www. rhona.

cl Installation, Operation, and Maintenance

INSTALLATION AND MAINTENANCE MANUAL OF

POWER TRANSFORMERS

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GENERAL INDEX
OBJECTIVES........................................................................................................................ 2
1. GENERAL INSTRUCTIONS................................................................................. 2
2. SECURITY PRACTICES..................................................................................... 2
3. GENERAL RECOMMENDATIONS.
3.1 Reception.............................................................................................................. 3
3.2 Transport and Unloading............................................................................................... 3
3.3 Storage ....................................................................................................... 4
4. ASSEMBLY OF POWER TRANSFORMERS ..................................................... 4
4.1 Installation
4.2 Cooling system ............................................................................................. 5
4.3 Aisladores ............................................................................................................... 5
4.5 Silica Gel Respirators.......................................................................................... 6
4.6 Indicator elements............................................................................................... 6
5. FILLING OF TRANSFORMERS........................................................................ 7
5.1 Transformers without oil conservator
5.2 Transformers with oil conservator......................................................... 8
5.3 Instructions for Completing Refrigerant Fluid Level in ATMOSEAL Systems............. 9
6. MAINTENANCE
6.2 Coolant liquid level indicator...................................................................... 11
6.3 Pressure Relief or Blow-Off Valve ............................................................................ 12
6.4 Relé de Presión Súbita............................................................................................. 13
6.5 Buchholz Relay........................................................................................................ 14
6.6 Fans................................................................................................. 15
6.7 Radiators.
6.8 Refrigerant Liquid................................................................................................. 15
6.9 Field Tests.................................................................................................. 16
[Link] DIAGNOSTICS....................................................................................... 19

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OBJECTIVES

This manual aims to provide the 1. GENERAL INSTRUCTIONS

necessary information for reception,
installation y maintenance of All staff associated with the
Power transformers manufactured by reception, assembly and maintenance of
RHONA S.A. transformers must be aware of the
standards of the electrical sector and practices of
All transformers are manufactured from security for the performance of work with
according to the international ANSI standards, electrical equipment
IEC 76 and national standards.
2. SECURITY PRACTICES
The follow-up from the guidelines
established in this manual is The following practices do NOT replace in
essential to obtain a good in no case the responsibility of the user of
performance of the RHONA transformers implement an adequate security program
S.A., additional information that is not with electrical equipment.
The cover in this manual should be consulted.
directly to RHONA S.A. IT MUST BE PRESUMED THAT ALL THE
DRIVERS ARE
ENERGIZED UNLESS YOUR
POTENTIAL HAS BEEN MEASURED AND
BROUGHT TO GROUND FOR PREVENTION
Involuntary energizations

It is recommended that all work is

make with the teams
DE-ENERGIZED and grounded
with adequately sized connections.

The use of locks is important

to reduce the risk of accidents
while himself
takes a cable a
maintenance. All the people who
they are going to intervene in a maintenance
you must keep in mind the possible risks
what can happen. The most important
to prevent an accident is the
knowledge of the equipment since the
construction viewpoints,
operation and maintenance.

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[Link]
GENERAL.

Each and every one of the transformers is 3.2 Transport and Unloading
tested in factory, this guarantees a
optimal functioning of the equipment. The maneuvers of download of the
Depending on the type of transformer this transformers must be carried out by
can be supplied with all its qualified personnel to prevent possible damage
accessories or part of them. charged with mismanagement.

