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Y0SB.460.

5483

Instruction Manual of 220 kV, 330 kV


and 500 kV Shunt Reactor

Y0SB.460.5483

Content
1 Scope and application requirement .........................................................................................3
2 Lifting and jacking of heavy package .....................................................................................3
3 Transportation of heavy package and accessories ................................................................4
3.1 Transportation vehicle.........................................................................................................4
3.2 Transportation method .......................................................................................................4
3.3 Loading and fixing requirement ..........................................................................................4
3.4 Transportation.....................................................................................................................4
4 Acceptance inspections ..............................................................................................................5
4.1 Acceptance inspection for incoming goods ........................................................................5
4.2 Acceptance inspection of the accessories after unpacking.................................................6
5. Moving and locating of reactor heavy package ....................................................................8
6. Storage and keeping ...............................................................................................................9
6.1 Preliminary check.............................................................................................................9
6.2 Storage of reactor transported with gas ..........................................................................9
6.3 Storage of reactor transported with oil.............................................................................10
6.4 Components storage .........................................................................................................11
7. General assembly at site ......................................................................................................... 11
7.1 Preparation work before installation ................................................................................11
7.2 Check of active part...........................................................................................................12
7.3 Installation of heavy package and accessories..................................................................19
8. Safety Precaution at site .........................................................................................................24
9. Oil-filling under vacuum, hot oil circulation and standing ..............................................24
9.1 Evacuations to remove the moisture and gas ...................................................................24
9.2 Oil filling under vacuum....................................................................................................25
9.3 Hot oil circulation..............................................................................................................25
9.4 Resting...............................................................................................................................25
9.5 Assembly of other components ........................................................................................26
10. Preparation and touch-up for external surface of reactor .............................................26
11. Check and hand-over test before putting into operation ................................................26
11.1 Check before hand-over test...........................................................................................26
11.2 Hand-over test.................................................................................................................28
12. Operation................................................................................................................................29
13. Delivery and acceptance of technical documents and spare parts ................................29
14. Inspection and maintenance ................................................................................................29
15. Flow chart of main works for reactor installation ...........................................................30
Appendix A: (Data appendix)Influence on environment, safety and health from
transformer oil and relevant protection measures .................................................................40
Appendix B:data appendixMain equipments and tools for the requirement of general
assembly ........................................................................................................................................41

Y0SB.460.5483

1 Scope and application requirement


1.1 This manual provides the requirements for transportation, installation, operation
and maintenance of 220kV, 330kV and 500kV oil-immersed shunt reactor (for short
reactor in the following), excludes the installation & operation instructions for
separated componentsfor that part see the instructions for separated components.
1.2 During lifting, transportation, acceptance, storage, installation and putting into
operation of the reactor, apply the instruction to direct the mentioned works in order
to avoid quality problem occurring as well as make proper record.
1.3 The installation and operation departments should perform according to the
ex-work document, the instruction and the operation instruction for separated
components all that are provided by the manufacturer. If you have any doubt on the
instruction, dont hesitate to contact with the manufacturer to solve it properly.
1.4 For quoted standards without date in the instruction, their latest version is
applicable.

2 Lifting and jacking of heavy package


2.1 Lifting facilities & devices and foundation at loading and unloading place must
have the ability of withstanding the lifting weight (transportation weight) of the
reactor.
2.2 Before lifting, all the bolts on the frame shall be tightened to prevent the cover
from deforming.
2.3 While lifting the reactor at specified point, the lifting lugs shall be forced at the
same time. The sling with suitable length shall be forced evenly and the angle
between lifting sling and plumb line shouldnt exceed 30, otherwise the lifting beam
shall be used.
2.4 When using jack, the jack shall be put under the jacking pad of the tank. Its
forbidden to use one jack or use jack not enough for the safety of reactor. Its
permitted to withstand the even force simultaneously at the two points of the short
tank side, alternately lifting or lowering at the two sides of short tank side. Each
lifting height shall be not more than 50mm. Before jacking, place the crosstie and
padding board well and take measures to prevent the jack slip and reactor vibration.

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3 Transportation of heavy package and accessories


3.1 Transportation vehicle
Car, train and boat can be chosen for transportation if necessary.
3.2 Transportation method
To prevent the heavy package of reactor and inside of accessories from being
moistened, normally two transportation ways either filled with gas or oil is adopted
(filled with nitrogen or dry air).
3.2.1 Transported with oil
When the reactor filled with oil in the transportation, the tank shall be filled with
qualified transformer oil, distance between top oil and tank cover is about 100mm to
200mm at normal temperature, the space without oil above top oil shall be filled with
nitrogen or dry air, and check and make sure no leakage.
3.2.2 Transported with gas
3.2.2.1 The reactor to be transported with nitrogen should be filled with pure nitrogen
of which the dew point is not higher than -40, with the purity not less than 99.9%.
The tank should be kept positive pressure between 0.02MPa and 0.03MPa before
transportation and between 0.01MPa and 0.03MPa during transportation, otherwise
the nitrogen fulfilled the above mentioned requirement should be refilled in time.
3.2.2.2 The reactor to be transported with dry air should be filled with gas of which
the dew point is not higher than -40. The tank should be kept positive pressure
between 0.02MPa and 0.03MPa before transportation and between 0.01MPa and
0.03MPa during transportation, otherwise the dry air fulfilled the above mentioned
requirement should be refilled in time.
3.3 Loading and fixing requirement
Loading and fixing for transportation shall be carried out according to the regulations
from the relevant transportation department and the dismounting drawing for
transportation. Normally, the large-size reactor shall be equipped with impact recorder
that shall be returned to the manufacturer after the heavy package of the reactor
arrives at site.
3.4 Transportation
3.4.1 Before transportation of the heavy package of the reactor, the transportation
route and the installation conditions on the two locations (from manufacturer to
installation site) must be thoroughly investigated and understood, and the security
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technical measures shall be worked out.


3.4.2 In the whole course of transportation (including railway, highway and shipping),
the heavy package shouldnt incline more than 15. Pay much attention to the
transportation direction.
3.4.3 Its not permitted to be impacted by sliding during load & unload and
transportation. The transportation accelerations are limited: not more than 3g for
transportation direction, 3g for horizontal direction and 1.5g for vertical direction
without obvious displacement of heavy package.
3.4.4 For transporting on road, the speed on expressway and class A road shouldnt
exceed 15km/h, and the speed on other roads shouldnt exceed 10 km/h.
3.4.5 During the bushing transportation, special attention to prevent bump and
collision. The package case of bushing shall accord with the requirement in the
bushing installation manual.
3.4.6 When pulling the heavy package, the pulling point shall be lower than the
gravity center of reactor. Normally, the steel rope shall be hanged on the pulling hole
at the lower of tank but not on the components or pipe couplers that couldnt
withstand force.
3.4.7 When loading and unloading the heavy package on the slope, the angle of the
slope shouldnt exceed 15 while some slide proof measures should be taken under
such conditions as pulling both from the front and the back and moving
synchronously. If the reactor is moved after oil filling, the sudden sliding caused by
the deviated gravity center due to the waggled top oil shall be concerned.
3.4.8 The dismounted connection pipe, turret, oil conservator, radiator, bushing type
current transformer shall be sealed by cover in the transportation, while for the ones
inside with insulation parts and components shall be transported with oil or dry air.
4 Acceptance inspections
4.1 Acceptance inspection for incoming goods
4.1.1 The consignee shall check the type, specification and quantity of the products
according to those specified in the order contract.
4.1.2 For the reactor installed with three-dimensional impact recorder, the record in
the three-dimensional impact recorders shall be checked, and the figures in all three
dimensions must fulfill the requirements in Item 3.4.3. The record list shall be kept
well.
4.1.3 The heavy package and accessories shall be checked if there is any displacement,
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collision and deformation happened during the transportation, and these notes shall be
taken. If any problem is found, please contact the manufacturer and forwarder
immediately and ask the forwarder to provide the record taken during this
transportation so as to find out the cause and proper solution.
4.1.4 For the reactor transported with oil, check the sealing condition and see if there
is any oil leakage, and make the record well. And for reactor transported with gas,
check gas pressure inside tank and see if it keep positive pressure (more than
0.01MPa), check this pressure twice a day and make record well.
4.1.5 The packages of accessories shall be checked if there is any damage or missing
happened during the transportation and notes shall be taken. If any problem is found,
please contact the manufacturer and forwarder immediately.
4.2 Acceptance inspection of the accessories after unpacking
4.2.1 The Customer, Erection Company and Supervision Company shall inform the
service department of the manufacturer and forwarder three to five days before (in
written form) the unpacking acceptance inspection on site for joint inspection,
checking and hand-over of the accessories.
4.2.2 The quantities of arrived boxes shall be checked if it is consistent with the
summary of packing, short delivery or misdelivery. The contents in the box shall also
be checked if the details, parts and components in each box are correct according to
the packing list, if there is any damage or short delivery, and these notes shall be taken.
And the gas relay, winding thermometer, top oil thermometer, quick-action oil
pressure relay etc. shall be calibrated again before installation. Please contact the
manufacturer and forwarder immediately if there is any problem.
4.2.3

Check if the ex-factory documents, technical documentation and certificates

are complete.
4.3 Measure taken for non-conformity during acceptance
If any damage, missing and other abnormal situation to be found in above inspection,
the detailed note shall be taken and also take photos at site, and it shall be confirmed
by signature of both parties (buyer and seller). The photos, short delivery and
damaged parts list as well as inspection note (copy) shall be provided to manufacturer
and transportation department in time for finding the reason and solved.
4.4 Acceptance and storage of transformer oil
4.4.1 Check if the type of transformer oil is the same as those used in this product.
Its forbidden to mix and store with other type of insulation oil so as to prevent the
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suddenness.
4.4.2 Check the sealing condition of oil container and the dehydrating condition of
breather, and note it.
4.4.3 Check the oil quantity by volume or weight measurement
4.4.4 Sample-taking and spot acceptance shall be conducted after oil arrival at site.
The acceptance standard shall as per the requirement of GB2536 Fluids for
electrotechnical applications- Unused mineral insulating oils for transformers and
switchgear. When the oil meets the standard GB/T 7595 Quality criteria of
transformer oils in service after treatment, they can be filled into reactor. Their main
performance standard is shown in table 1.
Table 1 The oil must meet following criteria before reactor is put into operation
No.
1
2
3
4
4.4.5

Content

220kV
40
0.01

Index
330 kV
50
0.01

500 kV
60
0.005

Breakdown voltage, kV
Dielectric loss factor tan(90)
Moisture content in oilmg /L
15
10
10
(oil sample is taken while the oil
temperature within 40~60)
Gas content in oil % (volume fraction)
1
1
1
The acceptance of imported oil is conducted according to the relative

international standard or the criteria specified in the contract.


