ABB UBBRN Installation And Commissioning Manual

Type
Installation And Commissioning Manual

This manual is also suitable for

On-load tap-changers, type UBB
Installation and commissioning guide
1ZSE 5492-118 en, Rev. 4
This document must not be copied without our written permission, and the
contents thereof must not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be prosecuted.
Recommended practices
ABB recommends careful consideration of the following factors when installing on-load tap-
changers:
Before you install or commission a unit, make sure that the personnel doing the job have
read and fully understood the Installation and Commissioning Guide provided with the unit.
To avoid damaging the unit, never exceed the operating limits stated in delivery documents
and on rating plates.
Do not alter or modify a unit without rst consulting ABB.
Follow local and international wiring regulations at all times.
Use only factory authorized replacement parts and procedures.
WARNING, CAUTION and NOTE
WARNING
A WARNING provides information which, if disregarded, could cause injury or death.
CAUTION
A CAUTION provides information which, if disregarded, could cause damage to the equip-
ment.
NOTE: A NOTE provides additional information to assist in carrying out the work de-
scribed.
Safety precautions
WARNING
Unused transformer oil is slightly harmful. Fumes from unused warm oil may irritate
the respiratory organs and the eyes. After long and repeated contact with transformer
oil skin becomes very dry.
Used on-load tap-changer oil from diverter switch housings and selector switch
housings contains harmful substances. Fumes are irritating to the respiratory organs
and the eyes and are very easily set on re. Used transformer oil may well be carcino-
genic.
Avoid contact with the oil as much as possible and use oiltight protective gloves
when handling the oil.
First aid:
Skin contact: Wash the hands. Use skin cream to counteract drying.
In the eyes: Rinse the eyes in clean water.
Swallowing: Drink water or milk. Avoid vomiting. Call a doctor.
Collect used oil in oil drums.
Waste and cleaning up: Should be absorbed by an absorber. Treat it as hazardous to
the environment.
At re: The re is extinguished by using powder, foam or carbon acid.
WARNING
Be aware of the risk for slipperiness caused by oil spillage for instance when working
on the transformer cover.
The motor-drive mechanism must not be installed in any explosive atmosphere. The
electrical equipment creates sparks which can cause an explosion.
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly carried
out. Obtain a signed certicate from the engineer in charge.
Before carrying out work on the on-load tap-changer, put the LOCAL/REMOTE switch
in the motor-drive mechanism to position ”0”. It is also recommended to shut the door
of the motor-drive mechanism and pad lock it when work is carried out on the on-load
tap-changer. The key should be kept by the operator. This is done to avoid unexpect-
ed start of the motor-drive mechanism.
Before starting any work inside the motor-drive mechanism, the auxiliary power must
be switched off.
N.B. The motor, contactors and heating element may be energized from separate
sources.
During drying of the transformer
CAUTION
During drying with hot air and vacuum, the maximum permitted pressure difference for the
on-load tap-changer is 100 kPa at a maximum permitted temperature of 135 °C (275 °F).
During drying by the vapour phase process the cover of the selector switch housing and the
bottom valve should be left open. The maximum permitted temperature is 135
o
C (275
o
F).
Use the special bottom key only (delivered with the on-load tap-changer) to operate the bot-
tom valve. The use of a stiffer tool may damage the valve.
Do not operate the on-load tap-changer during the drying process or afterwards until it is
lled with oil, to avoid seizing.
Mounting of gaskets
CAUTION
Sealing surfaces and gaskets must be clean and undamaged. Diametrically opposed bolts
in sealing joints must be tightened alternately several times, beginning with a low tighten-
ing torque and nally with the recommended tightening torque as described in section 1.7
Tightening Torque, in this guide.
During oil lling
WARNING
When oil that has been used in a selector switch housing is pumped out, conducting
tubes and hoses that are earthed should be used to avoid the risk of explosion due to
the gases produced by the arcs during service.
CAUTION
Do not ll oil into the on-load tap-changer if the transformer tank is under vacuum and the
on-load tap-changer is not.