3.1 Reception The lifting hooks of the transformer are

near the top of the transformer
These transformers due to their weight and for its handling by a crane
size is dispatched with part of the suitable for the equipment's tonnage. The cable
volume of oil and pressurized with to maneuver, it should not form an angle greater than
dry nitrogen. Upon arrival that 30º with respect to the vertical. In case of
from the transformer to the installation site or if the above is not possible, it must be used
downloads must be checked: a poop distributor to avoid damage to
pond or to the hooks. DO not try to hoist the
The state of the transformer for transformer using two lifting hooks in
to find possible impacts or breaks in case he has four available;
of pipes, flanges or valves. use the four lifting points to connect
The nitrogen pressure must be four strobe lights suitable for the weight of
positive. team to hoist and that they are of the same length and
Carry out a verification of the list characteristics.
packaging of the accessories of the
transformador: radiadores, bombas, If the transformer cannot be hoisted with a
["conservator","pipes","insulators"] crane, can be unloaded safely
protection relays, indicators of about rollers or platforms with wheels. To
level and temperature, valves of lift the equipment with a jack system
overpressure, control panels hydraulic systems, to position the rollers under the base,
etc. use at least 2 cats under the points of
support of cats supplied in the mantle of
If something abnormal is found, please communicate. transformer and start the maneuver by lifting
immediately with RHONA S.A. to uniformly the team.
take the corresponding measures to
solve the problem found, in If the transformer is unloaded in a place
in no case carry out any work without a provisional, it must be ensured that the land is
written authorization from RHONA as stable as possible, although never in
S.A. since the warranty may be lost direct contact with the ground. Use sleepers
team. made of wood to set the transformer.
distribution of the efforts must be
suitable, in order to prevent damage to the equipment.

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3.3 Storage 4. ASSEMBLY OF TRANSFORMERS

OF POWER
The transformer must be stored in it
possible with its dielectric refrigerant liquid. Power transformers that require
assembly tasks must be verified with
For short storage periods special care to avoid possible damage to
less than 3 months, the transformer can be transformer, if it is not going to be assembled from
kept without oil, but it must be kept with It must be immediately kept pressurized with
positive pressure of dry nitrogen. In this nitrogen and conduct periodic reviews to
in case a daily inspection must be carried out prevent moisture from penetrating the active part of the
from the gas pressure in order to detect transformer. The assembly must be done in the
possible leaks that cause entry of possible in moisture-free or low environments
humidity. controlled conditions to prevent entry
of humidity.
When are they going to be stored for a long time?
periods, power transformers
they should preferably be armed and 4.1 Installation
stored in a dry place free of
possible pollutants or far from areas of 4.1.1 Precautions
a lot of movement to avoid hitting the
transformer. Apply empty in dry environments.
Never open the low transformer
For power transformers that have empty.
accessories that must be stored When you open the transformer, verify
apart, one must take the precaution to that loose elements are not taken in
store the accessories in dry places. the pockets that may fall into the
The radiators must be stored transformador.
avoiding hitting them and also seal your Install all the cooling equipment
extremes to prevent moisture entry. before the final vacuum process.
Disconnect or isolate the accessories that
The insulators must be stored in the They cannot be subjected to vacuum.
possible in dry places and within their Open the valves of the equipment
respective transport boxes. cooling.
Store the oil drums in the
The refrigerant can be stored position as indicated in the attached figure.
in drums or in external tanks
properly packaged.

The control circuits of cabinets and

load changers must maintain
connected to their heating systems and
regulated at a temperature of 30 °C.

Before putting a transformer into service

after a prolonged period of time
it should be verified at a minimum:

• Dielectric Strength of Oil

• Oil Moisture Content
• Ventilation, alarm, and circuits
control

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Inspect the radiators for detection
dirt or moisture entry, in 4.3 Insulators
in case of any inconvenience, these must
be washed with hot oil (50°C) Before installing the insulators, these must
be completely clean, dry y
In case there is a conservator, it must tested (delta tangent and insulation) for
check check its normal functioning.

