USER MANUAL FOR 20kV/6.3MVA TRANSFORMER CONTAINER Document …

Document No.: Document Title:

M02.0109 USER MANUAL

6.3MVA Transformer H 14/05/2007

Issue: Date:

USER MANUAL

FOR

20kV/6.3MVA TRANSFORMER CONTAINER

Document M02.0109




Issue: Date:




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TABLE OF CONTENTS

1 OVERVIEW

2 SAFETY

2.1 GENERAL INFORMATION ................................................................................................ 1

2.2 ELECTRICAL .................................................................................................................... 1

2.3 MATERIALS ...................................................................................................................... 1

2.4 OPERATIONAL PRECAUTIONS ....................................................................................... 2

2.5 SAFETY LABELS .............................................................................................................. 2

3 NOISE EMISSION

3.1 NOISE CONTROL PROHIBITED ACTS ............................................................................. 3

3.2 TRANSFORMER NOISE EMISSION CONTROL INFORMATION ....................................... 3

4 HANDLING

4.1 LIFTING / HANDLING ........................................................................................................ 4

4.2 STORAGE / TRANSPORT ................................................................................................. 4

5 INSTALLATION

5.1 UNPACKING ..................................................................................................................... 5

5.2 LOCATION OF THE PLANT .............................................................................................. 5

5.3 ELECTRICAL CONNECTION AND COMMISSIONING ...................................................... 5

6 GENERAL DATA

6.1 GENERAL DESCRIPTION ................................................................................................. 6

6.2 TRANSFORMERS ............................................................................................................. 6

6.3 SWITCHGEAR ................................................................................................................... 8

6.4 METERING ...................................................................................................................... 10

6.5 PROTECTION .................................................................................................................. 11

6.6 CONTROL PANEL LAYOUT ............................................................................................12

6.7 LOW VOLTAGE ISOLATOR SECTION.............................................................................15

6.8 HIGH VOLTAGE CONNECTION SECTION .......................................................................16

7 OPERATING INSTRUCTIONS

7.1 TRANSFORMER OPERATION .........................................................................................17

7.2 SWITCHBOARD OPERATION..........................................................................................18

7.3 METERING OPERATION ..................................................................................................19

7.4 PROTECTION OPERATION .............................................................................................19

8 MAINTENANCE

8.1 DAILY MAINTENANCE/CHECK SCHEDULE................................................................... 21

8.2 WEEKLY MAINTENANCE/CHECK SCHEDULE ...............................................................21




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9 TROUBLE SHOOTING

9.1 ALARM CHART ............................................................................................................... 22

9.2 TROUBLE SHOOTING CHART ........................................................................................23

APPENDIX A: General Arrangement

Drawing number: Rev.

D210474 SHT. 1 of 1 C 216/MM04021 Pauwels drawing

APPENDIX B: Transformer Equipment Data Sheet, Rating Plate

Drawing number: Rev. G08.0173 E S01.0608 SHT. 1 of 1 E 1677/NM04021 Pauwels drawing

APPENDIX C: Single Line Diagram

Drawing number: Rev. D1900611 A

APPENDIX D: Schematics and Terminal Layout Drawings

Drawing number: Rev. Title D080722 SHT. 1 of 15 E Transformer No.1 Low Voltage Load Break Isolators Schematic D080722 SHT. 2 of 15 E Transformer No.2 Low Voltage Load Break Isolators Schematic D080722 SHT. 3 of 15 H Transformer No. 1 Overcurrent Protection Schematic D080722 SHT. 4 of 15 H Transformer No. 2 Overcurrent Protection Schematic D080722 SHT. 5 of 15 G Transformer No. 1 High Voltage Load Switches Schematic D080722 SHT. 6 of 15 G Transformer No. 2 High Voltage Load Switches Schematic D080722 SHT. 7 of 15 F Transformer No. 1 Metering Schematic Diagram D080722 SHT. 8 of 15 F Transformer No. 2 Metering Schematic Diagram D080722 SHT. 9 of 15 E Transformer No. 1 Cooling Fans Control Schematic D080722 SHT. 10 of 15 D Transformer No. 2 Cooling Fans Control Schematic D080722 SHT. 11 of 15 J Utilities and Control Schematic D080722 SHT. 12 of 15 G Protection and Alarm Annunciation Control Schematic D080722 SHT. 13 of 15 G Protection and Alarm Annunciation Control Schematic D080722 SHT. 14 of 15 D Circuit Breaker Intertripping Control Schematic D080722 SHT. 15 of 15 D Circuit Breaker Intertripping Schematic D140140 SHT. 1 of 3 E Terminal Layout Diagram D140140 SHT. 2 of 3 D Terminal Layout Diagram D140140 SHT. 3 of 3 C Terminal Block Location Diagram

APPENDIX E: Transformer Layout Drawing and Data Sheet

APPENDIX F: ABB Safeplus Switchboard User Manual

APPENDIX G: Deif MIQ96 Multi-instrument User Manual

APPENDIX H: Automation 2000 DGPT2 Protection Device User Instructions

APPENDIX I: ABB SPAJ 142C User Manual

APPENDIX J: Selco M4100 User Manual




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APPENDIX K: Euromold Cable End Installation Manual

APPENDIX L: Material Safety Data Sheets

APPENDIX M: Manufacturer’s Component Data

APPENDIX N: Livery Layout

Drawing number: Rev. D200097 SHT. 1 of 1 A

APPENDIX O: Certificate of Conformity

APPENDIX P: Container Certificate

APPENDIX Q: International Contact Information




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1 OVERVIEW

This user manual describes the operation, safety considerations and maintenance of WPS 6.3MVA/20kV transformer containers. WPS 6.3MVA/20kV transformer containers can be used to step up generating voltage levels in the range 400 – 480 V to medium voltage levels (2.9 – 15 kV) for power station applications and to step down medium voltages to low voltage levels for applications including substations and supplying loadbanks. The transformers can operate at either 50 or 60 Hz.