Do not ll oil into the transformer tank if the on-load tap-changer is under vacuum and the
transformer tank is not.
Leave a gas cushion on top of the oil in the on-load tap-changer.
After oil lling
CAUTION
Do not energize the transformer earlier than three hours after oil lling in atmospheric pres-
sure. This waiting period is needed to allow airbubbles to disappear.
NOTE: Check the oil level one month after lling. It is usual for the oil level of the oil
conservator to fall due to gas absorption in the oil from the gas cushion in the on-load
tap-changer, if the on-load tap-changer is not operated. Restore the gas cushion and
the oil level according to section 7.5.
During service
WARNING
Small amounts of explosive gases will always come out from the breathing devices
(dehydrating breather or one-way breather). Make sure that no open re, hot surfaces
or sparks occur in the immediate surroundings of the breathing devices.
If a failure in power supply occurs during operation, the operation will be completed
when the power returns.
The hand crank must not be inserted during electrical operation.
If the on-load tap-changer is not in its exact position and the hand crank is pulled out,
the motor-drive mechanism will start and go to the exact position if the power supply
is on.
CAUTION
The pressure relay is a calibrated monitoring instrument. It must be handled with care and
protected against careless handling or any kind of mechanical damage. Do not open the
package of the pressure relay until you are about to install it on the on-load tap-changer.
Contents
1. Introduction _______________________________________________________9
1.1 Required tools _________________________________________________11
1.2 Required material _______________________________________________11
1.3 Oil ____________________________________________________________11
1.4 Oil conservator _________________________________________________11
1.5
Oil lter unit for continuous oil ltration ________________________________ 12
1.6 Weights _______________________________________________________12
1.7 Tightening torque _______________________________________________12
2. Receiving _________________________________________________________13
2.1 Unpacking _____________________________________________________13
2.2 Inspection upon receiving ________________________________________13
2.3 Temporary storage before assembly _______________________________13
3. Installation in the transformer _________________________________________14
3.1 Cover-mounting ________________________________________________14
3.1.1 Connection to outside terminals _______________________________15
3.2 Yoke-mounting ________________________________________________16
3.2.1 Mounting of the on-load tap-changer when transformer ratio
measurement is carried out before drying ____________________________17
3.2.2 Mounting of the on-load tap-changer when transformer ratio
measurement is carried out after drying _____________________________19
3.2.3 Mounting to the transformer cover from the yoke ________________21
4. Drying ____________________________________________________________24
4.1 Observations before processing ___________________________________24
4.2 Observations after processing ____________________________________24
5. Final assembly _____________________________________________________25
5.1 Mounting of the motor-drive mechanism ___________________________25
5.2 Mounting of accessories _________________________________________28
5.3 Mounting of external drive shafts __________________________________29
5.3.1 Mounting of horizontal drive shaft _____________________________31
5.3.2 Mounting of vertical drive shaft ________________________________33
5.4 Connection to the oil conservator _________________________________36
5.5 Before operation ________________________________________________36
5.5.1 Transformer ratio measurement after drying _____________________37
6. Pressure relay _____________________________________________________38
6.1 General _______________________________________________________38
6.2 Installation _____________________________________________________38
6.3 Checking at commissioning of the transformer ______________________39
7. Oil lling __________________________________________________________40
7.1 Filling methods and restrictions ___________________________________40
7.2 Filling at atmospheric pressure ____________________________________40
7.3 Filling under vacuum ____________________________________________41
7.4 Correct oil level _________________________________________________41
7.5 Restoring the gas cushion _______________________________________42
8. Electrical connection and testing _____________________________________43
8.1 General _______________________________________________________43
8.2 Connecting and testing __________________________________________43
8.3 Electrical tests on transformer ____________________________________44
8.4 After energizing _________________________________________________44
9. Transport _________________________________________________________45
9.1 General _______________________________________________________45
9.2 Transport preparations __________________________________________45
9.2.1 Transport with complete transformer ___________________________45
9.2.2 Transport with dismounted conservator ________________________45
9.2.3 Protection of motor-drive _____________________________________45
10. Commissioning ___________________________________________________46
10.1 Reassembly __________________________________________________46
10.2 Oil lling ______________________________________________________46
10.3 Electrical connection and testing _________________________________46
10.3.1 Motor protection ___________________________________________46
10.3.2 Disc brake ________________________________________________47
10.3.3 Counter __________________________________________________47
10.3.4 Position transmitter and other multi-position switches ___________47
10.3.5 Light _____________________________________________________47
10.3.6 Heater ___________________________________________________47
10.3.7 Pressure relay _____________________________________________47
10.4 Putting into operation __________________________________________47
1ZSE 5492-118 en, Rev. 4
9
fm_00001
1 Introduction
1. Introduction
The delivery consists of on-load tap-changer, motor-drive mechanism and drive shaft sys-
tem.
