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Content

Compilation Reference.......................................................... 1
General Introduction and Characteristics............................. 1
Construction Organization and Schedule........................... 4
Preparation........................................................................... 4
Installation Process and Implementation Procedure.......... 6
Quality control................................................................... 15
Safe/Civilized Construction.............................................. 16

Compilation Reference
0

1.1

Relevant construction drawings from NEPDI herein read as follows:


Drawing No

Descriptions

F324S-D0301B

#1generator transformer and #1auxiliary transformer installation

F324S-D0302B

#2generator transformer and #2auxiliary transformer installation

1.2 Specifications for Construction and Acceptance of transformer and oil immersed type
reactor for Electrical Device Installation Works, GB50168-92;

1.3 Quality Inspection and Evaluation Specification for Electrical Facility Installation Works,
DL/T 5161.1~5161.17-2002;

1.4 Regulation of safe operation for electric power construction, Part I Thermal Power Plant,
DL 5009.1-2002;

1.5 Manufacturers Documents of transformer

General Introduction and Characteristics


Each generator is connected to the bus of the 150kV substation via a 150MVA
(ONAN/ONAF/OFAF) 157.5+12/-41.25%/13.8kV, 3-phase 2 windings generator
transformer with On Load Tap Changer. Generator is connected to generator
transformer through IPB rated 8000A 15.8kV.A 6800A 63kA GCB is equipped for each
generator.
For each generator, a unit auxiliary transformer (25MVA, 13.82X2.5%/6.3KV 3 phase
2 windings) with no Load Tap Changer is provided, its HV side connected to IPB
between row A and generator transformer, its LV side is connected to two sections of
6.3kV bus through NSPB. The two unit auxiliary transformers have the capacity to take
the shut down load each other.
Generator transformer neutral point is solid grounded. The unit auxiliary transformers
HV neutral is grounded through resistance.
Bills of Construction Quantities for Each Generator transformer:
Item

Specification

Unit

QTY

Wt.

Main Body of GT

SFPZ-150000

Set

117t

157.5+12/-41.25%/13.8kV
1

Item

Specification

Unit

QTY

H.V and O-phase tower

PC

L.V tower (with L.V bushing)

PC

Main Control Box(with key)

PC

Terminal Box (with Key)

PC

Control Box of Tap-change

PC

Pump(With Oil flowing Relay )

PC

Main Conservator

PC

Pressure Relief Valve and Rubber

PC

Gas Relay Drip-proof cap

PC

PC

PC

PC

H.V Bushing

PC

O-Phase Bushing & tie-in

PC

Earthing Bushing Accessories

PC

Radiators

Set

18

Control Cable

615

Adding Oil with oil

PC

10

Wt.

Yn,d1 Ud=12% OFAF

Dehumidifier
Winding Temperature Controller
Display and Matcher
Signal Thermometer Indicator and
Display

41.3 T

Bills of Quantities for Each HV Unit Auxiliary Transformer:


Item

Specification

Unit

QTY

Wt.

Main Body of GT

SF-25000/13.8

Set

33.6T

PC

Main Conservator

PC

Ascending Flange of Relief Valve

PC

H.V Ascending Devices

PC

O Phase -L.V Ascending

PC

PC

Pressure Relief Valve

PC

Gas Relay

PC

Dehumidifier(3kg)

PC

Winding Temperature Controller and

PC

Earthing Bushing

PC

HV bushing

PC

LV bushing & tie-in

PC

Control Cable

202

Adding Oil with oil

PC

Radiators

PC

13.822.5%/6.3kV ON LOAD AVR

D,yn11 Ud=10.5% ONAF


L.V Ascending Devices (with main
body)

Devices(incident one bushing and one


tie-in)
Oil Level Indicator and Connection
Pole

Matcher

Terminal Box

3T

Construction Organization and Schedule


3.1 Construction Organization
Manpower plan will read as follows. Forman shall be experienced with rich experience in
transformer installation.