May this be clean and

dry, if necessary wash it with For the installation of the insulators, pay special attention
hot refrigerant liquid. be careful when tightening these in their bases
If there is a preservation system to prevent the possibility of oil leaks
of the oil such as Atmoseal or or deteriorate the porcelain if applicable by
membrane, check that it is excessive tightening.
find in good.
The conservator must be installed If possible, carry out the assembly of the
in their respective bases and with the isolation devices one by one, to prevent the entry of
level indicators. moisture to the transformer. To do this
follow the following procedure:
4.2 Cooling system Release the seal flange on the cover of the
transformer.
The normal operation must be verified. Prepare the attached copper spike
of the fan motors, the pumps of Install the flange and place a new O-ring.
circulation of refrigerant liquid or Strobe and isolate with it
heat exchangers in case of being Levante team.
necessary (consult the technical sheets for Install the bushing in position,
the end. passing the ear of grain through the interior,
place the O-ring on the terminal in the
Radiator Installation: top

Relieve internal pressure of

transformer, for this open the When it is required to perform connections to
upper valve. inside the transformer ensure all the
Release the metal sealing flanges keys and tools in order to prevent that
superior e inferior in the fall into the interior of the transformer. In case of
transformer retire the high voltage insulators to follow the
new gasket. assembly instructions provided by the
Align the radiators with the flanges manufacturer of the same.
of the transformer coupling and
tighten the valve bolts. 4.4 Pipelines.
Open the upper valves of the
radiators. Check that these are not dirty or
obstructed, if necessary wash them with oil
hot (50°C)

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4.5 Silica Gel Respirators.

For transformers with a conservator

the oil should be checked as normal
operation of the ventilators, these
they must be installed with their respective
completely dry silica, if necessary
this can be reactivated in an oven at 90
°C.

4.6 Indicator elements.

All protective elements that

be supplied with the transformer(
Sudden pressure relays, Buchholz relays,
Termómetros de aceite, Válvulas de
overpressure, level indicators,
voltage changer under load) must be
verified for normal operation.

In each case, consult the specifications

from the manufacturer of said elements.

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5. FILLING OF
TRANSFORMERS
5.1 Transformers without conservator
oil

5.1.1 Install the vacuum system on the 5.1.5

lid Carry out the bleeding of the radiators to
del transformador. Si el transformador eliminate the possible bubbles if it is from the
It is equipped with a low switch case.
load, balance the pressure of this
with the main tank.

5.1.2 Create a vacuum in the tank for 2 hours

from the transformer until obtaining a
vacuum of 0.6 Tor. Once obtained, open
the valves inferior of the
radiators.

5.1.3 Fill the transformer

through the upper valve until reaching
the desired level, transfer the liquid
soda from the drum or
pond up to the transformer
passing through a machine of
vacuum.

5.1.4 When the normal level is reached

breaking the void with dry nitrogen or
dry air.

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5.2 Transformers with conservator

oil.

5.2.4 This position of nicel is proceeded to

5.2.1 Install the vacuum equipment in the break the empty with nitrogen and inflate it
conservative del transformer neoprene bag that is inside
merging the ATMOSEAL system and the of the conservator (see procedure for
Load switch for balancing filling ATMOSEAL)
the internal pressures.
5.2.5 Install the silica gel vents.
5.2.2 Carry outempty to thetank del
transformer until obtaining a vacuum Purge all pipes, radiators,
from 0.6 Tor for 2 hours. Obtained Buchholz relay and insulators FOR
this, open the lower valves of the REMOVE AIR BUBBLES.
radiators.

5.2.3 Carry out the filling of the transformer

through the upper valve until reaching
the normal level, the liquid passed through
soda from the drum or
pond to the transformer
passing through a machine of
vacuum.

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5.3 Instructions for Completing Level of

Refrigerant Liquid in Systems
ATMOSEAL

To complete the oil, the process is

in the following way:
Open the valve (1) that communicates to the
pond with the conservator
Open valve (11) to evacuate to
air inside the refrigerator.
Inflate the bag with Nitrogen or air
dry at a pressure of 1 psi by the
valve (4), check that there is no
pressure loss in the bag.
Introduce oil through the valve (6) or to
through the valve (1) until
drain oil through the valve (11)
make sure all the air is evacuated and
close the valve (11)
Open valve (4) for evacuation
from the interior gas of the bag until
obtain atmospheric pressure.
Connect the silica gel respirator.
Check that the level (7) remains in the
measured at 25°C, if it remains low add
oil through the valve (6)
For filling to the level of the holder
from the changer, it is possible to use the
valve (12) or by the draining valve
from the changer, with a pump
adequate.
Let it rest for at least 8 hours.
and I made the "despiche" of all the
pipes, insulators, and Buchholz relay.