4.4.6 The transformer oil transported to the site, if which has made full analysis and
has the checking record, only need taking sample to do the simple analysis. If the oil
is from refinery or purchased by the user, or with some doubts, full analysis must be
conducted.
4.4.7

Generally, the insulation oil supplied by manufacturer shall be used as more as

possible. If insulation oil from other sources needs adding, the mixed oil test shall be
carried out, and the performance of mixed oil meets the stipulation of section 6 in
GB/T 14542-2005 Guide for maintenance and supervision of transformer oil in
service, and then the oil can be mixed to use, otherwise its forbidden to use it.
4.4.8 The transformer oil shall be stored in the clean sealed special oil vessel or
container, and different type of the transformer oil shall be stored and kept separately
and with marking. The influence description of transformer oil on environment, safety
or health and protection measures see appendix A.
Attention: It is forbidden to pour oil between different container or filtering oil in a
rainy, snowy, or foggy day. When the oil to be filtered and filled into the oil container,
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prevent impurities and moisture entering and contaminated by the air.

5. Moving and locating of reactor heavy package


5.1 The steel wires have to be fastened on the pulling holes at the lower part of tank
for pulling when the heavy package is moved to the installation position. The
foundation flatness of heavy package of reactor shall be within 3mm.
5.2 The jack pad on the lower part of tank must be used when using the jack to raise
or down the heavy package if necessary. The operation is carried out according to
clause 2.4 of this manual.
5.3

When the heavy package is located or taken out from the rail by using the trolley

underneath the bottom of tank, the position-limiting device must be removed in


advance, lubricate the trolley axes. The pulling speed shall not exceed 0.1km/h.
5.4 The rail of reactor foundation shall be horizontal, and the rail gauge and trolley
gauge shall match each other well. After their exact match is confirmed, disassemble
the falling-preventing support, and loosen the jack or the lifting sling. Lower the
reactor slowly, and let the roller go into the rail.
5.5 For the reactor with roller, the roller shall be aligned after installation. Otherwise
it needs to do some adjustment. The roller shall be turned flexibly, and it shall be
removed after heavy package location.
5.6

For the reactor without roller, the installation foundation shall keep horizontal.

The reactor and foundation embedded plates shall be connected reliably.


5.7 During the heavy package location, pay attention to make the bushing center line
correspond with the connected isolated phase bus bar and the GIS etc. The bottom
support of reactor shall be put onto the foundation of reactor fully, and shall not be
suspended. After the putting the heavy package into the right position, the user,
Construction Company, supervisor shall signed to confirm the location direction and
position of heavy package.
5.8

Since the incline degree of reactor tank cover and the connection pipe has been

considered according to the requirement of standard, so it is no need to incline while


the reactor installed horizontally on the foundation. Special structure such as placing
of the vibration reduction pad etc shall be conducted in advance before location
(please refer to the final-assembly drawing for details).

Y0SB.460.5483

6.

Storage and keeping

6.1

Preliminary check

Check if the reactor is moistened during transportation once arrival at site. The
primary check if the reactor is not moistened as per table 2. The reactor can be
installed and put into operation only when the product is confirmed not moistened. If
the installation not to be done immediately, the product transported with gas shall be
stored as per clause 6.2, and the product transported with oil as per clause 6.3.
Table 2
No.
1
2
3

The primary check if the reactor is not moistened

Item
Gas pressure (ambient
temperature)MPa
Oil
Voltage
sample withstand kV
analysis Water
content
mg/L

With oil

With gas

220kV 330kV 500kV 220kV 330kV 500kV


-

0.01~0.03

35

45

55

30

30

40

15

10

10

30

30

30

Notes:
1. The oil sample analysis for the reactor transported with gas means the residue
oil test.
2. Withstand voltage means that use the standard oil cup to do the test.
6.2 Storage of reactor transported with gas
6.2.1 Storage with gas
6.2.1.1 As for the reactor transported with gas to the site, if the gas pressure and
insulation strength of residue oil in tank shall meet the stipulation in table 2, it is
permitted to store for short time, but the storage time shall not exceed 3 months.
Otherwise it shall be stored filled with oil according to clause 6.2.2, and if it not meet
with table 2, contact immediately with the manufacturer to solve it well.
6.2.1.2 When reactor stored with gas, the pressure monitoring device is needed. The
requirements and pressure of the gas is the same as stipulation of clause 3.2.2 and
3.2.3 of this manual.
6.2.1.3 During the period of storage with gas, check at least 2 times every day and
take a note of the pressure inside the tank and refilled gas amount. If the pressure
decreases quickly and the gas-consuming amount increases, it shows there is some
leakage. Check and take quick action to prevent the active part from moistening.
6.2.2 Storage with oil-filling and gas-releasing
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The working process and requirements for storage with oil-filling and gas-releasing
are as follows.
a)

Drain off the residue oil in the tank bottom fully. It is forbidden to refill residue

oil into reactor again.


b)

Oil-filling and gas-releasing: Open the butterfly valve on the top of tank (prevent

the moisture air, water, or sundries falling into the tank), and fill transformer oil which
meets the requirements in table 1 into tank from any valve on the lower part of tank.
c)

Install the conservator system ( including the dehydrating breather) temporarily

and continue filling oil and adjust the top oil to the position where its a little bit
higher than the normal oil level in the conservator, and release the air in the
conservator according to installation manual of conservator.
d)

During the period of storage with oil, check the external appearance of reactor

every 10 days. If any oil leakage is found out, take quick action. Take oil sample from
the tank for testing every 20 days, and the oil properties must meet the requirements
in table 1 and meanwhile the notes have to be taken.
6.3 Storage of reactor transported with oil
6.3.1 Oil sample shall be taken from the tank for testing after reactor arrives at site. If
the oil properties meet the requirement in table 1, then install reactor according to
clause 6.2.2.c) of this manual and store with oil. After that the check and test shall be
performed according to the requirements in the clause 6.2.2.d) of this manual. If the
oil sample cannot meet the requirement in table 1 after testing, the next work cannot
be conducted. Make an analysis of whether its moistened according to table 2 and
contact with the manufacturer.
6.3.2 If the reactor will not be installed within 3 months, the oil conservator must be
installed. Fill qualified transformer oil to the height corresponding to the temperature
of oil conservator, and install dehydrating breather on the oil conservator. Refilling oil
must be filled from the butterfly valve on the tank cover or oil conservator to prevent
the air entering the active part. If the oil conservator cannot be installed in time, the
space between top oil and tank cover where without oil shall be vacuumed, and fill the
dry air with a dew point of less than 40 and a pressure of 0.01MPa~0.03MPa into
this space to conduct monitoring. The check and test also shall be done according to
the requirements in clause 6.2.2.d) of this manual.

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6.4 Components storage


6.4.1 The parts, accessories and components after being checked shall be kept
according their performance. Take measures to prevent the rain, snow and corrosive
gas entering directly. For those having sealing transportation, the sealing condition
shall be checked.
6.4.2 The bushing and accessories (such as measuring instrument, temperature
controller, relays, terminal box, control cabinet, conductor, cable and gasket etc.) must
be stored in the dry and ventilation room.
6.4.3 If the storage time of condenser bushing is over 6 months, the top end of
bushing must be raised to ensure the angle between it and horizontal level more than
15, or the bushing can be taken out from the packing box and is stored vertically with
the two ends wrapped by plastic cloth.
6.4.4 Equipment shall be checked regularly during storage. For equipment stored with
oil-filling, check whether any leakage exists, whether the oil level is normal, whether
rust exists on the surface. And take oil sample to check the withstand voltage,
dielectric loss factor, and moisture content every 6 months. For equipment stored with
gas-filling, check the gas pressure and record it.
6.5 Requirements after acceptance
The acceptance formalities shall be carried out after the unpacking acceptance
inspection, The acceptance certificate shall be made in duplicate and the manufacturer
will provide technical service at site based on this certificate. The heaviest piece and
the package boxes with accessories of the reactor shall be stored in proper place, and
the consignee shall be responsible for the safety and intactness.
7. General assembly at site
7.1 Preparation work before installation
7.1.1 Technical prepare: According to ex-factory technical information and document,
get known of the structure and working principle of the main part and component,
master the installation requirement in the installation manual, make out the
installation procedure and working schedule as well as the safety measures.
7.1.2 Measure the insulation resistance, transformation ratio, polarity and DC
resistance and check whether they conform to nameplate and other technical
documents.
7.1.3 Test and check the performance index of each component according to their
manuals, and make sure it can meet the requirement of operation of reactor. All the
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preparation work shall be done well. The main equipments and tools used for
assembly are shown in table B.1 of appendix B.
7.1.4 Clean all the accessories strictly to guarantee its internal clean and without dirty
substances. Accessories, which are not cleaned, are not permitted to install on the
reactor.
7.1.5 The sealing surface of each connection flange shall be cleaned by using cloth
dipped with ethanol (without water), and make sure it clean. Check if the sealing
surface is clean, flat and without damage. Check if the sealing gasket is complete,
without deformation, crack and other defects. Confirm the item no. of such parts as
tubes.
7.1.6 When tightening flange, tighten each bolt alternately and gradually in diagonal
direction with tightening torque wrench (recommended tightening torque value see
Table 3). Finally tighten all bolts once again to ensure they have the same compaction
force.
Table 3: Tightening torque value
Diameter
of bolts
mm