2 SAFETY

2.1 GENERAL INFORMATION

Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.

Ensure that the Operation and Maintenance manual, and the manual holder, are not removed permanently from the machine.

Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.

For high voltage operation or maintenance, no one will work or operate any High Voltage Equipment unless they are suitably qualified personnel and are authorised by WPS to do so.

Make sure that all protective covers are in place and that the container doors are closed during operation.

The specification of this containerised transformer is such that it is not suitable for use in

flammable gas risk areas. WARNING: NO ATTEMPT SHOULD BE MADE TO OPERATE IN SUCH AREAS WITHOUT EXPRESS AUTHORITY FROM WPS.

Installation of this transformer must be in accordance with recognised electrical codes and any local Health and Safety Codes.

2.2 ELECTRICAL

For the purposes of this procedure, Low Voltage (LV) is defined as any voltage below 600 V and High Voltage (HV) is defined as any voltage of 600 V or above.

Everyone working on electrical equipment should be aware of the dangers that may arise while working on and during operation of the equipment.

LV operation or maintenance must only be undertaken by persons who are suitably trained electricians and possess the technical knowledge and experience to ensure that the work is carried out in a safe manner and the equipment is left in a safe condition.

Before working on transformer containers, ensure that all possible power sources to the equipment have been disconnected and locked off so that it cannot be energised. For WPS 6.3MVA/20kV transformer containers, the following must be ensured:

All LV and HV isolators and circuit breakers are open and that the appropriate earth switches are in the closed position.

Any external supply is disconnected and that the EXTERNAL/INTERNAL SUPPLY switch is in the OFF position provide

WARNING: Operating or working on High Voltage Equipment requires particular care and expertise. HV operation or maintenance must only be undertaken by suitably qualified personnel who are authorised by WPS to do so.

2.3 MATERIALS

The following substances are contained within this machine and may be hazardous to health if used incorrectly:

Transformer Oil

Battery Electrolyte

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Sulphur Hexafluoride

AVOID INGESTION AND SKIN CONTACT.

When handling transformer oil, wear appropriate personal protection equipment.

A battery contains sulphuric acid and can give off gases, which are corrosive and potentially explosive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water. When handling battery electrolyte, wear appropriate personal protection equipment.

For further information, consult Material Safety Data Sheets contained in appendix L of this manual.

Transformer oil and batteries must NOT be disposed of along with general refuse. Ensure that transformer oil and batteries are disposed of properly when they require replacing. Contact local authorities for guidelines on the disposal of these materials.

2.4 OPERATIONAL PRECAUTIONS

Fully read the operating instructions contained within this manual before operating this machine.

Ensure that all safety warnings are observed and understood before operating this machine.

IF IN DOUBT CONTACT WPS.

Do not alter or modify this machine.

During operation, WPS 6.3MVA/20kV transformer containers present the following potential hazards:

1. Low Voltage (LV) electrical power (< 600 V)

2. High Voltage (HV) electrical power (> 600 V and up to 24 kV)

3. Rotating parts (cooling fans)

The following areas of best practice must be observed during operation:

Never operate unit with guards, covers or screens removed.

Rotating fan blades can cause serious injury. Do not operate without guards in place and keep hands, hair, clothing, tools etc well away from moving parts.

Only suitably qualified, WPS authorised personnel are permitted to operate WPS High Voltage Equipment.

Never enter transformer compartments during operation.

Minimise time spent within the Switch Room during operation.

Avoid standing in front of Switchgear during Circuit Breaker operation (opening or closing). Where possible, always use the remote control unit.

2.5 SAFETY LABELS

Look for these signs on the machine, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions.

CAUTION Live Busbars

CAUTION High Voltage




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3 NOISE EMISSION

3.1 NOISE CONTROL PROHIBITED ACTS

Tampering with noise control system prohibited

The following acts or misuse of the unit are prohibited:

1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new transformer for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use.

Or

2) The use of the transformer after such device or element of design has been removed or rendered inoperative by any person.

Among those acts included in the prohibition against tampering are these:

Removal or rendering inoperative any of the following:

a) The air intake system or parts thereof.

b) Enclosure or parts thereof.

Removal of any of the following:

a) Fan shroud

b) Sound absorption material

Operation of the transformer with any of the enclosure doors open.

3.2 TRANSFORMER NOISE EMISSION CONTROL INFORMATION

A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or replacement of any noise control device or element of design incorporated into this transformer in compliance with the noise control act;

B. The use of this transformer after such device or element of design has been removed or rendered inoperative.

THIS TRANSFORMER HAS BEEN SPECIFICALLY DESIGNED WITH A SOUND ATTENUATING ENCLOSURE. THE CONTAINER DOORS SHOULD REMAIN LOCKED SHUT UNDER NORMAL OPERATING CONDITIONS. UNDER ANY OTHER CONDITIONS EXCESSIVE NOISE LEVELS CAN BE PRODUCED AND PROLONGED EXPOSURE IS HAZARDOUS TO HEARING.