Post

QTY

Post

QTY

Post

QTY

Forman

Rigger

Others

Technician

Welder

3.2 Implementation Schedule

Item

mouth
August

September

October

Novemb

December

er
#1 GT
#1 Unit auxiliary transformer
#2 GT
#2 Unit auxiliary transformer

Preparations
4.1 Preconditions
4.1.1 Transformer positioned nicely, circumjacent ground leveled and compacted, and
road cleared.
4.1.2 Front Mast of transformer installed; No dust-producing works e.g. back filling in
adjacent area.
4.1.3 Prepare adequate manpower under rational assignment. Those assigned person
shall be clear about their responsibilities and post.
4.1.4 Site checked by rigger and crane operator to know parking position of crane.
4.1.5 Manufacturer has confirmed verification in writing of gas relay, which need not to
check on site; thermometer checked on site.
4.1.6 No scratch and crush injury found during visual inspection of transformer; value
of voltage meter on body is normal without leakage.
4.2 Layout of Installation Site
4

Generator transformer is of great weight with gross weight of 42t, has one 20t and
one 25t oil tank, an oil purifier, and 20 accessory boxes. Site layout shall be
surveyed and properly planned combining actual condition on installation site as
per the following requirements:
a. Place transformer accessories at where is convenient for installation on body of
transformer directly without the necessity for moving at a second time. Place
bushing rack stably and securely.
b. Park crane at where covers all accessories in effective range of hook.
c. Layout of oil purification facilities shall be neatly. Place vacuum pump, oil purifier
and oil tank nearby purification facilities. Lay vacuum pipe and oil supply pipe at
shortest distance and convenient for operation and monitoring by persons on duty
as well.
4.3 Check by sampling and test supplementary oil in barrel for transformer.
4.4 Oil tank has been cleaned and marked with series number. Oil for supplement has
been purified satisfactorily.
4.5 Scaffolding and handrail have been erected and passed inspection with certificate.
4.6 Prepare complete machines and tool for installation, oil equipment, consumables,
and spare materials; oil equipment is available after trial run.
4.6.1 Lifting Machines and Tools
1 mobile crane (30t); 2 chain blocks (1t); 2 chain blocks (2t); several sleepers;
1 set of flexible rope, shackle, and wire rope for each; 4 slingers (1t); 4 slingers
(2t);
4.6.2 Oil Filling Euqipment
2 oil tanks; 1 small tank (4t); 1 set of vacuum oil filter; 1 psychrometer;
5 tanks of high purity nitrogen; 1 vacuometer; 1 set of hose and joint;
4.6.3 Common Tools
Oxygen Meter, psychrometer and thermometer, tape measure, steel tape, plumber,
water pass, level tube, torque spanner, pipe wrench, adjustable spanner, solid
wrench, box spanner, feeler,

, long hemp rope, long bamboo ladder, plier,

scissors, hammer, flashlight, file, wire brush, nylon rope and waterproof cloth.
4.6.4 Common Materials
Dry air, alcohol, white cloth, teflon tape, sealant, plastic clothing, white cloth strip,
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pledget, white cap, cotton waste.


4.4 Equipment Transportation
There are 20 accessory boxes for generator transformer and 5 accessory boxes
for HV unit auxiliary transformer.
Bind the accessories securely for transportation. Drive slowly and stably. Lay down
in proper location and proper sequence to avoid secondary transportation. Check
quantity with packing list and make sure that specifications meet design
requirement, accessories and spare parts are complete without scratch by visual
inspection. Recheck and confirm that sub-base plate is placed stably and joint
between sub-base plate and frame is welded securely. Erect HV bushing on steel
frame 24 hours in advance.