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5.3.1 Detail Conservative with Bag

MUSTANG

Valve of connection to the 11. Oil filling or purge valve

pond from the air of the conservator
2. Output to Bucholtz Relay of 12. Oil filling or purging valve
pond conservative LTC
3. Respirator Silica gel 13. Conservative low changer
pond keeper load
4. Connection valve of the 14. Level of the LTC conservator
bag to the respirator 15. Oil drain valve of
5. Union pipe valve conservative LTC
vent conservative Pipe of union valve
transformer conservative LTC respirator
6. Oil drain valve 17. Conservator connection valve
7. Conserved level indicator LTC exchanger
of the transformer 18. Protection relay output of
8. Floating of the level changer
9. Neoprene bag (Mustang) 19. Breather connection valve
10. Side cover of the cooler from LTC
20. LTC respirator

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6. MAINTENANCE
6.2 Liquid level indicator
The operation of the substations soda
transformers must be accompanied by
an appropriate maintenance program This must be checked for possible
newspaper to detect anomalies or refrigerant fluid leaks.
possible failures.

Depending on the criticality of the

unit substation is suggested
WEEKLY VISUAL INSPECTION, for
timely detection of possible leaks of
liquid, breakdowns or external conditions
unsafe. This visual inspection should
be more rigorous after the implementation
service for the first time.
GENERALITIES
A good program of
It is equipment used to indicate the level
maintenance should consider of various liquids.
inspect the following
aspects:
OPERATION
6.1 Refrigerant liquid thermometer.
The pointer of the Magnetic Level Indicator is
Keep a record of temperatures of moved by means of two magnets
transformer, that can indicate some permanent), which are coupled to a float
problem for overload o bad type buoy. The movement of the pointer is
functioning. carried out by the buoy, according to the level
of liquid, which transmits precise indications to
same, due to the great sensitivity of the
magnetos.

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6.3 Pressure Relief Valve or

explosora. PRINCIPLE OF OPERATION

When an increase in internal pressure occurs

in the pond, that exceeds the pressure of
calibration of the valve, it will act
immediately relieving the excess of
pressure, thus preserving the physical integrity of the
tank and connected equipment
the same. After the relief of pressure, the
valve automatically returns to the position
The valves equipped with contacts
electric, have a signaling plug
located in the center of the valve, which will remain
in sight after their performance, taking action
the contacts, remaining this way until their
manual rearm

MAINTENANCE

Pressure Relief Valves do not require

maintenance estimate although
we recommend that in the case of valves with
alarm contacts should be reviewed at least
once a year the operation of
valve trigger microswitch.

The Pressure Relief Valve or bursting valve

it is used against pressure increases in the
transformer tank. It has a
reaction speed less than 50 ms.
Depending on the model, it can be
supply with signal contacts for
alarm and/or disconnection.

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6.4 Sudden Pressure Relay. OPERATION
The Pressure Relays Sudden son The Pressure Relays are composed of:
equipment of protection for
sealed type transformers, installed Relay Body(1)
above the maximum level of the insulating liquid, in Equalizer(2)
the space included between the liquid Metal bellows (3)
insulator and the transformer cover or Microrruptor(5)
alternatively in the liquid area Terminal box (7)
insulator. Manual relief valve (4)
Connection terminals (6)
The relay activates when a sudden occurs.
internal pressure, regardless of the
transformer working pressure.
This relay does not operate due to slow changes in
pressure.