Recommended
tightening Recommended tightening torque
torque value of conductor value of turret assemblyNM
NM

M10

2510%

M12

5910%

4010%

M16

9810%

10010%

M20

18010%
7.1.7 Prepare the lifting device, vacuum generator, oil filter, tools, illumination etc.
7.1.8 The above check shall be conducted before the check of active part, so that the
whole parts of reactor can be installed in time.
7.2 Check of active part
Active part check can be divided into directly entering tank inspection without
removing cover and un-tanking inspection. If one of following conditions is met, it is
no need to carry out un-tanking inspection. But entering tank inspection must be
performed.
a)

Manufacturing factory specifies that un-tanking inspection of active part may not
be conducted, or it is clearly specified in technical agreement.
b)

As for the Local manufactured product only with short transportation, customer

takes part in final assembly of active part in manufacturing factory in advance and
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confirm that the quality meets requirements, effective supervision is carried out
during transportation without emergency brake, serious shake, impact or severe bump
and other bad phenomena, and confirms no abnormity exists during transportation.
7.2.1 Inspection at site without removing cover (enter tank for inspection through
manhole)
7.2.1.1 Before open manhole or inspection hole to have active part inspection,
temporary protective cover shall be prepared outside the hole.
Note: If its raining, snowing, sand windy (above level 4) and the relative
humidity exceed 75%, its not permitted to carry out inner inspection and wiring.
For the product transported with nitrogen, anybody cannot enter tank for
inspection before nitrogen is not released thoroughly and the oxygen content
below 18%.
7.2.1.2 Working procedure of inner inspection and wiring for the product as per Table
4.
Table 4 Working procedure of inner inspection and wiring for the product
Procedure

Transported
and
stored
with
gas-filling
1
Transported
and
stored
with
oil-filling
Transported
and
stored
2
with
gas-filling
Transported
and
stored
with
oil-filling
Transported
stored
3 and
with

Items and
process

Description and requirement

1. Property index of oil meet the requirement in


Table 1.
Prepare
2. Temperature in heating evaporator shall be
qualified oil
controlled within the range of 655 when
and clean
vacuum filter filtrates oil.
conduit
3. Conduit shall be made of nylon or metal hose and
inside of metal hose must be clean without impurity.
Test
oil
1. Take oil sample from transformer tank for testing.
sample in
The detailed property index shall meet the
transformer
requirement in Table 1.
tank
and
2. Conduit shall adopt nylon or metal hose and
clean
oil
inside of conduit must be clean without impurity.
conduit
1. Impurity such as grease and dust on outer surface of all
conduits and accessories (including bushings) must be
removed.
Clean
2. Check whether inner surface of all turrets and reactor oil
transformer conduits (such as pipes connected with cooler, radiator and
accessories conservator) are clean. Clean inner surface with clean white
cloth until no visible grease and impurity exist.
3
If the conduits and accessories are qualified by
checking, cover them by plastic temporary for reserve.
Check gas
Check gas pressure in reactor tank as per clause 3.2.2
pressure in
and clause 3.2.3 of this installation manual.
tank
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gas-filling
Transported
and
stored
with
oil-filling

Check
Transported
Drain residual oil into separate container through
residual oil
and
stored
valve at bottom and carry out oil sample test as per
4
in
the
with
Table 1. Untreated residual oil shall not be refilled
bottom of
gas-filling
into reactor.
tank
Transported
and
stored

with
oil-filling
Following three methods can be chosen:
1oil filling and gas release fill transformer oil into
tank from oil storage tank through vacuum filter and
oil filter device; speed of oil filling shall be not more
Transported gas release than100L/min; stop oil filling when oil level over
and
stored transport active part; all exposed earthing parts, reactor tank
5
with
ed
with and oil filter device shall be earthed reliable.
gas-filling
nitrogen
2If there are sufficient dry air, the method of filling
dry air and releasing nitrogen can be adopted.
3If conditions permit, we can vacuum firstly, extract
nitrogen and then add dry air.
Transported
and
stored

with
oil-filling
Transported
1Oil in transformer shall be drained out through
and
stored
drain valve and filtered by oil filter device and then
6
with
return back to oil storage tank.
gas-filling
2Dry air shall be filled from top valve on the oil
conservator and it shall meet the following
requirement: dew point -40; pressure shall be
0.005MPa0.010MPa.
3In order to avoid abnormity occurring in the tank,
Replace oil
Transported with dry air open gas releasing plug on the conservator.
4In case no dry air at site, heat active part to make
and
stored
the temperature exceed ambient temperature 10
with
15 before draining oil. Put the 5kg cleaned and
oil-filling
sieved silica gel into clean cloth bag, and place the
silica gel bag on butterfly valve on the top of tank,
open the butterfly valve, then drain oil.
5The residual oil at the bottom of tank shall be
drained out completely.
Inner
1Put thermometer and hygrometer inside of tank and
7
Transported inspection,
outside of manhole to measure temperature and
and
stored
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humidity after above procedure is finished.


2Humidity inside the tank shall be lower than 50%,
and atmosphere humidity shall be lower than 75%
while entering tank.
3Disassemble corresponding installation covers for
parts, fastening support and filling material used for
fixing during transportation as per final assembly
drawing and disassembly transportation drawing of
reactor. Attention shall be paid not to damage other
parts or leads.
4Tools taken along with operator who enter tank
shall be numbered and registered and all dust and
impurity must not be taken into tank.
5Carry out inner inspection as per the requirement in
the instruction manual prepared by manufacturer to
confirm whether active part shifts, support of leads
loosens and insulation part falls off or cracks, and
Transported
and inner whether the inner wiring is in good condition, and
and
stored wiring
make a note.
6Measure insulation resistance of core to earth,
with
clamp to earth, and core to clamp using 2500V
oil-filling
megohmmeter, check whether grounding systems of
shield of side yoke (11 pcs in total) are in good
condition, and make a note
7Dry air with dew point ( -40) shall be filled into
tank with speed about 1.5m3/min during inner
inspection and wiring.
8Measures shall be taken to prevent dust at manhole
during the whole inner inspection and wiring. And a
person is specially assigned for waiting at manhole so
as to contact with person inside the tank
9After finishing the work, the person can come out
of tank after confirming no impurity left in tank and
checking tools as per number, then place cover on the
manhole.
10Exposed working time is shown in Fig.1.
7.2.2 Un-tanking inspection at site
with
gas-filling

7.2.2.1 In order to prevent moisture entering into active part, the following principle
shall be followed:
a) Un-tanking inspection shall be carried out in good weather( without wind and
sand) with ambient temperature 0, relative humidity 75%, The temperature of
active part shall be higher than the ambient temperature. When it is lower than the
ambient temperature, the active part shall be heated to make its temperature is higher
than the ambient temperature about 10.
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Y0SB.460.5483

b) Clean and dustproof measures and emergency rainproof measures shall be


available around the checking site; the exposure time of active part shall be shortened
as much as possible during the untanking inspection.
c) The exposure time of active part in the air shall be as follows: the exposure time
shall be 24h if relative humidity is 50; the exposure time shall be 20h if relative
humidity is within the range of 50~60; the exposure time shall be 16h if relative
humidity is of 60~70; the exposure time shall be 12h if relative humidity is of
70~75. At the same time, the total exposure time including untanking inspection
time and time for putting active part back into tank shall be controlled according to
Figure I. If the estimated total exposed time exceeds stipulated time, the control and
treatment for equivalent exposure time shall be followed strictly under the instruction
of the personnel assigned by manufacturer.
d) The exposure time calculates from start of oil draining (transported with oil-filling)
or opening any cover or oil plug (transported with gas-filling) until the start of
vacuum.
e) In special cases or the exposure time exceeds stipulated time, corresponding
emergency protection measures shall be taken in time, and monitor the insulation and
make sure it is not moistened, otherwise all works shall be stopped.

