ET10412+O&M+MANUAL+ENGLISH_25.04.15

OPERATION & MAINTENANCE MANUAL

FOR

80 MVA, 220/13.8/6.9 kV

HV TRANSFORMER

CGL W.O. ET10412

CLIENT : Black & Veatch on behalf of Minera Escondida Ltd.

SUBSTATION : BHPB Escondida Water Supply Project

EQUIPMENT : HV POWER TRANSFORMER

ORIGINATED BY APPROVED BY DATE: 16/02/2015

CROMPTON GREAVES LTD.

TRANSFORMER (T1) DIVISION

MUMBAI 400 042, INDIA

Tel : 0091 22 67558200

Fax : 0091 22 67558307

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1

CROMPTON GREAVES LTD; POWER TRANSFORMER DIVISION (T1) : POWER SYSTEMS

Kanjur Marg (East), Mumbai 400 042, India

INDEX 1. Introduction

1.1. Purpose of O & M Manual

1.2. Instruction Guide – Guide to Important Drawings

1.3. General Safety Measures

1.3.1. Overview

1.3.2. Basic Safety Practice

1.3.3. Transformer Specific Safety Practice

1.4. Contact Details

1.5. Health, Safety and Environment considerations at site

2. General Transformer Features

2.1. Technical Characteristics

2.2. Mechanical Features

2.3. Transformer Grounding

2.3.1. Transformer Grounding

2.3.2. Temporary Grounding of Transformer Body

3. Packing, Transport, Handling & Storage

3.1. Packing

3.1.1. Overview

3.1.2. Packaging of transformer

3.1.3. Condenser bushings

3.1.4. Oil

3.1.5. Radiators

3.1.6. Fabricated Items

3.1.7. Control Cabinets

3.1.8. Instruments

3.1.9. Marking

3.2. Transport & Handling

3.2.1. Overview

3.2.2. Road Transport

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3.2.3. Rail Transport

3.2.4. Water Transport

3.2.5. Loading

3.2.6. Shipping Documents

3.3. Receiving Main Unit and Accessories

3.3.1. Checking Shipping & Consignment Documents

3.3.2. Unpacking & Inspection

3.3.3. Standard Receiving Tests

3.4. Storage of Main Unit and Accessories

3.4.1. Overview

3.4.2. Storage of Transformer

3.4.3. Storage of Accessories

3.4.4. Storage of Oil Drums

3.4.5. Periodic Inspection during Storage

3.5. Safety Measures during Transport, Handling and Storage

4. Assembling & Installation

4.1. Installation Equipments & Tools

4.2. General Installation Topics

4.3. Locating Transformer on a Plinth

4.3.1. Moving a Transformer on Wheels

4.3.2. Moving a Transformer on Steel Rods

4.4. Recommended Steps for Assembling & Installation

4.5. Installation of Transformer Main Unit

4.6. Installation of Radiators

4.7. Installation of Cooling Fans

4.8. Installation of Bushing Turrets

4.9. Installation of Condenser Bushings

4.10. Installation of Other Bushings

4.11. Installation of Conservator and Pipes

4.12. Installation of Current Transformers (CT’s)

4.13. Wiring on the Transformer

4.14. Installation of Other Items

4.14.1.Gaskets for Liquid Filled Transformers

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4.14.2.Breather Installation

4.14.3.OTI and WTI

4.14.4.PRD

4.14.5.Plate Valves and their Assemblies

4.15. Oil Filling Procedure

4.16. Do’s and Don’ts during Assembling and Installation

5. Pre-commissioning checks

5.1. Overview

5.2. General Guidelines

5.3. Mechanical Checks

5.3.1. Location on Foundation

5.3.2. Bushings and Terminal Connectors

5.3.3. Valves and Pipe-work

5.3.4. Radiators and Cooling Systems

5.3.5. Leak Test

5.4. Tests on Transformer and Accessories

5.4.1. Oil Sampling and Testing

5.4.2. Ratio, Polarity and Vector Group Test

5.4.3. Winding Resistance Measurement

5.4.4. Insulation Resistance (Meggar) test

5.4.5. Insulation Resistance Test

5.4.6. Measurement of Magnetising Current

5.4.7. Magnetic Balance Test

5.4.8. Power Factor Measurement (Tan-Delta) of Transformer Windings & Bushings

5.4.9. Tests on Auxiliary Instruments

5.4.10. Tests on Tap Changer

5.4.11. Checking of Fans and Pumps

5.4.12. Checking of Marshalling Box

5.4.13. Checking of Oil

5.4.14. SFRA Test

5.5. Instruments used for Pre - Commissioning Tests

5.6. Start Up Instructions

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6. Commissioning

6.1. Repeating Pre-Commissioning Checks

6.2. Operational System Tests

6.2.1. Relay Settings

6.2.2. Alarm Circuits and Contacts

6.2.3. Trip Circuit and Contacts

6.2.4. Temperature Settings

6.2.5. Rating of Pressure Relief Device

6.2.6. System Voltage, Frequency & Phase Sequence Check

6.2.7. Oil Sampling and Checking

6.3. Transformer Energization

6.3.1. Minimum Settling Time after Final Oil Filling

6.3.2. First Energization on No Load

6.3.3. Loading the Transformer

7. Maintenance

7.1. Introduction

7.2. Safety during Maintenance

7.3. Periodic Inspection and Checks during Service

7.3.1. External Cleaning

7.3.2. Transformer Body

7.3.3. Gaskets

7.3.4. Oil

7.3.5. Bushings

7.3.6. Conservator and Magnetic Oil Gauge

7.3.7. Tap Changer

7.3.8. Dehydrating Breather

7.3.9. Cooling System

7.3.10. Temperature Indicators

7.3.11. External Circuits and Control Equipment

7.3.12. Buchholtz Relay

7.3.13. Explosion Vent

7.4. Preventive Maintenance Inspection Chart

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8. Trouble shooting

8.1. Indication Signals of Malfunction or Abnormality

8.2. Trouble Shooting Chart

8.2.1. Trouble Shooting Flow

8.2.2. Trouble Shooting Flowchart for Abnormal level of Fault Gases

8.3. Trouble Shooting Process

8.4. Emergency Response for Unexpected Events

8.5. Energizing Transformer after Fault

9. End of life Disposal

9.1. Planning for disposal

9.2. Human safety

9.3. Environment safety

10. Transformer Drawings and Catalogue

10.1. Transformer Details

10.2. List of Approved drawings

10.3. List of Reference Drawings

10.4. Brochures for Accessories and Fittings

11. TMDS (SMART MONITOR)

11.1. Operation and Maintenance Manual

12. GAS GUARD

12.1. GAS-Guard Site Preparation Guide

12.2. GAS-Guard Installation Guide

12.3. GAS-Guard Operation and Maintenance Guide

12.4. GAS-Guard Software User's Manual

13. Neutral Grounding resistor / transformer

13.1. Installation And Maintenance Instructions

14. Oil discharge Instruction

14.1. Oil Discharge Procedure

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SECTION – 1

Introduction

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1.1 Purpose of O & M Manual Every product comes with a user manual and a transformer is no exception. The main purpose of this Operation and Maintenance manual (O&M manual) Is to educate and familiarize the end user about the product, its installation procedure, operating procedure and maintenance activities. 1.2 Instruction Guide – Guide to

important drawings All the relevant drawings including Outline general arrangement drawing (GA) etc. have been attached at the end of manual for ready reference. 1.3 General safety measures 1.3.1 Overview Being a high voltage product, safety to life and property is of utmost importance. Keeping this in mind, relevant caution and safety instructions have been provided at relevant places, the reason being that safety instructions specific to specific tasks have been covered at respective places. 1.3.2 Basic safety practice Every operator must have a safety program and he has to know how to use it in the event of an accident. Ensure that safety equipment and tools are always close at hand, and suitable fire extinguishing equipment and qualified personnel are available. Make sure that the equipment used is suitable for fire involving oil filled electrical installations. Make sure that it is correctly charged and that you know how to use it.

Always be alert to emergencies. If an accident should occur, quickly utilize the safety equipment, emergency tools and equipment at hand. Before you begin a project, ensure that at least two people know first aid procedures and that they have the proper first aid kits at hand. Ensure that all protective equipment required for the job is available to all workers and ensure that it is used correctly. This equipment may include helmets, breathing apparatus, eye protection, gloves, foot protection etc. Ensure that all electrical circuits to be worked on have been traced and de-energized. Ensure that all safety grounds have been correctly applied to protect personnel against the accidental application of power to these circuits (refer to chapter 2 for more information on temporary grounding.) DO NOT assume that someone else has turned off the power, check for yourself. Use the padlock and key interlock system where available to protect yourself and others. DO NOT work under equipment that is raised and insecurely blocked. DO NOT walk under equipment that is suspended from a crane. DO NOT walk holding a ladder or any other long object near a transformer or overhead lines under voltage. Before lifting any object by any means, ensure that its weight can be handled correctly. Use the appropriate lifting or handling tools. DO NOT work on or adjust moving equipment. DO NOT work on or adjust mechanical equipment unless its motive source has been deactivated.

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1.3.3 Transformer specific safety practice

DO NOT walk on a transformer or its parts unless the unit has been de-energized. DO NOT walk on a transformer under vacuum. Never perform any electrical tests on a transformer under vacuum. Do not apply vacuum when it is raining or when the transformer is unsupervised. When pressure tests are being performed or when vacuum is being applied, the pressure must be equalized between the main tank and the (On) Load Tap Changer compartment if these compartments are separated by terminal panels which might not be able to withstand pressure differences. Find out which parts will not be able to withstand a complete vacuum. Before removing any cover plate or transformer fitting, ensure that the overpressure inside the transformer is zero and that the oil level is lower than the opening in question. In the event of a sudden change in the weather bringing penetrating rain or snow, provisions must be made for closing the tank quickly and pressurizing it with dry air in order to preserve the insulation. To allow anyone entering a transformer the air has to support life with a sufficient oxygen level (19.5%). Extreme precautions are to be taken to protect the insulation of the transformer from any damage and to prevent the ingress of foreign objects and moisture during the checking and erection of the transformer. Whilst the transformer is open, no one may be allowed on top of it, unless this person has emptied his/her pockets, has checked himself/herself for the presence of objects such as watch, rings etc. and has removed them. These precautions

must be taken to prevent objects from falling into the transformer. Anyone going inside a transformer must wear clean clothes and clean synthetic-rubber boots. Never stand directly on any part of the insulation. Correct operation of all protective circuits and protective devices for the transformer should be checked on a regular basis. Neglecting of these circuits or devices, or overriding of the functions of these circuits or devices could allow minor problems to develop into a major problem. This may result in a total loss of the transformer, damage to other equipment and injury of personnel. A pressure relief device incorporates heavy spring in compression, DO NOT dismantles such a device, unless suitable safeguards have been implemented, otherwise personnel injury may occur. Recommended commissioning checks must be performed before the first energization of the transformer. 1.4 Contact details

Customer Services Dept. Crompton Greaves Ltd; Power Transformers division (T1) Kanjur Marg (East), Mumbai- 400042 Tel.: +91 22 6755 8000/25782451

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1.5 Health, Safety & Environment

considerations at site 1. In view of the hazards associated

while working with transformers all

personnel who work or support the

work must demonstrate a

responsible attitude.

2. The personnel working must

undergo orientation, of the HSE

requirements through the employer.

3. Categorization of Risk & Hazards

must be done before carrying out

related activity.

4. Prohibit entry where there is

potential Risks & Hazards.

5. Documentation of preventive actions

/ remedial actions in case of high

risk areas.

6. Storage of accessories (including

high risk material) as per guidelines

given in the Manual/MSDS.

7. Disposition of hazardous waste as

per guidelines given in MSDS.

8. Documentation for Permit To Work.

9. Inspection of tools/ tackles/

instruments and safety equipment

for suitability before start of work.

10. Review of Calibration status for

testing/measuring instruments.

11. Ensure Use of personnel protective

equipment like safety

harness/Safety shoes, Helmet

goggles.

12. Ensure personnel are not permitted

to enter confined spaces i.e spaces

which have the risk of encountering

hazardous conditions like fire,

fumes, and vapors, deficiency of

oxygen, drowning, and high

temperature.

13. Ensure use of weather proof hand

lamps, scaffolding, man lift, bucket

crane, crane, belts and ropes

wherever required.

14. Transformer Oil is capable of

catching fire ensure extinguishers

are available during work.

15. Use appropriate clothing

considering nature of work and

climatic condition at site.

16. Ensure availability of assistance in

case of emergency like first aid box,

details of nearest medical care

facilities.

17. Any other statutory requirements as

per customer or local authority to be

followed.

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SECTION - 2 General Transformer Features

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2.1. Technical characteristics

A transformer is essentially an electrical product. The technical characteristic which are of utmost importance are MVA rating, kV rating & impedance of the transformer. Please refer Rating & Diagram plate for details specific for the transformer. The other technical aspect is the insulation level for which the transformer is designed. The transformer being a tailor-made product, every transformer differs from any other transformer as far as electrical characteristics and features are concerned.

2.2. Mechanical features

By looking at the transformers around us, we find that majority of the transformers resemble each other. This tells us that though the electrical features may differ, mechanical features do not differ much. The point made here is that the transformer has a body (tank), and is mounted with accessories such as radiators, fans, breather, conservator, breather, Buscholz relay, bushings etc. as applicable. To know the mechanical features specific to the transformer, please refer General Arrangement (OGA) drawing along with the drawings of the accessories enclosed at the end of the manual.

2.3. Transformer grounding 2.3.1. Transformer grounding

Parts that are to be grounded are as shown in the figure 2.1. Please refer General arrangement drawing before proceeding. The generic items are as shown in the schematic and the corresponding parts are as follows:

1. Breather 2. Conservator and parts 3. Tap changer 4. Bushing 5. Cable box 6. Current transformer 7. Lightning arrester 8. Current transformer

9. Marshalling kiosk and OLTC Motor- drive unit 10. Oil-air cooler 11. Radiators and mounting structures 12. Fan 13. Oil-water cooler 14. Pump

2.3.2. Temporary grounding of transformer body Temporary groundings, used while personnel are working on de-energized transformers, must always be applied in accordance with the approved safety and operation practices issued by the employer. In addition, they must be in accordance with the instructions for the specific grounding equipment used. Temporary grounding is required for a number of reasons: · Induced voltage from adjacent energized lines. · Fault current feed-over from adjacent lines. · Lightning strikes anywhere on the circuit. · Switching equipment malfunction or human error. · Accident initiated contact with adjacent lines.

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Figure 2.1 Parts to be grounded

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SECTION – 3

Packing, Transport,

Handling and Storage

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3.1 Packing 3.1.1 Overview The main unit is dispatched oil filled or Dry air filled. The packing type depends on:

• Dimension/ Weight constraints during transportation and handling

• Customer specification

• Legal obligations concerning mode of transport The parts/accessories detached from main unit assembly for transportation are listed in the Outline drawing. These are transported separately in suitable crates. Preserve packing lists enclosed with each package to facilitate onsite check.

3.1.2 Packaging of Transformer

The transformer body is not packed (unless otherwise specified). Shock recorders are provided if specified. Bushings mounted on transformer during dispatch are guarded with transport hoods made of steel/wood. Valves fitted on main units are to be properly locked and protected by providing valve guards. All dismounted parts are packed separately (see below). 3.1.3 Condenser bushings Condenser bushings are packed in wooden crates, as per the OEM instruction.

3.1.4 Oil

• Oil filled Dispatch: Oil is transported filled in the transformer tank. Oil is filled to fully cover the core and winding assembly..

• Dry Air Filled Dispatch: Oil is packed in sealed-drums of standard size.

• Oil in Tanker/ container: Oil transported in clean oil tanks/ containers

• Flexi bags in Container: Oil can also be filled in flexi bags transported in containers.

3.1.5 Radiators Radiators are packed in crates. 3.1.6 Fabricated Items All fabricated items like headers, cooler pipes, conservators, cable boxes etc are packed in wooden cases.. 3.1.7 Control Cabinets

RTCC, Marshalling box and Thermo-Junction box are individually covered and packed in wooden case. Sometimes Marshalling box and Thermo –Junction box may be mounted on the main unit. 3.1.8 Instruments Instruments line Winding Temperature Indicator, Oil Temperature Indicator, Dissolved Gas Analyzer and relays etc are individually covered and packed in wooden case 3.1.9 Marking For ease of identification, fabricated items are punched marked.

a) Work Order Number (W.O. No.) b) Serial Number c) Item Number

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3.2 Transport & Handling 3.2.1 Overview In many cases, a transformer has to travel long distances before reaching its final destination. During this journey many handling operations are needed for loading, transportation, unloading and transfer to other carrier types. All necessary precautions need to be taken during transit to assure safe handling of the transformer. Transformers may be transported by road/ rail/ sea depending on size of transformer, destination, delivery time and the route limitations. Detached parts are packed/crated and normally dispatched along with the main body of the unit, so that all the parts are received at the destination station with the unit. During transportation, make sure that the Transformer body is blocked and secured on all sides. This should be done to prevent the Transformer body from shifting its position. 3.2.2 Road Transport Transport by road necessitates availability of good condition roads and route permit. Route survey to cover following aspects is to be done: (i) Width of road: Adequacy of passage at all

places. (ii) Bridges and Culverts: Adequacy to take the

moving load. (iii) Encumbrances En-route: Presence of

telephone, telegraph, traction and electric utility wires, subways etc across the roadway

(iv) Sharp bends (v) Road Worthiness: Check for road condition,

locality, presence of schools and other public places

(vi) Operational Constraints: Of Tractor-trailor Necessary clearance from local authorities, for movement shall be ensured.

3.2.3 Rail Transport Transformer is transported to loading railway station either by a rail network or road tractor-trailers. Rollers of transformer are removed before leaving works.

3.2.4 Water Transport

Ocean going ships for high seas and barges for inland navigation routes are used for water transportation. Special care is to be taken for prevention of rusting of parts and ingress of moisture like use of anti corrosive paints, silica gel packing, and sealing using polythene covers etc.

3.2.5 Loading

3.2.5.1 Lifting and Jacking Before lifting the complete transformer it should be ensured that all cover bolts are tightened. Use lifting points provided on the tank for the purpose of lifting. Simultaneous use should be made of all such lugs or lifting bollards in order to avoid any unbalance in lifting. It is advisable to use a spreader between slings so that the lift on the hooks is in the vertical direction. The slinging angle is not to exceed 60°. Safe loads of wire ropes and the multiplying factors to be used corresponding to the lifting angles are furnished in Fig. 1. When using jacking for lifting, only the Jacking pads provided for the purpose of jacking should be used. Jacks are also not to be left in position with load for a long time. The transformer should always be handled in the normal upright position. During the handling operation care must be taken to prevent overturning or uneven tilting. 3.2.5.2 Lashing The transformer is lashed on all four sides by wire ropes or chain of adequate size and Tightened using turn buckles with locking facility. Tightness of lashing is to be checked after short movement.

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3.2.6 Shipping Documents Contents, route, destination of each shipment, invoices of shipment, bills of loading etc and packing list accompanies the shipment.

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3.3 Receiving Main Unit and Accessories 3.3.1 Checking Shipping and Consignment

Documents On receiving the transformer unit, check the consignment against packing list enclosed. Also ensure all consignment documents including various bills etc are in order before proceeding further. 3.3.2 Unpacking and Inspection A thorough external examination shall be made immediately on arrival of the transformer at site. If any damage is suspected, open delivery is to be taken and a claim made against the carriers in accordance with the terms of contract. The manufacturers and under-writers are also to be informed about the details of inspection done jointly in carriers. Packages are to be opened carefully so that the tools used for opening do not cause damage to the contents. 3.3.2.1 External Inspection 1) Preliminary Inspection: Check for signs of damage on the exterior like damage to blocking, impact on covers, paint scraping etc. 2) Check of Impact Recorder An Impact recorder is installed if specified. The impact recorder shall be returned to the Manufacturer. Please refer the outline drawing for the locations

Type of Impact Levels of Acceleration

X-Axis 2g

Y-Axis 2g

Z-Axis 1.5g

The Manufacturer shall be consulted in case the acceleration is exceeding the above limits. 3) Check of Gas Pressure/ Oil leak Inspect the dry air pressure system (if given).

The gas pressure varies in proportion to gas temperature. Check the gas pressure upon arrival against gas pressure and temperature at the time of dispatch. Consult Manufacturer in case Main tank received with zero pressure. When the transformer is dispatched filled with oil, oil level in main tank at the time of receipt is to be verified visually through the dispatch oil gauge on the tank. Any shortage, theft or damage is to be duly recorded and reported to Carrier, Underwriters and manufacturer. 3.3.2.2 Inspection of Accessories Refer Packing list and check off each inspected accessory. Below checks important: 1) Oil Drums: Drums containing transformer oil, which have been dispatched separately, shall be examined carefully for leaks. All drums are dispatched filled up to their capacity and any shortage should be reported. 2) Bushings: Oil level shall be checked (in Condenser bushings). The porcelain portion is to be checked for any crack or chipping. The terminals should be checked for any bends. 3) Instruments: Fragile instruments like oil level gauge, temperature indicators, etc. are to be inspected for breakage or other damages. Any shortage, theft or damage is to be duly recorded and reported to Carrier, Underwriters and manufacturer.. 3.3.3 Standard Receiving Tests 1) Core Grounding Megger test Refer Section 5.4.4.2 The Core Frame and Tank Isolation should be verified upon receiving.

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3.4. Storage of main unit and accessories 3.4.1 Overview In case when the transformer is not immediately commissioned, ensure below guidelines for storage:

• Storage area should be adequate and should be easily accessible for inspection.

• The surface on which it is to be stored is strong and leveled.

• Surrounding area of storage place is not polluted and water does not accumulate in/around this area.

3.4.2 Storage of Transformer The preferred method of storage is to store transformer under oil with all the accessories fully installed. Heaters in the control cabinet should be connected to a power supply and energized to prevent condensation. The transformer main tank may be stored in Dry air for storage till six months. Storage in oil is advised for storage above to six months. While in storage, the gas pressure, oil samples, breather condition are to be checked frequently. Wherever feasible, the transformer should be fully assembled; vacuum filled with oil and made operation ready in case of storage is exceeding six months. 3.4.3 Storage of Accessories After receiving the accessories at site those should be inspected and kept ready for immediate erection. If erection work is not to be done immediately then those accessories should be repacked into their own crates properly and packing list should be retained. All packings should be kept above ground by suitable supports so as to allow free air flow underneath. The storage space area should be such that it is accessible for inspection, water does not collect on or around the area and handling/transport would be easy.

Also note the following points:

• Equipment meant for indoor use, such as control panels should be stored indoor

• All fragile material should be stored in a closed room.

• All openings should be blanked off with suitable blanking plates.

• Crate should be positioned as per markings on the crate.

• Do not stack crates one along the other except those for radiators. However, for radiators also maximum three crates could be stacked.

• Heaters for Control Cabinets, etc., shall be kept energized.

• Refer specific storage instructions given in respective leaflets for accessories. Those should be strictly followed.

• Refer Table-A for further details. 3.4.4 Storage of Oil Drums,if applicable

• Store drums containing oil either in a shed or covered with tarpaulin.

• The drums must be stored in a place free from fire and explosion hazards.

• Keep bungs tight. Protect the drums from weather and contact with water.

• Drums should not be stored standing on ends.

• Store drums horizontally with bungs at 45 deg. This will ensure that bungs are under a positive oil pressure

3.4.5 Periodic Inspection during Storage

During storage period the main unit and accessories should be inspected regularly as specified in Table-A. Observations, readings and dates should be noted in separate register. In case a fault or abnormality is observed, CGL should be contacted. Check at regular intervals especially when weather changes such as heavy rains storm etc.. Carry out periodic inspection for possible external fault/ damage rusting or leakages of main unit and accessories periodically. Condition of silica-gel on oil filled unit

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should be inspected periodically. Oil samples and should be tested periodically.

TABLE-A

Instructions for Storage of Accessories and Inspection During Storage

Sr. No.

Accessories Storage Position

Storage Location

Precaution Special Instruction

Inspection Checks

1. All condenser bushings

Into their

own crates

Protected from Rain

Cover with Tarpaulin

Refer Manual for Bushings

Physical damage

2. Porcelain bushings

and Pin/Post insulation

-do- -do- Physical damage

3. Radiators -do- -do- All openings must be blanked off

Damage and rust

4. Conservator (COPS) -do- -do- Damage and rust

5.

TJ box, Marshalling box (if supplied loose) and RTCC panel

Into their own

crates

Protected from Rain

Space heater should be connected to electric supply to be kept ON.

Space heaters ON. Should be free of dust and condensation

6. OLTC Drive Mechanism (if supplied loose)

-do- -do- -do- -do-

7. Buchholz Relay, MOG, Breather, Pressure relief device, Valves, Hardware items paint, Oil operated relays, small brackets. Clamps, pipes for bleed valves and other small items.

-do- -do- Refer respective Instruction Manual

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Sr. No.

Accessories Storage Position

Storage Location

Precaution Special Instruction

Inspection Checks

8. Pipe work Uncrated Protected from Rain

-do- Physical damage

9. Fan assembly & Pumps -do- -do- Refer

respective Instruction Manual

10. Air insulated cable boxes/ disconnection chambers

-do- -do- Physical damage

11. Gaskets In its own crate

Into a closed room

Store in stress free condition. Do not fold. Do not roll

Physical damage

12. Oil drums No crates Oil leakage Physical damage

Ga

ug

e P

ressu

re –

kG

/CM

2

10

TEMPERATURE IN °°°°C.

EXAMPLE :

- 30

- 0.05

- 10- 20 0

1.5

1

3.5

3

2.5

2

0.50.05

0

0.1

0.2

0.15

0.25

5

lb/ in2

4.5

40.3

0.35

503020 40

PER M ISSIBLE

RANGE

GRA PH SHOW ING V A RIA TION OF PRESSURE V /STEM PERA TURE OF GA S FOR GA S FILLED UNITDURING TRA NSPORT OR STORA GE

FO R 40°CTEMPERATURE(DEPENDING UPONTHE PRESSURE OFG AS AT THE TIME OFFILLING

---M INIM UMPRESSURE O F G ASCAN BE 0.185KG/CM

2

AT PO INT A1.M AXIM UMPRESSURE O F G ASCAN BE 0.32 KG /CM

2

AT PO INT A2.

A2

A1

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3.5 Safety measures during transport, handling and storage

Safety measures/precautions should be given the due importance during transport/ handling/ inspection/ storage. Any mishap during the process will result in delay in erection, endangering human life, endangering equipment life.

• Ensure that the transformer is evacuated and purged with breathable air. Ensure minimum 25% oxygen level in air before allowing personnel entry. Continuously purge dry air through the tank.

• Follow warning and precautions stated on accessories

• Earth the transformer tank for the period of mounting works

• Before entering the tank, make sure there is air inside. Also take appropriate measures to secure air during work.

• When transporting or carrying the tank, use equipment corresponding to the lifting weight.

• When lifting parts, lift them leveled. Attach guide ropes so that they do not hit surrounding objects.

• Never leave the secondary circuit of Current Transformer open.

• When connecting conductive parts inside the transformer, tighten them with specified torque.

• Do not loosen bolts that maintain oil tightness.

• Do not leave tools/ screws etc inside the tank

• Close the inspection holes and other openings immediately after work inside the transformer finishes preventing moisture ingress.

45°

OIL DRUMS

AIR RELEASE HOLE

OIL FILTER HOLE

FLOOR

STORAGE OF OIL DRUMS, IF APPLICABLE

1



SECTION – 4

Assembling & Installation

2



4.1 Installation equipment & tools

1) 1/2 Nos. mobile crane having a free vertical lift suitable for lifting HV bushing and lifting capacity 3 tones each.

2) Steel/Manila/Nylon ropes and ‘D’ shackles for lifting 3 tones weight.

3) Filter machine of capacity 6000 liters per hour or more in excellent working condition. It must be capable of heating transformer oil upto 80°C (heating should be indirect) and must be equipped with in-built high vacuum degassing chamber filter elements. The following accessories should also be provided. a) Non-collapsible hose pipes of adequate length and size provided with

nipples/adapters.

Hose pipes should be of oil resistant material, natural rubber should not be used. b) 3 Nos. flanges each of sizes 25, 50 & 80 mm pipe suitably threaded for connecting

the hose pipes and provided with holes for fastening on main unit valves. c) The incoming electricity supply capacity must be adequate to operate the

machine with all its heaters ‘ON’.

4) Vacuum pump of capacity 1500-2500 LPM with booster of 60-900 cub-m/hour and capable of an ultimate vacuum of 1 x 10

-3 milli-bar, along with the following accessories :

a) Non-collapsible hoses with suitable flanges for connecting to main tank.

b) Condenser for condensation of moisture.

c) MacLeod gauge for measuring up to 10

-3 milli-bar vacuum to confirm efficiency of

vacuum pump.

5) Storage tank for transformer oil of adequate capacity provided with 50 mm bottom drain-cum-filter valve and another 50 mm top valve. The tank should have an air tight inspection cover at the top and must be provided with a breather and oil level sight windows. Tank must be painted with oil resistant paint from inside and must be cleaned thoroughly before storing the oil. Capacity of the storage tank should be equal to the total oil quantity of complete unit.

6) Tarpaulin for covering main unit during filtration.

7) Adequate number of aluminum trays for salvaging oil leakages while connection of pipes.

8) 2 complete sets of fixed ended spanners metric sizes 4-36.

9) 2 complete sets of ring ended spanners metric sizes 4 to 36.

10) 1 complete set of Allen keys.

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11) Set of screw drivers, centering tummies, flat ended tummies, pipe wrenches, pliers, hammers, ladders, hole punches and other tools normally required for such work.

12) 6 mm thk 3 ply nylon ropes of 15 meters length.

13) Oil test set in good working condition having 2.5 mm gauges for adjusting the sphere gap.

14) 2.5/5 kV megger, preferably motor driven and capable of reading up to 50,000 meg. ohms.

15) 500 volt megger, hand driven, capable of reading up to at least 50 meg. ohms. OR digital testers with adjustable voltage

16) 2 Nos. multimeters, preferably digital type having the following ranges :

AC voltage:0 - 2.5, 0 - 25, 0 - 100, 0 - 250, & 0 - 1000 AC current:0 - 100 mA, 0 - 1A, 0 - 10A

17) Single/3 phase supply with DP ICTPN switches.

18) 2.5 mm single core copper leads (approximately 30 meters).

19) 3 litres of Surface cleaning agent..

20) Muslin cloth and waste cloth in sufficient quantities, as may be required at site.

21) Hot air blower for drying porcelain bushings.

22) Vacuum Hose pipes for oil connections should be of oil resistant material. Natural rubber should not be used. Should withstand full vacuum. Necessary adapters for connecting to filter machine outlet; filter m/c inlet, filter valves on main unit, Buchholz relay pipe, oil filling pipe on conservator etc.

23) Instruments for checking humidity

24) Adequate length of 10 mm I/D PVC pipe suitable for vacuum with suitable adapters for connecting this pipe to std. 25 mm or 50 mm flanged valves.

25) Pulling winches/pulleys

26) Steel ropes

27) Steel plates

28) Grease

29) Wooden sleepers.

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30) Hydraulic/mechanical screw jacks with locking arrangement capacity of each should be minimum 50% of the total weight of main unit with oil.

31) Power pack system to operate all the jacks simultaneously.

32) Measure tapes.

33) Level bottle/Level tube (plastic).

34) Stainless steel bottles for oil samples.

35) Dry Air generator or cylinders with regulator and pressure gauges.

36) Welding machine (for attending damages of Fabricated parts if required.)

37) Gas cylinders with nozzles. Torch for gas cutting ox Acetele (for attending damages of Fabricated parts if required.)

38) Pressure/vacuum equalization pipes and valves

39) Adapters : 80 mm to 25 mm - 3 nos. each 80 mm to 50 mm - 3 nos. each

50 mm to 25 mm - 3 nos. each

40) Valves: 25 mm flanged type with position indicators and locking devices. 50 mm flanged type with position indicators and locking devices.

41) Adapters suitable for valve and pressure gauge.

42) Bushing lifting equipments as specified in the instructions on bushings.

43) Capsule vacuum gauge range 0-50 mbar with least count of 1 mbar.

44) Tube: 5I/D transparent tube to use as oil gauge shall be capable of withstanding full vacuum.

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4.2 General installation topics Although power transformers are designed and manufactured to National or International Standards, every transformer ends up being designed for a specific site, as well as for a specific electrical network. Hence they usually are of a completely unique design. For this reason, every transformer installation is a unique event as well. People involved in the installation have to study the specific design and have to use their experience alongwith this Operation and Maintenance (O&M) manual for the installation. A well-prepared installation is the first condition to make it a successful event. Furthermore the installation of a transformer requires specialized equipment as well as services. These services may be sourced internal in your organization or may be sourced from the service department of CGL. Accurate scheduling is required in order to make efficient use of these sources. We assume in below text that the transformer is correctly positioned on its foundation according to the instructions in the previous chapter and that all necessary transformer components and accessories are available for installation. 4.3 locating transformer on a plinth The instructions below are meant as a guideline to position a transformer on plinth and its accessories safely and with a minimum of risk for damages. 4.3.1 Moving a transformer on wheels Transformers supplied with wheels can be moved in directions at right angles to the tank base. Usually these movements are executed on ground level on special tracks Assembling the wheels:

• Jack up the transformer.Raise the transformer the height required just to install the rollers. Block the transformer with suitable timbers or support blocks (for safety purposes) placed near the jacking steps under the lateral skids or stiffeners.

• Attach the wheels to the mounting pads located under the tank using the necessary four bolts (a

center bolt may also be provided to easily turn the rollers by 900 on itself). The wheels are quite heavy. Therefore, the smaller the distance they have to be lifted, the easier the installation will be.

• Once the wheels have been attached, use the jacks to raise the transformer just enough to remove the blocking.

• Gently lower the transformer until it is resting on the rollers.

• The transformer may be now rolled into position. Moving at right angles

• Place a jack under each of the jacking steps, and ensure that the surface under the jacks is solid and suitable for the weight to be lifted. Raise the transformer the height required just to clear the rollers above the ground. Block both ends of the transformer by placing suitable timbers or support blocks (for safety purposes) placed near the jacking steps under the lateral skids or stiffeners.

• Unbolt each roller and turn 90deg. Bolt each roller into the new position using all available bolts.

• Raise the transformer slightly, and remove the blocking.

• Lower the transformer gently until it is resting on the rollers.

• The transformer may now be moved in the new direction.

• To remove the wheels, Follow the guidelines to assemble the wheels in opposite order.

4.3.2 Moving a transformer on steel rods A transformer is moved by "skidding" whenever lifting and moving by crane is impossible or unpractical. Transformers with a skid base are made to be skidded in directions at right angles to the tank base using steel rods. Transformers with a flat base can be moved in any direction. The estimated force to start horizontal movement is 15-20% of the weight to be moved.

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Steel rods must all be the same diameter, evenly and closely spaced. Refer to the table below for the minimum required number of rods in relation to the weight being moved.

• Use at least three sets of rods side by side. The rods must be of sufficient width to suit the transformer being moved. Do not use a single row or two rows of rods.

• Rods are preferably iron-pipe profiles, double extra strong IPS pipe.

• If rods are to be used with timbers, the timbers must be steel faced. Each set of rods must have its own set of timbers.

Table NO. Minimum number of rods required per set under the transformer

Remarks:

• The table above assumes the use of 3 – 300 mm (3 - 12 inch) wide steel faced timbers

• The table above gives the number of rods per set under the transformer. Different steps in moving a transformer on steel rods:

• The first step is to prepare the route for moving the transformer:

• The truck bed, the railcar deck or the transfer car bed must be jacked up and blocked so that it is level and firm.

• Ensure that the supporting surfaces are firm enough to support the weight of the transformer

• Assemble the necessary tools (such as jacks, "tow and drag" winches etc...), support blocks, rods, greased turning plates or greased skids etc…, required for all events of the movement.

• Connect appropriately sized cables to the haulage eyes located near the transformer base. Only pull a transformer by the correct attachment points. Haulage eyes are mentioned on the general arrangement drawing. Utilize a spreader bar if required to limit the strain on the haulage eyes.

• Raise the transformer using four hydraulic jacks. Place the rods on the steel faced timber (or on the rails in the event of using a transfer cart with embedded rails) and roll them under the transformer. The longitudinal skid members serve as stops for positioning the rollers. When all of the rollers are in place, carefully lower the transformer onto them.

• Move the transformer into the next position. Once the transformer is situated on its foundation:

• Remove the haulage cables.

• Jack the transformer to remove timbers and/or rollers from under the transformer.

• Set the transformer onto its foundation. 4.4 Recommended steps for assembling & installation Below sequence is recommended during installation and energization of transformer though the steps followed depend on the situation and are different from case to case. 1. Installation and preparation of the transformer tank 2. Inspection of availability of all parts and equipment 3. Installation of main accessories:-Conservator,

radiators, pipes, pumps, bushing turrets and bushings. When all metal parts have been installed the risk for damaging bushings while installing these parts is minimized.

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4. Cable boxes 5. Oil treatment (if necessary) 6. Vacuum processing and initial oil filling 7. Topping up the oil 8. Installation of remaining accessories: fans,

measurement devices, control cabinets, wiring on the transformer. When the transformer has been completely filled there is no more risk to spill any oil on electrical accessories.

9. Pre-operational tests and checks. 4.5 Installation of transformer main unit Once transformer has been located on the plinth, ground the transformer tank before proceeding for the installation of accessories. To install certain accessories, the transformer tank will have to be opened. Depending on the specific shipping or storage conditions:

• Oil has to be (partially) drained and the removed oil has to be stored in dry and clean containers.

• Inert gas has to be replaced with breathable dry gas.

• Try to open only one manhole or hand hole at a time to prevent cross breathing of the tank (which lets in moisture) while opening a transformer. OR Open two covers and pass dry air through the transformer.

• Do not open a transformer if bad weather threatens, and try not to open the tank during periods of high humidity. Temporary weather shields may be necessary as a last resort.

• Besides following the above measures, always limit the exposure time of core and windings to 24 hours. This is the total allowable time the active part may be exposed to atmospheric conditions. If exposure time exceeds 24 hours, the vacuum pulling process has to be extended.

4.6 Installation of radiators Every transformer uses custom designed radiator assemblies to provide proper cooling for the specific design. The transformer might be shipped:

• completely assembled including radiators: no special installation or filling is required

•when partially filled with oil: the radiators have to be filled with oil by the transformer tank one by one. Note that small amounts of oil may leak out of closed throttle valves, make sure that an oil can is placed underneath the throttle valves. Connect the radiators as soon as possible.