Installation Process and Implementation Procedure


5.1 Construction Workmanship Flow chart

Positioning and Regulation of Trans. Body

Certification of Shock Recorder Untank or Nonuntank


Non-untank
Visual Inspection on Trans. Body

Technical Presentation before Installation

Disposal of Supplementary Oil and Satisfactory Oil Test

Exhaustion (fill oil, relief Nitrogen, open cover plate)

Sampling of Residual Oil at Bottom of Tank

Trans. Body Inspection


Main Accessories Installation and Test
Connection Pipe Installation

Dew Point Test / Vacuum Tightness Test

Oil Filling Under Vacuum / Hot Oiling


Supplementary Oil and Oil Level Regulation
Overall Leak Test

Placement and Air Relief


Body Touch-up and Surrounding Cleaning

Finished

Flow Chart

5.2 Installation implementation sequence


5.2.1 Prior to positioning, measure and mark with ink marker the major and minor axis
centerline of oil tank on foundation surface, and measure foundation elevation;
during positioning, centerline of oil tank shall be aligned with ink line on foundation.
Beware that HV side of 4 transformer shall face substation. Refers to the table
below for details of centerline coordinate and foundation elevation of oil tank.
7

#1 GT

#1 Unit Aux. Trans.

#2 GT

#2 Unit Aux. Trans.

ce

Distance from Major Axis to

Distance from Major Axis

Distance from Major Axis

Distance from Major

nt

Axis A center: 23250mm

to Axis A center:

to Axis A center:

Axis to Axis A center:

erl

Distance from Minor Axis to

13250mm

23250mm

13250mm

in

Axis #5 center: 4410mm

Distance from Minor Axis

Distance from Minor Axis

Distance from Minor

to Axis #5 center:

to Axis #5 center:

Axis to Axis #5 center:

co

5500mm

4410mm

5500mm

0.00

0.00

0.00

or
di
na
te

0.00

F
ou
nd
ati
on
El
ev
ati
on

5.2.2 After transformer being positioned, technician from manufacturer shall authenticate (in
writing) triaxial shock recorder on transformer body immediately to check whether it need
untanking.

5.2.3 Record temperature and pressure of generator transformer (transported with


Nitrogen) as required and make sure that theres no leakage on it.
5.2.4 Choose a fine day on when start installation of transformer. Make precautions for
rainproof to prevent internal of transformer from wetting on account of rainy
weather.
5.2.5 When untanking, beware of the following: when lifting, bind wire rope to
marked position; wire rope (rigger) separation angle shall be less than 60.
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5.2.6 Technical Presentation Prior to Installation


Prior to installation, call together testing superintendent, installation superintendent
and technical superintendent, to whom technical presentation will be made by staff
from manufacturer to confirm installation procedure, to ascertain everyones
responsibility, and to improve cooperation among departments.
5.2.7 Check of Active Part
Oil tank of generator transformer body is transported with Nitrogen. In view of the
frequent rain and high relative air humidity, and to protect active part from wetting,
method or may be applied:
Method : open cover on top of transformer, exhaust nitrogen, and fill dry air visa
bottom valve into oil tank. After approximately 1 hour, measure the oxygen content
in tank with oxygen detector. Worker is allowed to enter oil tank for checking till
oxygen content reach 19.5%.
Method : exhaust nitrogen by filling oil. Fill disposed, tested and accepted
transformer oil (as stated in IEC60296, Electrical Strength
Content