Equivalent exposure time (h)

24h
20h
16h
12h

Average relative humidity of air (%)

Note:
1) When transformer manhole is opened to carry out inner inspection and wiring or
un-tanking inspection, active part will absorb moisture. So the exposure time shall be
controlled within specified period.
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Y0SB.460.5483

2) When work inside the tank, dry air shall be filled into tank all the time to ensure
humidity inside the tank remain 50%.
3) When stop or finish inner work or assemble upper part of tank after finish
un-tanking inspection, cover the manhole or other hole immediately. Stop working at
night. If the air is filled in tank, each exposure time can be regarded as 4h. When the
air inside tank is replaced by dry air, the exposure time can be regarded as 2h.
4) The allowed exposure time of active part refers to Figure1.
5) If the exposure time exceeds the total exposed time stipulated in the above figure
due to some reason during work at site, it shall be controlled as per equivalent
exposure time. And evacuated before finish under the instruction of technician
assigned by manufacturer.
7.2.2.2 Preparation and notes for un-tanking inspection
a)

Prepare enough qualified transformer oil.

b)

Prepare the lifting device, vacuum generator, oil filter, tools etc., and

distribute tasks for everyone; all the tools and equipment used during check shall be
complete and clean. Special person shall be assigned to number and record their using
condition, and make sure no foreign substances drop into the tank
c)

Drain oil from heavy package. Put 5kg dry and clean screened silicon gel into

a clean cloth bag and put the bag on the butterfly valve on the top of tank before open
the valve. Connect the draining pipe to the valve on the bottom of tank and drain the
oil off; Drain residual oil from reactor filled with gas.
d)

Before lift the upper part of tank, open the cover of the turret in the middle of

tank, disassemble fixtures for transportation as per disassembly transportation


drawing; remove the bolts of fixtures carefully and avoid the falling down of nuts into
heavy package of reactor, see final assembly drawing for detailed information and
make marks. If it will not be transported, it is unnecessary to assemble the fixtures
again for transportation.
e)

The eyes should be forced at the same time when lift the upper of tank with

the angle between sling and plumb line not more than 30. The lifting beam can be
used if necessary to remain balance and to avoid the abnormal events like collision
and block of tank wall and active part.
f)

Lift the upper part of tank and lay down the horizontal sleeper or wooden

block to avoid the damage or contamination of seal of frame. The succeeding work
and lifting should be considered when choose the tank location.
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g)

The ladder for checking of active part and the articles with sharp corner

should not lean against the leads, the insulations and the cable clip. The cable supports
and the leads are forbidden to climb on.
h)

The leads of winding shall not be bent discretionarily, and it shall be kept in

the original installation position.


i)

The insulation material used inside the reactor must conduct dry treatment

previously, and dry it 24h at a dry temperature of 955.


7.2.3 Check content of active part
7.2.3.1 Check if the core has displacement and deformation. Disassemble the
shielding board and earthing wiring of the pad. Check if the insulation between the
pad and clamp as well as pad and core is well by megger. Check the insulation
between the core pad and lower part of tank. Check if the damping rubber has
displacement, falling, and if the bolt and nut of fixed pad has loose, and if the
insulation tube is in good condition. If there is problem on insulation, it shall be
solved in time. If the insulation is good, connect the earthing wiring and shielding
board of the pad.
7.2.3.2 Check if the active part has obvious displacement and deformation. Check if
the spacer ring and spacers have loose and displacement, and if there are impurities
blocking oil ducts between layers.
7.2.3.3 Check if leads of earthing shileding (1pc), leads of upper and lower yoke
shielding board (4pcs in total), leads of side yoke shielding board (2pcs in total) and
leads of core pad shielding board (4pcs in total) are earthed well.
7.2.3.4 Check if all the fixing parts, bakelite locking nut and support clamping bolt is
locked firmly.
7.2.3.5 Check if there are impurities and dirtiness etc. on inner wall of tank and
shielding device of tank wall, and clean them.
7.2.3.6 Check if the insulation of leads is good, and the position of leads is correct.
7.2.4 Test of Active Part Inspection
7.2.4.1 The core shall be earthed and the resistance from core to earth after removing
the earth strip shall be not less than 500M (2500V megameter). Check whether the
earth strip on core is tightly.
7.2.4.2 Measure the insulation resistance of winding and check the absorption ratio.
When insulation is abnormal, please contact with the manufacturer in time to solve it
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Y0SB.460.5483

in proper way.
7.2.4.3 Measure the DC resistance on winding if necessary.
7.2.4.4 After finishing the inspection on active part, shall be rinse with qualified
transformer oil, and clean the bottom of tank, nothing is permitted to be left inside.
The failure and the defect found during check of active part shall be duly settled and
recorded to keep in the archives for check.
7.2.4.5 Install back the upper part of tank after the inspection and test of active part.
Clean the seal of upper and lower frame, replace the sealing strips along frame, make
it straight and secure it with clamp, after that, put down the tank slowly and tighten all
the screws along the frame with uniform force.
7.3 Installation of heavy package and accessories
7.3.1 The installation of heavy package shall be in accordance with following
requirement:
7.3.1.1 The installation foundation for reactor shall be level, the heavy package and
foundation embedded plates shall be connected reliably.
7.3.1.2 The jacks shall be used on the specified positions.
7.3.1.3 See Table 5 for the preparation before installation of heavy package.
Table 5 Preparation for Final Assembly
Items
Procedure
1. Prepare
qualified oil
rinsing the
pipe

and

Key Point and Requirement

the 1. The property of oil shall be in accordance with GB/T7595


for Quality Standard of Transformer Oil in Operation.
oil 2. The oil temperature in heating dehydrator shall be controlled
within 655 when filter the oil by vacuum filter.
3. The oil pipes shall be nylon or metal hose in which must
clean and free of impurity.
2.Clean
the 1. Clean the smear, dust and impurities on the external surfaces
accessories
of of all the pipes and accessories including every specification of
transformer
bushings.
2. Check whether the oil conduit and inside surface of turret is
clean. Wipe the obvious smear and impurities off the surface by
clean white cloth.
3. Check the pipe and accessories and seal them with plastic
temporarily.
3. Assembly of 1. Confirm the assembly of sealing parts in bushing turrets.
product
2. Assembly the flange according to the sign of end to end
joint.
3. Confirm the horizontal and vertical degree of turret.
4. Assemble the accessories like conservator, connection pipe
and bushing, and confirm it.
5. The gaps between seal surfaces shall be uniform.
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6. When assembling the accessories, the accessories shall be


assembled while dismantle the blind plate as could as possible to
avoid long-time open of assembly entry and lower the moisture
and dust entering into transformer.
7.3.2 The sealing treatment shall fulfill the following requirements:
7.3.2.1 The oil-proof gasket shall be without any distortion, deformation, cracks and
burs, the gasket shall be matched with the dimension of the flange surface.
7.3.2.2 The connection surface of flanges shall be flat and clean, the gaskets shall be
cleaned and with correct installation position. The thickness in overlapped area shall
be the same as the original thickness. The forces on all circumference surface of
gasket shall be even. The compressibility of rubber gasket shall normally not exceed
1/3 of its thickness.
7.3.3 Assembly of turret shall be done in accordance with following requirements:
7.3.3.1 Before assembly of turret, test the CT and firmly fix the connection screw and
fixing spacer. The terminal board for CTs exit leads shall be well insulated and sealed
without any oil leakage.
7.3.3.2 When assemble the turret, make the nameplate of CT faced to the outside of
tank, the air relief plug shall be installed at the highest position of turret. Additionally,
the leads out of reactor shall be packed up to facilitate the assembly of bushing.
7.3.3.3 When test the bushing CT, measure the change of contact of CT and check the
mark of terminal. Measure the insulation resistance, which normally is not less than
1000M(20),by 2500V ohmmeter.
7.3.4 The oil-guiding pipe shall be assembled according the final-assembly drawing
and the numbers shown on the oil-guiding pipe and cant be changed casually. The
valves in piping shall be operated freely with correct open and close position. The
sealing between valve and flange connection shall be well.
7.3.5 The radiator assembly shall be in accordance with following requirements:
7.3.5.1 Before radiator assembly, the sealing test shall be carried out by air pressure or
oil pressure according to the pressure values specified in instruction of radiator.
7.3.5.2 If the radiator has been rinsed in manufacturers factory and well sealed to
fight against rust, rain and smear inside it after they arrive at site, the rinse at site is
unnecessary. Otherwise, before assembly, rinse the inside to be clean with qualified
insulation oil through circulating by filter and drain the residual oil off.
7.3.5.3 When assemble the radiator, mutual collision shall be avoided. Forced
installation is not permitted to avoid radiator from damage and leakage.
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7.3.5.4 While assembling the radiator, the single group of radiator shall be fixed by
bolt, but not tightening the nut. After adjusting the distance between radiators and
connecting the adjacent radiator by flat steel, the nut shall be tightened.
7.3.5.5 After the radiator assembly, it shall be filled with oil under vacuum together
with the heavy package.
7.3.6 The assembly of conservator shall be in accordance with following requirement:
7.3.6.1 Before installation, the installation instruction for oil conservator shall be read
carefully and installation shall be done strictly according to the installation process in
instruction.
7.3.6.2 Before assemble conservator, clean the inside and outside surface.
7.3.6.3 The rubber bag or capsule of diaphragm conservator shall be complete without
damage, check the gas leakage after slow gas filling. There is no gas leakage after the
12h air pressure test of 0.02Mpa.
7.3.6.4 The capsule shall keep parallel with major axis of conservator along length
direction without any twist. The sealing of capsule mouth shall be good and with
smooth breath.
7.3.6.5 The action of oil level indicator shall be flexible, the indication of oil level
indicator and oil level pipe shall be in accordance with actual condition to avoid the
false oil level being indicated. The signal connection of indicator shall be correct and
well insulated.
7.3.6.6 Assemble the connection pipe, corrugated pipe, butterfly valve, Buchholz
relay and ladder, etc. after assembly of the conservator. Note: the breather is
assembled after oil-filling under vacuum.
7.3.7 The assembly of breather shall be in accordance with following requirements:
The connection pipe between breather and conservator shall be well sealed. The
transportation sealing gasket of breather oil cup shall be removed, and the breather
valve shall be open. The dehydrating agent shall be dry and the oil pipe shall be
smooth. The oil level of oil seal shall be high as the same as top oil line
7.3.8 The assembly of bushing shall be in accordance with following requirements:
7.3.8.1 The following inspection shall be carried out before bushing installation.
7.3.8.1.1 The porcelain surface shall be free from crack and scar.
7.3.8.1.2 The neck of the bushing flange as well as the outer and inner surface of the
shielding ring shall be clean.
7.3.8.1.3 The bushing shall be tested successfully.
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7.3.8.1.4 The oil-filled bushing shall be free from oil leakage and with correct oil
level indication.
7.3.8.1.5 The temporary support of leads in tank with fixing function during
transportation shall be disassembled. Details please see disassembly transportation
drawing.
7.3.8.2 The root of exit leads and the ends of leads entering into bushing shall not be
roughly drawn, twisted and bent. The covering of exit leads shall be complete and
good.
7.3.8.3 When assemble cable-through bushing, the stress taper of exit leads shall be
entered into the shielding ring, the connection position between exit end and bushing
shall be cleaned and tight to ensure the good connection and avoid the over heat of
conducting rod due to too big contact resistance.
7.3.8.4 The installation for sealing gasket on top of bushing shall be correct. Pay
attention to avoid the looseness of the top structure during lead connection, the sealing
shall be good to prevent the entering of the water and moistened.
7.3.8.5 When assemble the draw-rod bushing, firstly connect the draw-rod with lead
as bushing close to the installation position, at this time loose the shielding ring from
bushing and pull it over the lead. After that, connect the lead with draw-rod by bolts
and butterfly spring, tighten all the bolts with uniform force, hold up the shielding
ring and tighten it on the bottom of bushing. Finally, put the bushing into final
position and tighten the bushing installation bolts.
7.3.8.6 The indicator of oil-filled bushing shall face to the outside for convenient
observation of oil level in bushing. The test tap of bushing shall be well grounded.
7.3.8.7 The bushing shall be lifted and installed according to the installation
instruction of bushing. The detailed installation dimensions refer to the bushing lifting
drawing in final assembly drawing. Note: When disassemble the bushing, the pin that
fixes the leads joint must be removed, only after confirming that there is no
connection between connection wiring and the top & bottom of the bushing, the
bushing body can be lifted slowly to avoid the damage of the inner lead during
bushing lifting.
7.3.9 The assembly of Buchholz Relay and the rapidly actuated oil-pressure relay
shall be in accordance with following requirements:
7.3.9.1 The assembly of 220kV 500kV Buchholz relay and rapidly actuated
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Y0SB.460.5483