• with an inert gas and without any oil: the radiators should be filled during the vacuum filling process of the main tank. Refer Figure 4.1 for radiator assembly. In case, there are separately mounted radiators, please refer OGA drawing to find out the location of ‘A’ frame on which radiators are to be mounted. 4.7 Installation of cooling fans If the transformer has air cooling then, cooling fans are mounted once the radiators are installed. Please note that if unit coolers are used, then the main unit does not have radiators nor any fans. There is one consolidated unit of radiator fins and fans called unit cooler. Each unit cooler has pumps to be mounted separately So, if main unit has unit coolers, then radiators, fans and pumps are not mounted but unit coolers are installed directly on the unit. In this case, please refer OGA drawing to ascertain the location of the unit coolers. Cooling fans are used where additional forced air capacities or up ratings have been specified. Their operation is automatically controlled by temperature measurement devices (manual control is possible). When the oil temperature or winding temperature reaches the temperature setting, it switches the fans on. The fan units are usually attached to the radiators, but may sometimes be mounted on brackets affixed to the main tank. We refer to the General Arrangement drawing for more details on the amount of fans used, the type and mounting positions

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4.7.1 Mounting instructions 1. Unpack the fans and check them for damage. 2. Mechanically mount the fans on the radiators or on the brackets. If anti-vibration pads are used, careful stress-free mounting is required to prevent overstressing during operation. 3. Connect the fans to a temporary power supply and check for abnormal vibration. 4. Wire or plug the fans into the appropriate junction box and check for the right air flow. Correct direction of fan rotation is given with an arrow on the fan housing. 5. Remove drain plugs from the holes in the fan motors to allow condensation to escape. A typical fan mounting arrangement is shown in Figure 4.2 4.8 Installation of bushing turrets Due to shipping size restrictions, it may have been necessary to remove the bushing turrets from the transformer during transportation. These compartments are dismantled as an assembly and blind flanged. If there are CT’s in the turrets the same are to be inspected to ensure free of damage before installation of turret. For transformers shipped without oil it is important to open only a minimum number of compartments on the transformer at the same time in order to minimize exposure time of core and windings. Therefore remove blanking plates one by one and install one bushing turret at a time. 4.9 Installation of condenser bushings Condenser type bushings incorporate a capacitive voltage grading system to carefully control the electric field inside the bushing. This allows a minimum partial discharge design that is very important in many applications, especially when voltage ratings increase. Most condenser bushings are oil-filled and the internal parts are oil impregnated. Condenser bushings often incorporate a capacitive tap, where the final capacitive foil (the ground layer) is brought out through a special test tap. This test tap may be used for monitoring purposes as well as for testing the bushing. The test

tap must be directly grounded or fixed to the ground over the monitoring device Before proceeding with the installation of bushing, please keep the bushing drawing handy. Check the General Arrangement drawing to find out Which bushing type is used. Also find out how the lead connection is to be made. This is different for different bushings. The connection for draw-lead type bushing differs from that of draw-rod type of bushing. Some of the bushings may come with a corona shield that is usually manufactured from spun aluminum and is quite delicate. The shield must not be bended. The coronal shields are usually shipped separate from the bushings, in well-padded packaging. Ensure that the shield is properly attached to the bushing and all mounting bolts are tightened prior to installing the bushing. For mounting purposes, please follow the steps as listed below: 1. Unpack the bushing keeping it tilted with the top side higher than the bottom side to avoid air bubbles penetrating the insulation at the bottom. 2. Check the bushing carefully (for oil leaks as well). Check the center tube and remove the plastic sealing plugs if present. 3. Remove the outer terminal cap on the top of the bushing. 4. Clean the porcelain using clean rags. 5. If the terminals are dirty, clean them with clean, dry rags.. 6. Remove the blind flange on the transformer tank (cover), pull out the draw lead and check for damage, remove the shipping gasket and clean the gasket surface. 7. Sling the bushing at the correct angle according to Figure 4.3 9. Attach a strong cord or wire to the terminal stud and pull it through the central tube of the bushing. 10. Slowly draw the draw lead cable in the bushing while the bushing is placed into position. Fix the bushing flange into position and mount the upper terminal stud and cap (refer to the specific documentation for the bushing).

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11. Tighten the top terminal arrangement and the flange bolts with the correct torque according to the specific documentation.

12. Ground the bushing for personnel safety as well as to ensure that the transformer will not be damaged due to lightning.

4.10 Installation of other bushings These bushings are low-voltage bushings are normally of oil – communicating type. If the transformer main unit is already pre-installed with the bushing, just check the bushing physically for any damages in the transit. Otherwise, follow the same steps to mount the bushings in similar fashion. 4.11 Installation of conservator and pipes 1. Unpack all components, check them and clean all

gasket surfaces. 2. Mount the conservator support(s). 3. Mount the conservator on its supports (bolts are

not to be tightened at this time). 4. Mount the oil pipes on the cover, including new

gaskets (bolts are not to be tightened at this time): The oil connection between tank and conservator. The oil connection between bushing turrets and the oil pipe (if any). The oil connection between the tap changer head and its conservator. 5. Mount the vertical oil pipes and their components including new gaskets (bolts are not to be tightened at this time): The oil drain valve(s) (LTC and main conservator). The pipe to the silica gel breather and the breather itself. If all components are in place, tighten the bolts on the pipe connections in the same sequence as you have mounted them. Then tighten the bolts on the conservator support(s). If the oil (vacuum) filling process cannot follow immediately, insert dry air or nitrogen (dew point < - 510C) into the transformer and keep a slight positive pressure (± 0.2 bar) to prevent moisture ingress. Refer Figure 4.4 before installation of Conservator & pipes.

4.12 Installation of current transformers Turret mounted current transformers are installed along with the installation of bushings and turrets. However, for the CT details refer the Rating and Diagram Plate Drawing.. In case of outdoor current transformer, kindly consult appropriate drawing to understand the arrangement. 4.13 Wiring on the transformer The wiring on the transformer is always completed and checked during assembly in the factory. However, the connection between transformer and remote control cabinets is only made as a temporary base for testing. During disassembly for shipment of the transformer, some parts with an electrical connection must be disconnected. This will result in free cable-ends (or free plug-ends) that can be situated on the dismantled part or on the transformer. Free cable ends will be coiled and protected by plastic bags or another protection and tied to the transformer tank or assemblies. The wires of free cable-ends are marked with the same terminal number as the terminal to which they have to be connected during the final wiring on site. Current transformer circuits have been short-circuited before and during transportation for safety purposes. This short circuit wire has to be removed at the time of final wiring and/or testing. 4.13.1 Mounting instructions After mechanical installation of the parts that are to be electrically connected: 1. Remove the protection on the cable-end and check the wire marking with the wiring diagram. 2. Clean wire ends (and contact-pins of cable plugs, if any). 3. Fix the cable in the cable channel. 4. Introduce the cable into the cable gland. 5. Check with the wiring diagram. 6. Connect the wires to the right terminal. 7. Tighten the cable gland.

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Once again, make sure that the right connection has been established. 4.14 Installation of other items 4.14.1 Gaskets for Liquid Filled Transformers: The gaskets used on our liquid filled transformers are flat Synthetic Resin Bonded Cork or Flat Nitrile or Nitrile ‘O’ rings. All are suitable for sealing oil, water and gases. Gaskets are of two types, retained and non retained. The retained gasket is preferred for cantilever loads and where dimensional tolerances must be held. The gasket stop assures the correct compression of the gasket, the proper dimensional positioning of the mating parts and a uniform pressure over the entire surface of the gaskets. Non-retained or flat gaskets are normally full width gaskets with the bolting holes equal distance from the edges of the gasket. Non-retained gaskets should be uniformly compressed. The recommended compression for the various gasket materials is: Synthetic Resin Bonded Cork 43% Compression, Nitrile Rubber 33% Compression Gasket Installation: The gasket surfaces must be thoroughly clean. Remove all oil grease, varnish, old gasket cement, dust and dirt by scraping surface and wiping out with a cloth wetted with a solvent. Cut the gasket to conform to the surfaces to be sealed. If the gasket is not a one piece gasket, scarf the ends of the gasket so that the length of the overlap will be equal to four times the thickness of the gasket material. The mitering should be done with a fine toothed saw and a miter box to assure a clean uniform cut and to obtain full gasket thickness at the lap joint. Dovetail joints may have been used at the factory. A special tool is required to make this joint. A scarf joint may be used if this tool is not available. ‘O’ Rings: Clean the groove and then apply a very small amount of Grease at the top of the groove, before applying the ‘O’ ring.

Usage: Prior to replacing a cover of an inspection opening, the gasket should be examined to make certain that it has not been damaged and that it has sufficient thickness to reseal the joint. 4.14.2 Breather installation Breathers are dispatched loose. Assemble them as shown in Outline drawing. Check oil seal if necessary fill oil up to the level marked in oil cup. Also ensure breathing hole in oil cup is not obstructed. Check color of silica gel. Color (when dry) is BLUE, changes to PINK (with moisture)

OR Color (When dry) is ORANGE, changes to COLORLESS (with moisture) 4.14.3 OTI and WTI The Bulbs of these Instruments should be fitted on thermometer pockets welded to cover or on main oil outlet pipes of tank top. Before mounting the bulbs, thermometer pockets must be cleaned from inside and transformer oil must be filled up to half depth of the pocket. Precaution should be taken so that capillary tubing is not damaged, pulled or stressed for routing and supporting the capillary tube. Oil must be filled into all thermometer/RTD pockets wherever those are specified. 4.14.4 PRD

Pressure Relief Device (PRD):

a) Mount PRD as per leaflet of PRD and as shown in Outline drawing.

b) Check contact operation 4.14.5 Plate valves and their assemblies Radiator isolating valves are plate type. Fix these valves to tank as per Figure 4.5

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4.15 Oil filling procedure i) Erection Sequence:

Complete all erection work except those requiring opening of Main Unit. Radiators and Conservator mounting should be completed. ii) Planning & arranging facilities:

Make all necessary arrangements for oil filtration, evacuation, etc. so that once the bushings erection is completed, evacuation and oil filling will follow immediately.

iii) Controlling exposure:

Erect the bushings and complete the main Buscholz relay piping. Transformer exposure time should not exceed 12 hrs. It is advisable to start erection early in the morning on a day when rain is not forecast. It is good practice to inject dry air through one of the opening in order to reduce ingress of ambient air during installation.

iv) Immediate evacuation:

Drain oil to the level required for erection of bushings. As soon as bushing erection is complete, start evacuating the main unit. For this, it is necessary to keep the vacuum pump connected to the main unit in advance. Also, the efficiency of the vacuum pump should be checked in advance and necessary maintenance carried out before the bushing erection. Ensure Main tank and OLTC chamber are equalized prior to application of vacuum.

v) Concentrate on potential leak points:

There is a possibility of excess leakage of air through the various gasketted joints, through the drain plug/air release plug of radiators, the bushing air release plug and cap.

vi) Ascertaining Leak rate under vacuum:

Create vacuum of 70 millibar inside the tank and hold the vacuum by shutting the valve between tank and vacuum hose. Note down

the vacuum and calculate the leak rate as per formula given below:

Change in pressure (millibar)

Leak rate = ---------------------------------------- x Vol.ltrs. Time in seconds

The leak rate observed at various points of time should not exceed the limits given below:

Time in Hours Allowable Leak Rate MBAR Liter/Sec ------------------- --------------------------

After 1st hour 100

End of 3rd hour to end of 4th hr 75

End of 7th hour to end of 8th hr 50

End of 11th hour to end of 12th hr 25

If the leak rate is high, it indicates that there is excessive leakage. Then all gasketted joints should be attended to.

As soon as 25 millibar-litre/second leak rate is achieved, pull vacuum further to achieve 1.3 millibar or less. vii) Oil filling up to tank oil level gauge: Transformer shall be filled under 1.3 mbar vacuum with purified and degassed oil through top filter valve up to tank oil level gauge. Estimate time required for oil filling to enable reduce the oil filling rate in last half hour. The oil filling rate shall be less than 6 kilolitres per hour. The temperature at the filter outlet shall be

maintained below 65°C. As soon as oil level mark on tank oil gauge is reached, close top filter valve, switch off vacuum pump and break vacuum through breather by opening the valve. Refer Figure 4.6

viii) Hot oil circulation:

Connect bottom filter valve of tank to inlet point of filter machine. Connect top filter valve of tank to outlet of vacuum filter machine and start oil circulation. The filter outlet temperature should be

limited to 65°C. Continue filtration for two passes. Refer Figure 4.7

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Drain out oil as quickly as possible after oil circulation, if possible, use a pump to avoid excessive drop in temperature of the transformer.

ix) Creating vacuum and maintaining:

Refer Figure 4.6 Pull vacuum 1.3 mbar or less. Maintain 1.3 millibar or less vacuum as given below :

System voltage Duration in hours ------------------- ----------------------

Upto and including 145 kV 24

Above 145 kV & including 245 kV 24

Above 245 kV & including 420 kV 36

x) Oil filling under vacuum:

Fill oil upto tank oil level gauge as described in (viii.).

Measure dielectric absorption factor using 1 or 2 kV meggar and/or tan delta as given below:

Resistance at 60 seconds

Dielectric absorption factor = ------------------------------ Resistance at 10 seconds

Above value shall be at least 1.3. or Measure tan delta using 30 volts source.

Tan delta shall be max. 0.5 % at 20°C.

If the temperature at the time of measurement is

higher than 20°C then extrapolate the value.

If the above values are not within limits, repeat hot oil circulation vacuum and oil filling as above.

xi) Oil filtration :

(After oil filling operation) :

Carry out oil filtration as given in (viii.) (Hot oil circulation) for two passes. Take oil sample. Check BDV and water content.

Electric strength:

BDV kV (Min)

Upto 145 kV (rms) 50 kV Above 145 kV transformer (rms) 60 kV

Water Content ppm (max) :

Upto 72.5 kV 25 ppm 72.5 kV upto 145 kV 20 ppm Above 145 kV transformer 15 ppm

If BDV of oil sample is equal to or greater than the above value and water content is equal to or less than the above value, then the oil sample is O.K. otherwise carry out filtration for two more passes. Check again oil sample. If the oil sample is not O.K. then check if anything is wrong with filter machine.

The above process cycle is for a maximum exposure of 12 hours. If the exposure is excess of 12 hours, repeat heating and vacuum cycle, if required. In any case exposure should not exceed 36 hours.

xii) Oil filling in Main unit with separately mounted radiator (Refer Outline drawing):

After the unit processing is complete as per procedure given above, for filling oil in coolers and main unit adopt following procedure. (Refer Figure 4.7 & Figure 4.8)

a) Keeping top & bottom valve between tank &

coolers close, fill previously filtered oil at ambient temperature in each cooler bank through valves on bottom header. Precautions should be taken to open valves on radiator as well as air release plug on headers. Close air release plug after filling the oil.

b) Each bank should be filled separately. c) Immediately after filling oil, each bank should be

filtered separately. For this, oil should be taken from storage tank, fed to filter machine and output of filter connected to top filter valve of cooler bank and drain out from valve on bottom header to storage bank.

d) Take oil sample from each bank and check for

BDV and water content. Values of BDV and water content should match as given earlier. Continue filtering for such duration, till BDV and water content are achieved.

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xiii) Air release :

Release air from cover, header, radiator, buchholz relay, cooler pipe and any other air release plug provided on Transformer after observing the standing time, given below. Ensure complete air release before applying voltage. Air release for main unit and separate cooler banks with pump: Adopt the same procedure given above but have additional air release as given below.

Run the pumps in pipe work for 8 hours. Pumps in both pipe work should be run individually for 8 hours so that reverse flow blocking device should get operated. After the pump operations observe the standing time as given below.

After observing the standing time, release air from cover, radiator, buchholz relay, cooler pipes, header and any other air release plug provided on transformer. Ensure complete air release before applying voltage. xiv) Standing Time: The Standing Time given below shall be strictly adhered to, after topping up oil in conservator & before aplication of voltage. Air release shall be done after observing the Standing Time. xv) Dew Point Measurement. During field installation, parts of a transformer may be subjected to exposure. Dew point measurement is one of the methods to measure the humidity inside the transformer tank. 4.16 Do’s and Don’ts during assembling and installation Strictly follow the below mentioned Do’s and Don’ts to avoid any kind of mishap, accidents and damage pertaining to goods as well as human life. 4.16.1 Do’s 1. IMP. : Insulating oil and insulation for windings

and connections are inflammable. Watch for fire hazards.

2. Replace Nitrogen gas completely with air if it was

filled in main unit for transport/storage. 3. Make sure that nothing is kept inside the

pockets before one enters inside main unit. Also take off the wrist watches and shoes.

4. List up all the tools and material to be taken

inside and check it after coming out to make it sure that no tools is left inside.

5. There must be a protective guard for lamp to be

taken inside. 6. Keep inspection covers open for supply of fresh

air, when working inside. 7. When one person is working inside, second

person must be outside for emergency. 8. Use fix spanners and tie them to the wrist of

the person or somewhere outside the tank. 9. Be careful during connections where bolted

joints (jumper connection) are involved. So that, nuts/washers etc., are not dropped inside the tank.

10. Attach the caution tags "DO NOT OPERATE

THE SWITCHES" while working on energized unit.

11. Make sure that the fire-fighting equipment

are available at the oil- treatment equipment as well as work place and adjacent to the transformer.

12. Transformer tank as well as oil treatment

equipment shall be connected with permanent earthing system of the station.

13. Check air cell in conservator 14. Attend the leakages on the bushing. 15. Examine the bushings for dirt deposits and

coats, and clean them periodically. 16. Check the oil in transformer for di-electric

strength and moisture content and take suitable action for restoring the quality.

14



17. Check the oil level in oil cup and ensure air

passages are free in the breather. If oil is less, make up the oil.

18. If inspection covers are opened or any gasket

joint is to be tightened, then tighten the bolts evenly to avoid uneven pressure.

19. Check and clean the relay and alarm contacts.

Check also their operation, and accuracy and if required change the setting.

20. Check the pointers of all gauges for their

free movement. 21. Clean the oil conservator thoroughly before

erecting. 22. Check the OTI and WTI pockets and replenish

the oil, if required. 23. Fill the oil in the transformer at the earliest

opportunity at site and follow storage instructions.

24. Check the door seals of Marshalling

Box/Thermojunction Box. Change the rubber lining if required.

25. Ensure proper tightness of top terminal cap

of condenser bushings to avoid rain water entry. 26. Check oil level in condenser bushing, any

discrepancy should be reported to Manufacturer. 4.16.2 Don’ts 1. Do not take any fibrous material such as cotton

waste inside while repairing. 2. Do not drop any tools/materials inside. 3. Do not stand on leads/cleats. 4. Do not weld, braze or solder inside the tank. 5. Do not weld anything to tank wall from outside. 6. Do not weld anything to conservator vessel if

bag is inside.

7. Do not Smoke on or near the transformer. 8. Do not use Fibrous cleaning material, as it

can deteriorate oil when mixed with it. 9. Do not leave off circuit tap switch handle

unlocked if any. 10. Do not use low capacity lifting jacks on

transformer for jacking. 11. Do not change the settings of WTI and OTI

alarm and trip frequently. The setting should be done as per the site condition.

12. Do not leave any connection loose. 13. Do not meddle with the protection circuits. 14. Do not leave Marshalling Box/Thermojunction

box doors open, they must be locked. 15. Do not switch off the heater in Marshalling

Box/Thermojuntion Box except to be periodically cleaned.

16. Do not leave a ladder unlocked, when the

transformer is `ON' in service, in case it is provided.

17. Do not store transformer for long after

reaching site. It must be erected and commissioned at the earliest.

15



Figure 4.1 Radiator Assembly

RADIATOR ASSEMBLY

VALVE

PLAIN WASHER

GASKET

SETSCREW

HEX. FULL NUT HEX. FULL NUT

GASKET

PLAIN WASHER

VALVEWELDED STUD

RADIATORRADIATOR

X Y

TOP

BRACING

LUG VALVE HANDLE

BOTTOM

DRAIN PLUGVALVE HANDLE

RADIATOR MOUNTED ON

PIPE WITH FLANGE

RADIATOR MOUNTED ON

HEADER WITH WELDED STUD

DETAIL 'X' DETAIL 'Y'

CAUTION NOTE NO.1 : RADIATOR LEAKAGE

RADIATORS IF DRAGGED ON THE GROUND OR ANY OTHER SURFACE, INVARIABLY GET STRUCK

SOMEWHERE CAUSING BENDING OF FINS, STRAINING WELDS, WHICH MAY LEAD TO OIL LEAKAGE.

IN ORDER TO PREVENT DAMAGES OF SUCH NATURE, IT IS SUGGESTED TO HANDLE THE RADIATORS

USING FORK LIFT FOR CARRYING TO THE TRANSFORMER AND RHEN RAISING IT TO THE POSITION

USING

16



Figure 4.2 Fan Mounting Arrangement

17



Figure 4.3 Lifting of Bushing

Figure 4.4 Conservator & pipe assembly

18



Figure 4.5 Plate valve assembly

19



Figure 4.6 Oil filling arrangement

80 M.M. DIA. PLATE TYPE VALVE ASSEMBLY

PLATE TYPE VALVE

80 M.M. DIA.

HEX. FULL NUT

PLAIN WASHER

CAP SCREW

CAP WITH INDICATOR

80 M.M. DIA.

PLATE TYPE VALVE

GASKET

GASKET

PLATE TYPE VALVE

80 M.M. DIA.

GASKET

20



Figure 4.7 Arrangement for hot oil circulation and filteration

21



Figure 4.8 Vacuum arrangement

22



AR

RA

NG

EM

EN

T F

OR

OIL

FIL

LIN

G U

ND

ER

VA

CU

UM

OF

MA

IN

UN

IT

TRANSFORMER

VACUUM

FILTER

OIL STORAGE

TANK

PUMP

VACUUM

SHUT-OFF VALVE BETWEEN

BUCHHOLZ RELAY AND TANK

FILTER VALVE ON TANK

VACUUM

GAUGE

TOP VALVE BETWEEN

TANK AND COOLER

TOP HEADER

BOTTOM HEADER

BOTTOM VALVE BETWEEN

TANK AND COOLER

AN

D S

EP

AR

AT

EL

Y M

OU

NT

ED

CO

OL

ER

BA

NK

RADIATORS

SEPARETELY MOUNTED

COOLER BANK

VALVE ON

BOTTOM HEADER

TOP HEADER

VALVE ON

BREATHER

SAMPLING VALVE

TANK TOP

CONSERVATOR

===============================================================

1



SECTION - 5

Pre- Commissioning Checks

===============================================================

2



5.1 Overview

Now that installation of transformer with all its accessories & fittings is complete, we need to conduct some pre-commissioning checks to ensure safe & successful energization.

In case of substantial time lag between installation and commissioning of transformer, it is recommended that transformer installation be fully completed with assembling of all accessories and oil filling for Safety and Completeness. It will also allow easy check before commissioning.

Mechanical and Electrical pre-commissioning checks are essential to ensure entire Transformer Functionality.

Pre-Commissioning checks involve a thorough check of transformer and accessories as well as external checks on installation system.

5.2 General Guidelines

• The transformer tank, all external metal parts and accessories should be permanently grounded according to the correct safety and operation practice and in accordance with instructions for the specific equipment being used. Tank should be earthed at atleast two points.

• All bushings have to remain grounded until final energization of the unit (except to perform the electrical tests).

• All cables that are connected to the transformer should be adequately grounded.

• Check all the gasketed joints to ensure that there is no leakage of transformer oil at any point.

• Release trapped air through air release plugs and valves fitted for the purpose on various fittings likeheaders, radiators and oil communicating bushings, buchholz petcock etc.

• Check direction of rotation of fan blades to ensure air blast to radiators.

• Check direction of Oil pump by switching on the pump and the oil flow indicator to indicate the pump on condition. If stand-by pump provided check all the pumps. Each pump should be operated for at least 8 hours at least and subsequently the air is again released from all points.

• Ensure conservator is filled upto the filling oil level mark on plain oil gauge side and corresponding to the pointer reading on MOG side.

• Ensure that silica gel in the breather is active and color is blue and oil in the breather cup.

• Check that the thermometer pockets on tank cover, header, etc., are filled with oil. Oil filling is not required in case of dry type probe arrangement.

• CTs secondary terminals must be shorted and earthed, if not in use. Also check that the CT terminals in Marshalling Box/Thermo Junction Box are connected to WTI CT terminals, as indicated in the rating and diagram plate and open the shorting link of the terminal block.

• Check for tightness of all external electrical connections.

• Clear off extraneous materials like tools, pieces of cloths, waste, etc.

• Check alarm/trip contacts of all accessories, instruments flow meters, differential pressure gauges etc.

• In the case of water cooled transformers, the pressure gauge readings on both water and oil sides to confirm that the water pressure is less than the oil pressure. The oil and water flow should not be less than that specified.

5.3 Mechanical Checks

5.3.1 Location on Foundation

Locate the transformer on the plinth precisely and anchor the unit with anchoring bolts. Confirm position with Outline Drawing.

===============================================================

3



5.3.2 Bushings and Terminal Connectors

• Check bushings for any crack or breakage of porcelain

• Oil level in condenser type bushings should be up to the level marked on oil gauge on side of top cap. Also check tightness of top cap for condenser bushing

• Check for the arcing horn gap on bushings, if provided

• Ensure that all bushings and bushing turrets are correctly air bled. Check for leaks, especially on bolted flanges and the bushing top terminals.

• Ensure that capacitive test taps on condenser type bushings are correctly grounded or connected.

• Check for sufficient voltage clearances.

• Confirm correct position of turrets with Outline Drawing.

5.3.3 Valves and Pipe-Work

• Check that all bolted joints are correctly tightened and that there are no leaks.

• Make sure that all valves (including radiator valves) are in the operation position.

• Ensure that all venting openings are closed.

5.3.4. Radiators and Cooling systems

• Check oil pumps, fans and their control system. Check for leaks. Observe operation for at least two hour.

• Check if all condensation release plugs are removed on electrical motors.

• Overcurrent motor protections.

• Check and set temperature controllers.

• Check the flow indicators for the correct flow direction.

• Other trip and alarm functions as per specification.

• Remote control function (if present). 5.3.5 Leak Test The simplest method for testing for leaks is by gas pressure. The gas space in the unit should be pressurized at 5 PSI with dry nitrogen. The gas pressure should be monitored for a period of approximately 24

hours. A change in pressure does not necessarily indicate a leak. Any temperature increase or decrease in the transformer will result in a subsequent increase or decrease of the gas pressure in the unit. Ambient temperatures and tank pressure should be monitored for a 24 hour period. If there is a significant drop in pressure during the 24 hour period, without any accompanying significant decrease in ambient temperature, the tank must be checked for leaks. Re-pressurize the tank at 5 PSI if necessary. Using a solution of liquid soap and soft water, brush all weld and threaded joints above the oil level, all bushing gasket flanges, and all hand hold cover gaskets. Any leaks in the gas space above the liquid will be shown in the form of soap bubbles. Paint welds with chalk dust dissolved in alcohol. Apply the chalk dust below the liquid level to check for leaks of liquid from the tank. All soap solution must be rinsed off or wiped off with a clean wet rag before removing pressure. 5.4 Tests on Transformer and Accessories Refer to Rating and Diagram Plate and all other instruction plates before tests. Refer section 5.5 on instruments for electrical tests before commencing below tests. 5.4.1 Oil Sampling and Testing Oil Sampling Oil takes up moisture readily and its condition should always be checked before use. Water and water-saturated oil are both heavier than dry oil and sink to the bottom of any container. Samples shall, therefore, be taken from the bottom. Samples should not be taken unless the oil has been allowed to settle for 24 hours

===============================================================

4



Samples from Tank: Dirt from the draw-off valve or plug should be removed. To ensure that the valve is clean, some quantity of oil should be allowed to flow into a separate container before collecting samples for testing. Samples shall be collected either in glass bottle (refer IEC 60567) or in stainless steel bottle. Oil must be taken from both top and bottom sampling valves and while drawing the sample the corresponding top oil temperature must be furnished. Test oil sample for BDV, PPM, Resistivity, Tan δ. It is a good practice to conduct DGA before commissioning to serve as a record for future. Sample from Oil Drum: The drum should first be allowed to stand with the bung vertically upwards for at least 24 hours. The area around the bung should be cleaned. A clean glass or brass tube long enough to reach to within 10 mm of the lowermost part of the drum should be inserted, keeping the uppermost end of the tube sealed with the thumb whilst doing so. Remove the thumb, thereby allowing oil to enter the bottom of the tube. Reseal the tube and withdraw an oil sample. The first two samples should be discarded. Thereafter, the samples should be released into a suitable receptacle. Sample from Diverter switch of OLTC: Oil of diverter switch should be checked for BDV at the time of commissioning and subsequently yearly or 5000 operations, whichever is earlier. Refer OLTC Manual for detailed instructions For further details on oil tests, refer section 4.14 5.4.2 Ratio, Polarity and Vector Group Test The ratio should be checked on all taps and between all the windings and the results should tally with factory test reports as well as the rating and diagram plate details. Ratio shall be checked by applying a single phase 230-300 V supply on the high voltage side and measuring the

voltage on the low voltage side at all tap positions. Polarity and inter-phase connections are checked while measuring the ratio. This can be checked by the voltmeter method. The primary and secondary windings are connected together at one point. A low voltage three phase supply is then applied to the terminals. Voltage measurements are then taken between various pairs of terminals and vector group is verified. 5.4.3 Winding Resistance Measurement Kelvin Bridge meter or automatic winding resistance measurement kit (ohm meter, preferably 25 A kit) should be used for the measurement of resistance. Tapped winding resistance shall be measured at all tap positions. Absolute steady reading should be obtained for minimum 1 minute. Pre-commissioning values are to be compared with factory values after applying temperature correction factors. 5.4.4 Continuity Impedance Test The continuity impedance test is meant to check the impedance and all internal connections, including the continuity of the current for the windings and all tap connections. Test to be conducted at Principal tap. Apply 3-phase 415V or preferably single phase 230V to the transformer HV side with LV side shorted. Calculate ohmic value i.e. V/I and convert to percentage impedance. Where practical, measure frequency and convert value by direct proportion. Test to be done for each pair of windings taken at a time for a 3 winding transformer. Compare the values with respect to pre-commissioning values. Any deviation beyond 1-2% needs further analysis.

===============================================================

5



5.4.3.1 Insulation Resistance Test The purpose of the insulation resistance test is to detect internal movement of parts that may have shorted out some of the insulation on the core and on the windings and leads, as well as to check for excessive moisture contamination. Compare values obtained with the factory test figures. Note:

• Insulation resistances measured without oil filling on a dry air-filled transformer are not comparable with the measured values in the factory.

5.4.4.1 Winding Insulation Meggar Test The insulation resistance between windings and between windings and earth should be measured with 5000/2500/1000 volts megger and the values should be compared to the test report values. If there is much variation, the same should be intimated to the manufacturer. IR at 600 sec The Polarization Index = --------------------- IR at 60 sec

should be ≥ 1.3 It is preferable to have a motor operated megger and the readings taken after one minute from starting. Prechecks:

• Before measuring the insulation resistance, it should be made sure that the bushings are cleaned thoroughly with clean cotton cloth. They should also give reading of infinity before connecting up.

• No external lines, lightning arrestors, etc, should be in circuit.

• Ensure that the lead wires of the megger do not have joints.

5.4.4.2 Core Grounding Meggar Test This test is used to determine the status of the core clamping structure. 2500 Volts meggar is used for this test. Insulation resistance is measured between: (i) Core to Frame (ii) Frame to Tank (iii) Core to Tank Tested values should be more than 10 MΩ at 20 °C. 5.4.5 Measuement of Magnetising Current A single phase low voltage supply is given to the HV winding of the 3 phase transformer and current readings of the phases are taken using low range A.C. ammeters. Reading should be recorded for future reference. 5.4.6 Magnetic Balance Tests Apply single phase 230V supply to each phase of a star connected winding, and measure voltage induced in other phases. When centre phase is applied the other phase voltage should be 30 to 70%. When extreme phase is applied, centre phase voltage to be 50 to 95%. 5.4.7 Power Factor Measurement of Transformer Windings and Bushings (a) For Transformer windings, measurements shall be done after opening the jumpers and isolating the transformer from other equipment and the ground. (b) The test kit should be suitable to work in charged switchyard environment i.e. induction suppression unit should be provided. (c) Test modes shall be selected as below : Bushings

===============================================================

6



UST mode between HV and test tap. Windings (i) Between two windings – UST mode (ii) Between winding to Earth-GSTg mode with other winding (s) guarded. Notes

• While carrying out the test, all 3 phases of the same winding are to be shorted to compensate/nullify the effect of winding reactance.

• The bushing porcelain and test tap are to be properly cleaned before the commencement of test.

• Pre-commissioning values are to be compared with factory values after applying temperature correction factors.

• Tan Delta/ Power Factor values should be more frequently monitored if faster deterioration trend is observed.

5.4.8 Tests on Auxiliary Instruments 5.4.8.1 Oil and Gas Operated Relays (Buchholz relay) Check whether the gas operated relay is mounted as per supplier’s catalogue. Confirm that the relay does not operate when pumps are switched on in forced oil cooled transformers. Check the operation of the alarm and trip contacts to the relay independently by injecting air through the top cocks using a hand pump. The air should be released after the tests. 5.4.8.2 Magnetic Oil Level Gauge : The float level of the oil level indicator is moved up and down between the end position to check the mechanism does not stick at any point. If the indicator has got signaling contacts, they should be checked at the same time for correct operation. 5.4.8.3 Temperature Indicators

The contacts of WTI and OTI for alarm and trip are checked and set at required temperatures depending upon ambient temperatures and loading conditions. 5.4.9 Tests on Tap Changer The sequence of operation of the tap changers shall be checked for : (a) Manual Operation. (b) Local Electrical Operation. (c) Remote Electrical Operation. (d) Group Operation, if applicable. 5.4.10 Checking of Fans and Pumps It shall be checked that the specified number of fans are mounted on radiators as per general arrangement drawing. IR values and settings for operation of fan motors and oil pumps are checked. Check also that the direction of rotation of fans and pumps is correct. 5.4.11 Checking of Marshalling Box The wiring from various accessories to marshalling box shall be checked. 5.4.12 Checking of oil The oil samples from the actual oil being used in the transformer shall be tested for oil properties and DGA analysis shall be performed. This data will be useful as a reference signature in future. 5.4.13 SFRA test SFRA (Sweep frequency response analysis) test shall be performed and the results compared with factory test results, if any.In any case this record will be useful as a signature for future.

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7



5.5 Instruments used for Pre - Commissioning TestUse the instruments with valid calibration certificates for conducting the tests at site

Sr.

No.

Test Measuring Instrument

Instrument Range

Required Accuracy

Least Count

1) Ratio, Polarity, vector group and Magnetic balance

Voltmeter 0 to 500 V ±2% 5 V

2) Resistance V-I method or Bridge

0-100 Ω ±2% 1 x 10-6

Ω

3) Insulation Resistance Megger 0-50,000 M

Ω ±5% 5 M Ω at the

lowest scale

4) Excitation Current

Ammeter 0-200 mA ±0.5% 1 mA

5) Impedance 6) Oil BDV BDV Meter

2.5 mm gauge

0-100 kV 2.5 mm

±2%

±0.1 mm

2 kV Go - No go

7) SFRA 8) Capacitance and tan delta

5.6 Start up Instructions

Step No.

Description Test equipment/ Controls

Inspection/ Action

Acceptance Norms

1) Oil BDV tester BDV BDV ≥ 60 kV

2) Air release plugs Spanner Release air All air expelled

3) Circuit breaker incoming/outgoing

Alarm/trip circuit Verify correctness

Satisfactory operation of breaker

4) Breathers Visual check Oil level in cup At designated level

5) Thermometer pockets

Visual check Oil inside pocket

To maximum

6) Earthing pad Spanner size M12 Tightness To be light at earthing terminal and the earth

7) Heater switch in control

Visual check Switch ON Switch ON

8) Incoming breaker Remote control to close the incoming breaker

Energise from incoming side keeping lowest voltage top

No abnormal humming

9) Outgoing breaker Remote control to close outgoing breaker

Synchronise Load current as per load shared

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1



SECTION - 6

Commissioning

===============================================================

2



6.1 Repeating Pre Commissioning Checks

The transformer is ready for commissioning after completion of installation with all its accessories and Pre-commissioning checks and tests as per Section 5.

Pre-operational tests need not be repeated if transformer is commissioned within 4 weeks of conducting Pre-commissioning checks and tests.

If energisation is done 4 weeks after installation and testing, air venting and all Pre-commissioning checks and tests are to be repeated on transformer and accessories as in Section 5.

6.2 Operational System Tests Before transformer energization, some operational tests are to be performed on the system including network, protection system and remote control facilities. 6.2.1 Relay Settings Recheck all relay settings associated with transformer, switchgear and other associated equipments in the installation system. Refer technical documents/ specifications supplied by respective vendors. 6.2.2 Alarm circuits and Contacts Alarms provide a warning for an abnormal condition on the transformer or its accessories. All alarm indications should be checked by closing alarm contacts. Following are commonly used alarms:

• Buchholz Relay

• Winding Temperature Indicator and Oil Temperature Indicator

• Oil Level Alarms

• Oil flow indicator.

• Oil Level Gauge

6.2.3 Trip Circuits and Contacts Trip contacts on the transformer or its accessories immediately place the transformer out of service in case of any abnormal situation that can damage the equipment/ environment. Check breaker tripping by closing all trip contacts. Commonly used Trip contacts are:

• Buchholz Relay

• Oil Surge Relay

• Pressure Relief Device (PRD)

• Sudden Pressure Relay

• Winding Temperature Indicator and Oil Temperature Indicator (WTI & OTI)

. 6.2.4 Temperature Settings Confirm settings (alarm/ trip) of Winding Temperature Indicators and Oil Temperature Indicator are as marked in the Schematic Control drawings.

6.2.5 Rating of Pressure Relief Devices

Confirm rating of all overpressure relief devices are as marked in drawings.

6.2.6 System Voltage, frequency & Phase

Sequence Check

Check incoming and outgoing system voltages, frequency and phase sequence again before energizing the transformer.

6.2.7 Oil Sampling and Checking

Repeat procedure of Oil sampling and testing as in section 5 to confirm oil is as per norms before energization.

