INSTALLATION AND USER’S MANUAL

Installation and use

Manual
OIL TRANSFORMER

P .O Box : 42123 Ham riyah Free Zone

Sharjah, United Arab Em irates
Tel: +971 6 5261 116
Fax : +971 6 5261 114
M obile: +97156 7966 457
Em ail: info@eurogulftransform ers.com
W eb: w w w .eurogulftransform ers.com

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INSTALLATION AND USER’S MANUAL

INDEX

1. GENERAL 02
2. OUTLINE OF THE TRANSFORMER AND THE ACCESSORIES 04
3. STANDARD COMPONENTS AND ACCESSORIES 05
4. RECEPTION, HANDLING, STORAGE 08
4.1 Reception 08
4.2 Handling 08
4.3 Storage 11

5. INSTALLATION 11
5.1 Standard installation conditions 11
5.2 Ventilation 11
5.3 Insulating distances 13
5.4 Earthing connections 13
5.5 LV and HV connections 13
5.6 Regulation of transformation ratio 15
5.7 Parallel connection of transformers 12

6. TRANSFORMER PROTECTIONS 16

6.1 Over temperature protection 16

6.2 Overloading and short circuit protection 16
6.3 Protection against over voltages 17

7. COMMISSIONING 17

7.1 Mechanical checks before the commissioning 17

7.2 Electrical checks before the commissioning 18
7.3 Insulating fluid level 18
7.4 Arcing horns 19
7.5 Air dryer 19
7.6 Buchholz Relay 19
7.7 Thermometer 19
7.8 Integrated safety device 19
7.9 Operations for commissioning 20

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INSTALLATION AND USER’S MANUAL

1. GENERAL

This document aims to guide users on the properties of power and distribution transformers insulated
with mineral, silicone or vegetable oil.
Two types of transformers are considered:

• Hermetically sealed total filled ( Picture 01)

• Breathing with conservator (Picture 02)

Picture 01: Hermetically sealed total filled

Picture 02: Breathing with conservator

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2. OUTLINE OF THE TRANSFORMER AND THE ACCESSORIES

Picture 03.a: Transformer Outline LV side

Picture 03.b: Transformer Outline HV side

1. Lifting Lugs/Eyes 11. HV Bushings

2. Oil Temperature Indicator (OTI) 12. HV Cable Gland Plate
3. LV Bushing ( Monoblock) 13. LV Cable Gland Plate
4. Inspection Cover 14. Cooling Fin
5. Magnetic Oil Gauge (MOG)
6. Pressure Relief Valve (PRV)
7. Oil filling Plug
8. Thermometer Pocket
9. Off Circuit Tap Switch Caution Plate
10. Off Circuit Tap Switch
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3. STANDARD COMPONENTS AND ACCESSORIES

I. Rating plate (Picture 04)
II. HV porcelain bushing (Picture 06)
III. LV porcelain bushing/Monoblock (Picture 05
IV. Off-load tap-changer (Picture 10)
V. Lifting eyes (Picture 03.a)
VI. Thermometer pocket (Picture 3.b)
VII. Drain valve (Picture 9)
VIII. Magnetic oil Gauge (MOG) (Picture 11)
IX. HV and/or LV cable boxes (Picture 17 & 18)

Optional components and accessories:

I. Plug-in HV terminals
II. Thermometer, to install on the thermometer pocket
III. RIS or equivalent for hermetically sealed transformer
IV. Buchholz Relay for breathing transformer
V. Safety valve
VI. PT100 thermo-resistance (to install in the thermometer pocket)

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Picture 04: Transformer Rating Plate

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Picture 05: LV Bushing (Mono block) Picture 06: HV Bushing (Mono block)

Picture 07: Pressure Relief Valve (PRV) Picture 08; Oil Temperature Indicator (OTI) Picture 09; Oil Drain Valve

Picture 10: Off Circuit Tap Switch Picture 11: Magnetic Oil Gauge (MOG)

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4 RECEPTION, HANDLING, STORAGE

4.1 Reception
The transformer is generally supplied totally assembled and ready to be connected to the medium and
low voltage line.