The on-load tap-changer may be specied for cover-mounting or for yoke-mounting.
Cover-mounting means that the on-load tap-changer is lowered through a hole in the trans-
former cover and then bolted straight onto the transformer cover.
Yoke-mounting means that the on-load tap-changer is temporarily put onto a fork located
on the active part of the transformer. Yoke-mounting allows the transformer manufacturer
to connect the windings to the on-load tap-changer before drying and without having the
transformer cover mounted. The transformer cover is then lowered onto the tank, and the
on-load tap-changer is lifted and bolted to the cover. Please use the appropriate instruction
for cover-mounting or yoke-mounting!
The motor-drive mechanism and bevel gear are tted to the transformer tank and the drive
shafts are tted to complete the assembly of motor-drive mechanism, bevel gear and on-
load tap-changer before oil lling and testing.
The general arrangement of an on-load tap-changer system is shown in Fig. 1.
The general arrangement of an on-load tap-changer type UBB is shown in Fig. 2.
On-load
tap-changer
(SS)
Fig. 1. On-load tap-changer system.
Bevel gear
(SA21)
Vertical drive shaft
and protection covers
(SA)
Bevel gear
Horizontal drive shaft and
protection covers (SA)
Motor-drive
mechanism
Hand crank
10
1ZSE 5492-118 en, Rev. 4
fm_00235
Bottom
Bottom valve
drain screw
Moving contacts
Fixed contacts
Fixed contacts
Moving contacts
Change-over selector:
Selector switch:
Cylinder
Flange
Bevel gear
Oil valve
Selector switch shaft
Fig. 2. General arrangement of on-load tap-changer, type UB.
Transition resistor
Current collector
terminal
Shielding rings
Indicator window
Air release valve to on-
load tap-changer
Connection to oil
conservator
Pressure relay
Air release valve
to transformer tank
Top cover
1 Introduction
11
1ZSE 5492-118 en, Rev. 4
1.1 Required tools
Air pump with hose, pressure gauge (0-250 kPa) and connection with internal thread
R1/8”
Normal set of open end wrenches (up to 19 mm)
Normal set of sockets (up to 19 mm)
Socket handle
Socket extender
Normal set of screw drivers
Allen key sockets 5 and 6 mm
Lifting bar LL 117 016-K (yoke-mounting only)
Dynamometric wrenches, 5-85 Nm
Bottom valve key (delivered with the on-load tap-changer)
Tool for opening of oil drum
Hack saw
Bucket, 10 litres
Lifting jack
1.2 Required material
Grease, (Ball bearing grease) GULF-718 EP, Mobil-Grease 28, SHELL-Aero Shell
Grease 22 or similar
Equipment for oil lling
Sealing tape
Rags (non-fuzzying) for cleaning
1.3 Oil
The oil quality should be of Class II according to IEC publication 60296. The oil weight ac-
cording to table 1 in section 1.6.
WARNING
Do not energize the transformer until oil has been lled according to chapter 7, Oil
Filling in this guide.