Temperature ≤ Values in Schematic

Settings Control drawings

===============================================================

3



6.3 Transformer Energization If the ambient temperature is < -20°C, special precautions should be taken before energization. Refer IEEE Std C57.12.00. 6.3.1 Minimum Settling Time after Final

Oil Filling The transformer oil should be stabilized after final oil filling i.e, allowed to stand for atleast 24 hours. Release air from all venting points before energization. Transformer with forced oil circulation using pumps Have the pumps run for at least 2 hours and wait for:

• minimum 8 hours if high voltage _ 245 kV

• minimum 24 hours if high voltage > 245 kV Transformers without forced oil circulation using pumps Wait for :

• minimum 16 hours if high voltage _ 245 kV

• minimum 48 hours if high voltage > 245 kV 6.3.2 First Energization on No-Load The transformer is first energized under no-load condition. Set the tap changer to obtain correct voltage ratio. Ensure drive mechanism of no-load tap changer is locked to prevent mal operation under voltage. After energization, check the secondary and no-load current. A noise-peak mayl be heard immediately after energization. It shall subside within an hour.

Post – Energization Checks After energization, conduct a general surveillance of transformer and other substation equipments for any abnormalities such as :

• Abnormal noise/ humming/ vibration from transformer or accessories

• Monitor temperature of oil, recording to

• be taken at regular time intervals (every hour) until stabilization

• Monitor temperature of winding hot spots, recording to be taken at regular time intervals (every hour) until stabilization

• Monitor ambient temperature

• Operate and check performance of LTC through all positions within rated voltages (if applicable)

• Operate and check performance of cooling pumps and fans (if applicable)

• Check Oil leaks After few hours of no-load energization, switch of the transformer and

• Check Buchholz relay for air/ gas collection

• Abnormalities noted above to be investigated and corrected.

Transformer can now be re-energized and loaded gradually. 6.3.3 Loading the Transformer

• Set the tap-changer at right tap position and check secondary voltage. If an Automatic Voltage Regulator (AVR) is provided, the tap changer will automatically run to the right tap position.

• In case of parallel operation, ensure voltage ratio and voltages match at all taps, principal and extreme tap impedances match, vector groups and phase sequence on all transformers is the same.

• Close incoming breaker and gradually raise the load on the transformer.

===============================================================

4



Post – Loading Checks

• Note transformer voltages and load currents, ambient temperature, oil levels.

• Record temperature of oil and winding hot spots at regular time intervals until stabilization. Also note loading.

• Monitor condition of accessories like breather, fans, pumps, bushings etc

• It is recommended to collect oil for DGA 24 hours after loading.

• In case of parallel operation, current should be carefully monitored between both units to make sure that one unit is not carrying a larger portion of the load under parallel operation. The units should be monitored for an additional period of at least one week to make sure that there is no abnormal temperature rise on either.

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1



SECTION - 7

Maintenance

===============================================================

2



7.1 Introduction

If a transformer is to give long and trouble-free service it should receive a reasonable amount of attention and maintenance. A rigid system of inspection and preventive maintenance ensures long life, trouble free service and low maintenance cost. Maintenance consists of regular inspection, testing and reconditioning where necessary. The principal objective of maintenance is to maintain the insulation in good condition. Moisture, dirt and excessive heat are the main causes of insulation deterioration and avoidance of these will in general keep the insulation in good condition. 7.2 Safety During Maintenance Maintenance activity is to be undertaken on the transformer following all safety precautions and under supervision. Follow below safety measures:

• Always ensure transformer is grounded during inspections.

• The transformer is disconnected and isolated from both incoming and outgoing ends. Connect discharge rods on transformer terminals to remove static and induced charges and earth the same.

• Confirm that all possible “remote” operations have been changed to “Manual mode”.

• Place locks/ warning cards stating breakers should not be operated during inspection period.

• Disconnect supply to control cabinet.

• Before entering the tank, ensure air is present inside. Also make arrangements for ventilation while working inside. Use dry air circulation and oxygen meter.

• Use only explosion proof lamp-s inside the tank and verify insulation condition of electrical cord.

• Do not allow persons to get close to the bushings in air while power is on. This can cause an electric shock. Before getting close to the bushing in air,

disconnect transformer from both ends, discharge the line terminals and earth the terminals.

• Do not remove the cap of bushing test terminal or cover of voltage measuring terminal. This may cause an electric shock or deteriorate the performance of moisture-proof seal.

• In case of accident inside the transformer, do not get close to the transformer.

• Do not climb the transformer under energized condition or immediately after shutdown. High temperature sections can prove hazardous.

• Do not leave open the secondary circuit of the current transformer.

• Do not use fire around the transformer or insulating oil as this can cause fire/ explosion due to insulating oil or decomposed gas leaks.

• Before inserting manual handle into the manual shaft of motor-driven mechanism, change operation mode to local from remote.

• Do not touch movable section (main driving axle, gear etc) in the motor driven operating mechanism when power is on.

• Do not touch circuit sections inside marshalling box when power is on. Keep the marshalling box doors closed when transformer is in operation.

• Do not touch cooling fans even when they are not rotating. They may start rotating from an internal signal without warning.

• Do not operate any valves when the transformer is in operation. It may prevent free flow of oil and consequently raise oil temperature.

• Do not stop all coolers when the transformer is in operation.

===============================================================

3



7.3 Periodic Inspection and Checks during Service Transformer Logbooks: It is recommended to record readings and observations during inspections in a logbook. This serves as reference for planning future maintenance activity and investigation during breakdown. Unusual Service Conditions: If a transformer is relocated to another site from its initial installation location with a different environment and different system configuration (like in parallel), The original parameters like temperature rise, loading limit etc may not be met. The permissible performance characteristics should be reworked. 7.3.1 External Cleaning Use an oil solvent to thoroughly remove all oil that appears on the outside of the tank or on the gaskets. This oil, later showing up on the painted surface, often gives the false impression of a leak. The bushing porcelains must be kept free from dust and dirt and have to be inspected at least once a year. Abnormal conditions such as sandstorms, salt deposits, dust, or chemical fumes require regular cleaning to avoid accumulations to the external surface. Accepted methods of hot line washing or cleaning with solvents may be used. Keep the heat radiating surfaces of the transformer clean. External surfaces of forced oil heat exchangers should be periodically cleaned as a particular dusty location may dictate. Transformers near the seacoast or in corrosive atmosphere areas should be painted regularly to prevent corroding or rusting of metal parts. If it becomes necessary to remove a radiator or air cooled oil cooler, first close the valves, top and bottom, and bolt them in the closed position. Next, drain the oil from the radiator by removing the drain plug from the bottom header and the vent plug from the top. After draining the oil, remove the radiator. If the radiator/cooler is removed for any length of

time, the transformer valves should be sealed with gaskets and covered with suitable plates. This also applies to the radiator-cooler openings. All breathers and small openings in pressure relief valves (and pressure vacuum bleeders on sealed tank system and inert gas system units) must be kept clean and in operating condition. All ground buses and wiring leads to ground must be kept in good condition. Proper relay operation depends on low ground resistance. Ground resistance must be measured annually. 7.3.2 Transformer Body

• Leaks & Painting: The transformer tank and other parts should be inspected periodically for any rust or and oil leak. Rusted portions, if any, should be cleaned thoroughly and repainted with proper paints. Transformer should be completely painted at proper intervals. If any leak is found, it should be investigated. If it is due to defective welding, the same should be rectified after consulting the manufacturer. Leaking joints can be rectified by tightening the bolts to the correct pressure or by replacing the gaskets. Refer Table 7.1 and Table 7.2 for maximum recommended torque are given here on the basis of the material properties.

• Groundings: Check the transformer grounding connections and all groundings of accessories.

• Valves: In case leakage is detected on the driving shaft, re-tighten the compression gland. Use only graphite-free sealing material when changing packings.

===============================================================

4



Table 7.1 : Maximum recommended Torque for Bolts marked 4.8 on the head

Bolt size Unplated

Torque N-m

Zn Plated Galvanised

Torque N-m

M10 20 25

M12 36 40

M16 90 110

M20 175 210

M24 300 360

M30 600 720

M36 1050 1260

Table 7.2 : Maximum recommended Torque for Bolts marked 8.8 or higher on the head or of Stainless Steel Bolt size Unplated

Torque N-m

Zn Plated Galvanised

Torque N-m

M10 35 40

M12 60 70

M16 145 170

M20 280 340

M24 490 590

M30 970 1160

M36 1700 2040

7.3.3 Gaskets

• Gaskets sometimes shrink during service. It is, therefore, necessary to check the tightness of all bolts fastening gasketed joints. The bolts should be tightened evenly round the joints to avoid uneven pressure.

• Leaking gaskets should be immediately replaced.

Recommended Torques for bolts/studs only for gasketed joints

Bolt size Unplated

Torque N-m

M10 20

M12 30

M16 50

M20 70

M24 100

7.3.4 Oil Oil Level and Quantity The oil level should be checked at frequent intervals and any excessive leakage of oil investigated. There may be slight loss of oil by evaporation; this need cause no concern if the tank is topped up at regular intervals. Oil for topping up should comply with IS 335 / IEC60296. New insulating oils and preferably oil from the same source as the original oil should be used. All leaks should be repaired as quickly as possible so as to avoid possible trouble caused by low oil level. Oil Inspection Samples of the oil should be taken at regular intervals preferably yearly and tested for DGA and other oil parameters If oil fails to meet standards, it should be reconditioned by suitable means i.e, filtration or the oil be changed. Note: Vacuum filtration only improves BDV, moisture content and dust/dirt/suspended materials etc from oil. This process does not improve any other parameters of oil.

===============================================================

5



7.3.5 Bushings

• The bushings should be inspected for any cracks or chippings of the porcelain at regular intervals and kept free from dust and dirt. In location where special and abnormal conditions prevail, such as sand storm, salt deposits, cement dust, oil fumes etc., bushings should be cleaned at more frequent intervals.

• Oil level in oil filled bushings should be checked periodically.

7.3.6 Conservator and Magnetic Oil Gauge

• Conservators are so arranged that the lower part acts as a sump in which any impurities entering the conservator will collect. A valve/plug is fitted at the lowest point of the conservator for draining and sampling.

• The inside of the conservator should be cleaned every two to three years. A removable end is generally provided for this purpose.

• The oil level indicator should be kept clean. Generally the oil level is visible through a transparent material. In case of breakage immediate replacement is essential. When conservator is stripped for cleaning, the mechanism of the oil gauge should be cleaned.

7.3.7 Tap Changer General guidelines given below. Refer manufacturer’s catalogue for further details. 7.3.7.1 On-Load Tap Changer

• Diverter Switch: The maintenance primarily consists of servicing of diverter switch contacts, checking the oil level in the diverter switch chamber, and replacement of diverter switch oil when the same becomes unsuitable for further service.

• Motor Driving Mechanism

Do not allow dirt to accumulate between contact rings of notching controller. Do not use oil/ grease on contacts

rings on notching controller. Check the operation of anti-

condensation heater If the contacts of contactors are

silver faced, no touching up be ever done, if any is worn out, it should be replaced. Copper contacts may be lightly touched up with a file when they become rough. The pole faces of electromagnet must be kept clean. Do not oil/grease the contact

surface of radial multi-contact switches, unless a special contact lubricant is used. The space between the rings should be cleaned occasionally. If necessary, a few drops of Benzene be used.

• Selector Switch: The contacts do not make/break current. As such, the wear is only due to mechanical movement of moving contacts. These may be inspected once in 2/3 years.

7.3.7.2 No-Load Tap Changer Perform switching operation on each tap and repeat 10 cycles. This is to be done atleast twice in a year. 7.3.8 Dehydrating Breather

• Silicagel is blue in color in its active stage but gradually turns pale pink as it becomes saturated with moisture. The gel should then be replaced or reactivated. The saturated gel can be regenerated by heating up to 110-130°C for 8 to 10 hours or 150-200°C for two to three hours and can be used again.

The frequency of inspection depends upon local climatic and operating conditions.

• The level in the oil seal must be maintained at the level marked in the cup.

===============================================================

6



• 7.3.9 Cooling System Radiators: Maintenance includes replacing damaged elements, cleaning the outer surface to remove settled dust, cleaning inner surface by oil flushing for removing sludge and repainting if required. Fans

• Fan blades are cleaned to remove dust; bearings of the fan motors should be lubricated occasionally.

• During extended periods of reduced transformer loading, the fans tend to remain non-operational. Operate the fans on a periodic basis (biweekly for 1 hour) to ensure satisfactory operation.

Unit Coolers and Heat Exchangers: Refer manufacturer’s catalogue. 7.3.10 Temperature Indicators

• The level of oil in the pockets holding thermometer bulbs should be checked and the oil replenished, if required. The capillary tubing should be fastened down again if it has become loose.

• Dial glasses should be kept clear and if broken, replaced.

• Recalibrate with standard thermometer immersed in hot oil bath if readings are found to be incorrect.

7.3.11 External circuits and control equipment Check:

• Control circuit voltage.

• Excess heating of parts - evidence by discoloration of metal parts, charred insulation, or odor. If connections appear to be blackened or corroded, the same can be cleaned or replaced.

• Freedom of moving parts (binding or sticking is not allowed).

• Excessive noise in relay coils.

• Excessive arcing in opening circuits.

• Proper functioning of timing devices, sequencing of devices, relief device

alarm contacts, thermometer contacts, etc.

• Check the heaters in the control cabinets.

• Also check temperature settings. These settings can be lower than the ones indicated on the schematic diagrams but never higher.

• Evidence of water or liquids in control cabinets and in air-filled cable boxes.

7.3.12 Buchholz Relay Routine operation and mechanical inspection tests should be carried out at one and two yearly intervals respectively. During operation if gas is found to be collecting and giving alarm, the gas should be tested and analysed to find out the nature of fault. The internal faults can be identified to a great extent by chemical analysis of collected gas. 7.3.13 Explosion Vent The diaphragm, which is fitted at the open end of the vent should be inspected at frequent intervals and replaced, if damaged. Failure to replace the diaphragm quickly may allow the ingress of moisture which will contaminate the oil. If the diaphragm has broken because of a fault in the transformer an inspection must be carried out to determine the nature and cause of the fault.

===============================================================

7



7.4 Preventive Maintenance Inspection Chart

Sr. No.

Periodicity Item/Area Maintenance Required Special Tools

Consumables Required

Warning Caution

1) -- Porcelain insulator such as bushing, lightning arrester, supporting insulator

Cleaning should be done periodically. Interval depends on actual condition at site

-- Water Safety arrangement for hot line washing

--

2) 5 Yearly Radiator

Oil flushing inside

Oil filter machine Transformer oil -- --

3) 5 Yearly Paint Repainting -- Emery Paper -- Outermost coat is Polyurethane

4) 10 Yearly Gasket

Change -- -- Gaskets in contact with oil are Nitrile based

Use teflon for plugs

5) 5 Yearly Conservator Cleaning -- Transformer oil No welding allowed on tank

Take care of COPS bag

6) Yearly Buchholz relay Operation and mechanical inspection tests

Test set -- -- --

7) Yearly On Load Tap changer As per supplier’s catalogue

As per catalogue

8) -- Condenser Bushings

===============================================================

1



SECTION – 8 Trouble shooting

===============================================================

2



8.1 Indication signals of malfunction or abnormality A structured and objective oriented trouble shooting is required when a transformer is tripped on some protective relay or when routine electrical tests shows some deviation. Below table shows major indication signals of malfunction.

Location Signal

1) Main Tank Buchholz Relay Alarm/Trip

2) OLTC Buchholz Relay Alarm/Trip

3) WTI Alarm/Trip

4) OTI Alarm/Trip

5) MOG Alarm/Trip

6) PRD/Diaphragm Tripped/Operated

7) Overcurrent Relay Trip

8) Differential Relay Trip

9) Earth Fault Relay Trip

10) Whether there is gas collection in buchholz relay of transformer. If yes, colour of gas. Quantity of the gas in cm

3

Test results of Buchholz Relay Gas

Yes/No Colourless/Dark Inflammable/Non-inflammable, its nature and composition.

11) Whether there is gas collection in the OLTC Buchholz relay If yes, colour of gas. Quantity of the gas in cm

3

Test results of OLTC Buchholz gas

Yes/No Colourless/Dark Inflammable/Non-inflammable

===============================================================

3



8.2 Trouble shooting chart

Having received some indication of abnormality in functioning of transformer, detailed trouble shooting steps are requisite for the fault diagnosis.

8.2.1 Trouble shooting flow

The table below depicts the flowchart of trouble shooting procedures.

Symptom Possible Cause Item to be checked

Differential relay and Buchholz relay or pressure relief device operate simultaneously

Shut down of the transformer

Electrical tests and DGA

Buchholz relay and pressure relief device operate simultaneously

Only differential relay operates

Excessive inrush current when the transformer is energized

Threshold values of relays Level of inrush current

Only Buchholz relay (trip) operates

Faulty operation of relay or device

Wiring continuity and condition Contacts Oil-stop valve position between tank and conservator

Only Buchholz relay (alarm) operates

Internal fault in the transformer

Trapped air or build up of gas

Gas analysis Any sudden drop in oil temperature Choking in breather

Over-current, ground arrestor and other relays operate Abnormal operation in the system or other recording device

External fault such as system short-circuit

If heavy current is flowing through the windings Whether OLTC is interrupting heavy short-circuit current The duration and value of short-circuit current

===============================================================

4



Symptom Possible Cause Item to be checked

Buchholz relay and pressure relief device operate simultaneously Operation of incomplete tap changing relay Either Buchholz relay or pressure relief device operates

Shut down of the transformer and the tap changer

Faulty divertor switch Simultaneous start of pumps Faulty Faulty diverter operation switch of relay or device

Electrical tests, including measurement of insulation resistance, voltage ratio, exciting current, and winding resistance Gas analysis Operation of relays Any external short circuits Whether trip due to simultaneous start of both pumps

Integrity of all circuits and contacts Malfunctioning of pressure relief device

Incorrect stopping positions because of incomplete tap changing of out-of-step tap positions

Shutdown of the transformer and the tap changer

Drive motor not operating

Operation of any circuit breakers Incorrect voltages Motors, pilot switches and relays Control circuit

Drive motor operates but incomplete tap changing takes place

Closing and opening positions of switch contacts Time setting for relay

Excessive drive torque

Tap position where excessive torque occurs Torque value when using the manual crack handle on the drive mechanism and the number of times the handle must be turned

High oil level of OLTC conservator

Oil leakage from main tank to OLTC compartment Faulty operation of oil level auge

Oil level of main tank and OLTC and oil temperature Operation of oil level gauge

===============================================================

5



8.2.2 Trouble shooting flow chart for abnormal level of fault gases.

Possible Cause Item to be Checked

Local overheating of oil and insulating materials

1) Perform the gas dissolved gas analysis. In particular, reaffirm that there are combustible gases detected by repeating the analysis. Also perform consecutive analysis at regular intervals to monitor changes in combustible gas concentration.

2) Check the condition of the load being placed on the transformer. There should be no overloading, over excitation or irregularity in the oil temperature.

3) Check that the transformer has suffered no system faults, such as external short circuits, ground lightning strikes, or operation of protective relays.

4) Check the condition of ancillary equipment for the transformer, such as overheating of oil pumps. In the case of pump, check the motor current.

Partial discharge and arcing

Deterioration caused by aging

Oil leakage between OLTC compartment and main tank

1) Check that the oil level of the divertor switch compartment is correct for the oil temperature.

2) Drain oil from the divertor switch compartment, and check the insulating cylinder, and gasketed joints for leakage.

External facts (caused by welding and use of contaminated oil for example)

Check the history for the tank, such as whether it was welded recently. Date of oil replacement, etc.

8.3 Trouble shooting process

Having followed the trouble shooting steps and having identified the fault, the actual flow of activities is as shown in the next page

===============================================================

6



TRANSFORMER TRIPPED

MALFUNCTIONED

UNFIT FOR USE

FAILURE INDICATION

DATA COLLECTION

SELECTED

TESTS

ANALYSIS OF

DATA

ROUTINE TESTS SHOW

DEVIATION FROM PAST

BENCHMARKS

MONITOR

RETURN TO SERVICE PROBLEM

TESTING

FOCUSSED

TESTS

ANALYSE TEST

RESULTS

TESTING

INTERNAL INSPECTION

ANALYSIS

DAMAGE IS

OBVIOUS

REPAIR

FIELD

REPAIR

FACTORY

REPAIR

PROBLEM

FOUND

SCRAP

SELECTED TESTS

PERFORM CORRECTIVE

ACTION

FURTHER

TESTING

DISASSEMBLY

ANALYSIS

YES

YES

YES

YES

YES

YES NO

NO

NO

NO

NO

===============================================================

7



8.4 Emergency response for

unexpected events

In case of any emergency concerning potential threat to human life and/or towards loss or damage to assets and properties, following steps are to be followed.

1) Do not panic. 2) De-energize the transformer. 3) Trip the circuit breaker to trip the

transformer from line. 4) Switch on the fire fighting system in

case any fire is detected. Also keep all fire fighting equipments ready and call fire fighting personnel.

5) Do not go near the transformer or touch any parts until authorized service personnel do not arrive.

8.5 Energizing transformer after fault.

Follow all the steps that are followed during pre-operational checks and energizing of transformer.

===============================================================

1



SECTION - 9

End of life disposal

===============================================================

2



9.1 Planning for disposal

When the transformer has reached the end of its useful life, it is important to ensure that it is disposed of activity is done in a safe and secure way without damage to environment. Once the decision is reached to scrap the transformer, the following steps may be followed.

Important: Since these events may occur many years after the writing of this manual, it is important for the user to consult latest the safety and regulatory requirements at the time of disposal.

9.1.1 Assessment of physical condition, to decide the location and method of dismantling.

9.1.2 Identifying major materials which can be separated out and the cost/benefit of the operation.

9.2 Human safety

9.2.1 Ensure that the persons are equipped with all the tools and protective equipments to safeguard them from injury during the dismantling process

9.2.2 The dismantling operation shall be carried out in a location which is approved by the local authorities

9.2.3 Ensure that the persons are well aware of the general construction of the transformer components, to avoid injuries due to heavy objects and sharp edges.

9.3 Environmental safety

9.3.1 The oil from the transformer is removed in a safe way and stored in containers for reprocessing. Ensure that there is no spillage of oil into the environment or water drainage systems.

9.3.2 The core laminations and the copper windings shall be separated out carefully for further processing/scrapping.

9.3.3 The insulation components are soaked in transformer oil and are potentially inflammable. Hence they should be incinerated in controlled conditions, avoiding leakage of hazardous fumes to the atmosphere.

9.3.4 Particular attention shall be paid while handling transformers contaminated with PCB if any. Agencies having experience in disposal of PCB in line with the local protocols should be contacted.

1



10.1 Transformer Details

Sl. No.

Description Details

1) Transformer type POWER

2) Applicable standard IEC 60076

3) Rating (MVA) 80 MVA

4) Voltage ratio (kV) 220 / 13.8 / 6.9 kV

5) No of phases / frequency 3 ph / 50 Hz

6) Vector group YNyn0d1

7) Type of cooling ONAN / ONAF

8) Tapping details +10% to -10% in steps of 0.625%

2



10.2 List of Approved Drawings

Sl. No.

Description Drawing No.

1) Outline and General arrangement T61B010412F

2) Foundation detail T63B062422Q

3) Transport Outline T64B082421Q

4) Rating and Diagram plate T62B080933H

5) 245kV/1600A RIP Bushing (HV) 2751377 - 10

6) 73kV/2000A Oil Communating Bushing (HVN) 2751362 – BBBr1

7) 24kV/3150A Bushing (LV & LVN) H - 0385

8) 24kV/5000A Bushing (TV) H - 0382

9) Valve Location Plate T62B082423Q

10) Schematic Wiring Diagram of Transformer Cooler Control

T30B110412E

11) LV Cable Box T60B082424Q

3



10.3 List of Reference Drawings

Sl.No. Description Drawing No.

1. Buchholz Relay Pipe Work T57B086189Q

2. List of Fittings T62B088768Q

3. Tag Identification Drawing T57B086192F

4. Pipe Work Assembly T57B086187F

5. Safety Hand railing T57B086214H

4



10.4 List of Brochures

1) Operating Instruction for OLTC MR GERMANY Leaflet

2) Installation and Maintenance Instructions of Temperature Indicators (WTI/OTI) perfect control make.

Leaflet

3) Transformer Temperature Indicator (WTI/OTI) Leaflet

4) Tech. Specification on Temperature Detector (RTD System) Perfect Control Make.

Leaflet

5) Pressure Equalizing Between OLTC & tank T005-0497

6) Plate Valve Assembly T010-0497

7) Gas and Oil Actuated Relay T016-0497

8) Silica gel Breather T020-0799

9) Magnetic oil level gauge T025-0497

10) Gas Collecting Device T029-0897

11) Constant Oil Pressure System (COPS) Conservator T034-0201

12) Long Term Storage of Gas Filled Main Unit & Accessories

T035-0998

www.siemens.com.br/energia/tlm

Smart Monitor

Operation and Maintenance Manual

© Siemens 2012. E T TR TLM.

SM – Operation and Maintenance Manual | April 2012

I

Índice

1 GENERAL DESCRIPTION ............................................................................. 1-1

1.1 INTRODUCTION ........................................................................................................................ 1-1 1.1.1 Data processing structure .......................................................................................... 1-1 1.1.2 Monitored Variables ................................................................................................... 1-3 1.1.3 Storage strategy ......................................................................................................... 1-4

1.2 MODELS AND CORE MODULE..................................................................................................... 1-6

2 WEB PAGE .................................................................................................. 2-1

2.1 GENERAL SCREENS ................................................................................................................... 2-1 2.1.1 Login ........................................................................................................................... 2-1 2.1.2 Home........................................................................................................................... 2-2 2.1.3 General Functions ...................................................................................................... 2-3

2.2 EQUIPMENT MENU ................................................................................................................... 2-4 2.2.1 Equipment selection................................................................................................... 2-4 2.2.2 Main variables ............................................................................................................. 2-5 2.2.3 All variables ................................................................................................................. 2-6 2.2.4 Charts ........................................................................................................................2-10 2.2.5 Duval’s triangle .........................................................................................................2-13 2.2.6 Diagnostics................................................................................................................2-14 2.2.7 System Events ...........................................................................................................2-17 2.2.8 Notes .........................................................................................................................2-22 2.2.9 Maintenance .............................................................................................................2-22 2.2.10 Maintenance - History ..............................................................................................2-24 2.2.11 Parameters ................................................................................................................2-24

2.3 EVENTS MENU.......................................................................................................................2-30 2.4 CONFIGURATION MENU ..........................................................................................................2-31

2.4.1 User ...........................................................................................................................2-31 2.4.2 Change Password .....................................................................................................2-33 2.4.3 Status ........................................................................................................................2-34 2.4.4 Loaded modules .......................................................................................................2-34

3 SENSORS .................................................................................................... 3-1

3.1 TEMPERATURES ........................................................................................................................ 3-1 3.1.1 Pt100 (ambient temperature).................................................................................... 3-1 3.1.1.1 Technical data ............................................................................................................. 3-1 3.1.1.2 General procedures and maintenance ...................................................................... 3-1 3.1.2 Pt100 (oil temperatures) ............................................................................................ 3-1 3.1.2.1 Technical data ............................................................................................................. 3-2 3.1.2.2 General procedures and maintenance ...................................................................... 3-2

3.2 LOAD CURRENT........................................................................................................................ 3-2 3.2.1 SIMEAS T ..................................................................................................................... 3-2 3.2.1.1 Technical data ............................................................................................................. 3-3 3.2.1.2 General procedures and maintenance ...................................................................... 3-3

3.3 COOLING GROUP CURRENT ........................................................................................................ 3-4 3.3.1 MCR-SL-S ..................................................................................................................... 3-4 3.3.1.1 Technical data ............................................................................................................. 3-4 3.3.1.2 General procedures and maintenance ...................................................................... 3-4

4 HARDWARE ................................................................................................ 4-1

4.1 IM151-8 PN/DP CPU INTERFACE ............................................................................................. 4-1 4.1.1 Technical Data ............................................................................................................ 4-3

4.2 ET200S I/O SYSTEM ............................................................................................................... 4-3



II

4.3 SIMATIC MICROBOX IPC ......................................................................................................... 4-3 4.3.1 Technical Data ............................................................................................................ 4-5 4.3.2 Basic software ............................................................................................................. 4-5



Important Information

Safety Notices

Security warnings in general are disposed prominently by the text and may or may not be preceded by

markings, depending on its level of criticality.

Indicates critical point in the installation and / or system configuration.

Do not install or operate the equipment without first carefully reading the operating manual.

Updated Information

Updated information about the product is found or can be requested via:

Internet – http://www.siemens.com.br/energia/tlm

Fax: +55 11 4585-1278

Smart Monitor customer support:

Email: [email protected]

Phone: +55 11 4585-1100

About the manual

This manual describes the Smart Monitor and all its functions. The availability of the functions described

is linked to the presence of appropriate sensors and the project itself.

Product disclaimer:

The customer expressly understands and agrees that Siemens and its subsidiaries, affiliates, directors, employees,

gents, partners and licensors shall not be liable for any direct, indirect, incidental, special, consequential or

exemplary damages, including but not limited to, lost profits, goodwill, use, data or other intangible losses (even if

Siemens has been advised the possibility of such damages), resulting from: (i) the use or misuse of the Smart

Monitor system, (ii) the cost the acquisition or replacement of goods and services resulting from any goods, data,

information and services obtained or transactions resulting from the use of the system, (iii) the failure or damage

of any transformers their property, or (iv) any problem with the Smart Monitor system. The liability of Siemens and

its subsidiaries, affiliates, directors, employees, agents, partners and licensed for any direct damage caused by its

proven guilty will be limited to 10% (ten percent) of contract value.



General Description 1-1

1 General Description

1.1 Introduction

Smart Monitor expert system primarily aims to aid the user with the registration and assessment of

relevant data pertaining to early detection of incipient fault formation inside the transformer. The system

helps prevent major and catastrophic failures by providing vital lead time in order to plan Smart Monitor

recommended actions or even, at its extreme, transformer replacement, at a minimum overall cost which

can include system disturbance cost, energy not served cost, failure cost, etc.

1.1.1 Data processing structure

Smart Monitor is a transformer expert system, based on multiple engineering models (mathematical

formulations to assess transformers physical parameters) which are implemented using the logic

structure for data flow and analysis illustrated in Figure 1-1.

Figure 1-1 – Generic structure of data processing.

According to Figure 1-1, the data flow process is:




Phase 1 – Data input

On-line data incorporated into Smart Monitor database and integrated with off-line values previously

configured on the system (transformer profile, parameters, limits, etc.).

Phase 2 – Calculation

The data is processed by the engineering models applicable to the specific monitored variables. For more

details about all available models on the system go to item 1.2.

Phase 3 – Data Assessment

Objective data analysis performed based on acquired data processed by the engineering models in order to

assess possible deviations from normality and to determine the significance of such deviations.

Smart Monitor also correlates the present value of a given variable (or acquired parameter) to its historical

behavior which is duly stored into the database.

Phase 4 – Diagnostic

In case a deviation is detected and a significant level of importance is also attributed to the parameter by

Smart Monitor expert knowledge, then the user is notified of such an occurrence. Before sending an alarm

message, however, Smart Monitor implements a historical investigation of all possible correlated variables

which could influence the observed deviation and also makes that correlation available to the customer.

Phase 5 – Recommendation

On detecting an incipient disturbance or deviation from normality and its relative importance, Smart

Monitor also generates a set of recommendations (e.g. on detecting a high rate of rise of combustible gas

formation inside the transformer main tank Smart Monitor immediately recommends confirmation

through a complete off-line Dissolved Gas Analysis to be carried out by the customer), particularly with

respect to maintenance and operation criteria, to mitigate the problem.

Phase 6 – Prognostic

Smart Monitor notifies the user about the implications of keeping the current operation conditions,

particularly on keeping the faulty variable at the current level or rate of increase.

Phase 7 – Trend

When applicable, the statistical behavior of variables is compared to their acceptable limits. The system

then informs possible trends which will lead to future alarms in case the current conditions are retained`.




1.1.2 Monitored Variables

This section describes the individual values monitored by the Smart Monitor, expert system and their

significance in gaining in-depth knowledge about the transformer operating conditions. The sensors or

IED’s required for each of them are optional. The software is configured to include them and the

respective engineering models.

Dissolved gas in oil

The main sources of dissolved gases in the transformer oil are thermal and electric in nature and

generally relate to a minimum level of disturbance. Usually, fault gases are associated to continuous gas

generation (relative increase) and to certain absolute levels that are indicative of a problem. Results are

confirmed by laboratory investigations.

Moisture in oil

Excess of moisture in oil leads to accelerated ageing of the isolation materials, reducing their isolation

capability. Usually, the mechanical resistance of the isolation is reduced as its water content increases.

Also, the thermal deterioration rate is proportional to the water content. It has been demonstrated that

the water contained in the paper may escape under the form of steam bubbles. These bubbles may move

with the oil flow, or get trapped inside the windings, in both cases breaking the isolation.

Temperatures (ambient, top and bottom oil) and load current

The load capability of power transformers is limited principally by the winding temperature. But the true

limiting factor is the hottest winding section, since the winding temperature isn’t uniform over its extent.

This section is called winding Hot Spot and it is located around the top of the winding. The Hot Spot

temperature may be determined by a mathematical model with ambient temperature, top and bottom

temperatures and the load current as inputs.

The isolation temperature is the main cause of transformer ageing. The cellulose isolation undergoes

“despolymerization”, caused by temperature and time. As the cellulose chain becomes smaller, the

mechanical properties of the paper, like traction resistance and elasticity are degraded. It’s possible that

the paper becomes fragile and is incapable to withstand the short-circuit forces and the normal

vibrations. This is points to the end of the life of the solid isolation, thus determining the end of

transformer life.

The hot spot monitoring allow taking advantage of cold ambient temperature, to extend the transformer

lifetime, providing the capacity of urgent overload.

Oil flow




The knowledge of oil flow on the pump pipe is necessary to assure the correct cooling of the circulating

oil inside the transformer.

Cooling system current

The measurement of fans and pumps current is necessary to verify the correct operation of each fan and

pump group.

Measurement of voltage or current at the tap of the bushing

Bushing failures usually occur in a sequence of small defects which impose the loss of intermediary

capacitive layers, frequently caused by short-circuit between two conductive aluminum sheets. This

progression is irreversible and provokes the elimination of one capacitive layer thus causing an increase in

the overall capacitance of the bushing. By monitoring the voltage or current on the capacitive tap

(voltage or test tap) of the bushings, it is possible to verify the variation on the capacitance relative

deviation between the phases and identify a possible fault.

Oil Level

The knowledge of oil level is necessary to calculate the total volume of the transformer oil. By comparing

this measured oil volume to the calculated (determined by the oil temperatures), possible oil leaks on the

transformer tank can be detected.

1.1.3 Storage strategy

In order to optimize the memory usage on the servers (hard disk) and avoid large amount of inconsequential data Smart Monitor does not store every data point received (frequency recording).

Instead, it defines a threshold for each variable above/below which this variable should be stored (event

recording).

The limit defined for each variable is shown on the table below:




Table 1-1 – Standard threshold of monitored variables

Variable type Standard threshold

Voltage 1% of nominal voltage (kV)

Overvoltage 1 kV

Load current 5% of nominal current (A)

Temperature 2º C

Relative capacitance deviation 0,1 %

Power 10% of nominal power (MVA)

Individual gases (C2H2, H2, etc) 1 ppm

Combined gases 5 ppm

Moisture in oil (relative saturation) 1%

Moisture in oil 1 ppm

Ageing rate 0,1 p.u.

Oil level 5%

Oil volume 100 liters

Air/oil flow on cooling groups 10%

Tap changer position 1 position

Tap changer number of operation 1 operation




1.2 Models and Core Module

Core Module, responsible for the execution of the mathematical models performs data handling in the

Smart Monitor expert system. The Core Module also generates the charts, makes the variables available

on the pages, calculates variables which are not handled by any model, issues system self-diagnostics

and manages all diagnostics and system events.

The models are responsible for the calculation of the relevant variables, evaluation of trends and

correlation between the input parameters (online and offline), issuing diagnostics and recommending

actions when an abnormality is detected. Data treatment will be done by mathematical models that

allow the correlation between several input parameters, inferring diagnostics and indicating

recommended actions when an anomaly is detected. Based on the scope of the project the following

models are available with Smart Monitor.

Table 1-2 – Models available on Smart Monitor.

Model Main Functions

Bushing relative capacitance deviation

Evaluation of bushing insulation condition, based on online and statistical learning.

Insulation moisture Evaluation of oil moisture condition and estimated moisture in paper, including trend analysis.

Load Guide The system calculates the future expected hot spot with the user defined values and actual operations conditions, assisting in equipment load management.

Thermal Hot spot evaluation by ANSI / IEC and Siemens methods.

Ageing and life expectancy

Evaluation of relative loss of life and relative ageing by ANSI, IEC or ABNT methods.

Cooling System Checks the adequate cooling system operation by monitoring the load current of the fan groups and oil/water flow (depending on the cooling system)

Conservator oil volume

Allows the incipient fault indication before reaching the lowest acceptable level, comparing the estimated insulating oil volume in the conservator based on the transformer temperatures distribution with the calculated volume based on the oil level sensor indication.

Cooling Control

Only by defining the desired transformer operation temperature, this model controls the cooling system calculating the future hot spot as a function of the current loading. Also factored in is the number of hours of fans and pumps usage, in order to balance the wear of each group (rotational use). Additionally, the system executes periodical cooling groups exercise.

LTC Monitoring Monitoring of average and maximum power on each tap change in order to detect alteration on the motor drive torque. Acceptable limit for each tap position is defined based on learning of tap transitions. It also calculates the wear of contacts.




Combined dissolved gas-in-oil

Dissolved gas-in-oil ratios, trends and limit values evaluation, based on an online statistical learning.

Three-gas online Chromatography

Evaluation and indication of incipient faults using standardized methods, including the Duval’s triangle. Evaluates ratios, trends and limit values, based on an online statistical learning.

Eight-gas online Chromatography

Evaluation and indication of incipient faults using standardized methods, including the Duval’s triangle. Evaluates ratios, trends and limit values, based on an online statistical learning. Includes the evaluation of the CO2/CO concentration ratio, for enhanced troubleshooting.



Web Page 2-1

2 Web Page

In this section, all available pages of the Smart Monitor website are detailed with comments to ease the

system usage. All functions available in the Smart Monitor Software are presented and some may not be

available with the purchased software configuration due to its scope. Smart Monitor web pages are not

automatically refreshed and if necessary the function key “F5” can alternatively be used..

When entering or modifying parameters of the system, the exclamation signal (!) may come

up at right of a data field, indicating an improper or out of limits value.. In this case, enter an

appropriated value to proceed.

2.1 General Screens

2.1.1 Login

Figure 2-1 – Login

Internet Explorer must be 6.0 or higher and Java plug-in available for charts.

To open this initial windows, open a new web browser tab, type

Smart Monitor IP address or DNS name (if available within the

intranet) and “enter”.