According to the specification, the transformer is shipped with a polythene protection, or packed into
wooden cage, for protection against dust and little shocks, or finally packed into a wooden case for
over-sea shipments.

On receipt of the transformer, both at the client's plants or at site, it is necessary to carry out the
following checks:

 Check there are no signs of damage on the packing or on the transformer occurred during
the transport.
 The characteristics of the transformer detailed on the rating plate must correspond to those of
the shipping documents and with those of the test report, which is attached to the transformer.
 Check each transformer is complete with the accessories foreseen in the contract (wheels,
bushing, etc.).

IMPORTANT:
In case any a anomalies are found, please contact immediately to EUROGULF TRANSFORMER
FZE. If within 5 days there will be no notification of anomalies or defects, it can be considered that the
transformer has been delivered in perfect conditions. The manufacturer, therefore, cannot be
considered responsible neither for what could happen to the transformer during service nor for the
eventual consequences.

4.2 Handling

During the transport or the handling, it is recommended to use only the special lifting eyes and tow
attachments ((Picture 12 & 13).

IMPORTANT: The transformer cannot be moved pushing the cooling fins or radiators or tank.

Ropes must be arranged so as not to interfere with the radiators or cooling fins.
Lifting can be made using the appropriate hooks remembering to use ropes long enough so that H is
never less than L (Picture 12).
Always use all the existing hooks and not only one of them.

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Picture 12: Lifting transformer

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Example of handling

Picture 13: Handling by means of bridge crane and forklift truck

Picture 14: Manual handling

Picture 15: Wrong handling

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4.3 Storage

4.3.1 Transformer for indoor installation

The transformer must be stored in a sheltered, clean and dry ambient maintaining the packing up to the
installation.

4.3.2 Transformer for outdoor installation

The transformer may be stored outdoor until the installation time.

IMPORTANT: The storage temperature must not be lower than -15°C.

5 INSTALLATION

5.1 Standard installation conditions

The maximum height of installation must not exceed 1000 m above sea level.
When the transformer is in service, the ambient temperature of the room must be within the following
limits:
• Minimum temperature: -25°C
• Yearly average temperature: +20°C
• Monthly average temperature: +30°C
• Maximum temperature: + 40°C

In case the height of the place of installation and/or the ambient temperature values are higher than the
ones specified above, it is necessary to specify it at the ordering stage since a particular dimensioning of
the transformer depends upon these values.

5.2 Ventilation

The electric current passing through the windings and the effect of the core magnetizing current
produce electrical losses resulting in localized heating of the windings and core.
The transformer is designed in such a way that natural cooling maintains the transformer temperature
under the maximum values foreseen by the standards.
In order to avoid temperature accumulation in the room where the transformer is installed, it is
necessary to provide suitable ventilation.

Each EUROGULF make transformer is equipped with a thermometer pocket where a thermometer
with contacts may be installed (optional accessory).

The suggested values for setting the contacts are following (oil temperature):
Description Alarm °C Trip °C

Oil 80°C 90°C

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INSTALLATION AND USER’S MANUAL

Dimensioning of air louvers

 Natural cooling

In the room where the transformer is installed, it is necessary to install air louvers sufficient
to dissipate the heat generated by transformer during service, in order to guarantee the
standard service conditions and to prevent exceed the over temperature limits of the transformer.
Therefore the room must be provided with a louver on the lower part S, in order to guarantee an
appropriate fresh air flow; and a louver S’ on the upper part of the opposite wall, in order to
extract the hot air (Picture 16)

Picture 16: N a t u r a l cooling

In order not to obstruct cooling is necessary that the transformer is installed at a distance not less than
30 cm from the walls and not less than 60 cm from other transformers.

 Forced cooling

Forced cooling is necessary in the following cases:

• Frequent overloading
• Low-dimensioned room
• Room scarcely ventilated
• Medium daily temperature higher than 30°C.