FOR SAFETY, EAR PROTECTION SHOULD ALWAYS BE WORN WHEN WORKING IN THE VICINITY OF AN

OPERATING TRANSFORMER SET.

WARNING




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4 HANDLING

4.1 LIFTING / HANDLING

The transformer set is enclosed in a standard size ISO 20ft container with integrated lifting forgings on the corners.

All lifting and handling equipment must be adequately rated for applicable weights.

During all lifting and handling operations the following weight must be considered.

Complete Package 24000 kgs (52911 lbs)

Ensure that the correct lengths of strop / wire rope are used to ensure a level lift. Also ensure that the included angle does not exceed 90°.

CAUTION: THE TRANSFORMER SET SHOULD NOT BE DRAGGED.

4.2 STORAGE / TRANSPORT

Carry out the following points before transporting the generator or preparing the generator for storage.

Ensure that the EXTERNAL/INTERNAL SUPPLY switch is in the OFF position.

Disconnect the battery terminals (in case of overseas transport).

Ensure all panels are securely fitted and close all doors.

Transformer containers are classified as “Not to be overstowed” and are only suitable for shipping on deck or on top of stack.

All units are to be loaded flat onto transport and properly secured.




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5 INSTALLATION

5.1 UNPACKING

Ensure that the correct marked lifting / tie down points are used whenever the machine is lifted or transported.

5.2 LOCATION OF THE PLANT

The transformer can be installed on any solid, flat and level surface capable of supporting the full operating load of the package. A dry, well-ventilated area where the atmosphere is as clean as possible is recommended. Ensure that the machine is positioned securely and on a stable foundation.

CAUTION: A minimum of 3 metres (9 ft) all round the transformer is recommended. Hot air will exit from the fan outlets. It is important that this hot air does not re-circulate to the louvre inlets.

The transformer must be allowed sufficient space all round to enable the effective removal of the cooling air which, in turn, will reduce the risk of re–circulating the cooling air back through the transformer. Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintenance tasks. Hard surfaces may reflect noise with an apparent increase in the decibel level. It is recommended that provision be made for lifting heavy components during major overhaul.

5.3 ELECTRICAL CONNECTION AND COMMISSIONING

CAUTION: Before undertaking any electrical connection work, read and fully understand General Information on safety and the Electrical section on safety.

Prior to installation of the transformer, checks should be made to ensure that the electrical load to be supplied is within the rated output of the transformer at the site ambient conditions.

Prior to connection, ensure that all isolators and circuit breakers are in the open position and earth switches are in the closed position.

NOTE: for operation at altitudes of above 1000 m, please refer to Transformer and Switchgear Manufacturer’s information.

CAUTION: Before commencing cable connections or selecting transformer tap settings, it must be ensured that the transformer container is de-energised.

Select the correct tap settings on the transformer(s), depending upon the output voltage required. With WPS 6.3MVA/20kV transformer containers, it is possible to configure the secondary connections a number of different ways to produce a range of output voltages. See section 7.1 Transformer Operation for details on adjusting the tap settings. For a list of tap settings available, refer to Appendix E.

Ensure that cables with the correct ratings are used.

Visual inspection: ensure that all cables and cable terminations are in good condition prior to connection. Insulation must be in good condition and intact along the entire cable length.

Ensure that the transformer container, load and generator sets are properly earthed in accordance with application requirements and local regulations.

Ensure that all phases are properly connected in the correct sequence.

Ensure all safety covers are securely replaced after electrical connection is complete.

Ensure that the safety procedure to be applied is based on the appropriate national and local regulations.

Ensure that the safety procedure is followed at all times.

IT IS THE RESPONSIBILITY OF THE OPERATOR TO ENSURE THAT THE RATINGS OF THE TRANSFORMER CONTAINER CIRCUIT BREAKERS AND ISOLATORS ARE NOT EXCEEDED.




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6 GENERAL DATA

6.1 GENERAL DESCRIPTION

WPS 6.3MVA/20kV transformer containers are arranged as three sections: two end sections, each containing a transformer and a central switch room containing the control/monitoring equipment, switchgear and the HV cable entry. The container is 20ft long and is manufactured from welded steel. Each transformer compartment is accessible via end cargo doors and from the switch room via a personnel hatch. The switch room is accessed via a lockable personnel entrance door. See Appendix A for a general arrangement drawing of the transformer container.

Each transformer of this type is uniquely identified by a Plant Number and Serial Number indicated on the identification plate affixed to the outside of the control panel. This information is required when ordering spare parts. See appendix B for details on the transformer container rating plate. Major component serial numbers are listed in appendix L.

The single line diagram of the transformer container is shown in appendix C.

Ensure that load is supplied via suitably rated cables. Checks should be made to ensure that the rating of one or both of the output isolator switches is not exceeded. If the rating of a single isolator switch is exceeded, it will be necessary to use both switches in parallel.

NOTE:

The technical data defining the transformers and the limits of operation are listed in the Equipment Data Sheet, contained in appendix B.

In order to assist in the operation and maintenance of the transformer, a full set of electrical and control panel terminal arrangement drawings has been included in this manual. These can be found in appendix D.