After typing Login and Password, click here to connect to Smart Monitor.

Selection of the languages available

for SM web site



Web Page 2-2

If a user does not have a Login and Password, the customer system administrator must be

contacted. Usually SIEMENS provides a initial system administration login/password and then various

users can be created (refer to 2.4). If the customer system administrator does not have a Login and

Password, contact the vendor at Siemens.

2.1.2 Home

Home page provides information for each monitored equipment, the latest active diagnostic and system

event. These messages remain active until they are acknowledged. Diagnostic messages relates to the

transformer condition or status. System Events relates to autodiagnostic of Smart Monitor software and

hardware issues, including sensors or IEDs, communication, cabling and panel (like open door

microswitch or an opened circuit breaker). If there are no active diagnostics and/or system events, “No

occurrence” caption shall be displayed under the Description column. In case the equipment is on

Maintenance mode (see item 2.2.9 for more details), system indicates “Maintenance” under Description.

From this page, the user can access the diagnostic/event of any equipment or use the menu on top of

the page to access other pages.

Figure 2-2 – Home.

Click on the menu items to access the

respective page

Click on the text in column Description to access the

diagnostic/event page

Smart Monitor status



Web Page 2-3

The operation status can indicate:

Online: Smart Monitor service is running normally.

Offline: Smart Monitor service is stopped. Turn off the SM microbox (microcomputer) and

restart. Wait 5 minutes and if the status remains the same, contact Siemens for support.

No service: The service used to publish the Smart Monitor page is not communicating with the

system data bank. Turn off the SM microbox (microcomputer) and restart. Wait 5 minutes and if

the status remains the same, contact Siemens for support.

Maintenance: The selected equipment was set to Maintenance mode. If the maintenance has

been finished, change the maintenance mode (refer to section 2.2.9).

2.1.3 General Functions

The screen below illustrates details of the system which are available during navigation:

Figure 2-3 – General Functions.

Click here to log off from Smart Monitor website

Click here to access Smart Monitor manual

Connected user name

Click here to print the currently displayed

page



Web Page 2-4

2.2 Equipment Menu

After selection of the monitored equipment, the left side Menu becomes available.

2.2.1 Equipment selection

This page shows the Substation and the transformer Denomination. A brief description of the equipment

– nameplates data and main characteristics - are displayed for surely identify the transformer.

Figure 2-2 – Equipment selection

Note: Smart Monitor is intended to monitor only one transformer at a time although this page includes the

Substation and Transfomer Denomination with scroll down box. The reason is due to the software code

which is exactly the same for TMDS – multiple transformers and substations monitoring –, only preparing

a different configuration.

After selecting the substation and transformer denomination, the

rated nameplate and main characteristics are displayed for

surely identify the unit Click Confirm to proceed.

Menu



Web Page 2-5

Main variables

The screen provides a picture of the equipment with current values of the main variables super imposed

over the transformer picture. This page is automatically updated every minute. The automatic log off

after 5 minutes don’t apply here.

Figure 2-3 –Main variables.



Web Page 2-6

2.2.2 All variables

All Variables page shows directly measured and calculated variables by the engineering models, and

displays the the last value stored in the system database.

Figure 2-4 – All variables.

The variables are joined in groups to ease the visualization. The following table lists all variables that can

be monitored by the system with an indication of its group. The table also lists the origin of each

variable. This page can be easily configured for each project according to customer preference and of

course according to the available sensors and models.



Web Page 2-7

Table 2-1 – All variables.

Group Variable Unity Origin

Voltage Phase-to-ground voltage - HV kV Bushing sensor

Voltage Phase-to-ground voltage - LV kV Bushing sensor

Voltage Phase-to-ground voltage - Phase A - HV kV Bushing sensor

Voltage Phase-to-ground voltage - Phase B - HV kV Bushing sensor

Voltage Phase-to-ground voltage - Phase C - HV kV Bushing sensor

Voltage Phase-to-ground voltage - Phase A - LV kV Bushing sensor

Voltage Phase-to-ground voltage - Phase B - LV kV Bushing sensor

Voltage Phase-to-ground voltage - Phase C - LV kV Bushing sensor

Overvoltage Overvoltage HV kV Bushing sensor

Overvoltage Overvoltage - LV kV Bushing sensor

Overvoltage Overvoltage phase A - LV kV Bushing sensor

Overvoltage Overvoltage phase B - LV kV Bushing sensor

Overvoltage Overvoltage phase C - LV kV Bushing sensor

Overvoltage Overvoltage phase A - HV kV Bushing sensor

Overvoltage Overvoltage phase B - HV kV Bushing sensor

Overvoltage Overvoltage phase C - HV kV Bushing sensor

Capacitance Relative capacitance deviation - HV % Bushing model

Capacitance Relative capacitance deviation - LV % Bushing model

Capacitance Relative capacitance deviation phase A - HV % Bushing model

Capacitance Relative capacitance deviation phase B - HV % Bushing model

Capacitance Relative capacitance deviation phase C - HV % Bushing model

Capacitance Relative capacitance deviation phase A - LV % Bushing model

Capacitance Relative capacitance deviation phase B - LV % Bushing model

Capacitance Relative capacitance deviation phase C - LV % Bushing model

Current Current HV A Current transducer

Current Current LV A Current transducer

Current Tertiary Current A Current transducer

Power Power MVA SM Core Module

Temperatures Smart Monitor local panel temperature ºC RTD sensor

Temperatures Core temperature - Measurement 1 ºC RTD sensor

Temperatures Core temperature - Measurement 2 ºC RTD sensor



Web Page 2-8

Temperatures Top oil temperature - Measurement 1 ºC RTD sensor

Temperatures Top oil temperature - Measurement 2 ºC RTD sensor

Temperatures Bottom oil temperature - Measurement 1 ºC RTD sensor

Temperatures Bottom oil temperature - Measurement 2 ºC RTD sensor

Temperatures Ambient temperature ºC RTD sensor

Temperatures Hot spot temperature HV - Calculated ºC Thermal model

Temperatures Hot spot temperature LV - Calculated ºC Thermal model

Temperatures Tertiary Hot spot temperature - Calculated ºC Thermal model

Temperatures Hot spot temperature HV - Measured ºC FO Direct measurement

Temperatures Hot spot temperature LV - Measured ºC FO Direct measurement

Temperatures Tertiary Hot spot temperature - Measured ºC FO Direct measurement

Temperatures Water temperature ºC RTD sensor

Gas in oil Hydrogen - H2 ppm Gas sensor

Gas in oil Methane - CH4 ppm Gas sensor

Gas in oil Acetylene - C2H2 ppm Gas sensor

Gas in oil Ethylene - C2H4 ppm Gas sensor

Gas in oil Ethane - C2H6 ppm Gas sensor

Gas in oil Carbon Monoxide - CO ppm Gas sensor

Gas in oil Carbon dioxide - CO2 ppm Gas sensor

Gas in oil Oxygen - O2 ppm Gas sensor

Gas in oil Nitrogen - N2 ppm Gas sensor

Gas in oil Total Dissolved Combustible Gases (TDCG) ppm Gas model

Gas in oil Gas in oil ppm Gas sensor

Moisture Oil moisture (relative saturation) % Gas/moisture sensor

Moisture Oil moisture ppm Moisture model

Moisture Moisture in paper at hot spot % Moisture model

Moisture RSoilper_calc % Moisture model

Moisture Woil_calc % Moisture model

Moisture Wcell_cold_bot_insul % Moisture model

Moisture Wcell_cold_top_insul % Moisture model

Moisture Wcell_bot_cond_insul_surf % Moisture model

Moisture Wcell_top_cond_insul_surf % Moisture model

Moisture Wcell_ bot_ cond_ insul % Moisture model

Moisture Wcell_top_cond_insul % Moisture model



Web Page 2-9

Moisture Wcell_avg % Moisture model

Moisture GPAOIL bar Moisture model

Moisture Temp Bubble ºC Moisture model

Ageing Relative aging rate - IEC p.u. Thermal model

Ageing Relative aging rate - ABNT p.u. Thermal model

Ageing Relative aging rate - IEEE p.u. Thermal model

Ageing Aging hours h Thermal model

Loss of life Accumulated aging rate - IEC p.u. Thermal model

Loss of life Accumulated aging rate - ABNT p.u. Thermal model

Loss of life Accumulated aging rate - IEEE p.u. Thermal model

DECT TAP position - Position indicator

Oil level Oil level of main tank conservator % Oil level indicator

Oil level Oil volume calc. as function of oil level liters Oil level model

Oil level Oil volume calc. as function of temperature distribuition in the tank and conservator

liters Oil level model

LTC Oil level of LTC conservator % Oil level indicator

LTC TAP position - Position indicator

LTC LTC motor current A Current transducer

LTC LTC oil temperature ºC RTD sensor

LTC Operations number of LTC - LTC model

LTC LTC oil moisture - Moisture sensor

Cooling Air flow - Fan group 1 % Flow sensor






Cooling Current - Fan Group 1 A Current transducer






Cooling Hour counter - Fan group 1 h SM Core Module



Web Page 2-10






Cooling Oil flow - Pump 1 % Flow sensor






Cooling Hour counter - Pump 1 h SM Core Module






2.2.3 Charts

In the Charts page, the user can select as many variables as needed, using a scrolling menu of all

variables. In order to ease the visualization not more than 3 variables should be selected at a time.

Selecting more than 3 can be useful only for downloading the values to a .csv file.



Web Page 2-11

Figure 2-5 – Charts

To select (or unselect) multiple variables for the chart, hold down the “Ctrl” key before toggling the

mouse left button over the item. Variables from other monitored transformers can be selected for

comparision purposes. Select the period and click the onscreen button “double arrow” to generate the

chart. . Every time the selections of variables or period are changed, it is necessary to click the onscreen

button “double arrow” to update the chart selections.

To zoom a portion of the chart, hold the left button of the mouse, drag the desired region and then

release the button. To zoom in, drag from the left to the right and to zoom out, drag from the right to

the left.

Values Table link opens a window with all values selected for the chart in a tabular format. From there, it

is possible to export the data in a .csv file by clicking on the link Export shown below. Before

downloading the file, the operational system software will open a window to choose the local, directory

and file name.

Selection of other transformers

Selection of variables

Click the onscreen icon “double arrow” to generate the chart

Select the period

Click on the link to open the values

table



Web Page 2-12

Figure 2-6 – Data table.



Web Page 2-13

2.2.4 Duval’s triangle

This feature is only available for Smart Monitor configurations with dissolved gases in oil device capable of

measuring the Duval’s triangle key gases (CH4, C2H2 and C2H4). The red dot indicates the region of fault

based on current gas concentrations and grey dots the previous concentrations.

Duval’s Triangle can only indicate the type of an ongoing fault, for any concentration of its key

gases. The diagnostic of an incipient fault need additional analysis, like concentration of gases,

trends, transformer fingerprints for comparison, etc. Do not make conclusions based only on Duval’s

triangle.

Figure 2-7 – Duval triangle



Web Page 2-14

2.2.5 Diagnostics

This page shows all the Diagnostics issued by the system for this transfomer. Diagnostics are related to

the transformer condition while system events are related to the monitoring hardware and software.

Each engineering model of Smart Monitor analyses accordingly the data available by filtering the raw

data from sensors/IEDs, storing values, performing statistics, learning from previous collected data, trend

calculations, comparison with proven or standardized limits and correlation with other variables. The aim

of the models is to indicate a possible fault or a developing fault as early as possible. In order to detect

these incipient faults sometimes is not possible to avoid false positives. By default, clicking on

Diagnostics link on the side menu, the system will show only the active diagnostics (not yet

acknowledged by any user). To view all diagnostics - active and acknowledged - issued by the system

click on the onscreen “Enable filters” button and select the box “All Diagnostics”.

Figure 2-8 – Enable diagnostic filter.

Figure 2-9 – Performing diagnostics filtering

Select the period



Web Page 2-15

Select the desired period and click the onscreen icon “double arrow” to perform the search.

To detail each diagnostic, click on View link to open a new window. Here we can find the description of

the diagnostic event, the prognostic or further analysis, recommended actions and if applicable, the

detected trend.

Figure 2-10 – Diagnostic presentation.

To include comments to the issued diagnostic, just type the desired text in the white box and click on the

button “Save Comments”. There is no limit for the number of added comments.

It is recommended to acknowledge the diagnostic just after the issue has been properly addressed, the

measurement values returned to normal conditon and comments have been inserted. Dependign on an



Web Page 2-16

expert technician analysis, some condfigured values can be changed because it can be normal for this

transformer fingerprint.

In case the conditions for a diagnostics persist after the acknowledgement the system will

issue the same diagnostic with values which could be newly calculated.

Generate Report button allow to Open or Save a report of this specific diagnostic.

Choosing Open, the system will open a new window to display the report in .html format, with all the

diagnostic information, including the added comments. To print it, click on the Print link.

Figure 2-11 – Diagnostic report



Web Page 2-17

2.2.6 System Events

System Events are related to the monitoring hardware and software and are generated by the Smart

Monitor Core Module. It can be triggered by any problem with sensor/IEDs integrated to the monitoring

system, malfunction of the computers or inconsistence of the calculations of the engineering models.

This page allows access to System Events issued for the selected equipment only (to visualize System

Events from all monitored equipment go to item Table 2.2).

By default, clicking the link System Events link on the side menu, only the active system events will be

shown. Active are those whose condition/alarm still persist. To visualize all system events - active and

inactive -, toggle the “Enable filters” button and then select the box “All Events”. Afterwards, select the

desired period and click the onscreen icon “double arrow” to perform the search.

Unlike Diagnostics, the system events do no require acknowledgement. It will automatically turn inactive

as the issue has been solved.

Figure 2-12 – Enabling System Events filtering.

The list of all events includes one line for the date/time when the system event turned active

and another line for the date/time when it was released (inactive). Hence, when “All events” is

selected, take care of not interpreting a released event as active.



Web Page 2-18

Figure 2-13 – System events.

To help the user to identify the root cause of the problem, the system indicates the origin of the event

detected on the column Origin shown above:

Table 2-2 – Available System Events on Smart Monitor and recommenedd actions.

Origin Description Recommended actions

Bu

shin

g s

enso

r

Bushing monitoring device - Action alert

This event is obtained directly from the bushing sensor and is related to the bushing conditions. For more details, refer to the sensor manual

Bushing monitoring device - Warning alert

This event is obtained directly from the bushing sensor and is related to the bushing conditions. For more details, refer to the sensor manual.

Bushing monitoring device - Information alert

This event is obtained directly from the bushing sensor and is related to the bushing conditions. For more details, refer to the sensor manual.

Bushing monitoring device - System fault

This event is obtained directly from the bushing sensor and is related to the sensor conditions. For more details, refer to the sensor manual.

Communication failure with bushing monitoring device

Ensure that there is communication between local and central panel. In case this communication is faulty, this event will come up among others. If the communication is established, verify if the bushing sensor is on and the LEDs of the respective module on ET200s are blinking. If not, check the wiring and the power supply.

LTC

sen

sors

Communication Failure TM100

Ensure that there is communication between local and central panel. In case this communication is faulty, this event will come up among others. If the communication is established, verify if TM100 sensor is on and the LEDs of the respective module on ET200s are blinking. If not, check the wiring and the power supply.

Output overflow - Oil level indicator – LTC

Turn the respective circuit breaker off and insert an ammeter in series with the ET200s module that is causing the event. Be careful not to short-circuit the module terminals. Turn the circuit breaker on and measure the current. If it is out of 4-20mA range, the sensor may be defective. If it is within this range, the ET200s module may be defective.

Output overflow - Motor current sensor - LTC

Wire break - Oil level indicator – LTC

Ensure that there is communication between local and central panel. In case this communication is faulty, this event will come up among others. If the communication is established, verify if TM100 sensor is on and the LEDs of the respective module on ET200s are blinking. If not, check the wiring and the power supply.

Wire break - Motor current sensor - LTC



Web Page 2-19

Load

Cu

rren

t se

nso

r

Output overflow - Load current sensor – HV Turn the respective circuit breaker off and insert an ammeter in series with the ET200s

module that is causing the event. Be careful not to short-circuit the module terminals. Turn the circuit breaker on and measure the current. If it is out of 4-20mA range, the sensor may be defective. If it is within this range, the ET200s module may be defective.

Output overflow - Load current sensor – LV

Output overflow - Load current sensor - Tertiary

Wire break - Load current sensor – HV Verify if the sensor is on and the wiring between the ET200s module and sensor is ok.

If so, turn the respective circuit breaker off and insert an ammeter in series with the ET200s module that is causing the event. Be careful not to short-circuit the module terminals. Turn the circuit breaker on and measure the current. If it is below 4mA, the sensor may be defective. Otherwise there may be a fault on the ET200s module.

Wire break - Load current sensor – LV

Wire break - Load current sensor - Tertiary

Bre

aker

s

Open circuit breaker - 24V DC power supply

Make sure there is communication between local and central panel. In case this communication is faulty, this event will come up among others. If the communication is established, try to close the circuit breaker. If it goes off again, make sure there is no short-circuit on the wiring from the circuit breaker and all components on the circuit are functional.

Open circuit breaker - AC power supply

Open circuit breaker - Gas in oil monitoring device

Open circuit breaker - Bushing monitoring device

Open circuit breaker - Light, heater and fan from local panel

Ga

s in

oil

sen

sor

Hydran sensor alarm - System failure

This event is obtained directly from Hydran and is related to the sensor conditions. For more details, refer to the sensor manual.

Hydran sensor alarm - Gas high

This event is obtained directly from Hydran and is related to the gas in oil conditions. For more details, refer to the sensor manual.

Hydran sensor alarm - Gas high-high

This event is obtained directly from Hydran and is related to the gas in oil conditions. For more details, refer to the sensor manual.

Hydran sensor alarm - Moisture in oil

This event is obtained directly from Hydran and is related to the moisture in oil conditions. For more details, refer to the sensor manual.

Helium low pressure - Siemens Gas-Guard

Verify the pressure of helium cylinder. If it is around 150 psi, it should be replaced.

Communication failure with gas in oil monitoring device

Ensure that there is communication between local and central panel. In case this communication is faulty, this event will come up among others. If the communication is established, verify if the gas sensor is on and the LEDs of the respective module on ET200s are blinking. If not, check the wiring and the power supply.

Output overflow - Hydran sensor

Turn the respective circuit breaker off and insert an ammeter in series with the ET200s module that is causing the event. Be careful not to short-circuit the module terminals. Turn the circuit breaker on and measure the current. If it is out of 4 - 20mA range, the sensor may be defective. If it is within this range, the ET200s module may be defective.

Wire break - Hydran sensor Verify if the sensor is on and the wiring between the ET200s module and sensor is ok. If so, turn the respective circuit breaker off and insert an ammeter in series with the ET200s module that is causing the event. Be careful not to short-circuit the module



Web Page 2-20

terminals. Turn the circuit breaker on and measure the current. If it is below 4mA, the sensor may be defective. Otherwise there may be a fault on the ET200s module.

Power relay - Siemens Gas-Guard

Ensure that there is communication between local and central panel. In case this communication is faulty, this event will come up among others. If the communication is established, verify that the power supply of the gas sensor is ok.

Programmable relay - Siemens Gas-Guard

This event is obtained directly from Gas Guard and can be related to the sensor or gas in oil conditions. For more details, the sensor manual shall be verified.

IM1

51-8

Communication failure Verify if the IM151-8 is connected.

Smar

t M

on

ito

r

Local panel door open

Verify if the local panel door is open. Make sure there is communication between local and central panel. In case this communication is faulty, this event will come up among others. If necessary, verify wiring and status of micro-switch responsible for this alarm.

Oil

leve

l in

dic

ato

r Output overflow - Oil level indicator - Main tank


Wire break - Oil level indicator - Main tank

Verify if the sensor is on and the wiring between the ET200s module and sensor is ok. If so, turn the respective circuit breaker off and insert an ammeter in series with the ET200s module that is causing the event. Be careful not to short-circuit the module terminals. Turn the circuit breaker on and measure the current. If it is below 4mA, the sensor may be defective. Otherwise there may be a fault on the ET200s module.

Co

ntr

ol c

ub

icle

sig

nal

s

High Pressure This event is related to the protection system of the transformer.

Low Pressure This event is related to the protection system of the transformer.

OLTC blocked This event is related to the protection system of the transformer.

Protection - Buchoolz - Alarm

This event is related to the protection system of the transformer.

Protection - Buchoolz - Trip This event is related to the protection system of the transformer.

Protection - Tank pressure relief - Trip

This event is related to the protection system of the transformer.

OLTC Overpressure This event is related to the protection system of the transformer.

Transformer Overpressure This event is related to the protection system of the transformer.

Empty Tank This event is related to the protection system of the transformer.

Co

olin

g s

yste

m

sen

sors

Output overflow - Current sensor of fan group 1, 2, 3, 4, 5 or 6

Turn the respective circuit breaker off and insert an ammeter in series with the ET200s module that is causing the event. Be careful not to short-circuit the module terminals. Turn the circuit breaker on and measure the current. If it is out of 4 - 20mA range, the sensor may be defective. If it is within this range, the ET200s module may be defective. Turn the respective circuit breaker off and insert an ammeter in series with the ET200s module that is causing the event. Be careful not to short-circuit the module terminals.

Output overflow - Air flow sensor of fan group1, 2, 3, 4, 5 or 6



Web Page 2-21

Output overflow - Oil flow sensor of pump1, 2, 3, 4, 5 or 6

Turn the circuit breaker on and measure the current. If it is out of 4 - 20mA range, the sensor may be defective. If it is within this range, the ET200s module may be defective.

Wire break - Current sensor of fan group 1, 2, 3, 4, 5 or 6 Verify if the sensor is on and the wiring between the ET200s module and sensor is ok.

If so, turn the respective circuit breaker off and insert an ammeter in series with the ET200s module that is causing the event. Be careful not to short-circuit the module terminals. Turn the circuit breaker on and measure the current. If it is below 4mA, the sensor may be defective. Otherwise there may be a fault on the ET200s module.

Wire break - Air flow sensor of fan group1, 2, 3, 4, 5 or 6

Wire break - Oil flow sensor of pump 1, 2, 3, 4, 5 or 6

Tem

pera

ture

sen

sors

Output overflow - Hot spot temperature – HV, LV or Tertiary


Output overflow - Core temperature - Spot1 or 2

Wire break - Ambient or local panel temperature sensor

Verify if the sensor is on and the wiring between the ET200s module and sensor is ok. If so, turn the respective circuit breaker off and insert an ammeter in series with the ET200s module that is causing the event. Be careful not to short-circuit the module terminals. Turn the circuit breaker on and measure the current. If it is below 4mA, the sensor may be defective. Otherwise there may be a fault on the ET200s module.

Wire break - Hot spot temperature – HV, LV or Tertiary

Wire break - Core temperature - Spot 1 or 2

Wire break - Bottom oil temperature - Sensor 1 or 2

Wire break - Top oil temperature - Sensor 1 or 2

Local panel temperature above maximum limit

Make sure local panel fan is working properly and the temperature sensor is not defective. If no problem is found, the cooling of this panel may be redefined.

Mo

istu

re s

enso

r

Output overflow - Temperature - Moisture in oil sensor


Output overflow - Relative humidity - Moisture in oil sensor

Wire break - Temperature - Moisture in oil sensor


Wire break - Relative humidity - Moisture in oil sensor



Web Page 2-22

2.2.7 Notes

This function allows the user to record general comments and notes regarding modifications or changes

made to the monitoring system or the monitored equipment. All the comments eventually added to

diagnostics are also available at this section.

Figure 2-14 – Adding notes.

2.2.8 Maintenance

If the user clicks on the Start Maintenance button, the Smart Monitor system would be taken off line,

then the user would enter what maintenance activity was performed on the Smart Monitor system. This

function must be used every time an action that may lead to interference with the monitoring system is

being taken. The purpose is to avoid improper alarms and data recording.

After typing the note, click here to save it.



Web Page 2-23

Figure 2-15 – Starting maintenance.

To Start Maintenance click the onscreen button and the status indicator of this transformer will change

to Maintenance and the values in Main Variables and All Variables will be frozen with the last readings,

in order to show the last situation before the maintenance period. From this moment on, the data

acquisition/recording and diagnostic/event issuing will be paused.

Additional information/comments can be added during maintenance status condition, without breaking

this condition. Type the information/comments and click onscreen button “Save message”.

To end the maintenance status condition, type a brief description (obligatory) and click onscreen button

Stop maintenance.

Figure 2-16 – Stopping maintenance.



Web Page 2-24

2.2.9 Maintenance - History

Use this link to view all maintenance periods that were recorded in the system for this transformer.

2.2.10 Parameters

This page shows the parameters used by Smart Monitor engineering models and also, for authorized

users, the modification of them.

Inadequate modifications of parameters can cause erroneous calculations and diagnostics.

Figure 2-17 – Changing parameters.

After the modification of any parameter, it is necessary to click the onscreen button Modify at the

bottom of the page in order to confirm the modification. Here you are not just saving new values but

introducing new behavior to the system.



Web Page 2-25

i. Parameters – Transformer

The basic transformer parameters are shown below:

Table 2-3 – Thermal Model parameters

Parameter Description Origin Un. Default

Serial number Transformer serial number. For identification purpose. Nameplate - NA

Technical data Transformer description and caractheristics. For identification purpose.

Nameplates values and customer tags

- NA

Energization date Transformer first energization date. Used in ageing model.

- date NA

Nominal voltage (phase-to-ground) – HV

Rated voltage (at center tap) of the transformer – HV. Used in various models.

Nameplate kV NA

Nominal voltage (phase-to-ground) – LV

Nominal voltage of the transformer – LV. Used in various models.

Nameplate kV NA

Voltage HV (phase-to-phase) for ratio

Used for HV/LV voltage ratio calculation (*). Nameplate kV NA

Voltage LV (phase-to-phase) for ratio

Used for HV/LV voltage ratio calculation (*). Nameplate kV NA

High Voltage Current CT – Max Range

Highest current value of HV CT primary. Related to secondary current of 5A. For example, a TC ratio of 600/5A has max range of 600. For a TC ratio of 600/1A the max range must be 3000.

Nameplate A NA

High Voltage Current CT – Min Range

Lowest current value of HV CT primary. Value is 0 (zero). For compatibility purpose.

Nameplate A NA

Low Voltage Current CT – Max Range

Highest current value of LV CT primary. Related to secondary current of 5A. For example, a TC ratio of 1200/5A has max range of 1200. For a TC ratio of 1200/1A the max range must be 6000.

Nameplate A NA

Low Voltage Current CT – Min Range

Lowest current value of LV CT primary. Value is 0 (zero). For compatibility purpose.

Nameplate A NA

(*) Specific for CenterPoint project.The ratio is used to estimate the HV line current from LV line measured

current. HV line current is not measured but necessary for the thermal model calculations.



Web Page 2-26

Parameters – Cooling Control Model

For the cooling control, the following parameters must be configured:

Table 2-4 – Parameters Cooling Mode

Parameter Description Origin of value Un. Default

Hot-spot temperature for control

Reference temperature for the cooling control model. It estimates the steady state hot spot temperature for all cooling mode and compares with this reference. The cooling mode which has the closest steady state hot spot temperature of this reference is then selected. Hence the cooling groups are activated accordingly. If the calculated ongoing hot spot temperature surpasses this value the cooling groups are also activated and only deactivated when the temperature is return to a value lower than this reference. There is no hysteresis (see next item)

Customer choice The default value is considered low by Siemens, but has been adopted for compatibility with usual customer choice.

ºC 85ºC

Minimum working period

Delay time for cooling groups control being revaluated (activation or deactivation) by the cooling control model. It is necessary to avoid excessive activation/deactivation.

Customer choice minutes 30 min

Duration of cooling exercise Interval of time the cooling groups will remain activated during the periodic exercise. Preventive maintenance purposes.

Customer choice minutes 30 min

Time interval between exercises

To adjust how frequent all the cooling groups will be activated for preventive maintenance purposes.

Customer choice days 7 days

ii. Parameters – Thermal Model

The table below shows all necessary parameters for Smart Monitor Thermal Model:



Model for hot spot calculation

Hot spot temperature algorithm calculation selection (IEEE, IEC or SIEMENS model). When using Dynamic Loading Guide, select Siemens model for compatibility.

Customer choice NA SIEMENS

Maximum winding temperature

Limit for the highest (among the windings) hot spot temperature, directly measured or calculated. A diagnostic will be issued as an alert.

Based on standard recommendation or customer choice

ºC 120ºC

Maximum aging rate

Limit of ageing rate for issuing a diagnostic as an alert. Based on standard recommendation or customer choice

p.u. 2.7 p.u.

Maximum accumulated loss of life

Limit of equivalent aging factor (refer to IEEE standard). For issuing a diagnostic as an alert. Some authors use the term “accumulated loss of life in p.u.”

Based on standard recommendation or customer choice

p.u. 1.2 p.u.

Loss of life prior to the monitoring (ABNT NBR, IEC or IEEE)

Equivalent aging factor from the period since the first energization date and the start date of the on-line monitoring system. For compatibility 3 standards are available, although they can be considered equal by

Evaluated by the customer according to the standard

p.u. NA



Web Page 2-27

approximation. For example if the transformer has been in operation for any number of years at exactly 110°C (hot spot temperature and using thermally upgraded paper), this value is 1.0. If the hot spot temperature is 89°C, this value is 0.1.

Monitoring start date

Start date of monitoring on the selected equipment. Used to include the loss of life prior to the monitoring to the Aging hours.

- date NA

Maximum ambient temperature

Maximum expected ambient temperature of the site. Used for calculations within the Thermal Model.

Customer input. Estimated.

ºC NA

Maximum top oil temperature

Limit of top oil temperature for issuing a diagnostic. Choice of the customer and based on standards.

ºC 105ºC

Maximum operation overload

Limit of Load factor for issuing a diagnostic. The same limit is applicable to HV, LV and tertiary currents of each cooling mode.

Choice of the customer based on technical design and operational pratices

p.u. 1.3 p.u.

Maximum design overload

Load factor above which a diagnostic will be issued. This limit is applicable just for the cooling mode of greatest power.

Supplied by the manufacturer

p.u. 1,3 p.u.

Hot Spot Factor (HV, LV or Tertiary)

Ratio of hot spot and average winding-oil gradient temperature. For some and average radientValue . Essential for an adequate estimation of the hot spot temperature. They are different for each winding and if not available from the manufacturer refer to IEC 60076-7 for a default value.

Supplied by the manufacturer. Should be mentioned and used in the heat run test report.

- 1.3

Winding Eddy Losses (HV, LV or Tertiary)

The percentage of eddy losses over the ohmic losses of the winding. As the temperature increases, the ohmic losses increases and the eddy losses decreases. To correct the temperature gradients (copper-oil and oil longitudinal) at a certain temperature of the windings the model need to evaluate the losses being dissipated by them. With this parameter this evaluation is improved.

Supplied by the manufacturer or estimated from the routine test report..

% NA

Core Losses at 100% of rated voltage

Used to improve the estimations of the Dynamic Loading Guide.

Routine test report kW NA

Core Losses at 110% of rated voltage

Used to improve the estimations of the Dynamic Loading Guide.

Routine test report kW NA

Standard for loss of life diagnostic

Loss of life is calculated according to IEC, IEEE and ABNT standards. This selection only defines which of them will be considered for a diagnostic.

Customer choice - IEEE

Paper type

Used to select the aging rate and loss of life formulas from Standards. If the specified hot spot temperature rise is 80°C (110°C if the ambient is 30°C), the cellulosic insulation is thermally upgraded.

Technical data of the transformer

- NA



Web Page 2-28

iii. Parameters – Cooling Modes

For each cooling mode and each winding, the following parameters must be configured to achieve an

adequate estimation of hot spot temperature:

Table 2-6 – Parameters Cooling Mode


Reference losses

Rated total losses at which other parameters are referenced. Used in the Dynamic Loading Guide to estimate the cooling system average oil temperature rise over ambient in steady state load.

Equipment heat run test

kW NA

Exponent for cooling system temp. calculation

Used in the Dynamic Loading Guide to estimate the average temperature rise over ambient of the cooling system in steady state for the new load.

Standard IEEE C57.91-1995/2002

- ONAN: 0,8 ONAF: 0,9 ODAF: 1,0

Average oil time constant

Used in the Dynamic Loading Guide to estimate the ongoing cooling system average temp. oil rise over ambient by the transitory thermal model.

Extracted from heat run test report or calculated acc. Standards and weights from nameplate.

minutes NA

Average increase of oil temperature in the cooling system

Or average temperature rise over ambient at the reference losses above mentioned. Used in the Dynamic Loading Guide to estimate the cooling system average oil temperature rise over ambient in steady state for the new load.

Heat run test report.

ºC NA

Longitudinal gradient of oil temp. in the cooling system

Or rated top oil minus the bottom oil temp. in the cooling system(radiators) at the reference losses mentioned above. Used in the Dynamic Loading Guide to estimate the cooling system bottom oil temperature after corrected by the transitory thermal model.


ºC NA

Exponent for winding temp. calculation

Used to calculate the new steady state copper-oil temperature gradient on each winding and then the hot spot temperature

Standard IEEE C57.91-1995/2002

- ONAN: 0,8 ONAF: 0,8 ODAF: 1,0

Longitudinal time constant of the windings oil

Time constant of the exponential temperature rise/decay of the longitudinal oil temperature gradient in the ducts of the windings. Used for hot spot partial calculations acc. to the transitory thermal model

Extracted from heat run test report. Can be also estimated as 1/5 of the oil time constant.

minutes NA

Percent of total eddy losses

The percentage of total additional losses (eddy and stray of the active part) over the ohmic losses of all the windings together. Used to correct the sum of winding losses at a certain temperature in the Dynamic Loading Guide.

Routine test report or heat run test report.

% NA

Rated current HV, LV or Tertiary

Reference currents for other parameters below. Used to calculate the load factor on windings, necessary for hot spot partial calculations.


A NA

Rated average copper-oil gradient HV, LV or Tertiary

At the reference current above for each winding. Used as partial calculation of the hot spot to estimate the the copper-oil gradient on each winding in steady state of the ongoing load factor and then corrected by the transitory


ºC NA



Web Page 2-29

thermal model.

Oil rated longitudinal gradient HV, LV or Tertiary

At the reference current above for each winding. Used as partial calculation of the hot spot to estimate the the longitudinal oil temp. gradient in winding oil ducts at steady state of the ongoing load factor and then corrected by the transitory thermal model.


ºC NA

Winding time Constant HV, LV or Tertiary

Time constant of the exponential temperature rise/decay of the copper-oil temperature gradient. Used for hot spot partial calculations acc. to the transitory thermal model

Extracted from heat run test report. Can be also estimated acc. to IEC 60076-7. Usually 5-15 min.

minutes NA

Reference losses HV, LV or Tertiary

At the rated current above mentioned. Used in the Dynamic Loading Guide as part of the estimation of the total losses after load factor and temperature correction. The result is part of the calculation of the cooling system average oil temperature rise over ambient.

Routine test report or heat run test report.

kW NA



Web Page 2-30

iv. Parameters – Cooling Group (fans)

On this item, besides hard limits for cooling diagnostics, it is possible to modify the hour counter of each

cooling group. To do so, type the new value for the counter at Hour counter field and click Modify at the

end of the page – see table 2-6.



Maximum current

Maximum cooling group normal current. In general close to the rated current of each fan times the number of fans. It can be evaluated on-site and an adequate tolerance be added in order to guarantee a correct diagnostic without false positives. A diagnostic will be issued if the measured value is above this limit.

Technical data of equipment

A NA

Minimum current

Can be calculated by subtracting the current of one fan from the evaluated minimum current of the group of fans during on-site measurements. A diagnostic will be issued if the group current is lower than this limit.


A NA

Period for maintenance

Partial operation time of the group of fans which requires maintenance action. A diagnostic will be issued.


hour 30000 hours

Number Number of fans per group. - - NA

v. Dynamic Loading Model

For dynamic loading mode, the following parameters must be configured:

Tabla 2-8 – Dynamic Loading Model parameters.


Maximum temperature of hot-spot in emergency

Maximum hot-spot temperature to be reached after the “Loading period in emergency” below at the load calculated by the Dynamic Loading Model. In fact the model consider this temperature to iteractively calculated the maximum final load in a emergency situation.

Customer choice based on Standards

ºC 120ºC

Loading period in emergency

Maximum time period for the overload calculated by the Dynamic Loading Model in order to reach the above configured hot spot.

Customer choice based on Standards

hour 2 hours

How to increase the current

The Dynamic Loding Model can increase the load linearly from the ongoing load to a final load, which is the output of the model. Alternatively it can increase directly to the final load (step).

Customer choice - NA

2.3 Events Menu

On this menu it is possible to access Diagnostics and Events of all monitored equipments.



Web Page 2-31

Figure 2-18 – Visualization of diagnostics from all monitored equipments.

The column marked above identifies the equipment of each Diagnostic or System Event. Each page lists 10

Diagnostic/Events. If the diagnostic/event to be visualized is not on the first page, click on the desired page

number as indicated on the figure below.

Figure 2-19 – Pages of diagnostics/system events.

2.4 Configuration Menu

Following are the pages that can be accessed using the Configuration menu.

2.4.1 User

This item is only available for users with Administrator privileges.

On this item, it is possible to add new users of the system, search existent users, include email address for

notification of diagnostics and system events and change the level of access for existing users.

The figure below illustrates the fields that can be used to refine a search. After defining the search

criterion, click on Refine list. To visualize all existent enabled users, choose Enable on Status and click on

Refine list without adding any other search criterion.

Click on the page number to access older diagnostics/events



Web Page 2-32

Figure 2-20 – Searching and adding users

To create a new user, click on Create. The following screen will come up:

Figure 2-21 – New user entry.

For Login, enter the name that will be used to login onto Smart Monitor and for User name, type the

entire name of the user.

Choose Enable for Status selection in order to allow the user to access the system. Choose one of the

following access levels for the new user under the Group field. The available levels are:

Visitor: Can view monitored variables, charts, diagnostics and parameters.

Monitor: Has the Visitor rights and additionaly can acknowledge Diagnostics, export data, start

maintenance and change parameters.

Click here to execute the search Click here to add a

new user

Fields for search criterion



Web Page 2-33

Administrator: Has the Monitor rights. Additionally can create or delete users and change

equipments (item 2.4.3).

On Password and Password confirmation fields enter the password according to the following Standards:

The first letter must be capital.

Must contain at least one numeric character.

Must contain at least one symbol within dot (.), comma (,) and asterisk (*).

Examples: Aaa11.aa

Peter.123

E-mails list: e-mail addresses which will receive the notification whenever there is a new diagnostic/event

available or there is a diagnostic acknowledgement. To include more than one address use comma (,) to

separate them.