oil-pressure relay shall be in accordance with requirement in relative standard and the
calibration and setting shall be carried out according to the Operation Instruction
Manual for gas relay and rapidly actuated oil-pressure relay.
7.3.9.2 The Buchholz relay shall be installed horizontally and the arrowhead shown
on the cover shall point to conservator.
7.3.9.3 For the Buchholz relay with gas collecting box, the gas-collecting pipe shall
be well connected. The gas collection pipe shall be guaranteed smooth after oil filling.
7.3.10 The assembly of pressure relief device shall be in accordance with
requirements:
The assembly direction of pressure relief device shall be correct with clean cover and
inside turret in good sealing. The electrical connected point shall be correctly acted
with good insulation.
7.3.11 The assembly of temperature measuring device shall be in accordance with
following requirements:
7.3.11.1 The thermometer shall be calibrated before assembly and the signal contact
shall act correctly with good conductive path. The winding thermometer shall be
adjusted according to the Operation Instruction Manual and the line oil temperature
difference of product. Generally, the line oil temperature difference of reactor is about
15K. The temperature rectified value of thermometer on top oil is as follows: at 90,
alarm; at 100, trip. As for the winding thermometer: at 105, alarm; at 115 trip.
7.3.11.2 The pocket of thermometer on the cover shall be filled with transformer oil
and well sealed without leakage. The stand-by thermometer shall be sealed to fight
against water.
7.3.11.3 The thin hose of expansive thermometer shall not be staved and sharply
twisted with radius of bending not less than 150mm (or according to the manual
instruction of the thermometer)
7.3.12 Following items shall be paid attention during assembly:
7.3.12.1 Check, position and seal the fixture on the top of tank if have according to
the technical specification.
7.3.12.2 For the components with air plugs on the top like bushings, Buchholz relay,
conservator etc., release air from them by opening the air plugs and close the plugs
immediately when the oil spill out.
7.3.12.3 All the pipelines supplied by owner or cut and welded at site should be
23

Y0SB.460.5483

washed and rinsed by qualified oil.


7.3.12.4 Owner shall get the permission from manufacturer if modify the pipelines to
ensure the efficiency of cooling.
7.3.12.5 All the thermometer pockets shall be filled with transformer oil fully.
7.3.12.6 For assembly and serial number of pipeline and valves of reactor, refer to the
final-assembly drawing and valve installation drawings.

8. Safety Precaution at site


8.1

Set up the precautions to ensure the safety for personnel and facilities. The

assembly site and other construction site shall have distinctive sign to distinguish and
avoid the interference of personnel.
8.2 Pay special attention to use the safety belt and helmet for the work high above the
ground according to the safety stipulation.
8.3 The entry of personnel is forbidden when oxygen content inside tank is less than
18%.
8.4 The lifting and handling shall be done according to relevant stipulation and the
instruction of product to avoid the damage of equipment and injury of personnel
during lifting and handling.
8.5 The fire control and distinguishing measures must be taken at site for hot work.
8.6 The test proposal including safety precautions shall be prepared for high voltage
test.
8.7 The dismantlement and assembly of details and parts at the place high above the
ground must be done by at least two persons.

9. Oil-filling under vacuum, hot oil circulation and standing


9.1 Evacuations to remove the moisture and gas
9.1.1 After all the accessories are installed, open all the valves on the oil tubes of
radiators and conservator, open the vacuum balance valve on top of conservator and
rubber bag tube to vacuum the conservator and the heavy package.
9.1.2 The vacuum gauge is installed on the oil plug on side of the conservator. The oil
filling hose shall be connected to the bottom of the tank, the vacuum pump system is
fixed at the connection tube of the breather.
9.1.3 After the completion of above preparation, start the vacuum pump for
evacuation for the tank. The sealing test and leakage rate test for tank and the
24

Y0SB.460.5483

connection tubes shall be measured during the vacuum evacuation. Method: when
vacuum degree goes below 133Pa, close the pump valve for an hour and read the first
pressure P1 from Macleod vacuometer, then close the valve for half an hour and open
the valve to read the second pressure P2. Calculate the difference between P2 and P1,
the leakage rate is regarded qualified when P2-P13240/reactor oil weight (t).
Otherwise, the bolt shall be tightened, the leakage repair for product shall be
conducted, then perform the leakage test again until it is qualified.
9.1.4 After the leakage rate meets the requirement, run the vacuum pump to continue
the evacuation of tank and begin to reckon the time when the vacuum degree less than
133Pa, and keep the vacuum degree less than 133Pa for the time in table 6. The total
exposure time of active part shall not be more than what stipulated in Item 7.2.2.1 and
vacuuming period shall be prolonged 12 hours every time when exposure time exceed
8 hours. Observe the deformation of tank during evacuation.
Table 6 Continuous vacuum evacuation time to reach required pressure
Voltage level
Time
220kV and below
24h
330kV
36h
500kV
48h
9.2 Oil filling under vacuum
9.2.1 Fill the qualified transformer oil through the valve on the lower part using the
second-class vacuum filter machine under vacuum with the velocity no more than
4t/h~6t/h and heated up to 50~60. The oil shall be filled to the normal oil level in
the conservator for one time.
9.2.2 The supplement oil shall be filled into the heavy package of reactor through the
special oil-filling valve on conservator and the oil filter. The air in heavy package and
accessories shall be released during oil filling.
9.2.3 The vacuum oil filling is preferably not carried out in rainy or foggy days.
9.3 Hot oil circulation
9.3.1 After oil filling under vacuum, the hot oil circulation shall be done from top to
the bottom continually to make the oil quality up to the standard. Generally, the time
for hot oil circulation shall be not less than 48h.
9.3.2 The oil temperature shall be 60~70 during hot oil circulation. Normally, the
total amount of oil should be circulated three or four times.
9.3.3 Take the oil sample and test it after 48 h oil circulation. Stop the circulation if
the oil quality is up to the requirement in Table 1, otherwise, prolong the duration of
circulation.
9.4 Resting
The reactor is in the resting condition after oil circulation. The resting time please see
table 7. During the resting, open all the vent plugs of turret and radiator to release the
residual gas.