6.2 TRANSFORMERS

The transformers used within WPS 6.3MVA/20kV transformer containers are ABB transformers, type CTMU24 HA 3150. The low voltage side of the transformers are permanently connected in a Star arrangement. The high voltage side of the transformers can be configured a number of different ways to obtain different transformer step-up ratios. See appendix E for the following technical information:

1. Layout drawing of transformer

2. Transformer data sheet including a list of tap settings available

Each transformer is cooled by three thermostatically controlled cooling fans. Later transformer containers also incorporate a ducting kit which improves the air-flow around the transformer.

Figure 6.1 on the following page is a series of photographs showing the mounting arrangement of the transformer within the transformer compartment, and the associated circuitry. See the electrical schematics in appendix D for wiring arrangements. Section 7.1 contains details on changing the transformer tap settings.




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H.V. CONNECTIONS

THERMOSTAT FOR FAN

OPERATION (ACCESS FROM SWITCH ROOM)

L.V. CONNECTIONS

COOLING FANS

TRANSFORMER DGPT2 PROTECTION

CURRENT TRANSFORMERS GENERATOR AUXILIARY SOCKETS

Figure 6.1 Mounting of transformer and associated equipment within the transformer compartment




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6.3 SWITCHGEAR

The switchgear used in WPS 6.3MVA/20kV transformer containers is ABB SafePlus SF6

insulated equipment. The switchgear comprises of the following:

2 off Safeplus – C (cable switch) units

2 off Safeplus – V (circuit breaker) units

Looking from the front of the switchboard, the arrangement, left to right, is C-V-V-C. See appendix F for a technical specification of the switchgear.

ABB SafePlus units contained within WPS 6.3MVA/20kV transformer containers have the following options specified:

Overcurrent and earth fault protection relay ABB type SPAJ 142C

Pressure indicator

Capacitive voltage indicator

Circuit breaker remote control unit and umbilical

Padlock devices

Control section:

Each circuit breaker has the following:

1 off shunt trip, 24 V DC

4 auxiliary contacts: 2 normally open (NO), 2 normally closed (NC)

Each isolator and earth switch has the following:

4 auxiliary contacts: 2 normally open (NO), 2 normally closed (NC)

Figure 6.2 on the following page is a series of photographs showing the mounting arrangement of the switchboard and associated circuitry. For wiring arrangements, see the electrical schematics in appendix D. For details on operation, see section 7.2.




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ABB SPAJ 142C Overcurrent and earth fault protection relay

EXT/OFF/INT supply switch (top) and lighting switch

Deif MIQ96 Multi-instrument Selco M4100 alarm

annunciator unit

Transformer 1 circuit breaker (Q2)

SF6 gas pressure indicator

Isolator (Q3) and earth switch (Q4)

Transformer 1 isolator (Q1B) and earth switch (Q1A)

10-pin socket for remote circuit breaker operation

Transformer 2 circuit breaker (Q6)

Isolator (Q7) and earth switch (Q8)

Transformer 2 isolator (Q5B) and earth switch (Q5A)

High voltage connections from Switchboard to output terminals

SWITCHBOARD ARRANGEMENT High voltage connections from transformer to switchboard and earth leakage CT (bottom).

Remote circuit breaker control box and umbilical

Operating handle

Figure 6.2 Switchboard arrangement




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6.4 METERING

Metering is provided by a Deif multi-instrument, type MIQ96. This provides a comprehensive range of electrical metering, consisting of the following:

Instantaneous measurements Parameters

Phase voltages U1, U2, U3

Average phase voltage Ū

Line voltages U12, U23, U31

Average line voltage Ū

Angle between phases 12, 23, 31

Current I1, I2, I3, It

Neutral current In

Active power P1, P2, P3, Pt

Reactive power Q1, Q2, Q3, Qt

Apparent power S1, S2, S3, St

Power factor cos1, cos2, cos3, cost

THD (Total harmonic distortion) THD (I1, I2, I3, U1, U2, U3, U12, U23, U31)

Frequency f

Integrated/maximum demands

Maximum demand It, Pt, Qt, St

Energy Wht, varht

Figure 6.2 on the previous page shows a photo of the Deif MIQ96 multi-instrument. All measured values are shown on the built-in display. The multi-instrument requires current measurement (CTs) and voltage measurement (VTs) to provide the above metering. It should be noted that the output feed of the transformer container requires to be energised in order to provide metering since the VTs are located on the output side of H.V. isolator Q1B. See appendix D for connection details of the Deif MIQ96 multi-instrument. See section 7.3 and the user’s manual in appendix G for details on operation.




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6.5 PROTECTION

Protection of the transformer container is provided by the following devices:

1. Transformer protection device DGPT2, located on the top of each transformer. This is shown in figure 6.1. The DGPT2 device provides the following transformer protection:

i. Discharge of gases protection. Detects the discharge of gases from the dielectric oil, which is generally caused by small discharges due to ruptured insulation or by a low dielectric level. A relatively slow form of protection.

ii. Excess pressure protection. Detects an increase in the tank pressure, which is generally caused by the transformer being overfilled, or by a clear short circuit within the transformer tank. A relatively fast form of protection.

iii. Excess dielectric oil temperature protection. Detects a high dielectric temperature, which is generally caused by an electrical fault or by intensive use of the transformer above its rated power output at site ambient conditions. Excess temperature protection has two stages. The first of these is used for annunciation only. The second is used to trip the transformer circuit breaker (and trip the circuit breaker of the corresponding 3 generators if intertripping is connected). A relatively slow form of protection.

Transformers are shipped with the excess pressure protection set to 0.5 Bar and the excess

temperature protection 1 and 2 set to 80C and 85C respectively.

