
13.6 The transformer check-up and maintenance under normal operation and the
abnormal operation and accident disposal in prescriptive operation mode should be
performed according as the relative regulations of transformer operation regulation
and load regulation.

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