25

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Table 7 Standing time


Voltage level

Time

220, 330kV

72h

500kV

120h

9.5 Assembly of other components


9.5.1 Assemble the small components like temperature measuring instrument.
9.5.2 When assemble the electrical circuit, according to control wiring drawing, firstly
assemble the control cubicle and cable chute, and then connect the connection box of
current transformer, Buchholz relay, pressure-relief device and thermometer with
cables, and finally fix the cable in the cable chute on the top of tank and the wall with
the agraffe before cover the chute well and tighten the screw. The exposed cable
outside the chute shall be protected with stainless steel metallic hose. The assembly of
electrical circuit shall be done in accordance with relevant stipulation in current
national standard GB50171 Erection Works of Electrical Installations Code for
Construction and Acceptance of Switchboard, Complete Cubicle and Secondary
Circuit.
9.5.3 Fill the insulation oil into thermometer and fix the thermometer in the position
according to the final-assembly drawing.
9.5.4 All the components and accessories, rating plates and nameplates etc. installed
outside of the reactor shall be fixed tightly to avoid any undesired noise or vibration.

10. Preparation and touch-up for external surface of reactor


After all the assemblies are finished, remove all the impurity and temporary devices
irrelevant to reactor, clean the external surface off with cleaning agent, remove the
stain tainted during transportation and assembly, and touch up the damaged places
with the same grade and color paint as the heavy package.
11. Check and hand-over test before putting into operation
11.1 Check before hand-over test
11.1.1 The heavy package, radiators and all accessories shall be checked no defect.
And the sealing condition for whole reactor shall be checked after final assembly is
finished. Method of checking: Apply an air pressure or oil pressure of 0.03MPa,
which the tank cover can withstand, on conservator for continuous 24h, there shall be
no leakage in whole reactor.
26

Y0SB.460.5483

11.1.2 The painting shall be well done, and the phase number is properly marked. No
impurities or pollutants are allowed at the top of the reactor, and the bushing shall be
cleaned. The emergency drain facility is well constructed, and the fire fighting system
shall be completely equipped.
11.1.3 The valves on such oil system as conservator, cooling device etc. shall be
opened, especially the valves of pressure relief device, gas relay and breather must be
in ON position.
11.1.4 Check whether the grounding system is correct and reliable. Check whether the
wring of CT is correct, the CT without load is short-connected to earth.
Open-circuited operation is not permitted. The reads from all temperature instruments
shall be different within the permissive tolerance range.
11.1.5 The oil level of conservator and oil-filled bushing should be normal. The
silicon gel inside dehydrator shall be in normal color with the transportation cap
having been removed. The oil inside the oil cup shall be clean and oil level fulfills the
requirement.
11.1.6 All electric wiring shall be properly connected. All control & protection and
signal system shall operate reliably, and the indication of meters & gauges shall be
correct. The rectifying value shall meet the requirement.
11.1.7 The assembly direction of Buchholz relay shall be done correctly with normal
oil-filling and the gas being released off.
11.1.8 Check dielectric space of external air and between bushings of various rated
voltage and bushing to ground.
11.1.9 Measure the winding and the DC resistance of bushing. The difference between
this measured value and the value measured at ex-factory at the same temperature
shall be not obvious.
11.1.10 Take transformer oil sample to testincluding oil test of transformer oil inside
bushing if necessary, of which the performance shall fulfill the specification in
national standard.
11.1.11 Measure the insulation property of reactor (under the same temperature):
a) Insulation resistance value of winding: for reactor up to 330kV, the measured value
shall be not less than 70% of the ex-factory testing value. For 500kV reactor, the
measured value shall be not less than 85% of the ex-factory testing value.
b) The difference of absorption ratio (R60/R15) between measured value and
27

Y0SB.460.5483

ex-factory value shall be not obvious. The measured value shall be not less than 85%
of ex-factory testing value under normal temperature.
c) The difference of polarization index (R10min/R1min) between measured value and
ex-factory testing value shall be not obvious.
d) Dissipation factor (tg): For reactor up to 330kV, the measured value shall be not
more than 130% of the value measured at factory. For 500kV reactor, the measured
value shall be not more than 120% of the value measured at factory. When tgis less
than 0.5% at 20, it may not be compared with the value measured at ex-factory.
e) Measure the insulation resistance of core (clamp) earth bushing to earth. Its value
shall be not less than 500M. The earth wire shall be connected well after measuring.
Measure the insulation resistance of core to clamp. Its value shall be not less than
500M.
11.1.12 Measure the DC leakage current of winding. It shall meet GB50150
stipulation of Engineering Electrical Equipment for Hand-over Test Standard for
Electrical Equipment.
11.2 Hand-over test
The following tests shall be start after all the inspection items that shall be carried out
and hand-over test fulfill the requirement of 11.1.
11.2.1 The voltage withstand test can be carried out while the condition is ready. The
testing voltage shall accord with corresponding standards or technical agreement.
11.2.2 Impulse switching-on test at rated voltage
Switching-on impulse test of circuit and shunt reactors of electric power
substation and circuit shall be carried out for 5 times. After the first excitation, the
duration shall be not less than 10 min and the duration of followed excitation shall
be not less than 5 min without any abnormal phenomenon.
11.2.3 Other tests shall be carried out according to national standards or technical
agreement. Other HV tests to be carried out on the reactor during commissioning of
system shall be discussed later.
11.2.4 The temporary earth wire shall be removed after tests.
11.2.5 Trial operation
11.2.5.1 Put the reactor into trial operation after the radiator has been in normal
operation.
11.2.5.2 Trial operation is end after 24 hours of continuous operation.
28

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12. Operation
12.1 Put into operation
After the trial operation, if there is no any abnormal phenomenon appeared, it is
considered that the reactor has been put into operation officially.
12.2 The method of oil refilling and draining during operation refer to instruction
manual of conservator.
12.3 The monitoring of reactor during operation
12.3.1 Monitor the top oil temperature, the change of oil level often and whether the
oil-bled or descent of oil level happens at the beginning of operation.
12.3.2 Check and listen often whether the sound of reactor operation is normal and
whether there is some noise as bursting.
12.3.3 After operation of 24h, 3 days and 1 week, oil samples shall be taken for test
and chromatograph analysis. If there is nothing abnormal in the test results, oil
samples shall be taken for normal chromatograph monitoring according to operation
regulations.
12.4 Other monitoring items during operation shall be carried out according to the
relative operation stipulation.
12.5 The operation maintenance of each component refer to its own instruction
manuals.
13. Delivery and acceptance of technical documents and spare parts
13.1 The original version of technical documents, such as product instruction, testing
record, product certificate, installation drawings of manufacturer.
13.2 Installation record (including the records of inspection performed in tank and
of accessories inspection), adjusting testing record, test report for transformer oil
and so on.
13.3 Delivery list of spare parts.
13.4 Other documents: technical agreement for ordering, technical document for
modifying design, important MoM and so on.
13.5 Except the items listed in contract, special tools and transportation cover etc.
shall also be included in the spare parts.
13.6 After checking and handing-over, both parties shall sign on the handing-over list
of equipments.
14. Inspection and maintenance
14.1 In order to ensure the long-time and safe operation of reactor and find the
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failure sign on heavy package and components, its necessary to inspect and
maintain the reactor.
14.2 The period of inspection and maintenance depends on the importance of the
reactor acting in power supply system, the operation environment, the
environment and climate at installation site as well as the operation situation over
past years and preventive test and so on. The following table 8 of maintenance
and inspection are necessary to carry out while the reactor is working normally.
At the same time, the settlements to the abnormal phenomenon are also shown in
following table 9. Associating with many years experience, the operation
company can constitute their own inspection and maintenance proposal as well as
plan according to their real situation.
14.3 Besides the routine inspection, reactor shall be inspected and settled
regularly according to the content and requirement of table 10.
14.4 Not mentioned part refer to DL/T572 Operation Specification For Power
Transformer and DL/T 573 Maintenance Guide For Power Transformer and other
relative standards.
15. Flow chart of main works for reactor installation
Refer to table 2.
Table 8 Inspection and Treatment
Inspecti
on
position
Heavy
package
of
reactor

Inspec
tion
Period
1-3
month
s

Inspection
items

Description
method

and Judgment and Measure

1)temperat 1) Indication of
ure
thermometer;
2) Indication of
winding
thermometer;
3)Moisture
condensation in
the thermometer
panel.
2)oil level 1 Indication of
oil level indicator;
2 Moisture
condensation in
the
oil
level
indicator panel.
3 Refer to the
standard
curve
and compare the
30

1) If the deviation between the


oil temperature and oil level
exceeds the standard curve, the
following parts shall be checked
especially:
a) Leakage on reactor tank;
b) Problem on oil level indicator
c) Problem on thermometer.
d) Rubber sack damaged.
e) Internal local overheat, check
the oil chromatogram further.
f When necessary use the
infrared
temperature
measurement device to check
further.
2)
Once
the
moisture
condensation happens on the
dial of oil level indicator and

Y0SB.460.5483

3)oil
leakage

4)pressure
relief
valve

relationship
between
oil
temperature and
oil level.
1 Check the
sealing of bushing
flange,
valve,
cooling device,
piping and so on.
2 Check the
quality of the
welding seam.

1) Check the oil


leakage on the
pressure
relief
device of the
heavy package
2) Check if the
pressure
relief
device on the
heavy
package
has acted.

31

thermometer, the reason for


dewing
shall
be
found
especially.
1) If oil is leaked at sealing area,
the sealing parts shall be
tightened again. If it still leaked,
the sealing parts must be
replaced.
2) If oil leakage happens on the
welding seam, it should be
re-welded for leakage part.
When the welding seam area is
too large or the re-welding time
is too long, the welding work
shall be carried out by the
professional personal from
manufacturer under vacuum
with oil (vacuumed above the
top oil).
1)if the oil is leaked at the
pressure relief valve, the
following items shall be
checked especially:
a) If the breather on the
conservator is blocked.
b) If the oil level is too high.
c) If oil temperature and the
load are normal.
d) If the spring and the sealing
of the pressure relief valves
function well, if not replace
them.
2) If the pressure relief valve
have acted, besides the above
items, the following items
should also be checked:
a) If the second circuit becomes
damp.
b) If there is air in the
conservator.
c) If the valve between gas relay
and conservator has been
opened.
d) Get contact with the
manufacturer, refer to the oil
chromatogram
result,
and
analyze the reason.