2. ABB protection relay, type SPAJ 142C, located on the control panel door, which provides overcurrent and earth fault protection. This is shown in figure 6.2.

3. Low control voltage level protection. If the control voltage falls below a pre-determined level (determined by low voltage relay U2), the transformer circuit breakers are tripped. Transformers are shipped with protection relay U2 set at 20 V.

4. Selco M4100 Alarm Annunciator. In addition to the above protection, the following indication is provided by a Selco alarm annunciator, shown in figure 6.2:

HIGH TEMP. TRAFOS 1 & 2

LOW CONTROL VOLTAGE LEVEL

MAINS SUPPLY FAILURE

OVERCURRENT RELAY ACTIVATED

PROTECTION ACTIVATED (transformer discharge of gases protection or excess pressure protection)

FAN PROTECTION TRIPPED

For wiring arrangements of the above protection devices and the alarm annunciator, see the electrical schematics in appendix D.

For a detailed description of the operation of the protection devices, see section 7.4.




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6.6 CONTROL PANEL LAYOUT

The layout of the control panel is shown below in figures 6.3 and 6.4. See the following page for a key to figures 6.3 and 6.4.

Figure 6.3 Layout of WPS 6.3MVA/20kV transformer container control panel – left hand side

Figure 6.4 Layout of WPS 6.3MVA/20kV transformer container control panel – right hand side

3 4

9 5 6

7 8

1 2

13 16

9




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Flag number Component Description

1

S3 Intertrip switch Local/Bypass

Selects between a local supply and an external site supply for intertripping of generators.

2

S4 ESD (Emergency shutdown) switch Local/Bypass

Selects between a local supply and an external site supply for generator emergency stops.

3

Fan control contactors and timers Q11A to C and Q12A to C

Perform a controlled sequential fan start once a pre- determined container temperature has been reached.

4

Fan protection circuit breakers F3A to C and F4A to C

Set to 3 A. Trip in the event of a fan fault.

5

TB1 terminals

Emergency stop connections. Inter-tripping connections. Isolator and earth switch auxiliary connections.

6

Diode terminals - various

-

7

Earth terminals – various

-

8

TB2 terminals

Transformer 1 C.B. (Q2) connections: Trip coil Remote trip signal SPAJ overcurrent protection relay

Sensing voltages for multimeter

9

TB3 terminals

Transformer 1 connections: Internal supply (Q9) Fan thermostat DGPT2 protection Current sensing for multimeter

Auxiliary connections (lighting, heating) Common alarm connections External supply connections.

10

TB10 terminals

Transformer 2 connections: Internal supply (Q10) Fan thermostat DGPT2 protection Current sensing for multimeter

11

TB9 terminals

Transformer 2 C.B. (Q6) connections: Trip coil Remote trip signal SPAJ overcurrent protection relay

Control voltage connections

12

Supply selector contactors Q9 and Q10

Select between an internal supply from transformer 1 or from transformer 2.

13

Miniature circuit breakers F6 to F9

F6 – 16 A RCD supplying 240 V control section socket F7 – 2 A MCB supplying 24 V DC power supply F8 – 6 A MCB from battery F9 – 2 A MCB supplying lighting and panel heater




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14

Control relays K1 to K6

K1 – Transformer 1 protection relay Trips transformer 1 C.B. (Q2) and emergency stops transformer 1 generators in the event of transformer 1 protection operating K2 – Transformer 2 protection relay Trips transformer 2 C.B. (Q6) and emergency stops transformer 2 generators in the event of transformer 2 protection operating K3 – Mains supply failure relay Annunciates in the event of a mains supply failure to the 24 V DC control circuit K4 – Low DC voltage relay Trips transformer 1 and transformer 2 C.B.s (Q2, Q6) and annunciates in the event of a low control voltage level (energised by D.C. voltage measuring relay U2) K5 – Transformer 1 C.B. off relay Trips transformer 1 generator C.B.s in the event of a transformer 1 C.B. (Q2) trip K6 – Transformer 2 C.B. off relay Trips transformer 2 generator C.B.s in the event of a transformer 2 C.B. (Q6) trip

15

D.C. voltage measuring relay – U2

De-energises control relay K4 in the event of a low control voltage level

16

24 V power supply – U1

Provides mains supply voltage for D.C. control circuitry

Figure 6.5 Key to Control Panel components




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6.7 LOW VOLTAGE ISOLATOR SECTION

One half of the L.V. isolator section of WPS 6.3MVA/20kV transformer containers is shown below in figure 6.6. Isolators Q9A, Q9B and Q9C are shown below. Also shown is the isolator handle, used to open and close the individual isolators and the external supply socket.

Figure 6.6 Input section of transformer container

L.V. input section

L.V. Isolators Q9A, Q9B, Q9C

Isolator handle

External supply

socket




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6.8 HIGH VOLTAGE CONNECTION SECTION

The H.V. connection section of WPS 6.3MVA/20kV transformer containers is shown below in figure 6.7. The load cables can be connected to either the left hand or the right hand H.V load terminals, which are supplied by H.V. isolators Q7 and Q3 respectively. In order for the VTs to measure voltage, Q7 must be closed.

NOTE: DO NOT EXCEED THE CURRENT RATING OF BUSBAR, CIRCUIT BREAKERS OR ISOLATOR SWITCHES.