E-mail notification box: The user can be enabled or disabled for receiving the notifications e-mails.

Finally, choose whether the password shall expire or not on the selection box Does the password expire?

If Yes is chosen, the password will expire in 90 days.

After entering all data, click on Save.

The Access to the database of the system is legally limited to five (5) users. Above this limit,

it is necessary to acquire additional licenses.

2.4.2 Change Password

All users can modify their passwords.

Figure 2-22 – Changing user password.

Fill in the blanks and click on screen button “Modify password” to confirm.



Web Page 2-34

2.4.3 Status

This item is useful when eventual maintenance or remote access is required. Under normal operation, the

status on the first line will display Waiting for next solicitation and on the second line it will show Active.

Figure 2-23 – System status.

2.4.4 Loaded modules

This information is useful for upgrading and tracking features and bugs already solved in the

system, although SIEMENS maintains this information for each supplied system.

Figure 2-24 – Loaded modules on the system.


SM – Operation and Maintenance Manual | December 2010

Sensors 3-1

3 Sensors

3.1 Temperatures

3.1.1 Pt100 (ambient temperature)

It consists in a RTD sensor (Resistance Thermometer Detector), 100 Ohm at 0 ºC type, encapsulated in a

steel tube. Installed inside Smart Monitor panel.

3.1.1.1 Technical data

Typical range: -40ºC to +100ºC Communication with SM: RTD Analog Protection: IP65

3.1.1.2 General procedures and maintenance

Pt100 sensors don’t need specific maintenance procedure.

3.1.2 Pt100 (oil temperatures)

It consists in a RTD sensor (Resistance Thermometer Detector), 100 Ohm at 0 ºC type, encapsulated in a

steel tube and assembled in an aluminum wiring box – Figure 3-1. It allows the measurement of the top

and bottom oil temperatures.

Figure 3-1 – Pt100 for oil temperature.



Sensors 3-2


Operation range: -50ºC to +300ºC Tube length: 80mm Communication with SM: RTD analog Protection: IP55


Pt100 sensors don’t need specific maintenance procedure.

3.2 Load Current

3.2.1 SIMEAS T

The passive SIMEAS T transducer converts the alternating input current (from the secondary of a CT) to a

load-independet direct output current. The input and output are highly insulated (5 kV) and auxiliary

power is not required .

Figure 3-2 – SIMEAS T working principle.

Transformer (1) transmits the input signal IE via the rectification and smoothing circuit (2) to the signal

evaluation (3), which controls the output amplifier (4). Supplied by the smoothing module, the output

amplifier delivers a load independent current IA, proportional to the input signal IE. The protective circuit

(5) provides the output with open circuit and transient overvoltage protection.The measuring range of the

alternating voltage transducer with expanded end range is adjusted via the expansion circuit (6).

The sensor is installed in the transformer main control cubicle to avoid cabling of the secondaries of the

TCs from main control cubicle to Smart Monitor, increasing safety to the circuitry – open secondaries may

damage bushing CTs and/or connections.

For more information, consult the sensor manual



Sensors 3-3

Figura 3-3 – SIMEAS T.


Model: 7KG6111-3EK10 (60Hz) / 7KG6111-2EK10 (50Hz) Provider: Siemens AG Insulation: Ueff= 5.5 kV 50Hz U= 5kV 1.2/50us (input against output) Short duration current withstand 200A for 1 s Accuracy: Ien to 0,05Ien : <0,5% Power/Working range: 0,9VA – maximum / 0.05Ien to 1.2Ien Temperature: -10ºC to +60ºC Nominal frequency: 50 Hz or 60 Hz CT nominal current: 5A Communication with SM: Analog 0..20mA Setting time (t99): <1 second Protection: IP40


SIMEAS T doesn’t need specific maintenance procedure.

Before any intervention in the current measurement circuit, short-circuit the secondary of the bushing CT at the main control panel.



Sensors 3-4

3.3 Cooling Group Current

3.3.1 MCR-SL-S

MCR-SL-S is a current measuring transducer for sinusoidal and non-sinusoidal alternating currents. The

input current is from 0 to100 A, with loop-powered output with 4...20 mA – Figure 3-4.

The sensor has a switch to control the current input range. The transducer is installed in the main control

cublicle, near the cooling group circuitry. The output signal is sent to the monitoring system.

For more information, consult the sensor manual – see section 2.1.3.

Figure 3-4 –MCR-SL-S transducer.


Model: MCR-SL-S-100-I-LP Provider: Phoenix Contact Power supply: 24VDC Operation temperature: -20ºC to +60ºC Frequency range: 30 – 600Hz CT nominal current: 50, 75 and 100A – with a switch selector Communication with SM: Analog 4..20mA Precision: <1% Setting time (t99): <340ms Protection: IP20


MCR-SL-S doesn’t need specific maintenance procedure.


SM – Operation and Maintenance Manual| April 2012

Hardware 4-1

4 Hardware

4.1 IM151-8 PN/DP CPU Interface

The IM 151-8 PN/DP CPU interface module is an "intelligent preprocessor for TMDS software". It

decentralizes control tasks, has all the PLC functionalities and can be integrated to ET200S I/O system

modules.

Figure 4-1 – IM151-8

The IM151-8 program, which is edited with Siemens STEP 7 language, controls all the IO cards connected

to the sensors/devices. It perform the readings, converts the readings into engineering values and filters

the the converted values. The filters algorithms remove spurious, overflow/underflow, outliers values in

accordance with the behavior of each device – marking them as unavailable. The PLC program is loaded

into a memory card and thus can be easily inserted in a new hardware if necessary to replace. The

communication with the Microbox is via PROFINET port (P1/P2/P3 ports are internally connected to an

ethernet switch).



Hardware 4-2

Table 4-1 – IM151-8 general description.

Position Description

1 RJ45 socket (port 1 of the PROFINET) R: Ring port for creation of ring topology with media redundancy.

2 RJ45 socket (port 2 of the PROFINET interface) R: Ring port for creation of ring topology with media redundancy.

3 RJ45 socket (port 3 of the PROFINET interface)

4 Mode selector switch

5 Status and error displays of the IM 151-8 PN/DP CPU interface module

6 Status displays of the PROFINET interface

7 Slot for the SIMATIC Micro Memory Card

8 Connection for supply voltage

The Figure 4-1 and the Table 4-1 show a general view of IM151-8. The table 4-2 and 4-3 present the mode

select settings and the error leds.

Table 4-2 – Mode selector switch settings.

Posición Description

RUN The IM 151-8 PN/DP CPU interface module processes the user program.

STOP The IM 151-8 PN/DP CPU interface module does not process the user program

MRES

Mode selector switch setting for Memory reset of the IM 151-8 PN/DP CPU interface module Backing up the firmware to the SIMATIC Micro Memory Card Resetting to the as-supplied state

A memory reset using the mode selector requires a number of steps to be carried out in a set order.

Table 4-3 – General status and error displays of the IM 151-8 PN/DP CPU interface module.

LED Color Description

SF Red Group fault for hardware or software error

BF-PN Red Lit: Bus fault (no cable connection to a subnet/switch; cable break or short-circuit). Flashes: Check IP addresses ; failure of a connected IO device

MT Yellow Maintenance information

ON Green Supply voltage for the IM 151-8 PN/DP CPU

FRCE Yellow LED is lit: Active force job LED flashes at 2 Hz: Node flash test function.

RUN Green IM 151-8 PN/DP CPU in RUN The LED flashes during STARTUP at a rate of 2 Hz, and in HOLD state at 0.5 Hz.

STOP Yellow IM 151-8 PN/DP CPU in STOP or in HOLD or STARTUP The LED flashes at 0.5 Hz when the CPU requests a memory reset, and during the reset at 2 Hz.

Note: engineering configuration issues are not included once the system has already worked before.



Hardware 4-3

4.1.1 Technical Data Model: 6ES7151-8AB01-0AB0 Provider: Siemens AG Power supply: 24VDC Work memory (RAM): 192kB Memory card: 2MB Bit rate: 10...100Mbps Communication: MPI/DP and PROFINET Communicaton with Microbox: RJ-45 (female)

4.2 ET200S I/O System The ET200S distributed I/O system is a discretely modular, highly flexible DP slave for connection to

process signals on a central controller or a field bus. ET200S supports field bus types PROFIBUS DP and

PROFINET IO. ET200S has protection class IP 20. Depending on the interface module, each ET200S can

consist of up to 63 modules - for example, power modules, I/O modules, and motor starters.

These modules are connected to the IM151-8 and translate the sensor data in PROFIBUS/PROFINET

compatible data – for communication.

The Table 4-4 shows all modules that can be found in Smart Monitor.

Table 4-4 –ET200S Modules.

Type Module Name Input / Output

Analog 0..20mA / 4..20mA 2AI 2

Analog RTD 2RTD 2 Digital Input 4DI 4

Digital output 4DO 4 Serial Modbus RTU USS 1

Serial Modbus ASCII ACSII 1

Power Source 24VDC PM-E - PROFIBUS DP - DP Master 1

4.3 SIMATIC Microbox IPC

The SIMTAIC Microbox IPC is an industrial PC system for high-performance and space-saving applications in

particular in the field of machine, systems and control engineering.



Hardware 4-4

Figure 4-2 – SIMATIC Microbox IPC (front).

Figure 4-3 – SIMATIC Microbox IPC (rear).

The Table 4-4 describes the Microbox components shown in the Figure 4-3.

Table 4-5 – Location of connection elements– SIMATIC Microbox IPC

Position Designation Description

1 24 VDC Connection for a 24 V DC power supply. 2 DVI/VGA DVI/VGA connection for CRT or LCD monitor with DVI interface. 3 USB 4 USB 2.0 connections, high-speed / low current. 4 PN/IND. ETHERNET RJ45 Ethernet connection 1 (exclusive PCI interrupt) for 10/100/1000 Mbps.

5 PN/IND. ETHERNET RJ45 Ethernet connection 2 (shared PCI interrupt) for 10/100/1000 Mbps (not for PROFINET versions).

6 PROFIBUS DP/MPI PROFIBUS DP/MPI interface (RS 485 electrically isolated), 9-pin D-Sub socket.

7 COM1 Serial port (RS232) 9-pin D-Sub connector.

8 PE Terminal The PE terminal (M4 thread) must be connected to the protective ground conductor of the plant, in which the device is to be installed. The minimum conductor cross-section may not be less than 2,5 mm2.



Hardware 4-5

4.3.1 Technical Data Model: SIMATIC Microbox IPC427C Provider: Siemens AG Power supply: 24VDC Main memory: 4 GB DDR3-SDRAM SODIMM Processor: Intel Pentium Core 2 Duo 1.2 GHz, 800 MHz FSB, 3 MB SLC Instalation / mouting: DIN rail

4.3.2 Basic software

Microsoft Windows Embedded 5.1

Microsoft IIS 5.1

Java RTE 6

Microsoft SQL Server Express 2005 or 2008

Microsoft .NET Framework 1.1 / 2.0 SP2 / 3.0 SP2 / 3.5 SP1

Microsoft ASP.NET 2.0 Ajax extensions 1.0

SIMATIC NET V6.3

Smart Monitor – TMDS software V 2.16

Microsoft IE 7.0 (other internet browsers are compatible).

SIEMENS

GAS-Guard 8 and GAS-Guard 3

Site Preparation Guide

810-1733-00 Rev A

Corporate Office: +1 (800) 880-2552

Technical Support: +1 (866) 273-7763 E-mail: [email protected]

Copyright © 2006 Serveron Corporation

All rights reserved Serveron, TrueGas, and LoadGuide are registered trademarks of Serveron Corporation. All other trademarks, registered trademarks, service marks, and trade names are the property of their respective owners.

810-1733-00 Rev A GAS-Guard 8 and GAS-Guard 3 Site Preparation Guide

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Table of Contents

Customer Information............................................................................................................................................ 3 Transformer Information ................................................................................................................................................ 4 Transformer Oil ................................................................................................................................................................ 4 Required Photographs..................................................................................................................................................... 4

Product Overview................................................................................................................................................... 5 Environmental Conditions .................................................................................................................................... 6 Items Needed for Installation................................................................................................................................ 7

Configured Items ............................................................................................................................................................. 8 Optional Accessories ....................................................................................................................................................... 8

Site Preparation Procedure .................................................................................................................................... 9 Choosing an Oil Supply and Return Port...................................................................................................... 10

Oil Supply Port ............................................................................................................................................................... 10 Bleed Fixture/Oil Return Port...................................................................................................................................... 11

Choosing a Mounting Location....................................................................................................................... 12 Mounting Stand.............................................................................................................................................................. 12 Mounting the Stand to a Concrete Pad ....................................................................................................................... 12 Transformer or Wall Mounting.................................................................................................................................... 13 Mounting to the Transformer or Wall......................................................................................................................... 13

Providing power ............................................................................................................................................... 13 Determining need for Oil Inlet Cooler ........................................................................................................... 14 Choosing a Communication Interface & Protocol........................................................................................ 14 Connections - Power, Sensor and Communication cables .......................................................................... 15 LoadGuide.......................................................................................................................................................... 16 Oil Moisture and Temperature (optional) ..................................................................................................... 16 Helium Cylinder ............................................................................................................................................... 16 Ordering Helium............................................................................................................................................... 16 Ordering Stainless Steel Tubing and Required Fittings .............................................................................. 17 Site Checklist...................................................................................................................................................... 18

Appendix................................................................................................................................................................ 19 GAS-Guard Dimensions .................................................................................................................................. 19 Concrete Pad Layout ........................................................................................................................................ 20 Wire Termination Drawing ............................................................................................................................. 21 Helium Specification and Ordering Information ......................................................................................... 22

Helium Suppliers ........................................................................................................................................................... 22 Tubing Specification and Ordering Information .......................................................................................... 23

Tubing Suppliers ............................................................................................................................................................ 23 Shipping Containers ......................................................................................................................................... 24

GAS-Guard 8 and GAS-Guard 3 Site Preparation Guide 810-1733-00 Rev A

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Table of Figures Figure 1: Oil circulation and gas extraction schematic ...................................................................................... 5 Figure 2: Installation schematic............................................................................................................................. 9 Figure 3: Oil Supply Port Assy............................................................................................................................ 10 Figure 4: Installed bleed fixture .......................................................................................................................... 11 Figure 5: GAS-Guard and mounting stand ....................................................................................................... 12 Figure 6: GAS-Guard wall mount....................................................................................................................... 13 Figure 7: Junction Box panel................................................................................................................................ 15 Figure 8: Overall dimensions .............................................................................................................................. 19 Figure 9: Concrete pad dimensions .................................................................................................................... 20 Figure 10: Wire termination drawing................................................................................................................. 21 Figure 11: Shipping containers............................................................................................................................ 24

Table of Tables Table 1: Customer information form.................................................................................................................... 3 Table 2: Transformer information form ............................................................................................................... 4 Table 3: Transformer oil information form.......................................................................................................... 4 Table 4: Required photographs checklist............................................................................................................. 4 Table 5: Items shipped............................................................................................................................................ 7 Table 6: Configured Items...................................................................................................................................... 8 Table 7: Optional Accessories................................................................................................................................ 8


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Customer Information In order to facilitate installation of your GAS-Guard, please fill out the following customer information form and mail, fax, or e-mail it to:

mail: Serveron Corporation Attn: Customer Support 3305 NW Aloclek Hillsboro, OR 97124 USA

fax: +1 (503) 924-3290

e-mail: [email protected] Customer Information

Company

Installation Site

Site Address

City State Zip Country

Primary Contact

Title

Address


Phone Mobile Pager

Fax Email

Secondary Contact

Title

Address


Phone Mobile Pager

Fax Email

Table 1: Customer information form


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Transformer Information Make: Type:

Year: Years in Service:

kVA Rating: kV Rating:

conservator nitrogen blanketed other:

Total Dissolved Gas (ppm): (sum of all measured gases, including

nitrogen)

attach all available DGA data

Table 2: Transformer information form

Transformer Oil

Oil Capacity: gallons /

liters

Manufacturer: Type:

Certified PCB free: yes / no

Table 3: Transformer oil information form

Required Photographs Attach photographs of the following items and illustrate them in the space provided:

Oil Supply Port Note thread size and units of measure:

Oil Return Port Note thread size and units of measure:

Control Panel

Mounting location of GAS-Guard

Table 4: Required photographs checklist


5 of 24

Product Overview This section describes the basic operational essentials for the Siemens GAS-Guard and the most common methods of collecting data.

The GAS-Guard technology from Siemens is a remotely deployed laboratory grade gas chromatograph which can be safely installed on an energized or non-energized transformer. The purpose of this Gas-Guard is to detect and measure fault gases found in electrical power transformer‘s insulating oil. The GAS-Guard is designed and constructed to resist environmental conditions relevant to a transformer substation.

The GAS-Guard is a precision device. The heart of the GAS-Guard is a specially constructed gas chromatograph designed to measure fault gases. Siemens offers two versions of products, application dependant. The GAS-Guard 8 measures eight IEEE recommend fault gases- hydrogen (H2), oxygen (O2), carbon dioxide (CO2), carbon monoxide (CO), methane (CH4), ethylene (C2H4), ethane (C2H6), and acetylene (C2H2). The GAS-Guard 3 measures the three Duval Triangle fault gases- methane (CH4), ethylene (C2H4), and acetylene (C2H2). The GAS-Guard may be used on conservator or nitrogen blanketed transformers; however, in all cases the sample of gas is extracted directly from the oil within the transformer.

Oil is circulated from the transformer to the GAS-Guard, and then returned to the transformer through ¼-inch O.D. stainless steel tubing. Stainless steel tubing is used in conjunction with compression fittings to minimize the risk of leaks. The GAS-Guard is outfitted with an internal gas extraction system which removes dissolved gases from the circulating transformer oil. Helium is used as a carrier gas to help transport the extracted sample gases through the gas chromatograph. The oil circulation and gas extraction paths in the GAS-Guard are shown below.

Data is collected in the GAS-Guard each time a gas chromatograph (GC) analysis is completed. The GC analysis takes approximately 40 minutes. Once an analysis has been completed, the optional Serveron Monitoring Service (SMS) or GAS-Guard View software can be used to view the GAS-Guard’s data. The GAS-Guard is set up to perform a sample analysis once every four hours (default). All data captured during an analysis is stored on compact flash memory within the GAS-Guard. The compact flash memory holds approximately (2) years of data. The GAS-Guard View software or Serveron Monitoring Service (SMS) will allow the end user to track the gas ppm levels over time and monitor the gas levels against user defined caution and alarm settings.

The GAS-Guard includes Ambient Temperature and LoadGuide® sensing devices. An optional Oil Moisture and Temperature sensor is available along with spare 4-20ma inputs for use with other external devices. External sensor information can also be correlated with fault gas information to allow a complete diagnostic overview of the transformer’s condition.

Figure 1: Oil circulation and gas extraction schematic

Gas Chromatograph

Oil Return toTransformer

Oil Supply fromTransformer

GasSide

OilSide

Gas supply to GC

Gas ExtractorUnit

Gas supply to GC


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Environmental Conditions The GAS-Guard 8 and GAS-Guard 3 are designed to operate within the following outdoor conditions:

Altitude up to 4572 m Humidity Range 5% to 95% Temperature Range -50C to 55C Installation Category II Pollution Degree 2

Please note that the altitude, humidity, and temperature ranges indicated are considered extended environmental conditions from the minimum ranges required by UL 61010-1, Clause 1.4.1.


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Items Needed for Installation Upon receipt of your GAS-Guard it is important to verify the contents of the shipping carton with the packing list. Inspect the contents Please notify Siemens directly if there are any signs of damage that may have occurred in transit.

Part # Description

140-0170-XX Sunshield

250-0130-XX (2) In-line Oil Filters, 1/4” SS Swagelok

250-0144-XX (2) Nut and Ferrule Set, 1/4” OD, SS

252-0013-XX (3) 10-32 Nut

253-0066-XX (6) 10-32x3/8” Screw

254-0075-XX (1) 1/4” Lock Washer

270-0004-XX (1) Helium Dryer, Q5 Copper Catalyst (GAS-Guard 8 only)

290-0017-XX

290-0021-XX

(1) Verification gas cylinder (GAS-Guard 8 only) OR

(1) Verification gas cylinder (GAS-Guard 3 only)

Note: The verification gas cylinder is shipped separately from the

GAS-Guard because of UN1956 classified non-flammable gas shipping

requirements and may ship at a later date depending upon installation.

291-0014-XX (2) Helium Dryer Mounting Clips (GAS-Guard 8 only)

292-0018-XX (1) Helium Regulator, high purity, for cylinder valve type CGA-580

300-0004-XX (1) LoadGuide, Current Transformer

456-0022-XX (1) Valve, Oil Return Assy.

456-0023-XX (1) Valve, Sample Port / Secondary Shutoff Assy.

456-0026-XX (1) Oil Supply Port Assy.

610-0110-XX (1) Cable, 14’, RJ45, 8 Cond.

610-0121-XX (1) Adapter Assy., RS232

750-0088-XX (1) 10” Helium Supply Line (GAS-Guard 8 only)

750-0089-XX (1) 120” Helium Supply Line

900-0080-00

900-0081-00

900-0083-00

900-0084-00

(1) GAS-Guard 8 (115V) OR



(1) GAS-Guard 3 (230V)

900-0053-XX (1) Bleed Fixture

910-0025-XX

(1) GAS-Guard Software CD (English)

• Includes User’s Manual, Site Prep, Install, Ops & Maintenance Guides

Table 5: Items shipped


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Configured Items Part # Description

900-0064-XX

900-0059-XX

610-0179-XX

610-0180-XX

610-0181-XX

(1) Kit, Junction Box with Cables OR

(1) Junction Box

(1) AC Power Cable (black 3-wire)

(1) Sensor Cable (black)

(1) Communication Cable (gray)

900-0063-XX

610-0182-XX

610-0183-XX

610-0184-XX

(1) Kit, External 23 ft. Cables

(1) AC Power Cable 23 ft. (black 3-wire)

(1) Sensor Cable, 23 ft. (black)

(1) Communication Cable, 23 ft. (gray)

900-0057-XX

900-0066-XX

(1) Transformer Pad Mount OR

(1) Transformer Tank Mount

Table 6: Configured Items

Optional Accessories Part # Description

900-0082-XX Kit , Oil Moisture and Temperature Sensor

900-0058-XX Oil Inlet Cooler

900-0060-XX GSM Cellular Modem, USA

900-0085-XX GSM Cellular Modem, Europe

900-0062-XX Kit, Fiber Optic Ethernet

900-0067-XX Kit, Wireless Radio, Serial

Table 7: Optional Accessories


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Site Preparation Procedure Site Preparation consists of the completing the following steps:

Choosing an oil supply and return port Choosing a mounting location Providing power Determining need for (optional) Oil Inlet Cooler Choosing a communication interface & protocol Communication/Power/Sensor Cable Connections LoadGuide Moisture and Oil Temperature sensor (optional) Ordering Helium Ordering stainless steel tubing

Site Checklist

Figure 2: Installation schematic


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Choosing an Oil Supply and Return Port The GAS-Guard removes oil from the transformer, analyzes the oil, and then returns the oil to the transformer. The locations where the oil is removed (oil supply port) and returned (oil return port) are vital for the accurate analysis of the gases within your transformer.

Typically, oil is removed at the top of the transformer, and returned at the bottom of the transformer. The location of the oil supply port should produce a sample that is a well-mixed representation of the transformer oil. In this section we will discuss how to select the locations and what fittings are required.

CAUTION: Maximum Oil Inlet Pressure to the GAS-Guard is 45 psi (3 bar)

Oil Supply Port An Oil Supply Assy, part # 456-0026-XX, is provided with the GAS-Guard. The assembly consists of a 2” black iron tee, 2” x ½” reducing bushing, ½” plug, ½”ball valve, and a ½”NPT x ¼”Tube fitting (see figure 3). The assembly is integral to the installation and commissioning process to help remove air and bubbles from entering into the transformer tank when the transformer oil supply port is opened.

It is important to sample oil from a location on the tank where the oil is constantly mixing in order to provide a well-mixed representation of oil within the transformer. Typically a top tank valve is used for the oil supply. For Nitrogen blanketed transformers the oil supply port must be at least 6” below the transformer’s oil level at all times. If the optional Moisture and Oil Temperature sensor is to be installed, please refer to the Moisture and Oil Temperature Sensor section below for additional configuration of the oil supply port.

1) Select an appropriate oil supply port on the transformer 2) Verify the port valve is closed and remove any plugs or caps securing the end of the

port 3) Thoroughly clean the inside of the port of any residue or pipe sealing compound 4) Determine the thread size of the selected oil supply port

5) Purchase the necessary nipple and reducing bushing, as required to mount the 2” Oil Supply Assy, part # 456-0026-XX. Note: Depending on the Oil Supply Port valve size, alternate parts can be purchased instead of using the 2” assembly provided. If parts are purchased for the transformer valve size, they must be black iron, brass or stainless steel and the street side to the tee should be ½” NPT.

6) Install nipple and reducing bushing as required to the oil supply port using Teflon tape or pipe dope. Note: It is important for the street side of the tee be oriented in the vertical direction

Siemens does not recommend sampling oil from cooling loops or pressurized oil passages; doing so may void the warranty.

Figure 3: Oil Supply Port Assy


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Bleed Fixture/Oil Return Port Typically the bottom drain valve is used for the oil return port. The return port should not be located on the transformer cooling system or any pressurized oil passage. An air bleed fixture and bubble trap is required at the oil return port to allow air removal during commissioning of the GAS-Guard. This fixture is referred to as a “Bleed Fixture.” The Bleed Fixture assembly is included with the GAS-Guard.

1) Select an appropriate oil return port on the transformer 2) Verify the port valve is closed and remove any plugs or caps closing the end of the

port 3) Thoroughly clean the inside of the port of any residue or pipe sealing compound 4) Determine the thread size of the selected oil return port 5) Acquire necessary fittings to attach the bleed fixture to the oil return port

Note: The Bleed Fixture is designed to fit on a 2” NPT nipple. When using the Bleed Fixture, adapt the oil return port to accommodate a 2”NPT female thread.

6) Secure the bleed fixture to the oil return port using Teflon tape or pipe dope

Siemens does not recommend sampling oil from cooling loops or pressurized oil passages; doing so may void the warranty.

Figure 4: Installed bleed fixture

Oil Return Assy Part # 456-0022-XX


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Choosing a Mounting Location The GAS-Guard should be located in a position where it will not interfere with transformer maintenance or access requirements. The front of the GAS-Guard must be accessible for commissioning and maintenance. There at two types of mounting types for the GAS-Guards; pedestal mounting stand or transformer mounting kit.

Items to consider when choosing a location for the GAS-Guard are:

Location of oil supply and oil return ports Location of power supply Transformer maintenance points Access to the GAS-Guard Mounting of the GAS-Guard stand

The GAS-Guard must be mounted and operated in an upright position. Failure to do so will void the warranty.

Mounting Stand The Mounting Stand is a post style, requiring some assembly, and is intended to be mounted to a concrete pad. The hardware required for assembly and fastening to the concrete pad are included. Figure 5 illustrates a typical mounting. See the appendix for mounting and layout dimensions. For stand assembly, refer to the GAS-Guard Installation Guide, part # 810-1732-XX.

Mounting the Stand to a Concrete Pad 1) Position the stand in the predetermined mounting location 2) Using the stand as a template, mark four holes onto the

concrete pad 3) Remove the stand and drill four 3/8-inch x 3-inch deep holes

in the marked locations 4) Insert the four 3/8-inch concrete anchors included with the

stand into the holes 5) Position the stand over the four mounting bolts and secure

the stand checking to make sure the stand is plumb and level 6) Tighten retaining nuts/concrete anchors

Figure 5: GAS-Guard and mounting stand


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Transformer or Wall Mounting The transformer mounting kit includes the necessary hardware to mount the GAS-Guard, junction box, helium dyer and helium cylinder to unistrut (unistrut is not included). Siemens recommends using 1, 5/8-inch deep channel unistrut. To mount the GAS-Guard and its components a quantity of two 4-foot lengths of unistrut are required. The figures below are examples of tank and wall mount applications.

Mounting to the Transformer or Wall 1) The bottom rung of unistrut must be mounted

a. A minimum of 40-inches from grade if the helium cylinder will be secured to the unistrut.

b. A minimum of 12-inches above grade or water threat if helium will not be secured to the unistrut.

2) Secure the bottom unistrut rung in the predetermined mounting location in accordance with the appropriate height suggested in item 1.

3) Measure up from the center of the bottom rung 19.85-inches and mark the mounting location for the second rung.

4) Secure the top unistrut rung.

Figure 6: GAS-Guard wall mount

Providing power The GAS-Guard has a built-in AC to DC power converter and surge protector capable of utilizing 115 or 230 VAC ± 15% (50/60Hz); 6A max. @ 115 V; 3A max @ 230V.

NOTE: Siemens recommends installing a properly rated and marked switch or circuit breaker in close proximity to the GAS-Guard as a mains voltage

disconnect device.

SIEMENS GAS-Guard 8


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Determining need for Oil Inlet Cooler The GAS-Guard operates with transformer inlet oil temperatures ranging between 0°C to +55°C. If your transformer oil temperature frequently deviates outside of this range please notify the Siemens technical support team for assistance in determining whether or not an Oil Inlet Cooler is needed.

Choosing a Communication Interface & Protocol The GAS-Guard offers a range of communication options. The GAS-Guard can communicate over multiple interfaces and protocols simultaneously. The different communication options are as follows:

Internal modem - connects to any standard analog phone line (POTS). RS-232 - connection is provided to allow serial communications with an external

computer as well as interface to a cellular or external modem. RS-485 - connection is provided. Ethernet – connection can be configured as DHCP or a static IP address. The

GAS-Guard is supplied with a copper interface. A fiber optic interface kit can be purchased using part # 900-0062-XX.

Modbus or DNP3 – connection can be configured over all hardware interfaces including Ethernet, RS-232, RS-485, and modem. For more information regarding these protocols, please contact Technical Support.

An active communication channel is required for Serveron Monitoring Service (SMS) or to enable Siemens access for remote calibration and troubleshooting. All communications require an authenticated username and password.


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Connections - Power, Sensor and Communication cables The standard GAS-Guard package includes (3) short cables used in conjunction with the Junction Box. If longer cables are required, 23 ft cables can be purchased as an option using part # 900-0063-XX. Typically these cables are terminated at the junction box terminal strip that is included with the standard GAS-Guard package or at the transformer control cabinet. If the junction box was not purchased, a terminal strip will be required for cable termination. A 27-position terminal strip is recommended for flexibility of wiring connections. Depending on the wiring connections used, a larger terminal strip maybe required. See the appendix for the recommended wiring diagram.

Cable names and part numbers;

Power Cable, (black 3-wire) #610-0179-XX or #610-0182-XX 115 to 230 VAC ± 15% (50/60Hz)

6A max @ 115 V; 3A max @ 230V

Communications Cable, (gray) #610-0181-XX or #610-0184-XX Modem RS-232 RS-485 Auxiliary 12VDC, 1A max. (isolated)

Sensor Cable, (black) #610-0180-XX or #610-0183-XX LoadGuide (Transformer Load) Programmable Relay (NO/NC/C) Power Relay (NO/NC/C) (3) 4-20mA inputs (2 used for optional Oil Moisture and Temperature) Helium Pressure Switch (optional with regulator)

Figure 7: Junction Box panel

Junction Box


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LoadGuide The GAS-Guard LoadGuide can be used to correlate transformer load to transformer gassing. The LoadGuide sensor consists of a current clamp that is placed over a 0 to 5 amp high or low side CT. It is important that the CT give a good representation of total transformer load. Transformer load will be displayed on a relative scale with 0 indicating no load and 100% indicating full load. The standard cable length is 8 ft. Additional cable of 22 AWG or larger can be added to the LoadGuide sensor cable if required.

Oil Moisture and Temperature (optional) An optional sensor is available to provide oil moisture in parts per million (ppm) or as percent relative saturation (%RS) and oil temperature (°C). Depending on the location of the sensor, the oil temperature can be representative of top oil temperature. It is recommended the Oil Moisture and Temperature Sensor be installed on the top valve of the transformer. The necessary adapters are provided with the moisture sensor to install the moisture sensor at the Oil Supply Assy. If the moisture sensor will be installed in an alternative location, a reducing bushing made from black iron, brass, or stainless steel may be required.

Helium Cylinder The helium gas cylinder should be securely mounted to the GAS-Guard mounting stand or some other permanent surface. A mounting bracket that meets all compressed gas cylinder restraining requirements is provided. Siemens also provides the necessary 1/8-inch O.D. SS-tubing to connect the helium cylinder to the GAS-Guard.

Ordering Helium Helium carrier gas is vital to the performance of the chromatograph within the GAS-Guard. Using helium that does not meet the described specifications will substantially reduce the life of the GAS-Guard and void the warranty. See the appendix for ordering information.


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Ordering Stainless Steel Tubing and Required Fittings Stainless steel tubing is used to connect the GAS-Guard to the transformer for circulating the transformer oil for measurement. The amount of tubing you will need to purchase is based on the location of your GAS-Guard in relation to the valves on your transformer.

Note: Stainless steel is the only material that should be used. The use of any other tubing material will void the warranty of your GAS-Guard.

It is recommended that the tubing between the transformer and the GAS-Guard be installed as one continuous piece, reducing the possibility of oil leaks.

Listed below are items to consider when choosing where to route the tubing to the GAS-Guard:

Make sure tubing will not interfere with regular maintenance of the transformer Avoid long unsupported tubing runs Route tubing so that it will not be tripped over or damaged by activities in the

vicinity of the transformer If the length of the oil supply or return path exceeds 20-feet, a 1/4-inch stainless steel

union will have to be purchased and on site at the time of installation It is recommended that your tubing be secured every 2~4-feet using stainless steel

cable ties or other adequate clamps

Carefully measure the predetermined tubing route from the transformer oil supply port to the GAS-Guard. Take into consideration any corners or other obstacles that may add to the overall length of tubing. Tubing is typically supplied in 20-foot lengths and will require a union if any section exceeds 20-feet. Determine the number of 20-foot lengths and unions required for the installation. If the overall tubing length exceeds 50-feet “supply and return” contact Siemens for assistance.

Tubing and fittings must be on site the day of installation. See the appendix for ordering information.


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Site Checklist The following is a checklist that will help ensure that all the proper steps have been completed.

Customer Information form filled out and returned to Siemens

A location for mounting the GAS-Guard has been identified, and the GAS-Guard mounting stand is secured in place

The transformer oil supply valve (GAS-Guard oil supply port) and the transformer oil return valve (GAS-Guard oil return port) have been selected

Bleed fixture and oil supply fittings installed (additional fittings required if Oil Moisture sensor is to be installed)

Power is present and available at the installation site for the GAS-Guard

Communication is available to the GAS-Guard

A cylinder of chromatographic grade helium (99.9999% pure with < 0.2 ppm of H2O) has been purchased and is on location

A 0-5 Amp CT has been identified for the LoadGuide sensor

All shipped items and optional accessories have been located

Electrical conduit and enclosures have been installed (as required)


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Appendix GAS-Guard Dimensions

Figure 8: Overall dimensions


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Concrete Pad Layout

Figure 9: Concrete pad dimensions


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Wire Termination Drawing

UserDefined

UserDefined

LoadGuide (Brown)Input (White/Black/BRN)

Input (White/Orange)

Input (White/Violet)

+24vdc (White)

+24vdc (Orange)

+24vdc (Violet)SGND (Black)GND (White/Red)

AGND (Blue)

Helium NC (Red)

LoadGuide

COM(White/Yellow)NO(Green)NC(Grey)COM (Yellow)

Programmable

Relay

4-20mA Input Channel 3



TXD (Yellow)NO(White/Green)NC(White/Grey)Power

Relay

He Pressure Switch(optional)

DCD(White/Violet)CTS(White/Green)RTS(Green)

GND(White/Black)DTR(Grey)RI(White/Red)DSR(WhiteGrey)

RXD(White/Yellow)

LINE (Brown)

TIP(White/Blue)RING (Blue)GND (White/Black/BRN)RCVB (+) (Orange)RCVA (-) (White/Orange)TXB (+) (Brown)TXA (-) (White/Brown)

+12V (Red)12V GND (Black)

NEUTRAL (Blue)

EARTH GND (Green/Yellow)

Sensor Cable

White/Blue -

Not ConnectedWhite/Brown -

Not Connected

White/Black -Not Connected

RS232

RS485

12V@1A

Internal Modem

Communication Cable

White - Not UsedViolet - Not Used

From

Ana

lyze

r

Sensor Cable (black)PN # 610-0180-00 (3.5ft) PN # 610-0183-00 (23ft)

Communication Cable (gray)PN # 610-0181-00 (3.5ft)PN # 610-0184-00 (23ft)

AC Power Cable (black 3-wire)PN # 610-0179-00 (2ft)PN # 610-0182-00 (23ft)

Input/OutputsCommunications

AUX 12VDC Output

AC Power

3

1

4

2

5

1

91011

2120191817161514

26252423

27

12

6789

1011

13

22

Notes:

Figure 10: Wire termination drawing


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Helium Specification and Ordering Information

Helium Specification: 99.9999% pure, Chromatographic or Research Grade NO MORE than 0.2ppm H2O

Cylinder Size: 49.6-liter water capacity 9 inches x 60 inches including cap

Depending on vendor, cylinder size is indicated by:

300, 049, 49, 1L, A, K, T or UT

Cylinder Material: High-pressure steel

Cylinder Valve Type: CGA 580

Table 8: Helium specification and ordering information

Use of helium other than 99.9999% pure research grade or chromatographic grade with less than 0.2-ppm H2O content will greatly decrease the life of the GAS-Guard system components and VOID the warranty.

Helium Suppliers

(800) 772-9247 www.praxair.com

When ordering, please specify part number HE 6.0 RS – T.

(323) 568-2201 www.airgas.com

When ordering, please specify part number HER – 300-CT.

Table 9: Helium suppliers


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Tubing Specification and Ordering Information

Specification: 1/4-inch OD x 0.028 (or 0.035) wall T316 seamless steel tubing.

Order Information: Purchase in 20-foot lengths

Table 10: Tubing specification and ordering information

Contact tubing suppliers for tube unions.

Stainless steel is the only material that should be used with the GAS-Guard; the use of any other tubing material will VOID the warranty of your GAS-Guard.