1.4 Oil conservator
The on-load tap-changer has to be connected to an oil conservator. ABBrecommends the
use of a separate conservator for the on-load tap-changer with both oil and air side sepa-
rated from the main conservator of the transformer.
The volume of the conservator should be such that there is oil left in the conservator even
at the lowest oil temperature expected and such that no ooding can occur at the highest
oil temperature expected. Even transformers with more than one on-load tap-changer unit
require only one conservator.
A suitable dimension of the tube for connection to the conservator is an inner diameter of
approximately 20 mm. The tube should be inclined at least 3 degrees to avoid gas cushions
in the tube. A valve in the connection to the conservator is recommended.
The conservator must be equipped with a breathing device that does not allow moist air into
the conservator and that allows the gas from the arcs to disappear.
The conservator should also be equipped with an oil level indicator, and an alarm contact for
low oil level is recommended.
1 Introduction
12
1ZSE 5492-118 en, Rev. 4
1 Introduction
1.5
Oil lter unit for continuous oil ltration
If the on-load tap-changer should have an oil lter unit for continuous oil ltration from ABB,
installation and commissioning instructions can be found in the manual for the oil lter unit,
”Oil Filter Unit for On-Load Tap-Changers, Manual” delivered with the oil lter unit.
1.6 Weights
Motor-drive mechanism BUE, weight: 130 kg
Motor-drive mechanism BUL, weight: 75 kg
Drive shaft system weight: about 10 kg
The weights of the motor-drive mechanism and drive shaft system are not included in the
weights given in table 1.
Table 1. Weights of on-load tap-changer, type UBB.
On-load tap-changer
Type designation
Approx. weight in kg
Tap-changer without oil Required oil Total weight
UBBLN XXX/YYY 140 100 240
UBBRN XXX/YYY
UBBDN XXX/YYY
UBBLT XXX/YYY 155 125 280
UBBRT XXX/YYY
UBBDT XXX/YYY
1.7 Tightening torque
The following tightening torques are recommended: M6, 10 Nm ±10 %
M8, 24.5 Nm ±10 %
M10, 49 Nm ±10 %
M12, 84 Nm ±10 %
unless otherwise stated in this guide.
13
1ZSE 5492-118 en, Rev. 4
fm_00006
fm_00200
fm_00235
2 Receiving
2. Receiving
2.1 Unpacking
Check that the packages are free from transport damage. Open the covers of the transport
boxes. Remove the supporting blocks of wood. If the package is damaged a careful investi-
gation must be carried out.
Lift the on-load tap-changer, using the lifting eyes on the top.
2.2 Inspection upon receiving
1. Check that the on-load tap-changer, drive shaft system, motor-drive mechanism and
accessories are undamaged.
2. If transport damage is found, and it is judged that correct operation of the on-load tap-
changer is not possible, a damage report should be sent to the insurance company. It is
also recommended that photos are taken of the damaged details. Mark the photos with
ABB’s reference number and the serial number of the on-load tap-changer and send
them to ABB for comments.
3. Check that the parts delivered, type designations and the serial number agree with the
delivery documents, e.g. the packing list or ABB’s ordering acknowledgement. The se-
rial number is stamped on the rating plate and on the on-load tap-changer ange, see
Fig. 3. The serial number on the parts belonging to one on-load tap-changer unit should
all be the same.
2.3 Temporary storage before assembly
If the on-load tap-changer is not to be assembled immediately, once the delivery has been
approved the on-load tap-changer and the motor-drive mechanism must be kept warm and
dry indoors. Let the units be kept in their plastic enclosures and leave the drying agent until
assembly.
Serial No.
BUL
BUE
Serial No.
Fig. 3. Locations of serial number.
14
1ZSE 5492-118 en, Rev. 4
fm_00201
3. Installation in the transformer
The cover-mounting method or yoke-mounting method is used.
When lifting an UBB model it is recommended to use the lifting eyes on the on-load tap-
changer top section.
WARNING
To put down the on-load tap-changer to stand on the oor without any support means
a risk for tilting with risk for injuries to people and damage to the equipment.