Y0SB.460.5483

5)Abnorm
al
noise
and
vibration

Cooling 1-3
Device month
s

Bushin
g

1-3
month
s

Check
whether
the
operation
condition
is
normal.

1)oil
leakage

Check
whether
there
is
any
leakage
on
coolers
valves
and so on.
2)
Check
the
Contamin contaminated
ant
position
and
contaminated
degree on cooler.
1)
Oil Check
whether
leakage
there is any oil
leakage
on
bushing.
2)Crack,
1) Check whether
discharge, there is any crack
damage
on the porcelain
and
where
is
contamina contaminated.
nt
on 2) If there are
bushing
discharge traces
on the silicon
rubber shed and
RTV.
3)Overhea Infrared
t
temperature
measurement

1) If the abnormal noise and


vibration are resulted in the
loose of connecting parts, these
parts shall be tightened again.
2) Check whether the abnormal
noise and vibration have
something to do with the on
load current, if any, it must be
caused by the looseness of core
limb or winding.
Check the leakage situation by
group, if oil is leaked at sealing
area, the sealing parts shall be
tightened again or be replaced.
If it is very dirty, the cooler shall
be cleaned carefully. Otherwise
the cooling efficiency will be
influenced.
1) Replace the gaskets if there
is any oil leakage.
2) Check the force distribution
on the terminals.
1)
If
the
bushing
is
contaminated, clean it. If there is
crack on the bushing, replace it
in time.
2) If there is discharge trace,
replace it.

1) If the internal overheats, it


should be replaced.
2) If terminal overheats, handle
it reasonable.
4) End of Check
whether If there is discharge, remove the
the
there is discharge. rust
and
paint
the
porcelain
semi-conductor
insulation
of bushing
lacquer.
5)Oil level The indication of 1) If the oil level has sudden
the
oil
level change (rise or decrease), check
indicator
whether the bushing and heavy
package has oil leakage.
2) If the oil color becomes dark
or muddy, check the oil
chromatogram and the moisture
content, check whether it
32

Y0SB.460.5483

Breathe
r

Gas
relay

1-3
month
s

1-3
month
s

Termin 3-6mo
al box nths
and
control
box

Degree of 1) Check
desiccatio desiccative and
n
confirm its color.
2) Check the oil
level in oil cup.

breath

Check
whether
the breath is
normal.

Oil
leakage
gas

Check the sealing


conditions
Check
the
quantities of the
gas accumulation

1)sealing
2)contact
3)complet
eness

1) Check whether
there
is
rain
ingress.
2) Check whether
the
terminals
loose and rust.
3) Check the
completeness of
the
electric
element.

33

discharged and become damp


especially.
1) If the color of desiccative
changed from blue to light
purple or red, the desiccative
must be re-dried or replaced.
For the white desiccative,
should observe carefully or
change to other kinds.
2) If the oil level is lower than
normal level, clean the oil cup
and refill with transformer oil.
But the oil level shall not be too
high, otherwise it may be
absorbed into the desiccation
and reduce its function.
With the change of the load and
oil temperature, bubbles appear
in the oil cup. If no bubbles
come out, there is blocking.
That should be dealt with in
time.
The gasket should be tightened
or replaced.
If there is gas, take sample to
make
oil
chromatogram
analysis.
1) If the content percent of O2
and N2 are high, maybe it is
caused by the leakage, the
sealing conditions shall be
checked especially/
2) If it is metal discharge or
overheat, check further and
analyze.
1) If there is rain ingress, it shall
be sealed again.
2) If the terminals loose or have
rust, they shall be tightened and
cleared again.
3) If the electric elements are
damaged, replace them.

Y0SB.460.5483

Unusual conditions
Gas accumulation
Gas relay
First stage
Oil surge
Gas relay
Second stage

Pressure release

Trip

Oil
temperature-high
First stage-alarm
Second stage-trip

Winding
temperature-high
First stage-alarm
Second stage-trip
Grounding fault

Oil level-low

Table 9 Unusual Conditions Inspection


Causes
Measures
Analysis
Internal discharge
Extract gas from Gas
Light fault
the gas relay
chromatographic
analysis
Internal discharge
Reactor
out of Test the insulation
Serious fault
service
resistance, winding
resistance
and
excitation current
as well as gas
analysis
Internal discharge
reactor
out
of Gas
service
chromatographic
analysis
Internal discharge reactor
out
of Gas
inrush
service
chromatographic
analysis
The
valve
is Check the open Check whether the
opened
not condition of the valve of the coolers
completely or the cooler valve or are
opened
temperature
has strengthen
the completely,
and
been
set cooling.
whether the cooling
inappropriately.
system
function
well.
Overload or the Load reduction of Check the reactor
temperature
has reactor, check the loading and the
been
set setting.
setting
inappropriately.
Internal grounding reactor
out
of Check
operating
fault
service
conditions of other
External grounding
protection devices
fault
(gas relay, pressure
relief device etc.)
Oil leakage
Oil filling
Check the rubber
bag
of
the
conservator,
the
tank and oil sealing
parts

34

Y0SB.460.5483

Inspectio
n Position
Insulation
condition
s

Table 10 Periodic Inspection and Treatment


Period
Items
Method
1-3 years

Insulation
resistance(to
gether with
bushing )

Judgment and
measures
There shall be no
big difference for
each result from its
latest one. If there
is, find out the
reason.

1)Measure
the
insulation
resistance
of
winding to earth or
to other windings,
absorb ratio and
polarization
coefficient
with
2500V,
5000V
mega ohmmeter
2) The measured
value
is
the
resistance
of
winding
plus
bushing. If the
value is out of
normal
range,
separate
the
winding from the
bushing to measure
resistance
separately
at
overhaul or proper
time.
Insulation
1-3 years
Oil quality Check
whether The insulation oil
oil
there is impurities
shall be transparent,
has no impurities
and
suspended
solids.
Withstand Testing method and Voltage class:
voltage
devices see GB/ T 220kV:35 kV
507 Measurement 330kV:45 kV
of
Breakdown 550kV:5 0kV
Voltage
for If less, oil treatment
Insulation Oil, and shall be done.
GB/T264
Acid
0.1 mgKOH/g
Measurement
of If
number
higher,
oil
measuremen Acid Number for treatment shall be
Petroleum.
t
done.
1) Take sample
Gas
1)
Main gases If
unusual
to analyze 24h, dissolved in detected: O2, N2, conditions found,
3 days, and 1 oil analysis H2, CO, CO2, CH4, shorten
the
week
C2H2, C2H4, C2H6.
sampling
period,
respectively
2) Method see and take close
after
putting
GB/T 7252 Guide attention to the
into operation.
for Analysis of Gas increase speed. The
35

Y0SB.460.5483

Dissolved
in
Transformer
Oil
and Judgment
3)create
analysis
file

2) 3 months
after put into
operation
3) 6 months
after put into
operation
4)
Measuring
every year ever
after

Cooler
device

Bushing

1) Take
oil
sample
to
analyze 24 h
after
putting
into operation.
2) measuring
every year ever
after.
1-3years

Gas content

2-3years

General

Cleanness

36

Method see DL/T


423 or , DL/T 450,
DL/T 703

fault judgment sees


GB/T 7252
Main reason of gas
development
in
transformer oil:
1)oil decomposition
due to overheat
2)overheat of solid
insulation in oil
3)oil decomposition
due
to
spark
discharge
4)solid insulation
decomposition due
to spark discharge
1) hand-over
testing or newly
putting
inot
operation :1%
2) in service :5%

Check the stains


1)Clean the cooling
and corrosion of the fin with hot water at
cooling fin and
least once a year
brackets
2)Clean the cooling
pipes with
high-pressure water
every 3 years, and
then repaint the
bracket and external
surfaces etc.
1) crack
Check
the
2)stain (including conditions of these
the saline contents) items:
3) oil leakage
1) If the bushing is
4) overhead wires
too much stained,
5) rust
clean it with neutral
6) oil level
cleaning
agent,
7)discharge
rinse with clean
8)overheat
water and then wipe
9)moisture
it dry.
condensation in oil 2)
Tighten
the
level indicator
wiring terminal if
loose.
3) If the creepage
distance of bushing
is not enough, the
silicon
rubber

Y0SB.460.5483

Accessori 2 or 3 years LV control


es
(yearly check is circuit
suggested if the
control element
is to control the
distributed
circuit)

2 or 3 years
(yearly check is
suggested if the
relay is used to
control
the
distributed
circuit)

1)
Insulation
resistance of the
following relay etc.:
a) Protection relay
b)Temperature
indicator
c)
Oil
level
indicator
d) Pressure relief
device measure the
insulation
resistance between
the terminal and
earth with 500V
mega ohmmeter.
2)
Check
the
terminal box and
control cabinet etc.
for rain ingress,
loose and rust of
the terminals
Protection
1)Check
the
relay
,gas following items:
relay
a)oil leakage
b)gas volume in gas
relay
2) Check the action
of the relay contact
by the test button in
the relay.