60kV, Micro-water

5ppm) visa bottom valve into oil tank till active part is immerged by

oil. Soak it for 24 hours; a film of insulation oil will cover the surface of active part.
Drain all oil and fill dry air into oil tank.
Unscrew the bolt of manhole cover at flank of oil tank, open cover, enter into tank
and check active part. Transformer is allowed to enter into only when carry out
necessary installation and check; at any event, only trained and authorized
persons by manufacturer get the access to transformer.
Technicians from manufacturer will check the active part and wire HV bushing. We
prepare checking record. To guarantee installation quality and human safety and
protect transformer from contaminating, only manhole and opening for installation
parts can be unclosed. Any other openings shall be covered with dry wooden plate
or clean plastic film. By these means, loss of dry air may be reduced to minimum.
Testing person shall sample residual oil after manhole cover being opened.
After manhole cover being opened, keep filling dry air into oil tank to maintain
proper ventilation (ventilation direction: dry air tanktransformer bodyambient
atmosphere). Before entering into tank, measure the oxygen content with oxygen
detector and make sure reach 19.5%. Otherwise, workers are not allowed to
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entering into transformer or inbreathe air in it to prevent from choke. Person who is
to entering into transformer shall ware clean oil-proofing shoes to prevent from
slipping, wear clean coverall, and do not articles that have noting to doing with
work and that may drop off. Register all tools and tie them with white cotton tape.
Technicians (with testing persons) shall check the following items:
a

Whether active part is clean, fasteners are tight, iron core and clamp are not

displaced and securely grounded. Iron core shall be ground with one point.
b

Whether windings are in neat order and insulation layer are sound,

undamaged and not displaced.


c
d

Whether insulation parts and fasteners are tight.


Whether insulation shielding is tightly bound; whether lead-out wire is

satisfactory in insulation distance and securely fastened; whether wrapped leadout wire insulation is scratched and tight in joint; whether has burr or sharp tip on
naked part of lead-out wire, where shall be welded well.
e

Whether tap and circuit connections of on-load tap changer (OLTC) are

correct and tight; whether taps are cleaned.


f

Whether has sludging, water drop, metal chip, etc.

During checking of active part and accessories installation, minimize the time
active part exposed to air. Time shall be calculated from unscrewing of cover bolt
or opening valve for exhausting till tank vacuumized. Air relative humidity shall be
referred to control the expose time. Manufacturer stipulates that when relative
humidity>75%, expose denied; when at 65%-75%, expose time shall be less than
12 hours; when 65%, expose time shall not exceed 16 hours.
5.2.7 Installation of Main Accessories
a. Installation of Ascending Tower
Check CT before installation. Mount ascending tower as per series number on
products. Make sure the CT nameplate face outside of oil tank and place air lock at
highest part of ascending tower. When tightening bolts of flange, make sure that
gasket is placed in right position in advance, and then screw bolts gradually and
evenly.
b. Installation of HV Bushing
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Assign person specially monitoring the stand of HV bushing from horizontal status.
Erection is to be carried out by rigger cooperating with electrical installer with hook
and manual hoist as detailed in Plate 1. Place bolster e.g. rubber plate or timber
board under bottom end of bushing. Protect bushing at where may contact chain or
rigging with rubber plate. Prior to mounting bushing to transformer, clean carefully
the central hole and bushing end that immersed in oil. Move bushing slowly to
above of ascending tower, regulate position of Phase A and C, and let fall bushing
slowly into ascending tower. Do not hit bushing on ascending flange. Rigger and
crane operator shall cooperate closely. Open hand hole cover on ascending tower,
and wire HV lead to bushing panel.

Plate 1 Bushing Erection

c. Installation of LV Bushing
1). Check and confirm that no scratch on bushing surface, especially no scratch,
crack and flake off on porcelain sealing surface of flange. Clean bushing surface.
2) Tie the skirt of porcelain with nylon rope, lift slowly to above of installation hole
of transformer, and let fall it vertically and slowly into transformer. Do not hit
porcelain on oil tank case.
3) Screw bolts on flange gradually and evenly.
4) When wiring bushing and lead, make sure that no bolt or other article drop into
oil tank.
d. Installation of Cooler
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1). Installation of Rack, Cooler and Fan