Tubing Suppliers

www.swagelok.com

See website for local sales contact number

Table 11: Tubing suppliers


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Shipping Containers

Figure 11: Shipping containers

GAS-Guard

SIEMENS


Installation Guide

810-1732-00 Rev A

810-1732-00 Rev A GAS-Guard Installation Guide

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Table of Contents Product Overview ...................................................................................................................................................4 Product Symbols......................................................................................................................................................5 Environmental Conditions .....................................................................................................................................6 Items Needed for Installation ................................................................................................................................7

Items Shipped ...................................................................................................................................................................8 Configured Items..............................................................................................................................................................9 Optional Accessories........................................................................................................................................................9

Preparatory Tasks for Installation...................................................................................................................10 Site Preparation Guide Checklist .................................................................................................................................10

Installation Procedures .........................................................................................................................................11 Stand Mounting and Assembly .......................................................................................................................12

Stand Post Mounting .....................................................................................................................................................12 Assembling the Stand ....................................................................................................................................................13 Junction Box Mounting..................................................................................................................................................14 Oil Cooler (Optional) .....................................................................................................................................................15

Mounting the GAS-Guard................................................................................................................................16 Mounting with the Transformer Pad Mount Stand...................................................................................................16 Mounting without the Transformer Pad Mount Stand.............................................................................................17 Attaching the Sunshield ................................................................................................................................................17

Oil Connections..................................................................................................................................................18 Inline Oil Filters ..............................................................................................................................................................18 Oil Plumbing...................................................................................................................................................................19

Top-Oil Moisture/Temperature (optional)....................................................................................................21 Oil Transmitter Unit Mounting ....................................................................................................................................22

Gas Connections ................................................................................................................................................23 Helium Gas Cylinder and Dryer Mounting (GAS-Guard 8 only) ...........................................................................23 Verification Gas Cylinder..............................................................................................................................................25

Cable Connections .............................................................................................................................................26 Power Cable, (black 3-wire) 610-0179-00 2-ft/610-0182-00 23-ft..............................................................................26 Sensor Cable, (black) 610-0180-00 3.5-ft/610-0183-00 23-ft.......................................................................................26 Communication Cable, (gray) 610-0181-00 3.5-ft/610-0184-00 23-ft .......................................................................27

External Sensors.................................................................................................................................................28 Oil Moisture and Temperature Connections..............................................................................................................28 Ambient Temperature ...................................................................................................................................................28 LoadGuide (750-0058-XX) .............................................................................................................................................28

Relays ..................................................................................................................................................................29 Mounting Stand Assembly Drawing ..............................................................................................................30 Installation Checklist.........................................................................................................................................31

Forms.......................................................................................................................................................................32 Verification Cylinder Data Sheet.....................................................................................................................32


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Table of Figures Figure 1: Installation schematic ...........................................................................................................................11 Figure 2: Stand Post...............................................................................................................................................12 Figure 3: Stand Assembly.....................................................................................................................................13 Figure 4: Junction Box Installation ......................................................................................................................14 Figure 5: Oil Cooler mounting.............................................................................................................................15 Figure 6: GAS-Guard mounting ..........................................................................................................................16 Figure 7: Sunshield mounting..............................................................................................................................17 Figure 8: Oil Filter Housing .................................................................................................................................18 Figure 9: Bleed Fixture and Siemens Oil Return Valve....................................................................................19 Figure 10: Sample port/Secondary Shutoff Assy. ............................................................................................20 Figure 11: Top-Oil (Moisture/Temperature) Sensor Fixture ..........................................................................21 Figure 12: Transmitter Unit..................................................................................................................................22 Figure 13: Mounting Base.....................................................................................................................................22 Figure 14: Helium Dryer.......................................................................................................................................23 Figure 15: Helium Regulator................................................................................................................................24 Figure 16: Installed Verification Cylinder..........................................................................................................25 Figure 17: Wiring Terminations...........................................................................................................................27

Table of Tables Table 1: Product Symbols .......................................................................................................................................5 Table 2: Items Shipped............................................................................................................................................8 Table 3: Configured Items ......................................................................................................................................9 Table 4: Optional Accessories ................................................................................................................................9 Table 5: Oil Moisture and Temperature connections .......................................................................................28 Table 6: Verification cylinder datasheet .............................................................................................................32


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Product Overview The Siemens GAS-Guard 8 and GAS-Guard 3 are on-line laboratory-grade gas chromatographs which can safely be installed on an energized or non-energized transformer. The GAS-Guard detects and measures fault gases found in the oil of power transformers. The GAS-Guard is designed and constructed to resist the environmental conditions typical of a power substation or generation facility.

CAUTION: Do not attempt to install your Siemens GAS-Guard until you have read and fully understand the procedures outlined in this document.


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Product Symbols The following symbols are used throughout the GAS-Guard or accessories. They are defined by the International Electrotechnical Commission, IEC 878 and IEC 417A. It is important for safety reasons to have an understanding of their representation.

Voltage Output

Voltage Input

Fuse

High Voltage

Caution: Refer to GAS-Guard Installation Guide and accompanying documentation.

Protective earth (ground)

V~ Alternating Current and Voltage H Connect to mains live conductor (brown) L Connect to mains neutral conductor (blue)

__I__ O

The I position indicates the power switch is ON The O position indicates the power switch is OFF

This device has been tested and certified by the Canadian Standards Association International to comply with applicable U.S. and Canadian safety standards.

Table 1: Product Symbols

WARNING statements in this manual identify conditions or practices that could result in personal injury. CAUTION statements in this manual identify conditions or practices that could result in damage to the equipment or other property. NOTE statements provide additional important information.


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Environmental Conditions The GAS-Guard 8 and GAS-Guard 3 are designed to operate within the following outdoor conditions:

Altitude up to 4572 m Humidity Range 5% to 95% Temperature Range -50C to 55C Installation Category II Pollution Degree 2

Please note that the altitude, humidity, and temperature ranges indicated are considered extended environmental conditions from the minimum ranges required by UL 61010-1, Clause 1.4.1.


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Items Needed for Installation Note: As each transformer is different, some items may need to be provided by the installer.

Upon receipt of your GAS-Guard it is important to verify the contents of the shipping carton with the packing list. Inspect the contents for any sign of damage that may have occurred in transit. Please notify Siemens directly if there are any concerns. For return shipping instructions please see the Operation and Maintenance Guide (Part # 810-1734-XX).


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Items Shipped

Part # Description

140-0170-XX Sunshield

250-0130-XX (2) In-line Oil Filters, 1/4” SS Swagelok

250-0144-XX (2) Nut and Ferrule Set, 1/4” OD, SS

252-0013-XX (3) 10-32 Nut

253-0066-XX (6) 10-32x3/8” Screw

254-0075-XX (1) 1/4” Lock Washer

270-0004-XX (1) Helium Dryer, Q5 Copper Catalyst (GAS-Guard 8 only)

290-0017-XX

290-0021-XX

(1) Verification gas cylinder (GAS-Guard 8 only) OR

(1) Verification gas cylinder (GAS-Guard 3 only)

Note: The verification gas cylinder is shipped separately from the

GAS-Guard because of UN1956 classified non-flammable gas shipping

requirements and may ship at a later date depending upon installation.

291-0014-XX (2) Helium Dryer Mounting Clips (GAS-Guard 8 only)

292-0018-XX (1) Helium Regulator, high purity, for cylinder valve type CGA-580

300-0004-XX (1) LoadGuide, Current Transformer

456-0022-XX (1) Valve, Oil Return Assy.

456-0023-XX (1) Valve, Sample Port / Secondary Shutoff Assy.

456-0026-XX (1) Oil Supply Port Assy.

610-0110-XX (1) Cable, 14’, RJ45, 8 Cond.

610-0121-XX (1) Adapter Assy., RS232

750-0088-XX (1) 10” Helium Supply Line (GAS-Guard 8 only)

750-0089-XX (1) 120” Helium Supply Line

900-0080-00

900-0081-00

900-0083-00

900-0084-00




(1) GAS-Guard 3 (230V)

900-0053-XX (1) Bleed Fixture

910-0025-XX

(1) GAS-Guard Software CD (English)

• Includes User’s Manual, Site Prep, Install, Ops & Maintenance Guides

Table 2: Items Shipped


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Configured Items

Part # Description

900-0064-XX

900-0059-XX

610-0179-XX

610-0180-XX

610-0181-XX

(1) Kit, Junction Box with Cables OR

(1) Junction Box

(1) AC Power Cable (black 3-wire)

(1) Sensor Cable (black)

(1) Communication Cable (gray)

900-0063-XX

610-0182-XX

610-0183-XX

610-0184-XX

(1) Kit, External 23 ft. Cables

(1) AC Power Cable 23 ft. (black 3-wire)

(1) Sensor Cable, 23 ft. (black)

(1) Communication Cable, 23 ft. (gray)

900-0057-XX

900-0066-XX

(1) Transformer Pad Mount OR

(1) Transformer Tank Mount

Table 3: Configured Items

Optional Accessories

Part # Description

900-0058-XX Oil Inlet Cooler

900-0060-XX GSM Cellular Modem, USA

900-0085-XX GSM Cellular Modem, Europe

900-0062-XX Kit, Fiber Optic Ethernet

900-0067-XX Kit, Wireless Radio, Serial

900-0082-XX Kit , Oil Moisture and Temperature Sensor

Table 4: Optional Accessories


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Preparatory Tasks for Installation There are certain tasks that must be completed prior to installation of the GAS-Guard. These tasks are outlined in the “GAS-Guard Site Preparation Guide” that was sent to you upon acceptance of your order. Please review the Site Preparation Guide and ensure all items on the Site Preparation Guide checklist below have been completed.

Site Preparation Guide Checklist

Customer Information form filled out and returned to Siemens

A location for mounting the GAS-Guard has been identified.

The transformer oil supply port (GAS-Guard oil supply port) has been selected

The transformer oil return port (GAS-Guard oil return port) has been selected

Confirm use of Siemens bleed fixture or customer has constructed their own bleed fixture

Oil supply port fittings determined and provided. Additional fitting are required if Oil Moisture sensor will be installed.

Oil return port fittings determined and provided.

Power is present and available at the installation site for the GAS-Guard

Communication protocol (RS232, RS485, Ethernet, or Modem) selected

A cylinder of chromatographic grade helium (99.9999% pure with < 0.2 ppm of H2O) has been purchased and is on location

A 0-5 Amp CT winding has been identified on the transformer for the LoadGuide sensor

All shipped items and configurable accessories have been located

Electrical conduit and enclosures have been installed (as required)


11 of 32

Installation Procedures Installation consists of completing the following steps:

Stand Mounting and Assembly Mounting the GAS-Guard Oil Connections Gas Connections Cable Connections External Sensors Relays Installation Checklist

(Ethernet, phone)CommunicationsAC Power cable,

Electrical Panel

Transformer Pad

(Oil Return Port)transformer valveExisting

900-0053-XXFixtureServeron Bleed

tubingtransformer ¼" SSOil return line to

Valve 456-0024-XXSecondary Oil SupplyServeron Optional

456-0022-XXAssemblyServeron Oil Return StandAnalyzer

270-0004-XXHelium Dryer

456-0023-XXValve AssySupply/Sample PortServeron Oil

tubinganalyzer ¼" SSOil supply line to

SensorTemperatureOil Moisture and

(Oil Supply Port)transformer valveExisting

Helium Tank& Regulator

Tank Transformer

Figure 1: Installation schematic

Stand 900-0057-XX

Oil Supply Port Assy. 456-0026-XX

Sample Port/Secondary Shutoff 456-0023-XX

Bleed Fixture 900-0053-XX

Oil Return Assy. 456-0022-XX

AC Mains power cable Communications cable

(Ethernet, phone)


12 of 32

Stand Mounting and Assembly The transformer pad mount stand is the preferred method of mounting the Siemens GAS-Guard. However if the GAS-Guard is going to be mounted to the transformer without the stand, an optional transformer tank mounting kit can be purchased from Siemens (Part # 900-0066-XX). If the transformer pad mount stand was not purchased please proceed to the “Mounting the GAS-Guard” section.

Stand Post Mounting

1) Remove the stand post from the shipping container. 2) Position the stand on the transformer pad. The mounting location should have been

determined during completion of the “GAS-Guard Site Preparation Guide”

3) Use the stand as a template and mark the four mounting holes onto the pad. Orientation of the four mounting holes is not important.

4) Temporarily move the stand and using a hammer drill, drill a 3/8-in x 3-in (7.6 cm) deep hole at each of the marked locations.

5) Insert the four 3/8-in concrete anchors supplied with stand. 6) Reposition the stand over the four anchors and install a flat-

washer, split-washer and 3/8-in nut onto each of the four anchors and tighten evenly.

7) Using a level verify the stand-post is within ±5˚ of plumb in all directions. Use 3/8-in stainless steel washers as spacers under the four corners if leveling is required.

Figure 2: Stand Post


13 of 32

Assembling the Stand

1) Locate stand hardware, items 2-through-16 (refer to the “Mounting Stand Assembly Drawing” in the back of the guide) and assemble the stand per the figure below.

2) Attach (1) item 5, channel using (1) item 4, U-bolt assembly with (2) item 9, lock washer to the stand approx 3-in (7.6 cm) from the top. Using a 9/16-in deep socket and a level secure the items to stand without over-tightening ensuring the channel is ±5˚ of plumb. (Note: Over-tightening will crush the aluminum post.)

3) On the back side of the stand, mark from the top of the U-bolt assembly 20-in down and attach (1) item 5, channel using (1) item 4, U-bolt assembly with (2) item 9, lock washer to post. (Note: Do not fully tighten the lower U-bolts to the stand until the GAS-Guard is installed and secured.)

4) Attach (2) item 2, spring nut in top channel using (2) item 3, fully threaded bolt. 5) Attach (2) item 2, spring nut in bottom channel. 6) Attach (2) item 13, mounting strap using (4) items 14, 15 and 16, screw, lock washer and nut. 7) Attach items 11 and 12, helium support bracket and strap using (4) items 6, 7 and 9 bolt,

washer and nut.

Figure 3: Stand Assembly

8) If the optional oil cooler was purchased proceed to the “Junction Box Mounting” section. If the oil cooler was not purchased continue with step (9).

9) Position (1) 291-0014-XX helium dryer mounting clip provided with the Gas-Guard hardware to the outside mounting strap item 13, lower through hole. Attach the clip to the strap using (1) 253-0066-XX screw and (1) 252-0013-XX nut contained in the GAS-Guard hardware. (Note: If a Junction Box will not be installed, attach the second 291-0014-XX using (1) 253-0066-XX and (1) 252-0013-XX, to the second through hole from the top of item 13 outside mounting strap)


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Junction Box Mounting

The junction box must be mounted prior to mounting the optional oil cooler or GAS-Guard.

1) Remove the Junction Box from the shipping container taking care not to damage the cable glands protruding form the bottom of Junction Box.

2) Attach the Junction Box to the stand mounting straps as illustrated in figure 4. Use the mounting hardware included with the Junction Box.

3) Attach (1) helium dryer mounting clip 291-0014-XX using the Junction Box hardware to top right mounting position.

Figure 4: Junction Box Installation


15 of 32

Oil Cooler (Optional)

If the optional oil cooler was not purchased proceed to the next section “Mounting the GAS-Guard.”

The optional cooler must be installed on the stand prior to mounting the GAS-Guard and helium dryer retaining clips. If you have purchased the transformer pad mount stand follow the instructions below.

1) Remove the oil cooler from its shipping container and verify all parts are accounted for. 2) Mount the oil cooler to the upper GAS-Guard stand mounting bolts. The oil cooler will be

secured using the same hardware used to secure the GAS-Guard. 3) Position (1) 291-0014-XX helium dryer mounting clip to the predrilled and tapped hole

located on the upper right hand side of the cooler. Attach the clip to the cooler using (1) 253-0066-XX screw contained in the GAS-Guard hardware. Position (1) 291-0014-XX helium dryer mounting clip to the predrilled and tapped hole located on the lower right hand side of the cooler. Attach the clip using (1) 253-0066-XX screw contained in the GAS-Guard hardware. Discard (2) 252-0013-XX nuts contained in the GAS-Guard mounting hardware.

CAUTION: If the oil cooler will not be mounted to the transformer pad mount stand, the oil cooler must still be secured by the cooler frame. Oil line fittings and oil tubing can not support

cooler weight.

Figure 5: Oil Cooler mounting


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Mounting the GAS-Guard

CAUTION: The GAS-Guard must be mounted and operated in an upright position. Failure to do so will VOID the warranty.

Mounting with the Transformer Pad Mount Stand

1) Remove the GAS-Guard from the shipping container taking care not to damage the ambient temperature sensor or cable glands protruding from the bottom of the GAS-Guard enclosure.

2) Attach the GAS-Guard using the stand mounting bolts item 3 and secure with items 7 and 9, lock washer and nut provided with the stand hardware.

3) Position the lower channel so the spring nuts are in-line with the GAS-Guard mounting tabs. Loosely secure the GAS-Guard using (2) items 6, 8 and 9, bolts, lock washer and washer to the spring nuts.

4) Using a 9/16-in deep socket, tighten the lower channel on the post. (Note: Over-tightening will crush the aluminum post.)

5) Verify GAS-Guard is plumb and level, within ±5˚ and all mounting hardware is tight.

Figure 6: GAS-Guard mounting


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Mounting without the Transformer Pad Mount Stand

When mounting the GAS-Guard, ensure the following:

1) The GAS-Guard is mounted a minimum of 12-in (30.5 cm) above any possible water level. 2) The GAS-Guard is plumb and level within ±5˚. 3) 3/8-in hardware is used to mount the GAS-Guard to supporting structure.

Attaching the Sunshield

1) Locate the sunshield and the (4) 10x32 retaining screws, part # 253-0066-XX, included in the GAS-Guard hardware.

2) Position the sun shield over the GAS-Guard, see figure 7. 3) Install the four screws in predrilled and tapped mounting holes.

Figure 7: Sunshield mounting


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Oil Connections There are several steps that must be followed specifically when connecting the oil supply and return lines.

The GAS-Guard must be connected to the transformer’s main tank in two locations. The first connection supplies oil from the transformer to the GAS-Guard (Oil Supply Port). The second connection returns oil from the GAS-Guard back to the transformer (Oil Return Port). Refer to the Site Preparation Guide for recommended transformer oil connection locations.

To guard against oil leaks, Extra High Density, 1.45 SG or higher Teflon tape (PTFE) or Teflon paste should be applied to all NPT-type connections prior to assembly.

CAUTION: Ensure all fittings, valves, and fixtures are clean prior to installing. De-burr all tubing ends prior to swaging on fittings.

CAUTION: Oil lines, valves, and fixtures are not a step! Make sure all tubing is positioned out of the way of any foot traffic or maintenance areas on or around the transformer.

CAUTION: Maximum Oil Inlet Pressure to the analyzer is 45 psi (3 bar)

Inline Oil Filters

Two inline oil filters, Part # 250-0130-XX, are supplied with the GAS-Guard. The recommended installation location for the filters is as close to the GAS-Guard bulkhead fittings as possible. If the bulkhead is an inconvenient location to install the oil filters because of the installation of oil cooler or GAS-Guard orientation, the filters must be mounted in a location that will allow easy access for filter service.

1) Identify location for oil filter mounting 2) Locate the flow direction arrow on the filter housing. 3) Install the filter in the oil line with the flow direction orientated correctly. 4) Swage the two fittings onto the ¼-in oil tubing.

Figure 8: Oil Filter Housing


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Oil Plumbing

Locate the two bulkhead fittings for oil connections labeled “Oil In” and “Oil Out” on the left side of the GAS-Guard.

1) Secure the Oil Supply Port Assy, 456-0026-XX to the transformer oil supply port/Top-Oil (moisture/temperature) fixture. Please see the Top-Oil (moisture/temperature) section for fixture specifications.

2) Attach the Bleed Fixture 900-0053-XX or the customer supplied bleed fixture to the transformer oil return port specified in the Site Preparation Guide.

3) Secure the Oil Return Valve assembly 456-0022-XX to the Bleed Fixture. 4) Using ¼-in stainless steel tubing, join the oil supply fitting and the oil return valve assembly

to their respective “Oil In” and “Oil Out” bulk-head fittings on the GAS-Guard. 5) Using the supplied helium and regulator, purge fitted oil lines with helium for one minute

prior to final tubing connection to the GAS-Guard.

Figure 9: Bleed Fixture and Siemens Oil Return Valve


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6) Select a convenient location no higher than 6 feet (183 cm) above ground level to mount the

Siemens Sample port/Shut-off valve assembly 456-0023-XX.

Figure 10: Sample port/Secondary Shutoff Assy.

Note: The sample port/shut-off valve is used when performing manual DGA testing or for stopping oil supply to the GAS-Guard.


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Top-Oil Moisture/Temperature (optional) An optional sensor is available to provide oil moisture in parts per million (ppm) or percent relative saturation (%RS) and oil temperature in °C. Depending on sensor location, the oil temperature data can be representative of transformer top oil temperature.

Note: Siemens recommends the Oil Moisture/Temperature Sensor be installed on the top oil supply port of the transformer.

To install the sensor, use the fittings identified in the “Site Preparation Guide.” All fittings must be stainless steel, brass, or black iron. Please refer to figure 11 below for the Moisture/Temperature sensor fixture configuration.

1) Install the male nipple and Tee to the transformer oil supply port with the Tee orientation as

required. 2) Reduce the straight-through port on the Tee to ½-in FNPT and the 90˚ port to ¼-in FNPT. 3) Install the Siemens ¼-in Oil Supply Adapter to the 90˚ port. 4) Install a ½-in x 2-in nipple to the straight-through port. 5) Install the ½-in ball valve that comes with the Oil Moisture and Temperature sensor on the

½-in x 2-in nipple.

For proper installation of the Oil Moisture and Temperature sensor, it is important for the nipple connecting the Tee to the ½-in ball be no longer than required. Once the assembly is built, ensure the tip of the Oil Moisture and Temperature sensor is in the oil flow.

250-0138-XX

Tee (X) x (X) x (X)

Reducing Bushing (X) x 1/2"

Existing Transformer Valve

Nipple (X) x 2-3"

Temperature Sensor withServeron Oil Moisture and

Oil Moisture Sensor Cable

Nipple 1/2" x 2"

1/4" Tube x 1/4" MNPTServeron Oil Supply Adapter

Tran

sfor

me r

Ba s

e

Reducing Bushing (X) x 1/4"

Figure 11: Top-Oil (Moisture/Temperature) Sensor Fixture

Oil supply Port Assy 456-0026-00


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Oil Transmitter Unit Mounting

The moisture sensor is designed for industrial applications. The sensor assembly consists of (4) elements which are:

Probe with Cable (5m) Transmitter Unit Mounting Base Interface Cable (5m)

There are a few options to mount the transmitter unit depending on the valve location in which the sensor will be installed. The transmitter unit is secured with two 3-mm hex screws to the mounting base. If the installation of the sensor is conducive to having the mounting base attached to a structure (control cabinet, junction box, channel, etc.), the transmitter unit can be detached from the mounting based using a 3-mm hex driver, refer to figure 12. In the event the transmitter unit can not be hard mounted to a support structure, the transmitter unit can be secured via cable ties to the oil supply tubing.

Figure 12: Transmitter Unit

Once the transmitter unit is removed from the mounting base, the base can be hard mounted. If the transmitter unit is installed unprotected in an outside environment (-55 to 60°C), ensure the orientation of the connections are facing in the downward direction, refer to figure 13.

Figure 13: Mounting Base

3mm hex screws to remove transmitter unit from mounting base


23 of 32

Gas Connections Two gas sources must be connected to the GAS-Guard- Helium and Verification gas.

CAUTION: Use of helium other than 99.9999% pure research or chromatographic grade with less than 0.2-ppm H2O content will VOID the GAS-Guard warranty.

WARNING: When full, the helium gas cylinder is pressured to greater than 2000psi (138 bar). Helium is regulated to 80psi (5.5 bar), nominal, before entering the GAS-Guard. Always follow Compressed Gas Association (CGA) guidelines when handling and transporting compressed

gases.

Helium Gas Cylinder and Dryer Mounting (GAS-Guard 8 only)

WARNING: Never leave the helium input to the GAS-Guard or the helium dryer inlet and outlet ports exposed to the atmosphere.

The helium gas cylinder must be securely mounted. The GAS-Guard stand includes a mounting bracket that meets all Compressed Gas Association (CGA) cylinder restraining requirements.

The helium dryer is mounted vertically to the GAS-Guard mounting stand using the retaining brackets included with the GAS-Guard mounting stand.

A 10-ft (305 cm) x 1/8-in O.D. stainless steel tube is provided to connect the helium cylinder regulator to the top of the helium dryer. A 10-in (25.4 cm) x 1/8-in O.D. stainless steel tube is provided to connect the bottom of the helium dryer to the GAS-Guard.

CAUTION: Do not uncap or connect helium gas lines to the helium dryer at this time.

Figure 14: Helium Dryer


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1) Install the provided helium regulator onto the helium cylinder. Do not use Teflon tape or pipe dope.

2) Orient the gauge vertically and tighten the CGA fitting. 3) Orient the helium cylinder so that the gauge on the regulator can be clearly seen. 4) Mount the helium dryer to the stand in the vertical orientation as indicated in figure 14,

using the supplied retaining clips 291-0014-XX. 5) Install one end of the 10-ft stainless steel tubing onto the regulator. 6) Verify the helium regulator shutoff valve is closed and slowly turn the valve located on top

of the helium cylinder fully counterclockwise (open). 7) Slowly turn helium regulator shutoff valve counterclockwise (open) until helium begins to

flow. At this point, gas should be escaping from the stainless steel tubing.

CAUTION: Do not open the regulator shutoff valve completely to regulate the helium flow.

8) Leaving the helium flowing, attach the other end of the 10-ft. tubing to the top of the helium dryer.

9) While the helium is continuing to flow, install the one end of the 10-in stainless steel tubing onto the bottom of the helium dryer.

10) Let the helium continue to purge through the dryer and tubing for one (1) minute. 11) While the helium is still purging, attach the remaining end of the 10-in stainless steel tubing

to the bulkhead fitting on the right side of the GAS-Guard labeled “Helium In.” 12) Now turn the regulator shutoff valve fully counterclockwise (open). 13) Confirm all four helium connections and the helium regulator to helium tank connections

are leak-tight by applying a leak-check solution to the fittings.

Figure 15: Helium Regulator

Note: The leak check is very important as even the smallest leak can substantially reduce the life of the helium cylinder.


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Verification Gas Cylinder

WARNING: When full, the verification gas cylinder is pressured to greater than 500psi (34 bar). Verification gas is regulated to 8psi (0.5 bar), nominal, before entering the GAS-Guard. Always

follow Compressed Gas Association (CGA) guidelines when handling and transporting compressed gases.

The verification gas cylinder is used to automatically verify and calibrate the GAS-Guard. The cylinder contains a certified NIST-traceable concentration of the transformer fault gases measured by the GAS-Guard.

1) Open the analyzer door and locate the Verification cylinder mounting bracket and regulator. 2) Install the Verification cylinder into the mounting bracket and secure using the Velcro strap. 3) Connect the cylinder to the regulator union and tighten. 4) Turn the knob on the top of the Verification cylinder counterclockwise until it is fully open.

The regulator requires no pressure adjustment. 5) Confirm that the bottle to regulator connection is leak-tight by applying a leak-check

solution to the fitting. Wipe away any excess leak-check solution.

Note: The leak check is very important, as even the smallest leak can substantially reduce the life of the Verification cylinder.

6) Complete and return the Verification cylinder data sheet found in the appendix to Siemens.

Figure 16: Installed Verification Cylinder


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Cable Connections The GAS-Guard has three primary electrical cable connections: Power, Sensor, and Communication. Each cable comes with a preinstalled connector on one end and is marked with an identifying part number and a description.

CAUTION: Ensure GAS-Guard power switch is off before connecting cables.

Power Cable, (black 3-wire) 610-0179-00 2-ft/610-0182-00 23-ft

The GAS-Guard has a variable input power supply capable of receiving input of 115VAC or 230VAC ±15%, 50/60 Hz. Current draw is 6A max. at 115VAC and 3A max. at 230VAC. There are three 4A/250V type 3AG (T) fuses installed for the power supply (line and neutral) and the GAS-Guard’s enclosure heater (line).

CAUTION: Replace fuses with same type and rating only. CAUTION: The GAS-Guard enclosure heater is not a variable voltage input device and must be

used with the appropriate 115V or 230V mains voltage as marked within the GAS-Guard.

Note: Siemens recommends installing a properly rated and marked switch or circuit breaker in close proximity to the GAS-Guard as a mains voltage disconnect device.

1) Locate the cable-gland on the bottom of the GAS-Guard labeled “Power.” 2) Starting from the inside of the GAS-Guard Housing, route the Power cable through the

cable-gland until the ferrite core contacts the cable-gland. 3) Locate the in-line connector from the power supply and attach the power cable. 4) Tighten the cable-gland onto the Power cable. 5) Attach the green/yellow ground wire to the ground lug along with the communication and

sensor cable shield drain wires then tighten ground lug nut. 6) Route the blunt cut end of the cable into the Junction Box or control cabinet for termination.

Pull enough cable through and trim cable to length. When using the Junction Box, pull approx 10-in through and remove the cable jacket.

7) Terminate per the wiring termination in figure 17.

Sensor Cable, (black) 610-0180-00 3.5-ft/610-0183-00 23-ft

1) Locate the cable-gland on the bottom of the GAS-Guard labeled “Sensor.” 2) Starting from the inside of the GAS-Guard Housing, route the black Sensor cable through

the cable-gland until the ferrite core contacts the cable-gland. 3) Locate the connector J100 on the System board and insert the cable connector. 4) Tighten the cable-gland onto the Sensor cable. 5) Attach the shield drain wire to the ground lug with the communication and power

green/yellow ground wire then tighten ground lug nut. 6) Route the blunt cut end into the Junction Box or control cabinet for termination. Pull enough

cable through and trim cable to length. When using the Junction Box, pull approx 10-in (25.4cm) through and remove the black cable jacket.



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Communication Cable, (gray) 610-0181-00 3.5-ft/610-0184-00 23-ft

1) Locate the cable-gland on the bottom of the GAS-Guard labeled “Communication.” 2) Starting from the inside of the GAS-Guard Housing route the gray Communication cable

through the cable-gland until the ferrite core contacts the cable-gland. 3) Locate the connector J101 on the system board and insert the cable connector. 4) Tighten the cable-gland onto the Communication cable. 5) Attach the shield drain wire to the ground lug with the sensor and power green/yellow

ground wire then tighten ground lug nut. 6) Route the blunt cut end into the Junction Box or control cabinet for termination. Pull enough

cable through and trim cable to length. When using the Junction Box, pull approx 10-in (25.4 cm) through and remove the gray cable jacket.


UserDefined

UserDefined

LoadGuide (Brown)Input (White/Black/BRN)

Input (White/Orange)

Input (White/Violet)

+24vdc (White)

+24vdc (Orange)

+24vdc (Violet)SGND (Black)GND (White/Red)

AGND (Blue)

Helium NC (Red)

LoadGuide

COM(White/Yellow)NO (Green)NC (Grey)COM (Yellow)

Programmable

Relay




TXD (Yellow)NO (White/Green)NC (White/Grey)Power

Relay

He Pressure Switch(optional)

DCD(White/Violet)CTS(White/Green)RTS(Green)

GND(White/Black)DTR(Grey)RI(White/Red)DSR(WhiteGrey)

RXD (White/Yellow)

LINE (Brown)

TIP (White/Blue)RING (Blue)GND (White/Black/BRN)RCVB (+) (Orange)RCVA (-) (White/Orange)TXB (+) (Brown)TXA (-) (White/Brown)

+12V (Red)12V GND (Black)

NEUTRAL (Blue)

EARTH GND (Green/Yellow)

Sensor Cable

White/Blue -

Not ConnectedWhite/Brown -

Not Connected

White/Black -Not Connected

RS232

RS485

12V@1A

Internal Modem

Communication Cable

White - Not UsedViolet - Not Used

From

An a

lyze

r

Sensor Cable (black)PN # 610-0180-00 (3.5ft) PN # 610-0183-00 (23ft)

Communication Cable (gray)PN # 610-0181-00 (3.5ft)PN # 610-0184-00 (23ft)

AC Power Cable (black 3-wire)PN # 610-0179-00 (2ft)PN # 610-0182-00 (23ft)

Input/OutputsCommunications

AUX 12VDC Output

AC Power

3

1

4

2

5

1

91011

2120191817161514

26252423

27

12

6789

1011

13

22

Notes:

Figure 17: Wiring Terminations


28 of 32

External Sensors

Oil Moisture and Temperature Connections

The Oil Moisture and Temperature sensor can be configured for 4-20mA or RS-232 output; the recommended configuration is 4-20mA. The Sensor can also be installed as moisture only or moisture and temperature. Please refer below for the wiring configurations.

Sensor Type Sensor Signal Name

Sensor Wire Color

Monitor Signal Name

Monitor Wire Color

Moisture Only Supply (-) GREY Signal GND BLK Supply (+)

24VDC PINK CH 1 (+)

24VDC ORG

CH 2 GRN CH 1 Input WHT/ORG Moisture/Temperature Supply (-) GREY Signal Ground BLK Supply (+)

24VDC PINK CH 1 (+)

24VDC ORG

CH 2 GRN CH 1 Input WHT/ORG CH 1 YEL CH 3 Input WHT/BLK/BRN

Table 5: Oil Moisture and Temperature connections

Ambient Temperature

1) Push sensor through cable-gland marked “Amb Temp” so that sensor tip is exposed 2-in. (5 cm) below bottom of GAS-Guard enclosure and cable-gland.

2) Ensure sensor cable is plugged into connector J2 on the System board.

LoadGuide (750-0058-XX)

WARNING: High voltage can be induced by the LoadGuide sensor. Do not clamp the LoadGuide around the transformer CT winding until its wires have been terminated to the

GAS-Guard.

1) Locate the 0 to 5-amp CT winding identified in the Site Preparation Guide within the

transformer control panel. 2) Pull the LoadGuide leads from the transformer panel to the GAS-Guard junction box. A

wire size of 22 AWG or larger can be used to extend the length of the leads. 3) Connect the black and white wires of the LoadGuide to the brown and blue sensor cable

leads, polarity is not significant. 4) Unscrew white screws and remove back plate from device. 5) Place the U-shape of the device around the 0 to 5-amp tap. 6) Reinstall back plate and finger tighten screws.


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Relays There are two dry contact relays, (1) Power and (1) Programmable, User defined. The Power relay is triggered on loss of power to the GAS-Guard. The programmable relay can trigger on any GAS-Guard programmed parameter. The relay can be wired for normally-open (NO) or normally-closed (NC) configuration. The following parameters can be programmed:

Block all inputs (no operation) Gas alarm condition, both PPM and rate-of-change Gas caution condition Service required condition Sensor alarm condition (Oil Temp, Moisture, LoadGuide, Helium Gas (with optional

regulator), 4-20ma input CH2, etc.)

Note: The relays are capable of handling 100VA, 110VAC @ 1A or 50VDC @ 1A.


30 of 32

Mounting Stand Assembly Drawing

Part

/Des

crip

tion

140-

0190

-00

CM

P, S

tand

Pos

t

291-

0011

-00

Nut

—M

ount

ing

w/s

prin

g

253-

0144

-00

3/8

Bol

ts x

3” F

ully

Thr

eade

d

291-

0010

-00

U-B

olt A

ssy

w/M

tg P

late

291-

0009

-00

Uni

stut

– 2

feet

253-

0071

-00

3/8

Bol

ts x

1.5

”

252-

0014

-00

3/8

Nut

254-

0070

-00

3/8

Fla

t Was

her

254-

0071

-00

3/8

Loc

ker W

ashe

r

253-

0076

-00

3/8

Anc

hor B

olts

140-

0062

-00

He

Supp

ort B

rack

et

190-

0001

-00

Stra

p

140-

0193

-00

¾ x

1/8

Mou

ntin

g St

rap

252-

0013

-00

#10

-32

Nut

254-

0023

-00

#10

Loc

k W

ashe

r

253-

0070

-00

#10

-32

x ½

Scr

ew

010-

0047

-00

Pac

kagi

ng S

et (N

ot S

how

n)

140-

0203

-00

CM

P, B

rack

et B

ulkh

ead

253-

0148

-00

#10

-16

x ¾

” Sel

f Dril

ling

Scr

ew

253-

0151

-00

3/8

Bol

ts x

.875

”

254-

0094

-00

Stru

t Was

her,

Grip

Sty

le

Qty

1 4 2 2 2 2 4 4 10

4 1 1 2 4 8 8 1 1 2 2 4

Item

#

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

18

19

20

21

Figure 18: Mounting Stand Assembly


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Installation Checklist The following is a checklist to help ensure that all the proper steps have been completed prior to filling the GAS-Guard with oil.

GAS-Guard securely mounted

Helium cylinder securely mounted

Helium regulator installed

Helium dryer installed in the vertical orientation

Helium system leak-checked

Verification cylinder securely mounted

Verification cylinder system leak-checked

All oil plumbing components secure

(Optional) Oil Cooler securely mounted to stand

All compression fittings securely tightened and leak-checked

All cabling securely routed and safely out of the way

Electrical conduit and or termination strip enclosures installed, secured, and grounded as necessary

Sensor connections established

Communication connections established

Power connections established (power is OFF in the GAS-Guard)

CAUTION: DO NOT apply power to the GAS-Guard! Power will be applied as part of the commissioning procedure.