When the pressure changes inside the

transformer occurs slowly in
normal operation, the equalizer hole is
sufficient to equalize the pressure of the interior of
Relay with the pressure inside the tank of
transformer. When the pressure change in
the interior of the transformer occurs suddenly,
the equalizing hole will not be enough to
make the pressures equal, allowing
with this that the internal pressure in the
transformer is greater than the internal of
Relay, causing the bellows to extend and
activate the existing microswitch inside the
same(5).

MAINTENANCE

It is recommended that specialized personnel

conduct performance simulation tests
of the Sudden Pressure Relay with a frequency of 1
2 years according to the manufacturer's recommendations.

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6.5 Buchholz Relay

6.5.2 Loss of Refrigerant Liquid
Buchholz relays are located between the
main tank of the transformer and the
conservative. During normal operation, it
find completely filled with liquid
soda.

6.5.3 Liquid Circulation

Soda

FUNCTIONING

If a fault occurs inside the

transformer, the Buchholz relay responds to the
next way:

MAINTENANCE
6.5.1 Gas Accumulation
It is recommended that specialized personnel
conduct operational simulation trials
of the Buchholz Relay with a frequency of 1 to 2
years according to the manufacturer's recommendations.

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6.6 Fans Then fill to 90% of capacity
from the container (approximately 900 cc) and close it
Se debe observar que estos no se encuentren container. Do not seal with adhesive tapes
obstructed and check that the rotation sequence nor other similar elements.
be the same for all fans 7) Close the sample taking valve and
supplied. remove hose.

6.7 Radiators. 6.8.2 Sample for Chromatographic Analysis.

It should be noted that these are not found For a correct and effective analysis
blocked or too polluted about Chromatographic the person(s) in charge
everything in mining environments. they must know the procedure very well and
the practical way of taking the sample.
6.8 Coolant. In general terms, this is detailed in
continuation:
A sample must be taken at least once.
per year for physical-chemical analysis and to know the It must be done with a 50 syringe.
status of the transformer operation, 100 cc for sample extraction
, which is made of glass and has a mouth
for power transformers it is recommended
carry out a chromatography sample of stainless steel, in addition to
Gases once a year. to have a three-way key
positions.
NOTA:La frecuencia de los análisis puede A hose must be available.
["flexible","transparent","suitable"]
change according to the degree of criticality
what does the team represent y it will be to adapt the syringe nozzle and another
exclusive responsibility of the client for valve outlet of intake
sample. This will depend on the type of
define that frequency.
valve what posean the
6.8.1 Sample for Physical Analysis transformers.
3) Open the valve and let it drain for approximately.
Chemicals.
500 cc of oil to avoid
Place a container under the valve. contamination with particles
sample collection to avoid solids deposited in valve.
spills on the ground. 4) It is recommended, before sample
2) Place transparent hose to definitively, at least two passes of
sample collection in valve. oil by syringe and "unclog or
3) Open the valve and let drain approximately 500 empty syringe for each pass of
cc. of oil to avoid contamination oil, this in order to clean it of
with solid particles deposited in any type of pollutant
valve. existing in it.
4) In a glass container colored 'amber', The main thing in sampling
finally, there shouldn't be any type left
insert hose, place approximately
100 cc of extracted oil, close valve of air bubble in the sample
sample collection and proceed to inside the syringe (full of
Rinse the container well. Dispose of the oil. oil.)
Repeat this step 2 times, like this 6) Finally wrap the syringe for
will ensure that the container is located avoid UV or pollution
clean and free of contaminating residues. thermal effects in shipping the
Open the valve again and leave it sample, correctly packaged and
dispatch as quickly as possible
drain a little more oil
possible to the laboratory that will carry out the
essay.

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6.9 Field Tests.