Check and clean if theres any foreign matters inside of cooler. Flush it with
satisfactory transformer oil if necessary, and then carry out leak test again. (air
pressure 0.12 Mpa for 20min, no leakage shall be found.) Check and confirm that
motor and impeller of fan shall be securely installed, and smooth and no block in
rotation. No distortion of impeller and no contact with air duct.
After installation of rack, lift and move cooler slowly to avoid collision. Fasten it on
rack, apply flange bolts without tighten. Position cooler vertically and make it welldistributed. Fasten cross piece, and then tighten flange bolts.
2). Pipe Connection, Pump and Oil flow Relay Installation
Clean oil pipe before installation; pump shall be insulated before installation;
beware of the impeller direction when installing oil flow relay. Regulate impeller to
right position by tightening nut.
e. Check of On-load Tap Changer
Check contactor of on-load tap changer (OLTC) as required in manufacturers
instruction and confirm the correctness of position; check operation mechanism
and confirm the correctness of position
f. Installation of Pressure Relief Valve
Make sure flange connecting pressure relief valve on oil tank is level and no slag
on it. Place o-ring with adhesive to prevent it from displacing when tightening.
Fasten bolt at required moment by manufacturer. Face oil outlet on of
pressure relief valve to a open space.
g. Installation of Capsule-type Vacuum Conservator
1). Inside of conservator shall be clean. No scratches are found on capsule. Mount
a valve and pressure gauge on flange of capsule to test air tightness. Apply a 7kPa
pressure on capsule and close valve. Pressure shall not reduce within 0.5 hour.
2). Fix rack and mount conservator on it tightly.
3). Connect to gas relay pipe and install gas relay after filling oil under vacuum.
4). Fit exhaust pipe, oiling pipe, and oil discharging pipe. Install matching stop
valves at the bottom of these pipes. During pipe fitting, make sure that seal ring
has been place on the interface.
5). Tear off seal on cover of breather before installation. Tighten bolt after seal ring
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placed. Oil shall be filled in cup till 2-3cm above aluminum check tube to keep oil
tightness.
h. Installation of Gas Relay
1). Check whether outer appearance of relay if sound.
2). Install relay between two connection pipes in accordance with direction marked
on housing of relay, i.e. red arrowhead direct to conservator.
3). Install exhaust pipe of ascending towers, concentrate all gas may exist in
ascending tower in connection pipe of relay.
4). Pipe directly connected to relay shall have a proper gradient within 0

5.

5.2.8 Oil Fill under Vacuum


After installation of transformer, check and confirm that no tools and materials left
inside of transformer oil tank. Close cover of transformer, and fill oil under vacuum.
After installation of all accessories, open valve connecting gas chamber and oil
chamber at two sides of oil conservator. Make sure equal pressure inside of
capsule to avoid damage. After confirmation of all parts connecting of body of
transformer can bear vacuum operation by manufacturer (who shall confirm it in
advance. Parts unable to bear vacuum shall be isolated from vacuation), open all
valves connecting transformer body and start vacuation including body. During
vacuation of oil tank, check tightness at all times. Stop vacuum pump if necessary
for convenience of listen to leaking sound.

Plate 2 Filling Oil from Bottom Valve

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a. Connect vacuometer to proper valve on oil tank.


b. Connect vacuum pump to valve on the top of tank or to consevator.
c. Filling Oil and Adding under Vacuum
1)
Generator Transformer
If active part check and remounting are unable to be finished in one day, satisfied
transformer oil shall be filled into transformer. Resume remounting after draining
oil. When remounting complete, carry out vacuumizing and oil filling under vacuum.
Oil in on-load tap changer has been drained. Connected oil tank with on-load tap
changer chamber with U pipe to make both of them be vacuumized. Connect oil
pipe of on-load tap changer to make it be filled with oil under vacuum together with
transformer.
Connect vacuumizing pipe, and turn on vacuum pump. Vacuumize till 133Pa
(1torr), and keep it for 8 hours, during when, fill oil visa bottom valve at oil tank
(Plate 2) with oil flow less than 5t/h and stop filling till oil level is 100mm from cover
of oil tank. Meanwhile, fill satisfactory transformer oil to chamber of on-load tap
changer; keep it under vacuum for 8 hours. Release vacuum, and dismantle
vacuum pipe and evacuation equipment.
Install supplementary oil pipe at filling valve of conservator. (add oil visa top of oil
tank to prevent air from entering vacuumized oil tank of transformer.)
Add oil to proper level according ambient temperature when oil is filled.
2)
Unit Auxiliary Transformer
Vacuumize transformer till 21.3kPa (160rorr) as required by manufacturer. Hold the
status for 0.5-1 hour. Fill oil visa bottom valve at rate not bigger than 5t/h, and stop
filling and release vacuum till oil level reaching at where 100mm from top of oil
tank. Open all valves connecting body to accessories, and add oil till proper level
as per temperature at that time.
5.2.11 Hot Oiling (Plate 3)