1-3 years

Pressure
relief device

2-3 years

Oil
temperature
indicator

37

auxiliary shed can


be
added,
or
stain-proof paint (as
RTV)
can
be
painted.
1) The measured
insulation resistance
shall be not less
than 2M, but for
the relay in the
distributed circuit,
even
if
the
measured resistance
is more than 2M,
it shall be carefully
checked for the
moisture
ingress
etc.
2) Reseal if rain
gets in. Retighten
and clean if the
terminal is loosed
and rusty.

1) Retighten the
sealed
area
if
loosed, and replace
the sealing parts if
oil leakage still
exists.
2) Replace the
operating
mechanism of the
contact
if
the
contact
cannot
operate on and off
smoothly.
Check
the Replace
the
following items:
pressure
relief
a) oil spray
device in case of
b)oil leakage
worse condition.
c)spring pressure
1)
check
the 1)
Check
the
moisture
moisture
condensation in the condensation and
thermometer
indication in the
2)check (calibrated) thermometer.
the
temperature Replace
it
if

Y0SB.460.5483

indication

2-3 years

Winding
temperature
indicator

2-3 years

Oil
level 1)
check
the
gauge
moisture
condensation in the
indication panel
2)
check
the
following items:
the action of
the floating ball and
pointer
the action of the
contacts
3) Check the false
oil
level
with
transparent flexible
tube.

38

1)
check
the
moisture
condensation in the
indicator
2)check
the
temperature
indication

necessary.
2) Compare the
indication of the
thermometer
and
thermocouple, and
value
difference
shall be within 3.
1) Judgment and
measures are the
same as used for oil
level indicator
2) As temperature
indication
is
affected by loads,
please
compare
with
previous
records.
3) When perform
contacting
inspection,
the
product shall be out
of service.
1)
Check
the
moisture
condensation and
its influence to
measurement,
replace
it
if
necessary.
2) Check if the
floating ball acts
synchronously with
the pointer action,
as well as the action
of contacts.
3) Check the action
of contacts during
oil draining.
4) There shall be no
false oil level.

Y0SB.460.5483

Flow chart of main works for reactor installation


transportationaccording to clause 3

Incoming Acceptanceaccording to clauses 4


Putting heavy package into placeaccording to clause
Storage and keepingaccording to clause 6
Transported and stored with gasaccording to clause 6.2

Requirementsbeforeassemblyaccordingtoclause7.1

Transported and stored with oil according to clause6.3

Accessories installation

Final assembly (according to chapter 7

(as clause7.3)

Untankinginspection

Tankinginspectionaccordingto

(accordingtoclause7.2.1

clause7.2.2

Safe measurement at installation


siteaccording to clause 8

Preparation and touch-up


Oil-filling under vacuum, hot oil circulation and standingaccording to clause 9

for external surface


according to clause 10

Check and measurement before putting into operationaccording to clause 11

Hand-over testaccording to clause 11.2

Putting into operationaccording to clause 12

Hand-over and acceptance of documents and spare partsaccording to clause 13

Check and maintenanceaccording to clause 14

39

Y0SB.460.5483

Appendix A: (Data appendix)Influence on environment, safety and health from


transformer oil and relevant protection measures
A. General of hazard
A.1.1 Healthy hazard
If transformer oil contacts skin repeatedly or for a long time, degreasing is caused
possibly with an irritating reaction appearing simultaneously. Contacting eye will lead
to a rubefaction and transitory pain. Since it has an oral toxicity, inbreathing the oil
steam or mist produced under high temperature will irritate the respiratory tract, and
result in a nausea even a vomit and diarrhea. Mass oil steam being inbreathed into the
lung will cause the hurt of lung. In case of over-high concentration, anoxia such as
dyspnea will be caused in several minutes.
A.1.2 Burning and explosive property
State of transformer oil is stable under normal environment, however, when meeting
open flame and high heat, its steam and air can form an explosive mixture, which will
cause an explosion easily. Oxidant can have reaction with transformer oil or cause
combustion of it. Being heavier than air, its steam can spread to a quite far place in
lower area, and will be burned again with open flame.
A.1.3 Environmental hazard
Transformer oil will be biology-degraded slowly under natural state, and kept in
environment for a duration, which has a risk to pollute the surface water, soil,
atmosphere and drinking water.
A.2 First aid measures
In case of eyes touch, wash eyes with a plenty of clean water or physiological saline;
in case of skins touch, get off the polluted clothes immediately, and wash the body
with soap and flowing clean water; in case of inadvertent inbreathe, leave from the
site quickly and go to a place with fresh air.
A.3 Fire fighting measures
In case of the burning of transformer oil, use the dry powder, carbon dioxide or foam
extinguisher, and then transfer the container from fire to an open place possibly, and
spray water to keep cooling until its safe.
A.4 Leakage emergency measures
Evacuate people from leakage polluted area to a safe area with isolation, and restrict
entrance strictly and cut off fire source. It is suggested that the emergency treatment
personnel wear self-support positive pressure type respirator and extinguisher
40

Y0SB.460.5483

exposure suit. Cut off the leakage source possibly to avoid the spilled transformer oil
entering into or spreading to the barrel-drain, water channel and soil. Use clay, sand,
soil or other noncombustible materials to absorb small amount of leakage timely. In
case of large amount of leakage, build circle levee or dig a pit to take in the leakage;
cover the leakage with foam to reduce steam damage; transfer the leakage to the tank
car or the special collector with anti-explosion pump, and then recycle or transport it
to the rubbish treatment place. At the same time, inform the local environmental
protection department timely.
A.5 Protection measures and other items
A.5.1 In case of skin touch repeatedly, wear the oil withstand protection gloves
(composition: polychloroprene, nitrile, acrylonitrile and butadiene rubber), exposure
suit and protection glasses in case of splash.
A.5.2 The transformer oil should be avoid of overheating or fire, or mixed loading,
mixed transportation and mixed storage with oxidant, halogen and edible chemistry.
The shipping container should be sealed, and the tank car for transportation should be
with grounding chains.
A.5.3 Recycles the rubbish according to the sorts, burn or reuse the dependent sorts to
avoid environmental pollution.
Appendix B:data appendixMain equipments and tools for the requirement of
general assembly

41

Y0SB.460.5483

Table B.1 main equipments and tools for the requirement of general assembly
Item
Lifting
equipments
Oil filling equipment

No.
1
2

Designation
Crane lifter
Lifting tackle

Qty.
1
1set for each

Jack and pad

4 pieces

Crosstie and board

Suitable amount

Vacuum filter group

1 set

Two stages vacuum group

1 set

3
4

Macleod vacuometer
Vacuometer

Dry air generator


or bottled dry air

1
12 pieces
1 set
or
several
bottles

Oil storage tank

7
8
9

Wet
and
dry
bulb
thermometer
Pipe and non-return valve
used for vacuumizing
Pipe and valve for oil filling

Ascending
equipment

10

Ladder

Specification and description


Two units of 13t and two units of 5t
Not less than half transportation weight
of
heavy package
Oil filtering capacity6000L/h
operation pressure 100 Pa
vacuumizing speed 150L/sresidual
pressure>13.3Pa
3Pa700Pa
1Pa10 Pa100Pa
Dry air with a dew point -40

1 set

Depends on the oil volume, about 1.2


times of total oil volume of transformer

Measure air humidityRH0100%

1set
Joint flange match made as per valve
dimension specified in final assembly
drawing

1set
2 pieces

Fire protection
equipment
Sanitation -keeping tools

11
12
13

False work
Elevator
Safety belt

Several
1 set
Several

14

Fire extinguishers

Several

15

High-grade white cotton


cloth, and inferior cotton
cloth

Suitable
amount

16

Tarpaulin and plastic cloth

Suitable
amount

17

Dungaree

Several
amount

18

Plastic or cotton cloth


clothes
for
internal
inspection
woollen
clothes

Several
suits

19

Oil-proof boot

Several pairs

42

5m3m

To prevent accident occurring

Woollen clothes to be used in winter

Y0SB.460.5483

General tools
Consuming materials
Spare equipment
Testing
equipment

20

Nut wrench for bushing


positioning

1 piece

21
22

Wrench for tightening bolt


Flashlight

1 set
3 pieces

23

Torque wrench

1set

24
25

3
Suitable amount
3sets for each

To be used after drying

27

Nylon rope
File, sand paper
White cotton tape/electric
paper crape paper
Sealing glue

M8M16to be used for tightening


bolt of inner connection
8mm20m to be used for banding
Filing, milling

1kg

401glue

28

Insulation pressboard

Suitable amount

Drying

29

Silica gel

5kg

Coarse hole and coarse grain

30

Benzene or absolute ethanol

2kg

For cleaning vessel

31

Gas welding equipment

1set

32

Welding equipment

1set

33

Filter paper oven

1piece

34

Nitrogen with high purity

Self deciding

If necessary

35

Copper wire net

2m2

30 mess /cm2for making silica gel bag

36

Translucent nylon pipe

37

2 pieces
1 set

With protection veil

39

Brush
Illumination equipment at
site
Sieve

815m serve as temporary oil


indicator of transformer
For oil painting

1 piece

30 mess/cm2for sieving silica gel

40

Oil proof rubber plate

Several pieces

41

Empty oil barrel

Several

42

Multimeter
Measuring meter for oxygen
content

1 piece

MF368

Tramegger

1 piece for each

2500V/2500M 500V/2000M
1000V/2000M

26

38

43
44

43

M10M48
One for small size and two for big size