Figure 6.7 Output section of transformer container

TB4: MCBs for voltage measurement

H.V. output section

Insulating sheets

between phases

Voltage transformers and high voltage fuses

HV insulators

Output connections

Output feeds




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7 OPERATING INSTRUCTIONS

7.1 TRANSFORMER OPERATION

7.1.1 TRANSFORMER TAP SETTINGS

It is possible to configure the secondary windings of the transformers in a number of different ways to provide different transformer ratios and hence different output voltages.

CHANGING TAP SETTINGS MUST ONLY BE UNDERTAKEN WITH THE TRANSFORMER DE-ENERGISED AND BY SUITABLY QUALIFIED PERSONNEL.

Tap changers A, B and C are located on the top of the transformer.

Tap changer C changes the transformer secondary windings from a Star arrangement (position 1) to a Delta arrangement (position 2).

Tap changer B makes coarse adjustment to the transformer ratio, and hence output voltage.

Tap changer A makes fine adjustment.

See appendix E for the range of tap settings and output voltages available.

To change the position of a tap changer:

Remove cover on the top of the transformer container OR open cargo doors into transformer compartment for access (removing the top cover gives better access to the tap changers).

Lift the appropriate tap changer handle straight up and turn to the required position.

Press the tap changer handle down ensuring that the handle “locates” into the new position

7.1.2 TRANSFORMER COOLING SYSTEM

The operation of the 3 transformer cooling fans is controlled by the thermostat located on the wall of the transformer compartment. Access to the thermostat is gained from the Switchroom, through the access hatch to the transformer compartment. The fans operate when the temperature within the transformer compartment exceeds the set point of the thermostat. The starting sequence of the fans is staggered so that the starting current of all three fans is not drawn simultaneously. This sequential start is controlled by the fan control contactors and timers Q11A to C and Q12A to C (shown in figure 6.3).

Fan operation is entirely automatic. If required the set-point of the thermostat can be altered to suit running conditions.




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7.2 SWITCHBOARD OPERATION

Switch isolator: Close: Turn the operating handle clockwise Open: Turn the operating handle anti-clockwise

Earthing switch: Close: Turn the operating handle clockwise Open: Turn the operating handle anti-clockwise

Transformer breaker: SEE NOTE ABOVE Close: Turn the operating handle clockwise to tension the close/open spring. Then press the green button. Open: Press the red button.

All switches can be operated with the included operating handle.

An internal mechanical interlocking between the switch disconnector/circuit breaker and the associated earthing switches prevents incorrect operation. The operation of the switch disconnector/circuit breaker and earthing switches can be further interlocked by means of a padlock. The earthing switches are operated by a snap action mechanism, which ensures fast closing.

The earthing switch is closed by turning the operating handle clockwise. Turning the operating handle anti- clockwise opens the switch.

For closing the transformer circuit breaker, the spring mechanism must be charged. This is achieved by turning the operating handle clockwise. The green “on” button must be pressed to close the switch/breaker.

An anti-reflex system, standard on all operating handles, prevents the immediate re-operation of switches.

IT IS RECOMMENDED PRACTICE THAT WHERE POSSIBLE, THE REMOTE CIRCUIT BREAKER CONTROL BOX IS USED TO OPEN AND CLOSE THE CIRCUIT BREAKER

CAUTION: OPENING/CLOSING OF CBs, ISOLATORS AND EARTH SWITCHES IS ONLY TO BE CARRIED OUT BY SUITABLY QUALIFIED PERSONNEL WHO ARE AUTHORISED BY WPS TO DO SO. ENSURE THAT ALL WPS SAFETY AND OPERATIONAL PROCEDURES AS WELL AS LOCAL SAFETY AND OPERATIONAL PROCEDURES ARE COMPLIED WITH.

For a detailed description of the ABB Safeplus switchboard used, see the ABB installation and operating instructions in appendix F.




Issue: Date:

7.3 METERING OPERATION

Metering is provided by the Deif Multi-instrument, type MIQ96. This unit provides all electrical values for each transformer. It is possible to scroll through all measured values using the up/down scroll keys.

FOR FULL METERING, THE OUTPUT OF THE TRANSFORMER CONTAINER MUST BE ENERGISED SINCE THE MEASUREMENT VTs ARE PLACED ON THE OUTPUT SIDE OF H.V. ISOLATOR Q7.

For a full description of the operation and configuration of the MIQ96, please refer to the user’s manual in appendix G.

7.4 PROTECTION OPERATION

7.4.1 TRANSFORMER DGPT2 PROTECTION

As described in section 6.5, the DGPT2 protection fitted to each transformer provides:

Discharge of gases protection (1 changeover contact)

Excess pressure protection (1 changeover contact)

Excess dielectric temperature protection (2 changeover contacts)

In general the normally open (N/O) contacts are used for annunciation and the normally closed (N/C) contacts are used to trip the transformer circuit breaker. The first stage of the excess temperature protection only uses the N/O contacts for annunciation.

See appendix H for the DGPT2 instruction manual.

Under normal operating conditions, no adjustment of the DGPT2 should be necessary. If the Selco annunciator is displaying HIGH TEMP. TRAFOS 1 & 2 or PROTECTION ACTIVATED, refer to the DGPT2 instruction manual or section 9 TROUBLESHOOTING.

7.4.2 ABB PROTECTION RELAY, TYPE SPAJ 142C

As described in section 6.5, the SPAJ 142C device provides overcurrent and earth fault protection.