Insulation resistance between HT and
For Power Transformers Earth:
recommended to do at least once
every year field electrical tests The high voltage windings are short-circuited and
TTR, Insulation Resistance and Low voltage between themselves, the low voltage winding is

Winding resistance as land, a DC voltage is applied to

minimum), in order to detect or deriving from AT (5KV typical or 10 KV
prevent possible anomalies. for voltage transformers
higher than 110 KV), are recorded
Insulation Resistance: isolation readings for 10
minutes at intervals of 1 minute,
This test is conducted accompanied during the first minute, they take
with the measurement of the Index of readings at 10 seconds and 60
polarization y Coefficient of seconds.
Absorption of the windings and
insulation resistance of the core
in the case of transformers of
power, in no case the index of
polarization and the coefficient of
Absorption must be less than 1.

This test aims to find the

state del isolation of
transformer both internally and
externally since this test is
sensitive to pollution of the
insulators and connection terminals.

The test must be conducted as

details below:

Safety conditions before

to carry out the test:
- Disconnect totally the
transformer After time has elapsed, the calculations are made

- Remove the ground connection from the neutral. polarization coefficients (reading of
if it exists. minute 10/reading of minute 1, the
- In the case of bars in BT evaluate the absorption coefficient is determined
the alternative from to open the as 60-second reading / reading
associated switches to prevent 10 seconds) in both cases the
disconnect the entire system from readings must be greater than 1 for
bars. distribution and between transformers
- After each reading connect to 1.1-1.3 for transformers of
land the terminal under test before power.
to make the disconnection.

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Insulation resistance between high voltage Interpretation of the results:
y BT:
There is no absolute value for the
insulation resistance, however
it is possible to refer to values
typical historical data for similar teams.
Some megger come conditioned
with a guard cable that is used to conduct
the effects of adjacent scattering and
measure the true resistance of a
isolation. It is more commonly used in the
measurement of insulation resistances
of cables or connectors.
When the test is performed with the
use of the megger guard cable
The connection circuits are as follows:

The high voltage terminal is connected to the

megger next to AT, the neutral terminal
the megger connects to BT, the tank of
transformer must be grounded.
proceed to perform the insulation resistance
with the coefficient of polarization and absorption
respectively the same as in the case
anterior.

Low voltage insulation resistance to ground:

The high voltage winding is connected to ground and is

apply tension to the BT side, proceed to
the same way as in previous cases for
the calculation of the polarization coefficients
and absorption.

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Winding resistance Relationship of Transformation.

Measurement of Resistance of the Measurement of the transformation ratio

developed in all positions of the in order to detect possible variations
tap changer, with this test due to short circuit problems between turns
we can detect bad issues (especially in transformers of
contacts in the changer or connections very high relationships, there can be
defective, the small short circuits between turns and the
results of previous tests to the transformer continues to operate without
same unit. It should be taken into account the highlight it).
winding temperature to carry out Through this test, the determination is made of the
corrections of the resistance. polarity of the windings.

Equipment to be used: TTR (Transformer Turn

Relation).

For inquiries, call the phones 56-32-2320600 fax 56-32-2320619 or at the

[Link]
emailindustrial@[Link]

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7. FAULT DIAGNOSIS

Problem Cause

Continuous overload
Overheating Poor external connections
Poor ventilation - surrounding air is hot

The voltage is reduced to zero - Short circuit between turns

Loose connections internally
Failures in the changer.

Overvoltages in High input voltage

secondary Failures in the changer.

Failure of insulation Continuous overload

Damage from handling during installation
Atmospheric downloads.

Fuses blow or - Short circuit

the switches are opened Overload
High inrush currents

Warming of Fault in the connections.

Bushings Inappropriate connectors.

Valve operation - Isolation failures

overpressure Short circuit

Downloads in Highly polluted atmospheres

Bushings Abnormal operating voltages on the
bushings

Partido Bushings Mechanical load of the cables on the bushings

Inadequate handling

Pressure loss Check seals, welds, or dents in -

valves and radiators

Bajo nivel de Aceite Check for oil leaks.

Check gaskets

Corrosion Check the condition of the paint