The forced cooling can be realized by means of installation of air extractor located in the upper part
of the room controlled by a suitable thermostat or directly by a transformer thermal protection relay,
with a suggested flow of approx. 3.5 to 4 m3/min for each kW of total losses at 120 °C (if the losses are
at 75°C, they must be multiplied by 1.15).

ATTENTION: an insufficient air circulation, besides reducing the nominal life of the transformer,
causes over heating which, in the worst cases, can determine the intervention of the thermal protection
relay.

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5.3 Insulating distances

The transformer supplied for service without HV/LV cable-box must be installed in the room
respecting the insulating distances specified in the IEC standard (consult EUROGULF for detail).

The transformer, also with plug-in bushing, must be protected against direct contacts.

5.4 Earthing connections

EUROGULF is not responsible for the transformer installation. The installation must be carried out
according to the standards in force, to the applicable laws and to the present instructions.
The following points must be taken into consideration when the installation is carried out:

• Connect the earthing conductors to the relative earth points on the metallic parts of the
transformer and cable boxes.
• Connect the low voltage neutral to earth when required or when required by the protection
system to earth.

5.5 LV and HV connections

 Execution without cable boxes

Cables and the bus bars which are connected to the transformer must be duly fixed to avoid any
mechanical stress on LV and HV transformer terminals.
Both upper and bottom cable connections can be performed, being sure, however, to respect the
configuration showed in the drawings. In case the connections arrive from the bottom please ensure
that there is sufficient depth for the bending of the cables.

 Execution with cable boxes

Cables and/or the bus bars which are connected to the transformer must enter in the cable boxes
only through suitable flanges specified at the ordering stage.

IMPORTANT:

In any case the cables and/or the bus bars must be duly fixed outside the cable boxes to avoid any
mechanical stress on the LV and HV terminals of the transformer and also on the cable boxes. After
the installation please check the correct degree of protection is maintained near the passageway of the
cables and/or the bus bars.

HV cable box: cables coming only from the bottom

LV cable box: cables coming from the bottom or from the top

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Picture 17: H V ( 1 1 k V ) Cable coming from the bottom

Picture 18: L V ( 4 3 3 V ) a n d N e u t r a l Cable coming from the bottom

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5.6 Regulation of transformation ratio

The variation of the primary voltage is obtained by changing the position of the voltage off-loads tap-
changer located on the cover of the tank. Ensure always that the position of the tap-changer is properly
inserted and not in an intermediate position.
In case the primary voltage of the system does not correspond exactly to the voltage of the central tap, it
is necessary to modify the position of the tap duly positioning it on one of the other taps in order that the
secondary obtained is the no-load voltage shown on the rating plate.

Note:
At the time of shipping, the position of the voltage off-loads tap-changer are located on the central tap.

In case of transformers with double ratio, please be sure that the position corresponding to the voltage
of the system feeding the transformer is properly connected.

Note:
At the time of shipping, the position of the voltage off-load tap-changer are connected on the position
of the higher primary voltage.

Important:

 In case of transformers with double ratio, please be sure the tap corresponding to voltage of the
system feeding the transformer it-self, is duly connected.
 In case the position of the tap-changer has to be changed after the transformer has been put
into service the first time, it is recommended to put the transformer out of service and to connect
to ground the LV and HV circuits before approaching the transformer.

5.7 Parallel connection of transformers

If the transformer must be connected in parallel with other transformers, please verify the total
compatibility of the voltage ratio and of the conditions stated by the IEC 60076-1 standards, and
particularly:
• Identical voltage ratio
• Identical frequency of functioning
• Identical vector group
• Identical short circuit voltage (Tolerance ± 10%)
• The rated power (kVA) of the biggest transformer should not be larger than twice the
smallest transformer
• The LV connections must be the same length from the LV terminals (of two different units) to
the switch junction

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6 TRANSFORMER PROTECTIONS

6.1 Over temperature protection

The protection can be realized with:

 Thermometer (optional accessories)

 RIS or equivalent equipment (optional accessories for hermetically sealed transformer)

• The thermometer is generally installed in the thermometric pocket on the cover of the tank. The
thermometer may be equipped with two settable contacts, one for alarm, and the other for trip.
The suggested values are written at paragraph 5.2.