3.1 Cover-mounting
(For yoke-mounting, see section 3.2).
Proceed as follows:
1. Place the gasket (O-ring or plane gasket is usable) around the opening in the transform-
er cover. (This gasket is not included in the on-load tap-changer delivery).
2. Check that the on-load tap-changer ange is positioned in the right way in rotational
relation to the transformer cover.
3. Lower carefully without damaging the terminals the whole on-load tap-changer through
the hole in the transformer cover. If the on-load tap-changer is equipped with tie-in
resistors mounted on the outside terminals, they have to be removed during lowering
the on-load tap-changer through hole in the transformer cover. The studs on the trans-
former cover shall t into the holes in the ange of the on-load tap-changer. Fit washers
and nuts. Tighten.
3 Installation in the transformer
"a"
Top cover
O-ring
Gasket
Nut
Transformer cover
Max 90
o
Lift
Stud bolt
Washer
Tightening of the suction pipe
”a”
Fig. 4. Cover-mounting details.
15
1ZSE 5492-118 en, Rev. 4
fm_00013
3 Installation in the transformer
3.1.1 Connection to outside terminals
The connection to terminals for change-over selector, selector switch and current collec-
tor shall follow the connection diagram delivered with the on-load tap-changer. Connection
holes for bolts M10 are Ø11 mm for all terminals.
CAUTION
All connections shall be made carefully and in such a way that there is no risk for them to
come loose. Furthermore, the conductors must not cause mechanical stresses on the out-
side terminals. Make an expansion bend on every conductor. See Fig. 5.
Wrong
Right
CAUTION
It is recommended that the distance between the cylinder and any conductor is at least
50mm.
The transformer designer is responsible for providing sufcient insulating distances in the oil.
NOTE: There is no need of outer neutral connection leads at UBB.N-types, because
there is already a built-in connection in the on-load tap-changer insert.
Terminal
Fig. 5. Connection to outside terminals.
16
1ZSE 5492-118 en, Rev. 4
fm_00202
3.2 Yoke-mounting
(Pre-mounting on active part of the transformer).
(For cover-mounting, see section 3.1).
The top section of the on-load tap-changer is designed to be divided into an upper and a
lower ange, see Fig. 6, to t the yoke-mounting.
Before the on-load tap-changer is lifted and attached to the transformer cover it rests on a
fork consisting of two beams protruding from the upper transformer yoke.
NOTE: If guiding pins are used on the fork, they should be insulated with bushings to
prevent circulation currents in the fork when the transformer is in operation.
Mounting of the on-load tap-changer to the ”yoke-fork” can be made according to two alter-
natives depending on when the testing of the transformation ratio shall be performed:
Transformer ratio measurement before drying, see section 3.2.1.
Transformer ratio measurement after drying, see section 3.2.2.
Mounting onto the transformer cover from the yoke, see section 3.2.3.
3 Installation in the transformer
Fig. 6.
Top cover
Washer
Transformer cover
”Yoke-fork”
Lower
part
Upper
part
O-ring
O-ring
”a"
Sealing for the the suction pipe
Max 90
o
Stud
Nut
17
1ZSE 5492-118 en, Rev. 4
3 Installation in the transformer
3.2.1 Mounting of the on-load tap-changer when transformer ratio measurement is carried out
before drying
Mounting to the ”yoke-fork” of the transformer, see Fig. 6.
1. Mount the on-load tap-changer on the transformer’s ”yoke-fork”, the lifting lugs on the
upper part can be used, see Fig. 6. Handle with care without damaging the terminals
and tie-in resistors (if any).
NOTE: Check that the on-load tap-changer is positioned in the right way in rotational
relation to the transformer cover, before connection of conductors.
2. Connect the conductors according to section 3.1.1.
3. Transformer ratio measurement.
4. The on-load tap-changer can be operated by turning the shaft of the bevel gear. Use a
special hand crank, LL 117 016-M.
5. Two turns in clockwise direction (seen against the shaft end) for RAISE or two turns
anticlockwise for LOWER operation, will be equal to one switching between two taps.