CAUTION: It is vital that the SPAJ 142C protection relay is set-up and programmed correctly for each application to ensure that this device is able to provide adequate protection in the event of an overcurrent or earth fault condition.

Appendix I contains the user’s manual for the SPAJ 142C device supplied by ABB. This contains comprehensive set-up details which should be used to ensure that the protection relay is correctly programmed.

CAUTION: Correct set-up of the SPAJ 142C protection relay does not guarantee complete overcurrent or earth fault protection of the transformer container under all conditions. In order to provide complete protection, protection devices positioned up-stream (generator protection) and downstream must be correctly set-up.

7.4.3 SELCO M4100 ALARM ANNUNCIATOR

The Selco M4100 Alarm Annunciator provides indication that one or more of the following alarm conditions has occurred:

HIGH TEMP. TRAFOS 1 & 2

LOW CONTROL VOLTAGE LEVEL






Issue: Date:

- 20 -

PROTECTION ACTIVATED (transformer discharge of gases protection or excess pressure protection)


When an alarm condition has occurred, the corresponding LED flashes. When the alarm is acknowledged using the ALARM ACCEPT push button, the LED changes from flashing to constantly lit. The LED will remain on for as long as the alarm condition is present.

See appendix J for the Selco M4100 Alarm Annunciator user manual.




Issue: Date:

- 21 -

8 MAINTENANCE

CAUTION: Do not enter either transformer compartment or the high voltage output section while the transformer container is energised.

8.1 DAILY MAINTENANCE/CHECK SCHEDULE

- Check that no alarms are indicated on the Selco annunciator and that no warnings are displayed on the SPAJ 142C protection relay

- Check that the SF6 pressure gauge is indicating that the SF6 pressure is within the operating range

- Check that the fans are operating correctly

8.2 WEEKLY MAINTENANCE/CHECK SCHEDULE

- Check general condition of the switchgear and high voltage components, for example:

- Surface finish (scratches, corrosion etc)

- Connectors and terminals

- Cleanliness, particularly the H.V. insulators

- Any abnormal looks, smells or sounds

- Inspect cables and cable terminations for damage and wear

- Inspect the transformer container for oil leaks

- Check the oil levels of the two DGPT2 protection devices (see the DGPT2 user manual in appendix H)

IF OIL LEAKS ARE FOUND OR IF THE OIL LEVELS WITHIN THE DGPT2 PROTECTION DEVICES ARE FOUND TO BE LOW, CONTACT THE DEPOT THAT SUPPLIED THE TRANSFORMER CONTAINER. DO NOT ATTEMPT TO RE-FILL THE TRANSFORMER OR THE DGPT2 DEVICE WITHOUT AUTHORISATION.




Issue: Date:

- 22 -

9 TROUBLE SHOOTING

9.1 ALARM CHART

CAUTION: Do not enter either transformer compartment or the high voltage output section while the transformer container is energised.

ALARM CAUSE CORRECTIVE ACTION

HIGH TEMP. 1 & 2

One or both of the transformers has reached the warning or shutdown threshold for high temperature

Check fan operation. If fans are operating correctly, reduce the generating power passing through the affected transformer(s) if possible.

Check DGPT2 protection device for the production of gases. Refer to the DGPT2 user manual in appendix H. If gases are being generated, consult Depot that transformer was obtained from.

Check other protection devices for other alarms (alarm annunciator, SPAJ 142C, protection devices placed up and down stream)


Overcurrent fault (check SPAJ 142C for fault indication)

See the ABB SPAJ 142C User’s manual in appendix I to diagnose fault indication

Earth fault (check SPAJ 142C for fault indication)

See the ABB SPAJ 142C User’s manual in appendix I to diagnose fault indication

PROTECTION ACTIVATED

Transformer DGPT2 Discharge of Gases protection or Excess Pressure protection has activated

Check DGPT2 device for exact cause.

Contact Depot that transformer was obtained from.


One or more fan contactors have tripped on overcurrent

Reset contactors. If alarm persists:

Check contactor overcurrent settings. Should be set to 3 A.

Check fan wiring for damage/short circuits

Check fans for damage/short circuited windings


F7 MCB has tripped Reset F7

24V power supply U1 has failed

Replace U1

Internal AC power to U1 has failed

Restore internal AC power

External AC power to U1 has failed

Restore external AC power

LOW CONTROL VOLTAGE

LEVEL

No mains supply and S1 switch is in the off position

As “MAINS SUPPLY FAILURE” and turn S1 to position 1 or 2

No mains supply and MCB F8 has tripped

As “MAINS SUPPLY FAILURE” and reset F8. If fault persists, investigate control circuitry for a fault.

No mains supply and batteries are flat/damaged

As “MAINS SUPPLY FAILURE” and recharge or replace batteries as appropriate.




Issue: Date:

- 23 -

9.2 TROUBLE SHOOTING CHART

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

DEIF MIQ96 MULTI- INSTRUMENTS ARE NOT READING VOLTAGE OR

POWER

VTs are not connected to the bus voltage

Close H.V. isolator Q7.

A MCB in the voltage measurement line has tripped

Close all MCBs from voltage transformers. If problem persists check for a wiring fault.

A high voltage fuse has blown Consult Depot that transformer was obtained from

A voltage transformer is damaged

Consult Depot that transformer was obtained from

A TRANSFORMER CONTINUALLY TRIPS OUT ON

OVER-TEMPERATURE

Transformer is supplying too much power

Reduce power

DGPT2 protection set point is too low

The excess temperature set-points 1 and 2

should be set to 80C and 85C respectively. Adjust the temperature set points on DGPT2 device accordingly. Refer to the DGPT2 user manual in appendix H.