• The integrated safety device for hermetically sealed transformer (RIS or equivalent) provides:

 Two settable contacts for temperature, one for alarm and the other for trip. The suggested
values are written at paragraph 5.2.
 one settable trip contact for pressure (The suggested value is 0.3 bar)
 one trip contact for oil level

6.2 Overloading and short circuit protection

According to the parameters of the standards, the transformer is designed and manufactured in such a
way to withstand limited abnormal situation of over-voltages, overloading and short circuit. Therefore,
the transformer must be protected against thermal and dynamic effects caused by continuous
overloading and secondary short circuits by means of an automatic switch or suitable fuses, able to
disconnect the transformer in case of current flow higher than the one fixed by the protection.

The protections setting and/or the choice of fuses HV and LV side, must be carried out taking into
consideration the primary and secondary rated currents stated in the transformer rating plate, taking
also into consideration that when we feed the transformer, a very high magnetizing current is
established on the primary, by means of variable starting from a minimum of 10 times the rated
current (in the worst conditions of insertion depending from the instant when the feeding circuit is
closed, from the electric characteristics of the feeding network, from the reactance and resistance
values of the circuit network-transformer, the insertion current can reach also 20 times the rated
current), even if the automatic switch located on the secondary is open and therefore without loading.
Therefore, it is necessary to duly set the relay of maximum current HV side, in current and time value,
by introducing a little delay (approx. some tens of ms), in such a way that the protection relay will not
operate.

Furthermore, EUROGULF suggest limiting the number of connections and disconnection of the
transformer on the network.

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6.3 Protection against over voltages

In order to protect the transformers against over-voltages at industrial frequencies or the ones due to
atmospheric origin, it is recommended that voltage surge arrester with variable resistance are used.
The characteristics of the surge arresters depend on the transformer insulation level and from the
characteristics of the distribution system line.
It is recommended to install the surge arresters when the transformer is connected, directly or through a
short cable, to the main network

7 COMMISSIONING

7.1 Mechanical checks before the commissioning

• Check the earth connections

• Check of the insulating distance of the parts under voltage towards ground as shown at
paragraph 5.3
• Check the tightening of HV and LV terminals applying the following values of the
tightening torque.

Bushing

On the central conductor LV/HV in copper or brass

Bolts M8 M12 M20 M30x2 M42x3 M48x3 M55x3 M75x3

Torque 10 13 30 70 110 180 250 250

On the fixing stud screw HV insulators

Bolts M10 M12 M16

Torque 15 25 40

On the pinch bolts connecting flags

Bolts M10 M12 M16

Torque 25 40 90

Mechanical parts

Bolts M8 M10 M12 M14 M16 M18 M20 M22

Torque 20 45 75 125 190 275 385 530
N*
With torque wrench set in kgm, divide the values by 1

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7.2 Electrical checks before the commissioning

• Verify that the position of the tap-changer is inserted correctly. In case of double primary
voltages (Dual Ratio Transformer) , please check the feed to the transformer correspond to the
correct position.
• Check the correct functioning of the switches located as protection of the transformer on HV
and LV side.
• Check the correct setting and functioning of the overloading and short-circuit protection relay.
• Check the correct setting and functioning of the over-temperature protection relay and of the
thermometer.
• Check the functioning of the fans.
• Check the general conditions of the transformer and proceed with the measurement of the
insulating resistance (IR) by means of a Megger at 2500 V.

This measurement must be carried out with HV and LV terminals disconnected from the equipment, it
means before connecting the cables and/or the bus bars.
The values of the measured resistances must be approx. the following:

 HV terminals / LV terminals grounded ≥ 20 MΩ

 LV terminals / HV terminals grounded ≥ 10 MΩ
 HV terminals - LV terminals / ground terminal ≥ 10 MΩ

In case the measured values are lower, please contact EUROGULF after sale service.