Check the order documents if otherwise is stated according to the direction of rotation.
CAUTION
The on-load tap-changer should be operated through the whole operating range, both in
lower and raise direction, when carrying out ratio measurement.
The end positions must not be overrun during ratio measurement. When operating the on-
load tap-changer without drive system, check the designation of the end positions on the
single-phase diagram and watch the position indicator in the bevel gear in order to avoid
overrunning of the end position.
Watch the voltmeter during the on-load tap-changer operations. No fast voltage drops may
occur during operation. If such drops occur, the on-load tap-changer is not correctly con-
nected to the winding.
6. After the measurement, the position of the on-load tap-changer must be replaced to
the same position as the motor-drive mechanism indicates, check in the indicator win-
dow on the top cover.
7. Loosen all the twelve bolts and washers in the top cover and lift the cover carefully min.
10 cm straight upwards before moving it in horizontal direction. The bevel gear and the
pipe may not be damaged when lifting. If a crane is used arrange the straps according
to Fig. 8a.
8. Remove the upper part of the top-section by loosening the twelve M8-socket head cap
screws inside it. Keep the ange, the cover, the O-rings and the sealing for the suction
pipe, see Figs. 6 and 8 and store them temporarily on a dustfree place.
9. The on-load tap-changer and the transformer is now ready for drying. Follow the in-
structions in chapter 5.
NOTE: The gear mechanism on the gear base plate needs not and shall not be re-
moved, because it is xed in the lower part.
NOTE: Spacers (for example of wood) can be placed between the ”yoke-fork” and
the lower ange. The connectors can hereby be mounted on the right nal height.
The spacers must be removed before mounting of the on-load tap-changer onto the
transformer cover. See Fig. 7.
18
1ZSE 5492-118 en, Rev. 4
fm_00209
FM_00203
3 Installation in the transformer
Fig. 8a.
Fig. 8b.
Fig. 8c.
Approx. 15 mm
Sealing for suction pipe
max 90
o
max 90
o
O-ring for upper ange
O-ring for upper ange
Fig. 7.
O-ring for top cover
19
1ZSE 5492-118 en, Rev. 4
fm_00204
3 Installation in the transformer
3.2.2 Mounting of the on-load tap-changer when transformer ratio measurement is carried out
after drying
Mounting to the ”yoke-fork” of the transformer. See Fig. 9.
1. Loosen all the twelve bolts and washers in the top cover and lift the cover carefully min.
100 mm straight upwards before moving it in horizontal direction. The bevel gear and
the pipe may not be damaged when lifting. If a crane is used arrange the straps accord-
ing to Fig. 8a.
2. Remove the upper part of the top section by loosening the twelve M8-socket head cap
screws inside it. Keep the ange, the cover, the O-rings and the sealing for the suction
pipe, see Fig. 8 and store them temporarily on a dustfree place.
NOTE: The gear mechanism on the gear base plate needs not and shall not be re-
moved, because it is xed in the lower part.
3. When lifting the on-load tap-changer onto the ”yoke-fork” it is recommended that
lifting eyes M12 are mounted in the lower ange.
NOTE: Check that the on-load tap-changer is positioned in the right way in rotational
relation to the transformer cover, before connection of conductors according to sec-
tion 4.3.
NOTE: Spacers (for example of wood) can be placed between the ”yoke-fork” and
the lower ange. The connectors can hereby be mounted on the right nal height.
The spacers must be removed before mounting of the on-load tap-changer onto the
transformer cover. See Fig. 10.
max 90
o
Fig. 9.
20
1ZSE 5492-118 en, Rev. 4
fm_00209
4. Remove the lifting eyes when the on-load tap-changer is in right position on the ”yoke-
fork”.
5. The on-load tap-changer and the transformer is now ready for drying. Follow the in-
structions in chapter 4.
3 Installation in the transformer
Approx. 15 mm
Fig. 10.
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ABB UBBRN Installation And Commissioning Manual

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