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Forms Verification Cylinder Data Sheet

Upon successful installation of your GAS-Guard verification cylinder; please complete and fax or e-mail this Verification Cylinder Data Sheet to Technical Support at:

+1 (503) 924-3290 fax [email protected] e-mail

Attention: Siemens Product Support

From:

Customer Information

Company:

Site:

Site Address:

City, State and Zip:

Country:

GAS-Guard and Verification Cylinder Information

Installer’s Name:

Installation Date:

GAS-Guard Serial Number:

Helium high pressure gauge (psig):

Helium low pressure

gauge (psig):

Verification high pressure gauge (psig):

Verification low pressure

gauge (psig): N/A

Verification Cylinder Lot Number:

Manufacture/Analysis Date

Verification Cylinder Components Certified Concentrations

Hydrogen H2 ppm Oxygen O2 ppm Methane CH4 ppm

Carbon Monoxide CO ppm Carbon Dioxide CO2 ppm

Ethylene C2H4 ppm Ethane C2H6 ppm

Acetylene C2H2 ppm

Table 6: Verification cylinder datasheet

SIEMENS


Operations and Maintenance Guide

810-1734-00 Rev A

810-1734-00 Rev A GAS-Guard 8 and GAS-Guard 3 Operations and Maintenance Guide

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Table of Contents

Introduction..............................................................................................................................................................3 Product Symbols......................................................................................................................................................4 Operation ..................................................................................................................................................................5

Calibration ............................................................................................................................................................5 Alarm Settings......................................................................................................................................................5

New transformers or transformers with no previous gas data:.................................................................................6 Transformers with a stable gassing history: .................................................................................................................6 Gassing Transformers which have been degassed: .....................................................................................................7 Transformers with an unstable gassing history which have not been degassed: ...................................................7

Viewing GAS-Guard Data..................................................................................................................................7 Front panel lights (Indicators) ...........................................................................................................................8 Turning the GAS-Guard On/Off ......................................................................................................................9 Manual DGA Sampling ....................................................................................................................................10 Operational Parameters ....................................................................................................................................10

Maintenance ...........................................................................................................................................................11 Helium and Verification Gas ...........................................................................................................................11

Helium Gas .....................................................................................................................................................................11 Helium Dryer..................................................................................................................................................................11 Helium Cylinder and Dryer Removal and Replacement..........................................................................................11 Verification Gas ..............................................................................................................................................................13 Verification Gas Cylinder Removal and Replacement..............................................................................................13

Leak Check Fittings ...........................................................................................................................................14 Replacing Fuses..................................................................................................................................................14 Oil Filter Service.................................................................................................................................................15 Customer Replaceable Units (CRU’s) .............................................................................................................16 Cleaning ..............................................................................................................................................................16

Internal Cleaning............................................................................................................................................................16 External Cleaning ...........................................................................................................................................................16

Return Shipping Instructions...............................................................................................................................17 Forms.......................................................................................................................................................................18

Verification Cylinder Data Sheet.....................................................................................................................18

Table of Figures

Figure 1: Siemens GAS-Guard...............................................................................................................................3 Figure 2: Oil shut off valve .....................................................................................................................................9 Figure 3: DGA sample port ..................................................................................................................................10 Figure 4: Installed verification cylinder..............................................................................................................14 Figure 5: Filter assembly.......................................................................................................................................15 Figure 6: Internal foam support...........................................................................................................................17

GAS-Guard 8 and GAS-Guard 3 Operations and Maintenance Guide 810-1734-00 Rev A

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Table of Tables

Table 1: Product Symbols .......................................................................................................................................4 Table 2: Recommended caution/alarm settings for transformers with no previous gas data.....................6 Table 3: Recommended caution/alarm settings for transformers with a stable gassing history.................6 Table 4: Recommended caution/alarm settings for gassing transformers after degassing..........................7 Table 5: Front panel lights ......................................................................................................................................8 Table 6: Customer Replaceable Units .................................................................................................................16 Table 7: Verification cylinder datasheet .............................................................................................................18


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Introduction The Siemens GAS-Guard is an on-line laboratory-grade gas chromatograph. The GAS-Guard detects and measures fault gases found in the cooling oil of power transformers. The GAS-Guard is designed and constructed to operate under those environmental conditions typical of a power substation or generating facility.

Figure 1: Siemens GAS-Guard


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Product Symbols The following symbols are used throughout the GAS-Guard or accessories. They are defined by the International Electrotechnical Commission, IEC 878 and IEC 417A. It is important for safety reasons to have an understanding of their representation.

Voltage Output

Voltage Input

Fuse

High Voltage

Caution: Refer to GAS-Guard Installation Guide and accompanying documentation.

Protective earth (ground)

V~ Alternating Current and Voltage H Connect to mains live conductor (brown) L Connect to mains neutral conductor (blue)

__I__ O

The I position indicates the power switch is ON The O position indicates the power switch is OFF

This device has been tested and certified by the Canadian Standards Association International to comply with applicable U.S. and Canadian safety standards.

Table 1: Product Symbols

WARNING statements in this manual identify conditions or practices that could result in personal injury. CAUTION statements in this manual identify conditions or practices that could result in damage to the equipment or other property. NOTE statements provide additional important information.


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Operation Once installed, the Siemens GAS-Guard requires very little setup before operation commences. To retrieve DGA data from the GAS-Guard, set caution/alarm levels, sampling schedules etc. use either GAS-Guard View software or the Serveron Monitoring Service (SMS). Refer to the GAS-Guard View Software User’s Manual or the SMS User’s Guide. For more information, manuals are available for download from www.serveron.com or by contacting Technical Support at [email protected].

Calibration Every Siemens GAS-Guard is calibrated at the factory. Following installation and commissioning, the GAS-Guard’s auto-calibration feature verifies calibration automatically every three days. Siemens recommends confirming calibration of your GAS-Guard every six months by viewing the ‘Verification PPM in Gas’ graph in GAS-Guard View (Graph Tools→Maintenance→Verification Data). A manual recalibration should not be required unless a new certified verification cylinder is installed, approximately once every three years. If Siemens has connectivity to the GAS-Guard during the standard warranty period (12-months from date of shipment) Siemens will periodically confirm calibration of the GAS-Guard as well.

Note: For Serveron Monitoring Service customers, upon installing a new verification cylinder fill out and return the Verification Cylinder Datasheet located at the end of this

document and return it to Technical Support.

Alarm Settings Following installation of the GAS-Guard and after an initial 24 hour stabilization period, the gas caution and alarm levels can be set in the GAS-Guard. These levels can be set using the GAS-Guard View software which was included with your GAS-Guard or by the Serveron Monitoring Service.

There are no universal rules regarding the values at which to set the caution and alarm levels in the GAS-Guard. In the most general case caution and alarm settings are disabled while the GAS-Guard runs for approximately thirty (30) days to establish gassing trends and a baseline PPM level for each of the fault gases. After the GAS-Guard PPM data has been established, you can use the history to set the caution and alarm levels directly or consult with the support group at [email protected] to determine the appropriate caution and alarm settings for your GAS-Guard.

The following guidelines may be useful for setting the initial gas caution and alarm levels. Keep in mind that these are recommendations. The appropriate caution and alarm settings for your GAS-Guard may vary from these recommendations.


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New transformers or transformers with no previous gas data: Set the GAS-Guard caution level to 50% and the alarm level to 100% of the low-end CAUTION ppm limits proposed by IEEE PC57.104 Draft 11, published April 21, 2004; except acetylene, as noted below.

Gas Caution PPM Alarm PPM Notes:

Hydrogen 50 100

Methane 60 120

Acetylene 2 5 Per Draft 11

Ethylene 25 50

Ethane 33 65

Carbon Monoxide 175 350

Carbon Dioxide 1750 3500

Oxygen baseline+10% Baseline+20% above initial measured PPM

Table 2: Recommended caution/alarm settings for transformers with no previous gas data

Transformers with a stable gassing history: Use the GAS-Guard to measure the transformer oil for thirty (30) days in order to establish baseline levels of the eight fault gases. Set the GAS-Guard caution/alarms levels to the measured baseline levels + value (PPM) shown below.

Gas Caution PPM

+value (PPM) Alarm PPM

+value (PPM) Notes:

Hydrogen +50 +100

Methane +60 +120

Acetylene +2 +5

Ethylene +25 +50

Ethane +33 +65

Carbon Monoxide +175 +350

Carbon Dioxide +1750 +3500


Table 3: Recommended caution/alarm settings for transformers with a stable gassing history


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Gassing Transformers which have been degassed: Set the caution level to 50% and the alarm level to 100% of the low-end CAUTION ppm limits proposed by IEEE PC57.104 Draft 11, published April 21, 2004; except acetylene, as noted below.

Gas Caution PPM Alarm PPM Notes:

Hydrogen 50 100

Methane 60 120

Acetylene 2 5 Per Draft 11

Ethylene 25 50

Ethane 33 65

Carbon Monoxide 175 350

Carbon Dioxide 1750 3500


Table 4: Recommended caution/alarm settings for gassing transformers after degassing

Transformers with an unstable gassing history which have not been degassed: There are no recommendations possible for transformers in this category. In order to establish the caution and alarm levels, allow the GAS-Guard to run for thirty (30) days to establish gassing trends and baseline measurements. After this data has been collected, you should consult with Siemens ([email protected]) to determine the appropriate caution and alarm settings for the transformer.

Viewing GAS-Guard Data The GAS-Guard data can be viewed using the supplied GAS-Guard View software or the optional Serveron Monitoring Service Client software. A copy of the GAS-Guard View software and user’s manual can be found on the CD that shipped with the GAS-Guard. Alternatively, the GAS-Guard can present data to SCADA systems using DNP3 or Modbus protocols. Please contact a Siemens representative for further information regarding the Serveron Monitoring Service or to integrate the GAS-Guard with a SCADA system


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Front panel lights (Indicators) The Siemens GAS-Guard has three colored lights (LED’s) located on the front panel. These lights are described in the following Table as they appear on the front panel, from top to bottom.

Light Notes:

Alarm The GAS-Guard has detected one or more gas values equal to or greater than their respective alarm settings.

Service

The GAS-Guard needs service. The service indicator is activated by a number of GAS-Guard-specific parameters. For cause identification proceed as follows-

GAS-Guard View: Open GAS-Guard View program and update the unit database. After updating the database open the event-log and view recorded event condition.

Serveron Monitoring Service: Open the Serveron Monitoring Service Client program and view the event log. Contact Technical Support group at ([email protected]).

Note: Depending on the cause for Service, the GAS-Guard may need to perform an analysis before the blue Service LED is turned OFF.

Power The GAS-Guard is ON.

Table 5: Front panel lights


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Turning the GAS-Guard On/Off

CAUTION: Always ensure helium is being supplied to the analyzer. Never leave the helium inlet to the GAS-Guard exposed to atmosphere.

CAUTION: The GAS-Guard is designed to operate continuously. When powering down the GAS-Guard for extended periods of time (more than 24 hours), always close the oil supply and

return valves to the analyzer.

To isolate (shut off) the oil inlet and oil outlet ports, close the transformer oil supply and return valves or close the Siemens manual DGA (sample port/oil shutoff) valve as well as the Siemens oil return valve located on the bleed fixture.

The figure below is a typical example of one of these valves. There are at least two valves per installation, one for the inlet and one for the outlet. The exact location and number of these valves will vary by installation. The valve is shown in the ON position in the following figure.

Figure 2: Oil shut off valve

For whatever reason, if the GAS-Guard is consistently unable to complete its sample runs, Siemens recommends powering down the GAS-Guard and closing the supply and return valves (described above) until the exact nature of the problem is understood and/or corrected. This will ensure no damage is caused to the GAS-Guard.


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Manual DGA Sampling A manual DGA sample port is installed in-line with the GAS-Guard oil supply tubing. Siemens recommends this port for correlation of GAS-Guard data to manual DGA data. The location of the sample port will vary by installation. The sample port provided with the GAS-Guard is a ¼-in locking valve with a 1/4-in FNPT fitting. No special procedures are required when obtaining a manual DGA sample.

Figure 3: DGA sample port

Operational Parameters Please see the “Siemens GAS-Guard Data Sheet” available online at www.serveron.com.


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Maintenance The Siemens GAS-Guard has been designed to keep maintenance to a minimum. The following will help you determine the best service plan.

Helium and Verification Gas

Helium Gas The helium gas cylinder will last greater than four (4) years based on the default four hour sampling interval. It is important that the gauge on the regulator be checked quarterly and a leak-check solution applied to fittings biannually to ensure no leaks have developed. The helium cylinder should be replaced when the pressure gauge reads less than 150psi (10.34 bar).

Helium Dryer The helium dryer will last greater than four (4) years based on the default four hour sampling interval. A leak-check solution should be applied to the helium dryer fittings bi-annually to ensure no leaks have developed. The helium dryer should be replaced when the helium cylinder is replaced.

Helium Cylinder and Dryer Removal and Replacement

WARNING: When full, the helium cylinder is pressured to greater than 2000psi (138 bar). Helium is regulated to 80psi (5.5 bar), nominal, before entering the GAS-Guard, Always follow Compressed Gas Association (CGA) guidelines when handling and

transporting compressed gases.

CAUTION: Use of helium other than 99.9999% pure research or chromatographic grade with less than (0.2 ppm) H2O content will VOID the GAS-Guard warranty.

1) Turn off power to the GAS-Guard by opening the GAS-Guard door and toggling the power

switch located in the upper right hand corner to the OFF position. 2) Turn the helium cylinder valve clockwise to the fully OFF position. 3) Using a 7/16-in wrench, remove the 1/8-in helium inlet and outlet lines from the top and

bottom of the helium dryer.

WARNING: A small amount of high-pressure helium will be released upon loosening the fitting.

4) Using a suitable wrench, remove the helium regulator from the cylinder valve.


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5) Carefully support the regulator to prevent any damage to the 1/8-in helium line or regulator.

CAUTION: It is extremely important that no water or other foreign contaminates be allowed to enter the open regulator fitting or tubing.

6) Remove the helium cylinder from its mounting bracket. 7) Remove the helium dryer from its mounting clips. 8) Verify the replacement cylinder meets the following specifications:

Chromatographic grade helium 99.9999% pure/Grade (6.0) Less than 0.2 ppm H2O CGA-580 fitting

9) Position the new helium cylinder in the mounting bracket and secure the cylinder in place. 10) Reinstall the regulator onto the helium cylinder. Do not use Teflon tape or pipe dope. 11) Orient the gauge vertically and tighten the CGA fitting. 12) If necessary, reorient the helium cylinder so that the gauge on the regulator can be clearly

seen. 13) Install the new helium dryer in the mounting clips. The dryer is not flow directional.

Note: Do not remove the helium dryer plugs at this time.

14) Verify the helium regulator shutoff valve is closed and slowly turn the valve located on top of the helium cylinder fully counterclockwise (open).

15) Slowly turn helium regulator shutoff valve counterclockwise (open) until helium begins to flow. At this point, gas should be escaping from the stainless steel tubing.

CAUTION: Do not open the regulator shutoff valve completely to regulate the helium flow.

16) Leaving the helium flowing, remove the top helium dryer plug and attach the free end of the 10-ft helium line to the top of the helium dryer.

17) With the helium continuing to flow reinstall the line to the bottom of the helium dryer. 18) Now turn the regulator shutoff valve fully counterclockwise (open). 19) Confirm all four helium connections and the helium regulator to helium tank connections

are leak-tight by applying a leak-check solution to the fittings.

Note: The leak check is very important as even the smallest leak can substantially reduce the life of the helium cylinder.

The helium regulator outlet pressure is preset at 80psi (5.5 bar), nominal, and requires no adjustment.


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Verification Gas The verification gas certification is three (3) years and the cylinder holds enough gas for over 4 years worth of verification runs based on the default ‘every three days’ sampling interval. It is important that the gauge on the regulator be checked quarterly and a leak-check solution applied to fittings bi-annually to insure no leaks have developed. The verification cylinder should be replaced when the high pressure gauge reads less than 25psi (1.72 bar).

CAUTION: Use of verification gas that does not meet Siemens specifications will VOID the GAS-Guard warranty.

Verification Gas Cylinder Removal and Replacement

WARNING: When full, the verification gas cylinder is pressured to greater than 500psi (34 bar). Verification gas is regulated to 8psi (0.5 bar), nominal, before entering the GAS-Guard. Always

follow Compressed Gas Association (CGA) guidelines when handling and transporting compressed gases.

The verification gas cylinder is used to automatically verify and calibrate the GAS-Guard. The cylinder contains a certified NIST-traceable concentration of the eight-transformer fault gases measured by the GAS-Guard.

1) Turn off power to the GAS-Guard by opening the GAS-Guard door and toggling the power switch located in the upper right hand corner to the OFF position.

2) Turn the verification cylinder tank valve to the fully OFF (clockwise) position. 3) Using a 9/16-in wrench loosen the verification cylinder to regulator union. WARNING: A small amount of high-pressure verification gas will be released upon loosening the fitting. 4) While supporting the verification cylinder release the Velcro strap retaining the verification

cylinder in the bracket. 5) Install the new verification cylinder into the mounting bracket and secure using the Velcro

strap. 6) Connect the cylinder to the regulator union and tighten. 7) Turn the knob on the top of the verification cylinder counterclockwise until it is fully open.

The regulator requires no pressure adjustment. 8) Confirm that the bottle to regulator connection is leak-tight by applying a leak-check

solution to the fitting. Wipe away any excess leak-check solution.

Note: The leak check is very important, as even the smallest leak can substantially reduce the life of the verification cylinder.


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9) For Serveron Monitoring Service users, please complete and return the Verification cylinder

data sheet to Technical Support ([email protected]) after the Verification cylinder is replaced.

Figure 4: Installed verification cylinder

Leak Check Fittings After the first month of continuous use, all regulator, gas and oil fittings should be checked for leaks. A semi-annual check of these fittings is recommended following the one month initial check.

Replacing Fuses The GAS-Guard has a variable input power supply capable of receiving input of 115VAC or 230VAC ±15%, 50/60 Hz. Current draw is 6A max. at 115VAC and 3A max. at 230VAC. There are three 4A/250V type 3AG (T) fuses installed for the power supply (line and neutral) and the GAS-Guard’s enclosure heater (line).

CAUTION: Replace fuses with same type and rating only.


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Oil Filter Service The GAS-Guard uses two inline screen type oil filters. Under normal operation, no filter maintenance is required. If service is require, the filter consist of three main parts: the filter housing, filter screen and the filter cap. For filter service proceed as follows:

1) Turn off power to the GAS-Guard by opening the GAS-Guard door and toggling the power switch located in the upper right hand corner to the OFF position.

2) Loosen the filter cap while supporting the filter housing with an adjustable end wrench. The exact filter location will vary by installation.

3) After loosening the filter cap slowly back off the cap until transformer oil starts flowing out the purge hole located on the side of the filter cap.

4) Let the oil continue to flow until a clear stream of oil void of any contaminates is visible. 5) Tighten filter cap. 6) Turn on power to GAS-Guard.

Figure 5: Filter assembly


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Customer Replaceable Units (CRU’s) Customer Replaceable Units (CRU’s) are defined as customer replaceable parts onsite without decommissioning the GAS-Guard.

Part # Description 270-0004-XX Helium Dryer 290-0020-XX Regulator, CAL, 290-0017-XX Cylinder, Verification 292-0018-XX Regulator Helium 292-0019-XX Regulator Helium w/ Pressure Switch 370-0025-XX LED, Front Panel, Green 370-0026-XX LED, Front Panel, Red 370-0027-XX LED, Front Panel, Blue 430-0032-XX Fuse, TD, 4 Amps, 1/4" x 1 1/4" 750-0076-XX Column Assembly, GAS-Guard 8 750-0084-XX Assy, Power Supply 750-0090-XX Column Assembly, GAS-Guard 3 250-0130-XX Filter, Oil R750-0076-XX Replacement Column Assembly1, GAS-Guard 8 R750-0084-XX Refurbished Power Supply Assy

Table 6: Customer Replaceable Units

Please contact Technical Support ([email protected]) for removal and installation procedures.

Cleaning

Internal Cleaning No internal cleaning of the GAS-Guard is required; doing so may cause damage the internal components and void the warranty.

External Cleaning No external cleaning of the GAS-Guard is required. If external cleaning is desired, water is the only recommended cleaning solution. Direct spray of high-pressure water onto the GAS-Guard door seal, LED’s, oil/helium bulkhead fittings and cable glands should be avoided.

1 GAS-Guard 3 does not require replacement column assembly


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Return Shipping Instructions Prior to returning parts to Siemens a Return Material Authorization (RMA) number must be obtained from Siemens technical support:

Technical Support: +1 (866) 273-7763 E-mail: [email protected]).

Returned items should be shipped in the original packaging or like packaging to avoid shipping damage. If original packaging or like packaging is not available contact Technical Support for shipping assistance.

Warning: Shipping of the GAS-Guard without installing the internal foam support, part # 010-0038-XX, can cause damage to the GAS-Guard and void the warranty.

Figure 6: Internal foam support


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Forms Verification Cylinder Data Sheet

Upon successful installation of your verification cylinder; please complete and fax or e-mail this Verification Cylinder Data Sheet to Technical Support at:

+1 (503) 924-3290 fax or [email protected] e-mail

Attn: Siemens Product Support

From:

Customer Information

Company:

Site:

Site Address:

City, State and Zip:

Country:

Gas Cylinder Information

Installer’s Name:

Installation Date:

GAS-Guard Serial Number:

Helium high pressure gauge (psig):

Verification high pressure gauge (psig):

Verification Cylinder Lot Number:

Verification Cylinder Manufacture Date:

Verification Cylinder Gas Components

Certified Concentrations

Hydrogen H2 ppmOxygen O2 ppmMethane CH4 ppm

Carbon Monoxide CO ppmCarbon Dioxide CO2 ppm

Ethylene C2H4 ppmEthane C2H6 ppm

Acetylene C2H2 ppm

Table 7: Verification cylinder datasheet

GAS-Guard View Software User's Manual

v2.0 810-1735-01 Rev A

June 10, 2008

www.serveron.com 3305 NW Aloclek Drive Hillsboro, OR 97124 USA +1 (503) 924-3200 phone +1 (503) 924-3290 fax

Corporate Office: (800) 880-2552

Technical Support: (866) 273-7763 E-mail: [email protected]


All rights reserved Serveron and LoadGuide are registered trademarks of Serveron Corporation. Microsoft, Microsoft Internet Explorer, Microsoft .NET, Windows NT, Windows XP, Windows Server 2003, DirectX and Windows are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries. FreeWave is a registered trademark of FreeWave Technologies. Unicode is a registered trademark of the Unicode Consortium. All other trademarks, registered trademarks, service marks, and trade names are the property of their respective owners.

810-1735-01 Rev A GAS-Guard View Software User's Manual v2.0

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Table of Contents

Before You Begin .................................................................................................................................. 6 About This Manual .......................................................................................................................... 6 About GAS-Guard View 2.0 Software .......................................................................................... 6

GAS-Guard View 2.0 Feature Overview .................................................................................. 7

Installing GAS-Guard View 2.0 ......................................................................................................... 9 System Requirements ...................................................................................................................... 9 Choosing an Installation Configuration ....................................................................................... 9 Installation Procedure ................................................................................................................... 10 Upgrade Procedure ........................................................................................................................ 10

Using GAS-Guard View 2.0 .............................................................................................................. 12 Starting GAS-Guard View 2.0 ...................................................................................................... 12 Creating New Files (Adding an Asset) ....................................................................................... 13 Opening Files .................................................................................................................................. 14 Navigating to Company, Sites, Assets and Monitors ............................................................... 15 Navigation Pane Icons and Notification ..................................................................................... 15 Working with Files ......................................................................................................................... 17

Using Legacy Files ..................................................................................................................... 17 Corrupt or Invalid Files ............................................................................................................. 18

Removing a File from the Navigation Pane ............................................................................... 18 Using Commands........................................................................................................................... 19 Using Tabs ....................................................................................................................................... 20

Using the Asset Status Tab ....................................................................................................... 20 Using the Graphs........................................................................................................................ 22

Graph Toolbar .......................................................................................................................... 23 Installing and Using Licenses ....................................................................................................... 25

Overview ..................................................................................................................................... 25 Automatic Scheduled Polling Option ..................................................................................... 26 Diagnostics Package Option ..................................................................................................... 26

GAS-Guard View 2.0 Reference ....................................................................................................... 28 Navigation Pane ............................................................................................................................. 28 Viewing Pane .................................................................................................................................. 29

Transformer Asset Tabs ............................................................................................................ 29 Status Tab.................................................................................................................................. 29 Gas in Oil Tab ........................................................................................................................... 31 Limits Tab ................................................................................................................................. 33 Percent of Alarm Tab .............................................................................................................. 33 Rate of Change Tab ................................................................................................................. 34 Duval Triangle Tab .................................................................................................................. 34 Sensor Data Tab ....................................................................................................................... 34 Extractor Data Tab ................................................................................................................... 35 Retention Time Tab ................................................................................................................. 35 Verification Data Tab .............................................................................................................. 35

GAS-Guard View Software User's Manual v2.0 810-1735-01 Rev A

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Company Specific Tabs ............................................................................................................. 36 Welcome Tab ............................................................................................................................ 36 Polling Tab ................................................................................................................................ 36 Status Tab.................................................................................................................................. 38

Site Specific Tabs ........................................................................................................................ 38 Status Tab.................................................................................................................................. 39

Monitor Specific Tabs ................................................................................................................ 39 Sampling Tab (Monitor icon selected in Navigation Pane) ............................................... 39 Communications Tab (Monitor icon selected in Navigation Pane) ................................. 39

Menu Commands ........................................................................................................................... 39 File Menu ..................................................................................................................................... 40

File New… ........................................................................................................................... 40 File Open… .......................................................................................................................... 41 File Close… .......................................................................................................................... 41 File Archive… ...................................................................................................................... 41 File Export… ........................................................................................................................ 41 File Print… ........................................................................................................................... 42 File Print Preview ............................................................................................................... 42 File Exit ................................................................................................................................. 42

Action Menu ............................................................................................................................... 42 Action Select Modem ......................................................................................................... 42 Action Send Diagnostic Data… ........................................................................................ 43 Action Rename Company… (Company selected, Status tab) ...................................... 43 Action Rename Site… (Site selected, Status tab) ............................................................ 43 Action Rename Asset… (Transformer asset selected, Status tab) ................................ 44 Action Poll Now (Transformer asset selected, Status tab) ............................................ 44 Action Enter DGA… (Transformer asset selected, Gas in Oil tab) .............................. 44 Action Start Sample Run (Transformer asset selected, Gas in Oil tab) ....................... 44 Action Update Limits (Transformer asset selected, Limits tab) ................................... 44 Action Start Verification Run (Transformer asset selected, Verification Data tab) ... 45 Action Start Calibration Run (Transformer asset selected, Verification Data tab) .... 45 Action Change Monitor Password… (Transformer asset selected, Status tab) ......... 45 Action Set Monitor Date and Time (Transformer asset selected, Status tab) ............. 46 Action View Log… (Transformer asset selected, Status tab) ....................................... 46 Action Sample Hourly (Monitor selected, Sampling tab) ............................................. 46 Action Check Communications (Monitor selected, Communications tab) ................ 47 Action Update Communications (Monitor selected, Communications tab) .............. 47

View Menu .................................................................................................................................. 47 View Refresh (F5)................................................................................................................ 47 View Auto Refresh ............................................................................................................. 47 View Navigator ................................................................................................................... 47

Help Menu .................................................................................................................................. 47 Help User’s Manual ............................................................................................................ 47 Help Frequently Asked Questions ................................................................................... 48 Help Release Notes ............................................................................................................. 48 Help Licensing .................................................................................................................... 48


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Help Install Sample Files ................................................................................................... 49 Help About Siemens Client ............................................................................................... 49

Using the Duval Triangle .............................................................................................................. 49 Overview ..................................................................................................................................... 49 Interpretation of regions ........................................................................................................... 50 Interpretation of the Triangle ................................................................................................... 51 Multiple data points ................................................................................................................... 51 Summary ..................................................................................................................................... 51

Using the Rogers Ratio Viewer .................................................................................................... 52 Introduction ................................................................................................................................ 52 Functional Overview ................................................................................................................. 52 Interpretation of Regions .......................................................................................................... 54 Interpreting the Graphical View .............................................................................................. 55 Summary ..................................................................................................................................... 55

Maintaining GAS-Guard View 2.0 Installations ............................................................................ 56 Configuring Communications ..................................................................................................... 56

Introduction ................................................................................................................................ 56 Local Area Network (LAN) ...................................................................................................... 57 Telephone Modem ..................................................................................................................... 57 RS-232........................................................................................................................................... 58 RS-232 with radio (FreeWave®) ............................................................................................... 58 Telephone Modem with radio (FreeWave®) ......................................................................... 59

Configuring Modems .................................................................................................................... 60 Modem Initialization ................................................................................................................. 60 Advanced Dialing Strings ......................................................................................................... 61

Overview .................................................................................................................................. 61 Send/Expect Protocol ............................................................................................................. 61

Configuring TAPI Modems ...................................................................................................... 62 Troubleshooting ............................................................................................................................. 63

Corrupt or Invalid Files ............................................................................................................. 63 Overview .................................................................................................................................. 63 File Structure ............................................................................................................................ 63 Causes of File Corruption ....................................................................................................... 66 Repairing Damaged Files ....................................................................................................... 66

Menu Items Unavailable (“Grayed Out”)............................................................................... 67 Theory of Operations ..................................................................................................................... 67

Overview ..................................................................................................................................... 67 Viewer Component .................................................................................................................... 68 Poller Component ...................................................................................................................... 68


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Before You Begin

About This Manual This User’s Manual provides the information that you need to install, setup, and use the Siemens GAS-Guard View 2.0 software to monitor and diagnose the state of your transformer assets.

The manual is organized into chapters of increasing depth and detail. The chapters Installing GAS-Guard View and Using GAS-Guard View are informal user guides. The GAS-Guard View Reference chapter provides detailed descriptions of all parts of the user interface. Finally, the chapter titled Maintaining GAS-Guard View Installations provides additional information.

Note: this manual assumes you have basic familiarity with the operating principles of your Siemens Online Transformer Monitor. If you require

information regarding the features, operation, and installation of a Siemens transformer monitor please review the technical documentation available at the Serveron web site www.serveron.com or contact your local distributor.

Current contact information for authorized distributors and technical support is published on the Serveron web site.

About GAS-Guard View 2.0 Software GAS-Guard View 2.0 is a software application for Windows®-compatible PCs. It is used to retrieve and display data that has been collected by a Siemens GAS-Guard on-line transformer monitor and also to change settings within the monitor. GAS-Guard View 2.0 does not measure gas-in-oil levels; the GAS-Guard monitor makes those measurements. GAS-Guard View 2.0 retrieves these measurements from the monitor and displays them in a variety of formats. GAS-Guard monitors measure, record, and report the status of fault gases in transformer insulating oil.

GAS-Guard View 2.0 requires an Ethernet, dial-up, direct serial or radio link from the PC to the monitor in order to retrieve measurements and change settings. Transformer data retrieved by GAS-Guard View 2.0 is stored in ordinary files on the PC.

Retrieving data does not cause the monitor to lose or delete its internal measurement history. This allows more than one computer running GAS-Guard View 2.0 to remotely retrieve data from a single GAS-Guard monitor. Alternatively, the security features of GAS-Guard View 2.0 can be used to restrict monitor access to a single, privileged installation on a single computer.

http://www.serveron.com/


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Note: GAS-Guard View 2.0 is fully compatible with transformer data files created by GAS-Guard View version 1.6 or earlier. After you install or

upgrade to GAS-Guard View 2.0 software, however, all GAS-Guard View users at your site must upgrade to version 2.0. Files created or updated with

Siemens’ GAS-Guard View 2.0 software cannot be viewed using older versions of GAS-Guard View software. Users who have not upgraded will

be notified of an error when they attempt to view or update these files.

GAS-Guard View 2.0 Feature Overview

Figure 1. GAS-Guard View 2.0 User Interface Overview.

Navigation pane: allows selection of the company, site, transformer or monitor for viewing. In addition, the icons provide notification information (e.g. “attention required”, “data not accessible”) about the status of monitored assets.

Viewing pane: contains one or more tabs. The tabs collectively display the state of the asset or other item selected in the Navigation pane. Each tab contains a separate purpose-built display. For transformer assets, the available tabs include the Status view, Gas in Oil PPM graph, Limits view, Percent of Alarm graph, Sensor and Extractor Data graphs, Retention

Times graph, and Verification Data graph.

Viewing pane Tabs End date and time range controls

Menu bar

Application Toolbar

Transformer Asset

Graph Toolbar

Navigation pane


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Menu bar: allows selection of user commands.

Application Tool bar: contains the End Date and Range controls.

End Date and Range controls: affect the display of data for many of the tabs that appear in the viewing pane, particularly the graphs. Changing the setting of either control causes an immediate refresh of the viewing pane to conform to the new setting. The default End Date is the timestamp of the most recent available data while the default Range is 1 month.

Graph Toolbar: Displayed only when a graph is visible. Contains commands specific to graphs.

Later sections of this document describe all features of the user interface in detail.


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Installing GAS-Guard View 2.0

System Requirements Siemens GAS-Guard View 2.0 requires a computer with 533 MHz Pentium-III or higher and minimum 128MB of memory (192MB recommended). 1024x768 or higher screen resolution is highly recommended (visual anomalies may occur on an 800x600 display). The video system must be configured to display at least 256 colors. Siemens strongly recommends use of the highest color mode available from your display subsystem. This may be called “high color”, “true color”, “24-bit color”, or “32-bit color” depending on your vendor.

Installation requires approximately 50MB of hard disk space. At least 20MB of additional space should be available for normal use. Actual disk usage varies with the number of monitored assets.

Siemens GAS-Guard View 2.0 is a Windows®-based application. This product works with Windows 2000, Windows XP, or Windows Server 2003 operating systems. Windows 98, Windows ME, and Windows NT® operating systems are not supported. Microsoft Windows Vista® is not supported.

GAS-Guard View 2.0 requires the Microsoft .NET Framework version 2.0.

Choosing an Installation Configuration Siemens GAS-Guard View 2.0 may be installed in any one of three configurations: Viewer

Only, Server or Standalone. In order to choose the configuration that best meets your needs, it is helpful to know a little about the internal organization of GAS-Guard View 2.0 software.

GAS-Guard View 2.0 is made up of two major components, the Viewer and the Poller. The Viewer is the application you see and interact with. The Poller works "behind the scenes,” communicating with your Siemens monitor(s) and saving the data they gather in files.

In the Viewer Only configuration, as the name implies, the Poller component is not installed. Viewer Only installations are limited to accessing data retrieved and stored in files by some other GAS-Guard View 2.0 installation. This configuration is appropriate in a workgroup setting where some users access transformer data but do not have the need or the ability to communicate directly with Siemens monitors from their computer.

The Server configuration is the counterpart of the Viewer configuration. It functions as the point of communication with your Siemens monitors. A Server installation can receive monitor data when no user is logged in. Server installations are particularly appropriate when the host computer operates continuously and has ongoing access to the necessary communications resources (modems, network adapters, etc.) Server installations are frequently unattended and may be expected to operate “24x7” for long periods of time.

To install a Server configuration, you are required to specify an account identity under which the Poller component will execute. To be successful at this task, you should have


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knowledge of Windows file sharing and network security fundamentals. The account you choose must have sufficient privileges. These include the privilege to access all files (including network files) that will be used by the Poller and also privilege to use the system-wide portion of the Registry. In keeping with industry best practices, Siemens recommends that you do not assign unnecessary privileges to this account.

If these concepts are not clear to you, Siemens recommends that you create a Standalone configuration.

In the Standalone configuration, the Poller component is installed in your Startup folder and runs only when you are logged in. Data cannot be received from the monitor when you are not logged in. The benefit of the Standalone configuration is that it largely eliminates the need for special knowledge of file sharing and network security.

A Standalone installation of GAS-Guard View 2.0 behaves like a traditional desktop application program. Note that this configuration is intended for use by a single user on a single computer. If multiple user login identities will be accessing GAS-Guard View 2.0 on the same computer, Siemens recommends that a Server configuration be used instead.

Installation Procedure

Note: Administrative privilege is required to install the software.

When you insert the installation CD-ROM, GAS-Guard View 2.0 setup should start automatically. If it does not, please double click setup.exe in the INSTALL folder of the CD-ROM to start it. Setup will install the necessary prerequisite software and then install version 2.0 of GAS-Guard View.

GAS-Guard View 2.0 requires version 2.0 of the Microsoft .NET Framework. If the installation program detects that this mandatory prerequisite is not present, it will be installed automatically from the CD-ROM.

Siemens recommends that you use Windows Update to check for any recent updates to Microsoft components after installing GAS-Guard View 2.0 on your computer.

When installation is complete, you may start GAS-Guard View 2.0 using either the Start menu or the Desktop icon.

Upgrade Procedure

Note: Administrative privilege is required to upgrade the software.

Insert the installation CD-ROM. GAS-Guard View 2.0 setup should start automatically. If it does not, please double click SETUP.EXE in the INSTALL folder of the CD-ROM to start it.


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Setup will automatically upgrade your existing installation to version 2.0 of GAS-Guard View.

GAS-Guard View 2.0 requires version 2.0 of the Microsoft .NET Framework. If the installation program detects that this mandatory prerequisite is not present, it will be installed automatically from the CD-ROM.

Note: GAS-Guard View 2.0 is fully compatible with transformer data files created by GAS-Guard View version 1.6 or earlier. After you install or

upgrade to Siemens GAS-Guard View 2.0 software, however, all GAS-Guard View users at your site must upgrade to version 2.0. Files created or updated with Siemens GAS-Guard View 2.0 software cannot be viewed using older versions of GAS-Guard View software. Users who have not upgraded will

be notified of an error when they attempt to view or update these files.

Siemens recommends that you use Windows Update to check for any recent updates to Microsoft components after upgrading to GAS-Guard View version 2.0 on your computer.

When installation is complete, you may start GAS-Guard View 2.0 using either the Start menu or the Desktop icon.


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Using GAS-Guard View 2.0 This chapter contains an informal guide to the features of GAS-Guard View 2.0. Details of each part of the user interface appear in the GAS-Guard View Reference chapter later in this manual.

Starting GAS-Guard View 2.0 Upon successful installation, a GAS-Guard View 2.0 icon is created on the Desktop and a GAS-Guard View 2.0 item is created in Start Program Files Siemens. Use one of these shortcuts to launch GAS-Guard View. The navigation pane will display the message No Files and the Welcome screen will be displayed. The Welcome screen is shown in Figure 2. GAS-Guard View 2.0 Welcome Screen.

Figure 2. GAS-Guard View 2.0 Welcome Screen.

You can now install and open the sample files as described on the Welcome screen. You can also create a new transformer data file if your installation configuration supports this operation (Viewer Only configurations do not support the creation of new files).


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Alternatively, if this installation is an upgrade from GAS-Guard View 1.62 or earlier and you have existing transformer data files, you can open these files.

Creating New Files (Adding an Asset)

Note: this operation is available if you selected the Standalone or Server configuration during installation. If you selected Viewer Only, operations

that create and modify files are not available to you.

To add a new monitored asset to the navigation pane, create a new file. The file holds all measurements and other information about the asset, its monitor, and its place in the navigation hierarchy.

Use File New… to create a new file. This menu item displays the New File Creation wizard. The first page of the wizard is shown in Figure 3. New File Creation wizard, initial page.

Figure 3. New File Creation wizard, initial page.

When you click Next, the wizard presents a series of pages that collect the information required to display and communicate with a Siemens monitor. At the conclusion of the


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wizard, the new asset and its monitor are added to your navigation pane for display and/or update (polling).

For a detailed description of the wizard, see the section Configuring Communications later in this manual.

Opening Files To familiarize yourself with the GAS-Guard View 2.0 user interface, you may examine the sample files. To do so, first click the Install Sample Files button on the Welcome screen or click Install Sample Files… in the Help menu. Use the browse box to choose a location (e.g. your My Documents folder). When you click OK, the files are copied to the location you chose (e.g., My Documents). You do not need the installation media to install the sample files.