14

Plate 3 Hot Oiling


After filling oil under vacuum to transformer body, hot oiling shall be carried out in
following procedures as required by manufacturer:
1) Transformer connects to oil filter visa upper and lower filter valve to form a
closed circulation. Oil direction is from filter to top of transformer, and from bottom
of transformer back to filter.
2) Heat the oil to be transferred from filter to transformer to 50-60.
3) Keep oil circulating till total oil quantity through transformer exceeding 2 times of
oil tank capacity, while time of circulation shall not less than 48 hours as required.
4) After the whole oil filling process, sample transformer oil for test again.
5.2.17 Overall Tightness Check and Placement
Fill dry air or nitrogen visa breather at oil conservator to check the overall
tightness. Apply 0.03MPa pressure to oil cover for 24 hours and no leakage shall
be found. After filling oil and before apply voltage, place GT for 48 hours and HV
unit auxiliary transformer for 24 hours, during when release all gas visa air vent.
5.2.12 Grounding
1)
Wire grounding bolt M12 of on-load tap changer cabinet and tap to transformer
housing or oil tank.
2)
15

Wire ascending tower visa grounding bolt to transformer housing or oil tank.
3)
Connect HV neutral point bushing visa steel cored aluminum strand LGJ-300/25
and grounding post insulator ZS2-126/b to grounding grid.
Ground plate shall be welded to bottom of oil tank of transformer. After cleaning
interface, screw down nut to make the copper-cored cable contact closely to
grounding plate.

Quality Control
6.1 Active part check shall meet requirements in 5.2.6;
6.2 Bushing is installed in right position. No scratch, crack and spall on seal interface
of porcelain bushing flange;
6.3 Insulation oil test shall be in compliance with IEC60096;
6.4 Overall installation check of transformer shall be in accordance with requirements
of manufacturer.

Safe/Civilized Construction
7.1 To be in strict stipulations as shown in Electric Power Construction Safety Codes;
7.2 To be in strict obedience to construction safety protection specifications herein
involved;
7.3 After unpacking of the equipment, without any hesitation, remove and dispose all
the debris out of construction area in order to keep the gallery to be in smooth
access and no any injuries by the nails
7.4 While performing welding activities, anti-shock, explosion-proof and metal splashes
etc shall be carried-out, as for the shell of the electric welding machine, it shall be
well grounded.
7.5 On the site, all the tools and devices shall be kept in satisfactory storage and
custodian, the temporary power supply shall be in good conditions while
overlapping, as well, rainwater-proof, leakage-resistance methods and actions
shall be implemented. No any arbitrary dismantle those installed and assembled
16

scaffoldings and bamboo-centered structures, prior to completion of each


construction sequence or regular shift termination, take care to check those
electric-driven tools and grounding cable rolls to be shut-down or not.
7.6 In those energized areas, all the activities and operations shall be presented with
applicable Job Implementation Permits, if necessary to utilize flame, flamecentered Job Implementation Permits shall be issued.
7.7 During installation, oil filter and oil tank shall be grounded securely.

17