ATTENTION:
In case a transformer is put into service after a long storage period, or after a long de-energised period, it
will be necessary:

 Clean the HV/LV bushings from eventual dust and condensation by means of dry compressed
air jets and dry cloth.
 if the transformer has been held in stock far more than six months in normal climates or far more
than a month in damp climates, check the dielectric strength of the insulating oil. Using the
procedure established by the IEC standard to check the dielectric strength of the insulating oil, if
the test is negative proceed to dry the dielectric oil of the transformer, otherwise contact
EUROGULF TRANSFORMER FZE.

It is recommended, finally, to carry out always a visual check of the transformer in order to verify any
unlikely presence on the surface the cooling ducts

7.3 Insulating fluid level

Check that the reading on the level indicator approximately correspond to ambient temperature
(transformer with conservator or RIS for hermetically sealed).
If the insulating fluid needs to be topped up, only fluid with the same characteristic and not
containing PCBs must be used and with the required dielectric strength.

IMPORTANT

The oil transformer must be topped up according to the manufacturers’ instruction

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7.4 Arcing horns

If the transformer is equipped with arcing horns, check that the position of the spark gap rods mounted
on HV porcelain bushings corresponds to the insulation class, as shown in the following chart.

Insulation Class A B
[kV] [mm] [mm]

12 ≥15 70

17.5 ≥15 90

24 ≥15 100

36 ≥15 200

Picture19: Arcing horns

7.5 Silica gel Breather

If the transformer is equipped with Silica gel Breather (transformer with conservator), check that the
salts of silica gel are orange/Blue. If they are neutral color, they have already picked up moisture and do
not fulfil their function as dehydrating air. It is necessary to remove the salts and regenerate the dryer by
placing them in an oven at 150°C until they are come back to orange/Blue color.

7.6 Buchholz Relay

If the transformer is equipped with Buchholz relay (transformer with conservator) to avoid
unnecessary activation, proceed carefully with the leaking operation of the relay, acting on the taps
(see instruction relay). If during commissioning or in the first hours of the energization the Buchholz
relay should signal the formation of gas, in small quantities, first to believe that there is a fault in the
transformer and repeat the leaking operation.

7.7 Thermometer

If the transformer is equipped with the thermometer (Oil temperature Indicator (OTI) and Winding
Temperature Indicator (WTI) check the threshold of the alarm and trips are set at the operating
conditions. The setting temperature is provided to the manufacturers in according to transformer type
and the insulation class.

7.8 Integrated safety device

If the transformer is equipped with the inte grated safety device (RIS or equivalent) check the setting of
the alarm and trip of the thermometer and the values of pressure shown are matched to operating
conditions. For more additional information, consult the operating manual supplied with the integrated
security device, you must be careful not to change the orientation fixing RIS or equivalent (the exact
position should be required before delivery).

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7.9 Operations for commissioning

• Closing of HV switch

When the switch is closed the transformer gives out a sharp noise, which decreases in few ms until it
stabilizes.

• Check of secondary voltages

Before closing the low voltage switch or make additional checks for parallel operation with other
transformers, it is necessary:
 Check by means of a voltmeter the proper value between each two phases and of the
three wye-connected voltage.
 Check the proper phases displacement and the correct vector group.

In case the values correspond to those stated in the rating plate, it is possible to proceed and complete
the commissioning or to carry out the checks for the parallel service.

• Run in parallel service with other transformer

In case the transformer has to run in parallel with another, it is also necessary:
 Check the compatibility of the rating plates of both transformers
 Verify the concordance of the phases by measuring the voltage between the phase "one"
of the transformer already in service and the phase "one" of the transformer to be
connectedin parallel by means of a voltmeter. The value of this result must be zero.
Continue in the same way for phase 2 and phase 3

• Closing of LV switch

Complete the commissioning of the transformer closing the LV switch.

IMPORTANT

We remind you that qualified technical personnel must carry out the operation, commissioning and
energization. Furthermore, during the voltage measurements and the phase displacement checks on the
upper terminals of the LV switches, you are recommended to use suitable instruments and suitable
insulating gauntlets.

For more accurate and complete checks, please contact our Assistance Service

Phone (+971)-065261116
Fax (+971)-065261114
E-Mail [email protected]

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