Transformer has an internal fault


A TRANSFORMER CONTINUALLY TRIPS OUT ON

OVER-CURRENT

Transformer is supplying too much power

Reduce power

SPAJ 142 C protection relay is incorrectly set up

Re-programme SPAJ 142 C

Refer to the ABB SPAJ 142 C user manual in appendix I

A fault has occurred on the H.V. side of the transformer

Investigate power system for a fault. Check other protection devices.

OUTPUT VOLTAGE LEVEL IS

TOO HIGH OR TOO LOW

Input voltage level is incorrect Adjust generator voltage levels

Tap setting is incorrect Adjust tap setting. Refer to the transformer data sheet in appendix E.

Transformer has an internal fault


TRANSFORMER CIRCUIT BREAKER DOES NOT CLOSE

Closing spring is not tensioned Tension closing spring using handle provided

Closing spring is defective Consult Depot that transformer was obtained from




Issue: Date:

Appendix A - i

GENERAL ARRANGEMENT

AP

PE

ND

IX A




Issue: Date:

Appendix A - ii

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TRANSFORMER EQUIPMENT DATA SHEET

AND RATING PLATE

AP

PE

ND

IX B

Appendix B - ii

EQUIPMENT DATA SHEET

6.3MVA Transformer Container

No. G08.0173

Rev. E

Date May 2007

Page 1 of 2

1 Model Ref C20/6.3/../20kV

2 Part Number Ref 605004 & 605009*

3 Specification Ref TBA

4 Installation Drawing Ref D210474

5 Maximum Ambient °C (°F) 45 (113)

6 Electrical Rating 6300kVA, 0.8pf

7 Transformer

Manufacturer ABB / Pauwels

Type CTMU24 HA 3150 (ABB) /

TS 3150 (Pauwels)

Quantity 2

Rated Output 6300kVA (2 x 3150kVA) /

7500kVA ( 2x 3750kVA) with fans running.

Rated Voltages

Rated High Voltages -YNynO 20kV 10%

15kV (@max 2500kVA)

10kV 10%

- Dyn11 11.5kV 10%

5.7kV 10%

Rated Low Voltage 0.40kV

Type of Cooling 3150kVA ONAN /

3750kVA ONAF

Impedance (each transformer) 5.9%, 50Hz

No Load Losses (each transformer) 3400W, 50hz – ABB

3250W, 50Hz - Pauwels

Load Losses (each transformer) 32000W, 50Hz

8 LV Switchgear

Manufacturer Holec

Type QP2500N2

Number of Poles 4

Rating 2500A

9 HV Switchgear

Manufacturer ABB

Type SafePlus

Transformer Incomers 2 off SafePlus

Nominal Voltage 24kV

Nominal Current 630A

Breaking Current 12kV : 21kA

Technical Department – Dumbarton Approved by G Greene 09.05.07 / J A Casey 09.05.07

Appendix B - 3

EQUIPMENT DATA SHEET

6.3MVA Transformer Container

No. G08.0173

Rev. E

Date May 2007

Page 2 of 2

Making Current 12kV : 52.5kA

24kV : 40kA

HV Cable Feeders 2 off SafePlus

Nominal Voltage 24kV

Nominal Current 630A

Peak Withstand Current 12kV : 63kA

24kV : 50kA

Short time Withstand 12kV : 21kA

Current (3 sec) 24kV : 21kA

10 Electrical Terminations

LV M12

HV M12

11 Overall Dimensions

- Length Metres (feet) 6.06 (20’0”)

- Width Metres (feet) 2.44 (8’0”)

- Height Metres (feet) 2.59 (8’6”)

12 Weight Kg (lbs) 21000 (46297)

*Containers prefixed by -

XAAC – Non Stackable (605004) Design

XASP – Stackable (605009) Design

Appendix B - 4

09/12/99

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F I

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A I ST. Pll!irr l!EFLEtT

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CHECKED

Document No.. M02 0109

Document Title USER MANUAL

6.3 MVA Transformer

Issue H Date 14/05/2007

'

s 79

$ TRANSFORMER SET -$

Plant No, I I MaK.Al"lblent I s l'"C

Madel I C20/6.'.lJE/a:J I Ma.s:s: I lh'.g

Serial No.I I Nol"'llna.l Volta.ge I 20 lkV Nol"llno.l Power I 6.3 IHVA

Frequency O[]Hz LiL]Hz

Power Fa.ctor [];[] UL]

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Aggrl!'ka UK L-td

DuMbo.ri:on J U.K.

TeUJo. + 44 (0)1389 742214

..... F<1xJJo, + 44 (0)1389 742554 $




Issue: Date:

Appendix B - 5




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Issue: Date:

SCHEMATICS AND TERMINAL LAYOUT DRAWINGS

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Issue: Date:

Appendix E - i

TRANSFORMER LAYOUT DRAWING AND DATA SHEET

AP

PE

ND

IX E




Issue: Date:

Appendix E - ii




Issue: Date:

Appendix E - iii




Issue: Date:

Appendix F - i

ABB SAFEPLUS SWITCHBOARD USER MANUAL

AP

PE

ND

IX F

USER MANUAL FOR 20kV/6.3MVA TRANSFORMER CONTAINER Document …

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