Now select Open… from the File menu and navigate to the location you selected in the previous step. Select one of the sample files and click the Open button. The file contents are added to the navigation pane. The viewing pane displays the Status tab shown in Figure 4.

Figure 4. Asset selected in navigation pane and Status tab displayed in viewing pane.


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Note: since the contents of the sample files were captured some time ago, the Data Age section on the Status tab warns you that the file contents are not

up-to-date and the Alarm History section displays the message WARNING:

No Recent Gas Data.

Additional information about the Status tab can be found in the section Using the Asset

Status Tab later in this manual.

Navigating to Company, Sites, Assets and Monitors The navigation pane is used to select a company, site, transformer or monitor for display. It is organized as a hierarchy of Company, Sites, Assets and their Monitors. Its structure is similar to the navigation pane found in Windows Explorer and in many other software applications and web sites.

The navigation pane remembers all the files you have opened and provides easy access to their contents. When you open additional files, their contents are merged with existing sites and companies if the names match.

Click on the small + adjacent to an icon to expand it. Expanding the transformer icon, for example, displays the icon representing the monitor. If you then click the monitor icon, the viewing pane redraws to show tabs specific to managing the monitor’s operation (scheduling and communications).

Navigation Pane Icons and Notification Icons in the navigation pane change to notify you of conditions that may require your attention. By default, items in the navigation pane are represented by the basic icons shown in Figure 5.

Figure 5. Basic icons.

Folder icon representing a Company or Site

Icon representing a Transformer Asset

Icon representing an Online Transformer Monitor


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When an alarm or caution condition is encountered on a transformer asset, or a service required condition is encountered on a transformer monitor, the corresponding icon is temporarily replaced by the pending notification icon: a yellow triangle containing an exclamation point. The pending notification icon is shown in Figure 6.

Figure 6. Pending notification icon

After an asset or monitor with a pending notification is selected and displayed in more detail, the icon is replaced by an acknowledged notification icon. This appears as the original transformer or monitor icon with a tiny yellow triangle superimposed at upper right.

The acknowledged notification icon is displayed as long as the original condition (alarm, caution, or service required) is present. When an update (polling operation) is performed and the condition is cleared, the acknowledged notification icon is replaced by the company, site, transformer or monitor icon.

The acknowledged notification icons are shown in Figure 7.

Figure 7. Acknowledged notification icons

Pending and acknowledged notification icons propagate upward in the navigation pane. If any of the assets in a site are in a notification condition, the site icon displays the highest priority (pending or acknowledged) notification icon for any of its assets. Similarly, if any of a company’s sites are in a notification state, the company icon will also display the highest priority icon. This behavior allows you to determine at a glance when one of your assets or monitors requires attention.

Icon representing an item that requires your attention

Icon representing a Company or Site holding an item with a condition that has been acknowledged

Icon representing a Transformer condition that has been acknowledged

Icon representing an Online Transformer Monitor condition that has been acknowledged.


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Finally, distinct icons are displayed for companies, sites, assets or monitors when their data is contained in a file that cannot be accessed by GAS-Guard View 2.0. These icons appear as the original company, site, asset or monitor icon with a tiny white x on a red background superimposed at upper right. The inaccessible file icons are shown in Figure 8.

Figure 8. Inaccessible file icons

A file may be inaccessible because:

It has been moved or deleted, or

It is stored on a file share that is not accessible because of an interruption in your network service, or

You no longer have the permissions required to access the file, or

The contents of the file have become corrupted so that GAS-Guard View 2.0 can no longer load them.

When you click on an icon representing an inaccessible company, site, asset, or monitor, the item does not become selected and the contents of the Viewing pane do not change. Instead, a dialog box is displayed. The dialog box text provides a short explanation of the reason the item is inaccessible, e.g. file not found.

Working with Files

Using Legacy Files Files created by GAS-Guard View version 1.6 (or earlier) are considered “legacy” files. GAS-Guard View 2.0 is fully compatible with legacy files.

After you install or upgrade to Siemens GAS-Guard View 2.0 software, all GAS-Guard View users at your site must upgrade to version 2.0. Files created or updated with Siemens GAS-Guard View 2.0 software cannot be viewed using older versions of GAS-Guard View software. Users who have not upgraded will be notified of an error when they attempt to view or update a file created or updated by GAS-Guard View 2.0.

Icon representing a Company or Site contained in a file or files that are not accessible to GAS-Guard View

Icon representing a Transformer contained in a file that is not accessible to GAS-Guard View

Icon representing an Online Transformer Monitor contained in a file that is not accessible to GAS-Guard View


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Legacy files do not contain Company, Site or Asset Name information for use in the Navigation pane so GAS-Guard View 2.0 uses the default terms Company, Site, and Asset in the navigation pane. You can change these default names to your actual company, site and asset names.

To change a name, first select the Company, Site, or Asset icon in the Navigation pane and then click Rename… in the Action menu. Updated values are stored in the file itself so the change need only be performed once. Please see the Menu Commands section of this manual for more information.

Corrupt or Invalid Files GAS-Guard View 2.0 differs from earlier versions of GAS-Guard View in its handling of corrupt or invalid files. GAS-Guard View 2.0 generally detects and refuses to open corrupt or invalid files where earlier versions of GAS-Guard View may have provided partial functionality or behaved incorrectly.

If you encounter a Corrupt or Invalid message when opening a legacy file, please see the Troubleshooting section of this manual or contact Siemens or your Siemens representative for assistance. In most cases, corrupt or invalid files can be repaired without loss of data.

Removing a File from the Navigation Pane The contents of all the files you have created (File New…) or opened (File Open…) are shown in the navigation pane. If you close GAS-Guard View 2.0, the contents of the navigation pane are preserved: when you restart GAS-Guard View 2.0, navigation pane contents are unchanged.

If you no longer wish to view one or more assets or their monitors, you can remove them from your navigator using File Close. This menu item displays the Close Files dialog shown in Figure 9.


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Figure 9. Close Files dialog.

Select the row(s) containing the monitor(s) you no longer wish to view and click OK. The dialog clears and the screen is redrawn. If you close all files, the No files message is displayed in the navigation pane and the Welcome screen appears in the viewing pane.

Sites continue to be displayed so long as they contain any visible transformer assets, and companies continue to be displayed so long as they contain any visible sites. If you close all the transformers within a Site, the Site will disappear from your navigator as well.

Closing a file merely removes the file from the navigation pane. It does not delete or alter the file data itself. To again display information for a transformer and its monitor in GAS-Guard View 2.0, use File Open… to add the file to the navigation pane.

Using Commands Commands (user actions) appear in the GAS-Guard View 2.0 menu bar. Menu items are unavailable (“grayed out”) when they do not apply to the current selection; for example, the File Export… menu item is available only when the Viewing Pane shows data that may be exported. Otherwise, it is grayed out.


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Note: if your GAS-Guard View 2.0 installation is a Viewer Only configuration, all commands that update or modify data are unavailable to

you. These commands must be performed from a Standalone or Server configuration.

The contents of the Action menu change according to the currently selected navigation item and tab. The command to Enter DGA…, for example, is only available when viewing the Gas in Oil graph that displays the DGA data. The Enter DGA command does not appear in the menu when viewing other navigational selections or tabs.

Some Action menu commands are always present. These commands affect the GAS-Guard View 2.0 application as a whole and appear at the top of the Action menu. They include Select Modem and Send Diagnostic Data.

All GAS-Guard View 2.0 commands are described in the Menu Commands section of the GAS-Guard View Reference section of this manual.

Using Tabs This section provides an overview of the status and graphing tabs.

Using the Asset Status Tab When a transformer asset is selected, the default (leftmost) tab presents a dashboard-like status overview. The tab contains colored status indicators, an Alarm History display, and certain textual information. The tab is shown in Figure 10.


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Figure 10. Status tab.

The groups of colored indicators on the upper left show:

The state of the gas PPM level alarm.

The state of the gas rate of change (ROC) alarm.

The status of the monitor.

The data age (an indication of whether data has recently been obtained from the monitor).

The Event History section shows the status reported by the selected monitor over the previous several days. This display expands to fill the available screen width. The colored vertical bars represent the outcome of sample runs and other significant monitoring events. Bars that represent successful sample runs are colored green, yellow or red to indicate the most urgent condition detected by that sample run (normal, caution, or alarm). Black bars are displayed to indicate that the monitor aborted a run due an error, and blue bars indicate that the monitor encountered a Service Required condition. If the most recent data is more than about 48 hours old, the Event History label displays WARNING: No Recent Gas Data in red.


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Note: for more information about sample runs, Service Required conditions, and other Siemens Online Transformer Monitor principles of operation,

please consult the documentation that was provided with your monitor or visit http://www.serveron.com.

To obtain details of a particular day’s runs and other significant monitor events, move the mouse pointer over the rectangle (tile) representing that day and click. A small dialog box will be shown containing details of that day’s activity. Click OK to clear the dialog.

The Action menu for the Status tab contains several commands. For details of these commands, please refer to the GAS-Guard View Reference chapter later in this manual.

Using the Graphs The Gas in Oil PPM, Rate of Change, and Percent of Alarm graph tabs share several key features.

The content of a typical graph tab is shown in Figure 11.

Figure 11. Graph tab components.

These graphs display two vertical (Y) axes, one at the left and the other at the right. The values of gases are always displayed relative to the left or primary axis, which may be either logarithmic or linear. Sensor readings (LoadGuide, Ambient Temperature, etc) are displayed relative to the right or secondary axis, which always displays a linear scale.

Primary Y (gas value) axis

Primary Y axis label

X (time) axis

Graph toolbar Secondary Y (sensor) axis

Graph legend

Graph title

DGA

DGA legend



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A graph legend indicating the color of each gas or sensor data series appears to the right of the graph area. The graph legend relates colors to measured values. Carbon Monoxide (CO), for example, is always shown in red. When a graph is first displayed, measured gas values are shown while computed values and sensor values are hidden. The colored circle adjacent to each series names in the legend is a control buttons. To display or hide a particular gas or sensor data series, click the appropriate button.

Siemens GAS-Guard model GAS-Guard 8 and GAS-Guard 3 monitors support configurable labeling for external sensors. For these models, the external sensor labels are taken from information stored in the transformer monitor itself. The labels are normally configured when the monitor is installed. GAS-Guard View 2.0 does not support the ability to change the configured labels.

The legend information at extreme upper right indicates that one or more manual dissolved gas analysis (DGA) readings are currently being displayed on the graph. This legend block appears only when manual DGA readings are being shown. On the graph surface, manual

DGA data appears as small x markers in the color of the corresponding gas data series. To see the numerical values of DGA data, simply slide the mouse over the area of the DGA.

For more information about the Gas in Oil PPM, Rate of Change, and Percent of Alarm tabs, including instructions for entering manual DGA readings, see the corresponding section in the GAS-Guard View Reference chapter later in this manual.

Graph Toolbar

Graph tabs contain their own toolbar. It is distinct from the Application Toolbar that contains the End Date and Range controls. The graph toolbar is detailed in Figure 12.

Figure 12. Graph Toolbar

Copy to Clipboard

Print

Toggle: Point Labels

Toggle: Zoom

Toggle: Primary Y axis log/linear Toggle: Data

Table

Display Rogers Ratio Viewer

Toggle: Annotations

Annotate


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Copy to Clipboard. This button allows the graph contents to be transferred to the Windows Clipboard in one of three formats: bitmap, metafile, and text. Bitmap and metafile are image formats compatible with many other applications. Text format allows the graph data to be copied. In most cases, better results can be achieved with the File Export menu item, which is described in the GAS-Guard View Menu Commands section of this manual.

Print. This button allows the graph contents to be printed. Its behavior is identical to the File Print menu item, also described in the Menu Commands section.

Point Labels. This button allows point labels to be displayed or hidden. Point labels are most useful when only a limited number of points are displayed (for example, a 3-day view).

Data Table. GAS-Guard View 2.0 can display a data table which provides a tabular data view of the data that is linked to the graph contents. The Data Table button allows the data table to be displayed or hidden. When the mouse is moved over Data Table cells, the corresponding point in the graph series is highlighted. When the mouse is moved over a point in the graph series, the Data Table is automatically scrolled to display the corresponding cell and that cell is highlighted.

Zoom. The zoom button enables or disables “zooming” the graph. With zoom enabled, you can click in the graph area at the upper left corner of the area you wish to enlarge and drag the mouse down and to the right to define the area you wish to display. When you release the mouse button the selected area expands to fill the entire graph region and sliders (similar to scroll bars) are displayed to allow the graph to be repositioned. You may zoom repeatedly to magnify smaller areas or click the toggle again to restore the original resolution.

Log Scale. The log/linear button changes the primary Y axis from a log scale to a linear scale and back. Display of sensor values is not affected. Sensor values are displayed relative to the secondary Y axis, which is always linear and displays a fixed range suitable for sensors supported by Siemens.

Display Rogers Ratio Viewer. Clicking this button displays the Rogers Ratio Viewer, a graphical transformer diagnostic display. The Rogers Ratio Viewer requires a Diagnostic Package license from Serveron. For more information about licensing, see Installing and

Using Licenses. For more information about the Rogers Ratio Viewer, see Using the

Rogers Ratio Viewer.

Toggle Annotations. This button toggles the display of graph annotation markers. Annotations are notes attached to particular points in time on the graph while their markers are cartoon-style “thought bubbles.” To see the annotation contents, move the mouse over the marker or click within the bubble.

Annotate. Clicking this button displays the Annotate dialog box, which allows you to enter annotations (notes) that are associated with a point in time on the graph. In order to annotate graphs, you must obtain a Diagnostic Package license from Serveron. For more information about licensing, see Installing and Using Licenses.


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Installing and Using Licenses Your initial installation of GAS-Guard View 2.0 is a fully-functional application for monitoring and managing Siemens Online Transformer monitors. In addition, Siemens offers options that require separate licensing. The options include:

The Automatic Scheduled Polling option, which provides the ability to perform automatic scheduled polling for more than one monitor (automatic scheduled polling for a single monitor is included in the initial installation).

The Diagnostics Package option, which includes Duval’s Triangle, the Roger’s Ratio Viewer, and the ability to annotate graphs.

This section explains how to obtain, install, and use licenses for these extended features. To purchase licenses, please contact Siemens or your Siemens representative.

Overview Licensed features are enabled through a two-step process. The process begins when you transmit your Machine ID via email to Serveron and is completed when you receive the license key corresponding to the desired feature. You then install the license key into your GAS-Guard View 2.0 installation in order to enable the feature. Your installation has only one Machine ID, but you must obtain one license key from Serveron for each option you wish to access.

In order to obtain a license key, you must first install GAS-Guard View 2.0 in either the Standalone or the Server configuration. Requesting and installing license keys are administrative activities that cannot be performed from a Viewer Only configuration.

To begin the process, start GAS-Guard View 2.0 and then click Licensing… in the Help menu to display the Licensing dialog. After a moment, the dialog box displays your Machine ID and enables the Copy to Clipboard button.

Create an email message. Address it to [email protected] with subject License

Request. Paste the Machine ID into the body of the message. It should look like this (your Machine ID value will be different):

Machine ID: 5F01-7C60-F311-43B2-3A8D

Send the email message. Serveron makes every effort to respond to license key requests within two business days, but cannot guarantee response. If you do not receive a timely response to your email, please contact Serveron Customer Support or your Serveron representative.

When the email response arrives from Serveron, your license key will take the form of a text file attachment. Please save the file attachment to a known, and preferably backed up directory on your PC or another safe location. If you are ever forced to perform a complete re-installation of GAS-Guard View 2.0, you may need to re-install your license keys.

After saving the license key file attachment, open GAS-Guard View 2.0 and again click Licensing… in the Help menu to display the Licensing dialog. Click the Browse… button located at left to display a standard Open File dialog. Navigate to the license key file (the attachment you saved). Select the file and click OK. After a short pause, GAS-Guard View

mailto:[email protected]


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2.0 should respond with a dialog stating 1 license key installed. If it does not, please try the operation again. If the problem reoccurs, please contact Siemens or your Siemens representative.

You can now make use of the feature or features enabled by your license.

Automatic Scheduled Polling Option GAS-Guard View 2.0 maintains an internal table of licenses available for automatic polling. Each license enables automatic polling for a single monitor. When you install GAS-Guard View 2.0 in either the Standalone or Server configuration, the table is initialized with one (1) license.

An automated polling license key encodes a number of additional licenses. Licenses are available from Serveron in groups of 6, 12, or unlimited. When you install the key as described above, the additional licenses you purchased are placed in the internally-managed table.

To access your automatic polling licenses, select the Company node in the navigator and click the Polling tab. The viewing pane should show a list of monitors. Click on a monitor (row) to select it and then click Update Automatic Polling Status… in the Action menu.

The Update Automatic Polling Status dialog box appears. The dialog box shows the number of automated polling licenses available in the pool. The value is 1 when you first install GAS-Guard View 2.0. When you add licenses, the value increases by the number of additional licenses you purchased (6, 12, or unlimited).

Automated polling for a monitor is enabled by checking Automatically poll this monitor in the Update Automatic Polling Status dialog. When you click OK, one license is removed from the internally managed table and assigned to the selected monitor. The number of available licenses remaining in the table is reduced by one (if you purchased an unlimited license, the table still contains an unlimited number of licenses).

If you uncheck Automatically poll this monitor for an automatically polled monitor or use File Close to close the file, its license is automatically returned to the internally managed table. This increases the number of available polling licenses by one. This table-based design allows you to “float” a smaller number of licenses across a larger number of monitors should you choose to do so.

Diagnostics Package Option The Diagnostics Package includes the Duval Triangle display, the Rogers Ratio Viewer, and the ability to place annotations (comments) on graphs. Diagnostic license keys are available from Serveron in groups of 6, 12, or unlimited. License keys are obtained and installed using the procedure described earlier. Once installed, the licenses must be assigned to a particular monitor in order to take effect.


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Note: Diagnostic licenses cannot be reassigned. Unlike automated polling licenses, Diagnostic licenses do not “float.” When you install a license key for the Diagnostic Package, the licenses you purchased are placed in an internally managed table. When you assign a license to a monitor, the license is removed from the internally managed table and assigned to the monitor. Unlike Automated Polling licenses, the assignment of a diagnostic license to a monitor serial number is final and irrevocable. There is no “undo.”

To access your Diagnostics Package licenses, first obtain and install the license key using the procedure described earlier. Then click Licensing… on the Help menu and select the Diagnostics tab.

The tab shows a list of known monitors (from the Navigation pane) and the licensing status of each. To assign a license to a monitor, click in the left list to select it and then click Assign… You will receive a warning indicating that license assignment cannot be revoked or undone. Carefully check that you have selected the monitor you wish to license and then click OK. The monitor’s serial number transfers to the rightmost list indicating the monitor is now licensed.

Note: after assigning the license, you must poll the monitor before the license will take effect. Polling the monitor stores encrypted licensing information in the file so the Viewer can access it. You may use the Poll Now menu item in the Action menu or, if the monitor is being automatically polled, simply wait

for the next automatic polling cycle to occur.

After polling the monitor, click on the monitored transformer asset in the Navigation pane and access the Diagnostic Package features for the monitor. For example, select the Duval

Triangle tab to display the Triangle.

Each time a monitor is polled, GAS-Guard View 2.0 checks to see whether the monitor being polled has been assigned a Diagnostic Package license. If so, GAS-Guard View 2.0 stores licensing information in the file itself. Any GAS-Guard View 2.0 installation that opens the file checks for the presence of this licensing information. If valid licensing information is found in the file, GAS-Guard View 2.0 enables its diagnostic features for the data found in that file.

This design ensures that once a Diagnostics license is issued to a monitor, anyone viewing the monitor’s data using GAS-Guard View 2.0 will have access to all Diagnostic Package features. If, for example, you send a transformer data file to a transformer expert at another location within your organization, the file carries its own licensing information along with it. If the remote expert opens the file using their own standalone GAS-Guard View 2.0 installation, all Diagnostic Package features will be enabled. Similarly, workgroup users with Viewer Only installation configurations will have access to Diagnostics Package display features for any properly licensed monitor.


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Menu bar

Viewing pane

Navigation pane

Graph Toolbar

Transformer Asset

Application Toolbar

Tabs End date and time range controls

GAS-Guard View 2.0 Reference This chapter contains details of every tab and menu command in the GAS-Guard View 2.0 user interface. The next section describes the navigation pane. The tabs are discussed in the Viewing Pane section. Menu items are documented in the Menu Commands section that follows. For reference, the user interface overview is shown in Figure 13.

.

Figure 13. GAS-Guard View 2.0 User Interface Overview.

Navigation Pane The navigation pane contains a hierarchical list (sometimes called a tree) showing the company, sites, assets and monitors defined in all the files you have opened or created. Each item in the navigation pane is identified by an icon. The icons are shown in Figure 14.


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Figure 14. Navigation pane icons.

To expand an icon, displaying the items it contains, click the + (plus) adjacent to a collapsed icon. To collapse the icon, hiding the items it contains, click the – (minus) adjacent to an expanded icon.

When you select an icon by clicking on it, the viewing pane is redrawn with tabs that are appropriate to display information about the selected item.

Icons in the navigation pane change to notify you of conditions that may require your attention. For details of the alternative icons used for notification, please refer to Navigation Pane Icons and Notification.

To add to the navigation pane, click New… or Open… in the File menu. To remove items, click Close… in the File menu. For detailed descriptions of these commands, please see the Menu Commands section later in this manual.

Viewing Pane This section contains additional details about the tabs that appear in the viewing pane. The current selection in the navigation pane determines which tabs appear in the Viewing Pane.

Your selection will most frequently be an icon representing a transformer asset. All tabs associated with transformer assets are described in the next subsection, Transformer Asset

Tabs. Less frequently, you will select a Company, Site or Monitor icon in the navigation pane. Tabs associated with these selection types are described in subsequent sections,

Transformer Asset Tabs This section discusses the tabs that appear when a transformer asset is selected in the navigation pane.

Status Tab

The Status tab is the default when a transformer asset is selected. It displays a dashboard-like display of the status of the selected asset. The following indicators are provided:

Folder icon representing a Company or Site

Icon representing an Online Transformer Monitor

Icon representing a Transformer Asset


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Gas PPM Level Status and Gas ROC Status. These three-level indicators show the results of the most recent sample obtained from the monitor. They display alarm (red) to indicate that the monitor encountered a gas alarm condition on the most recent sample run or caution (yellow) to indicate a gas caution condition. If no cautions or warnings were detected on the most recent sample run, both indicators display normal (green). If no readings have ever been received, all three indicators display background gray.

Monitor Status. This two-level indicator displays service required (blue) to indicate that the monitor has encountered a service required condition. The blue indicator mimics the blue Service Required lamp on the front panel of the monitor itself. The indicator displays normal (green) to indicate a healthy monitor. If no data has ever been received from the monitor, both indicators display background gray.

Data Age. This three-level indicator shows whether gas in oil data from the monitor is up to date or needs to be refreshed by polling the monitor. 0 – 8 Hours Old (green) indicates that the timestamp of the most recently-received sample run is from 0 to approximately 8 hours old. 8 – 24 Hours Old (yellow) indicates the most recent sample is more than about 8 hours old but no older than about 24 hours. 24 Hours or Older (red) indicates that the most recent sample is more than about 24 hours old. If no sample data has ever been received from the monitor, all three indicators display background gray.

Event History. This horizontal region shows the monitor’s activity over recent days. Each rectangular block or tile displays one day’s activities with the most recent day’s activity appearing at right.

Within a day’s tile, the colored vertical bars indicate one significant activity by the monitor. Most activities are sample runs, which appear as green, yellow or red bars to indicate their most urgent outcome (normal, caution, or alarm, respectively). Service required conditions, if any, are displayed as vertical blue bars. Aborted runs are shown as black bars. Finally, non-sample runs are displayed as vertical white bars. Most non-sample runs are regularly-scheduled verification runs. If no data has ever been received from the monitor, the Event History block is empty.

Note: for more information about sample runs, Service Required conditions, and other Siemens Online Transformer Monitor principles of operation,

please consult the documentation that was provided with your monitor or visit http://www.serveron.com.

Textual Information. At the bottom of the screen textual information about the monitor is displayed. The Latest Monitor Timestamp is the timestamp on the most recent piece of significant information (service required event, sample run, etc) received from the monitor. Below the Latest Monitor Timestamp, the Status screen displays the monitor’s serial number and model information for reference purposes.

Many commands are available in the Action menu when viewing the Status tab. These commands are documented in the Action Menu section later in this manual.



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Gas in Oil Tab

Overview

The Gas in Oil tab is shown when a transformer asset is selected. Figure 15 shows the Gas in Oil tab.

Figure 15. Gas in Oil tab.

This tab displays a graph showing the measured levels of gases. Depending on the type of Siemens GAS-Guard transformer monitor used (8 gases or 3 gases), the display will include either eight gases (Hydrogen (H2), Oxygen (O2), Methane (CH4), Carbon Monoxide (CO), Carbon Dioxide (CO2), Ethane (C2H6), Ethylene (C2H4), and Acetylene (C2H2) – model GAS-Guard 8) or three gases (Methane (CH4), Ethylene (C2H4), and Acetylene (C2H2) – model GAS-Guard 3). By default, gas values are displayed on a logarithmic axis.

Siemens’s 8 gas analyzers also display a computed estimation of Nitrogen (N2), Total Dissolved Combustible Gas (TDCG), and Total Hydrocarbons (THC). TDCG is the sum of Hydrogen (H2), Carbon Monoxide (CO), Ethane (C2H6), Ethylene (C2H4), Acetylene (C2H2), and Methane (CH4). THC is the sum of Ethane (C2H6), Ethylene (C2H4), Acetylene (C2H2), and Methane (CH4). In all cases, gases are displayed in parts per million (PPM), gas in oil, over a selectable time period (default 1 month).

The Gas in Oil tab also displays the levels of external sensors including LoadGuide™, ambient temperature, and oil temperature as well as several optional sensors (oil moisture PPM, oil moisture percent relative saturation (%RS) and auxiliary temperature.)

End date and time range controls Tabs Viewing pane

Menu bar

Application Toolbar

Transformer Asset

Graph Toolbar

Navigation pane


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Note: data from optional oil moisture and temperature sensors is displayed only if sensors are installed and correctly configured. For more information

about oil moisture and temperature sensors, please contact your Siemens representative.

To display or hide a particular data series, click the small colored button immediately to the left of the series name in the graph legend. Gas values are displayed relative to the left (Gas

PPM) axis, which is logarithmic by default; the left axis may be changed to linear by clicking the Log button in the graph toolbar. Sensor values are displayed relative to the right (Sensor

Value) axis, which is linear. For more information about axis, legends, and the graph toolbar, please see the section Using the Graphs earlier in this manual.

The graph legend relates colors to measured values. Carbon Monoxide (CO), for example, is always shown in red. By default, gas values (except Nitrogen) are shown and all sensor values are hidden.

Commands

When viewing a Gas in Oil graph, the Action menu contains the tab-specific commands Enter DGA… and Start Sample Run.

Selecting Enter DGA… displays the Enter DGA Data dialog box, which contains a simple spreadsheet-like data editor. Set the date of your manual DGA report in the Record Time field and enter the values for the nine supported gases. You may enter multiple rows or correct existing entries. When you click OK, the DGA data is saved and displayed on the graph. For more details about the DGA data display, see Displaying Manual DGA Data below.

Selecting Start Sample Run immediately contacts the monitor to begin a sample run. Since sample runs are scheduled automatically by the monitor, use of this command is rarely required.

Note: to adjust the monitor’s sampling schedule, click the monitor icon in the navigation pane, then click the Sampling tab, and finally click Update

Sampling… in the Action menu. GAS-Guard View 2.0 displays the Update

Sample Schedule dialog box. When you click OK, GAS-Guard View 2.0 immediately contacts the monitor and updates the schedule you have

defined.

Values Below the Lower Detection Limit (LDL)

The lower detection limit (LDL) values for Siemens model GAS-Guard 8 and model GAS-Guard 3 monitors are specified in the Data Sheet for the respective monitor. The monitor may report values below these levels, however, and GAS-Guard View 2.0 will display them. Values below the LDL are visually distinguished by their pale translucent color. This pale color serves as a visual reminder that uncertainty is associated with the measurement.


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Displaying Manual DGA Data

Manual DGA data is displayed as one or more small colored x markers on the Gas in Oil graph. The colors match the corresponding data series, i.e. CO is displayed in red, H2 in blue, etc.

Moving the mouse pointer near a DGA reading on the graph surface displays a popup window showing the exact numerical value of each of the DGA measurements.

Note: if you have a Siemens model GAS-Guard 3 monitor, only the GAS-Guard 3 gases (CH4, C2H2, and C2H4) are displayed on the graph. You may enter values for all 9 fields in the dialog box, however. When you move the

mouse over the DGA sample area, all 9 gas in oil values are shown in the pop-up window.

Disabling a data series by clicking in the graph legend also disables the corresponding DGA value from appearing on the graph.

When DGA data is visible on the graph, a small DGA legend appears at the upper right corner of the screen to indicate the meaning of the display.

Limits Tab

The Limits tab is shown when a transformer asset is selected. It displays caution (warning) and alarm limits for the eight measured gases and TDCG (TrueGas and model GAS-Guard 8 monitors) or for three measured gases (model GAS-Guard 3 monitor). Limits are displayed for both gas in oil PPM level and gas in oil rate of change (ROC, reported in PPM/day). This tab also displays the most recently measured values reported by the monitor for gas in oil, rate of change, and goodness of fit (a quality metric for the current ROC value).

Note: ROC data is available from model GAS-Guard 8 and GAS-Guard 3 monitors only. The TrueGas monitor does not measure or report ROC data. ROC alarm and caution limits cannot be set for the TrueGas monitor.

To change the limits, click Update Limits… in the Action menu. This displays the Update

Alarm and Caution Limits dialog box. To change a limit, click in the desired cell and type the new value. When you click OK, the monitor is immediately updated. The viewing pane is refreshed when the update is complete.

Percent of Alarm Tab

The Percent of Alarm tab is shown when a transformer asset is selected. It displays measured gas values and TDCG normalized to their individual alarm or caution limit values.

Example: suppose the alarm limit for H2 is 50 PPM and the alarm limit for C2H4 is 120 PPM. Further, suppose the measured value for H2 is 40 PPM and the measured value for


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C2H4 is 60 PPM. Then the displayed value for H2 will be 80 (40 PPM is 80% of the limit value, 50 PPM) and the displayed value for C2H4 will be 50 (60 PPM is 50% of 120).

Values may be displayed relative to their caution limits instead of their alarm limits by clicking one of the buttons at lower right. Sensor values (LoadGuide, Ambient Temp, etc.) do not have alarm or caution limits. Their actual values are shown relative to the right axis for reference purposes.

No tab-specific commands are available in the Action menu when the Percent of Alarm tab is displayed.

Rate of Change Tab

The Rate of Change tab is shown when a transformer asset is selected and the transformer monitor is a Siemens model GAS-Guard 8 or GAS-Guard 3.

This tab displays the smoothed rate of change (ROC) of gas in oil values expressed in PPM per day. ROC is not computed for sensor values (LoadGuide, Ambient Temp, etc.). Their actual values are shown relative to the right axis for reference purposes.

No tab-specific commands are available in the Action menu when the Rate of Change tab is displayed.

Duval Triangle Tab

Note: the Duval’s Triangle tab displays data when a valid Diagnostic License accompanies the display data. To enable the Triangle, an administrator must obtain a Diagnostic License from Serveron or your Serveron representative,

install the license, assign it to the appropriate monitor, and then poll the monitor. The Diagnostic License enables the Triangle for all GAS-Guard View 2.0 installations that view the data contained in the file. For more

information, see Installing and Using Licenses.

The Duval Triangle is an analytical tool developed by Dr. Michel Duval of IREQ (Hydro Quebec), Canada. The Triangle presents DGA (dissolved gas analysis) results in a graphical form by sorting them according to a list of faults as codified by IEC Publication 60599, "Mineral oil-impregnated electrical equipment in service- Guide to the interpretation of dissolved and free gases analysis," March 1999.

For more information about the Triangle, see Using the Duval Triangle.

Sensor Data Tab

The Sensor Data tab is shown when a transformer asset is selected. It displays the values of internal sensors. This information is intended for use by trained Customer Service personnel.

No tab-specific commands are available in the Action menu when the Sensor Data tab is displayed.


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Extractor Data Tab

The Extractor Data tab is shown when a transformer asset is selected. This tab displays the status of internal sensors related to the transformer monitor’s gas extractor subsystem. This information is intended for use by trained Customer Service personnel.

No tab-specific commands are available in the Action menu when the Extractor Data tab is displayed.

Retention Time Tab

The Retention Time tab is shown when a transformer asset is selected. The tab displays internal information about the status of the chromatography subsystem. This information is intended for use by trained Customer Service personnel.

No tab-specific commands are available in the Action menu when the Retention Time tab is displayed.

Verification Data Tab

Overview

The Verification Data tab is shown when a transformer asset is selected. It displays the results of all verification runs performed in the selected time interval. Verification runs measure gas levels from reference gas contained in the monitor’s calibration bottle instead of sample gas from the transformer asset being monitored.

Sensor data is not displayed on the Verification Data graph.

Commands

When viewing the Verification Data tab, the Action menu contains the tab-specific commands Start Verification Run and Start Calibration Run.

Selecting Start Verification Run immediately contacts the monitor to begin a verification run. Since verification runs are scheduled automatically by the monitor, use of this command is rarely required.

Note: to adjust the monitor’s verification schedule, click the monitor icon in the navigation pane, then click the Sampling tab, and finally click Update



defined.

Selecting Start Calibration Run immediately contacts the monitor to begin a calibration run.

Note: Siemens monitors contain an auto-calibration feature. Manual calibration runs should only be performed by trained Customer Service

personnel.


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Company Specific Tabs This section describes the tabs that appear when you select an organization (typically your company) in the navigation pane. Your organization is usually the top of the navigation hierarchy.

Welcome Tab

The Welcome tab contains first-time startup instructions and a button that allows you to install the sample files. Note that you may also install or reinstall the sample files at any time by clicking the Help menu and selecting Install Sample Files.

Polling Tab

The Polling tab is the central point of administration for automatically scheduled polling. The tab shows a row-oriented display of all monitors known to the software. Each row contains several status columns. The display is updated every few seconds to reflect the latest status of each monitor.

Each row in the list may be selected by clicking on it. Selecting a row enables some menu items in the Action menu. To configure automatic polling for a monitor, click the monitor’s row to select it and then choose Update Automatic Polling Status… from the Action menu. This displays the Update Automatic Polling Status dialog box.


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Figure 16. Polling Tab and Update Automatic Polling Status dialog box.

The dialog box displays the number of available polling licenses. To enable automatic polling for a monitor, click the Automatically poll this monitor checkbox and then click OK. The dialog box displays the number of available automatic polling licenses. At least one license must be available to enable automatic polling. If no licenses are available, the checkbox is “grayed out” (unavailable).

The Polling Period control can be used to configure the maximum polling period. GAS-Guard View 2.0 will poll the monitor at least as often as the configured value. GAS-Guard View 2.0 may poll the monitor more often in case of communication errors (retries) and certain monitor conditions.

To immediately poll a monitor, click the monitor’s row and then choose Poll Now… from the Action menu (the Poll Now menu item performs the same function as the Poll Now item on the Asset Status tab.

For more information about these menu items, see the Menu Commands section of this manual.

Each row displayed by the Polling tab is composed of several fields (columns). The following fields are shown:

Asset Name. The name of the transformer asset.


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Serial Number. The serial number of Siemens monitor.

Auto Poll? This field displays Yes if the monitor is configured for automatic scheduled polling, No if it is not.

Period. This field displays the maximum period between automatic polling updates in hours. If the unit is not configured for automatic polling (Auto Poll column displays No), this column retains its previous value or displays the default value of 4 hours. GAS-Guard View 2.0 may contact the monitor more frequently than the value shown in this field. For further details, see the Next Poll subsection below.

Errors. This field displays the number of communication errors that have occurred since the monitor was last polled successfully. Each successful contact with the monitor resets the count to 0.

Successfully Called. This field displays the date and time of the last successful call to the monitor. If the monitor has not been successfully contacted, the field is empty.

Next Poll. This fields shows when the Poller component of GAS-Guard View 2.0 will next attempt to contact the monitor. In the simplest case, this value is approximately the time of the last successful call plus the value of the Period. The value may be different for several reasons. Two of the most common are:

If a polling attempt fails, the Poller component will retry the failed attempt using an internally defined retry algorithm. The retry frequency may be different than the normal polling frequency.

If the monitor begins sampling at an accelerated rate (e.g. hourly), the Poller will eventually detect the monitor’s behavior and begin polling more frequently in order to make timely data available to you. For more information about accelerated sampling, see Action Sample Hourly (Monitor selected, Sampling Tab) in the Menu Commands section.

Status. When GAS-Guard View 2.0 is communicating with the monitor, this field displays the most recent status of the conversation, e.g. downloading a record, updating the host data file, etc. The last status is displayed within parenthesis after the communication is complete.

File Name. This field displays the name of the file in which the monitor’s data is stored on the host.

Status Tab

The Status tab is shown when your organization (typically, your company) is selected in the navigation pane. The Status tab displays a flat list of your organization’s sites. The list is not navigable.

Site Specific Tabs This section describes the tabs that appear when you select a site icon in the navigation pane.


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Status Tab

The Status tab is shown when one of your organization’s sites is selected in the navigation pane. The Status tab displays a flat list of the assets of the selected site. The list is not navigable.

Monitor Specific Tabs This section describes the tabs that appear when you select a monitor icon in the navigation pane. The monitor icon is the lowest or “leaf” node in the navigation hierarchy.

Sampling Tab (Monitor icon selected in Navigation Pane)

The Sampling tab is shown when a monitor icon is selected in the navigation pane. Use this tab to review the monitor’s sampling and verification schedules.

To change the monitor’s sampling or verification schedules, click Update Sampling… on the Action menu while this tab is displayed. The Update Sampling Schedule dialog is displayed. When you click OK in the dialog box, GAS-Guard View 2.0 immediately contacts the monitor and updates the monitor’s sampling schedule.

The Action menu for this tab also contains the Sample Hourly… command. The Sample

Hourly command is described in the Action Sample Hourly (Monitor selected, Sampling Tab) section below.

Communications Tab (Monitor icon selected in Navigation Pane)

The Communications tab is shown when a monitor icon is selected in the navigation pane. It displays a textual summary of the communications settings for the selected transformer monitor. Use this tab to review the host’s communication settings.

To change the settings used by GAS-Guard View 2.0, click Update Communications… on the Action menu while this tab is displayed. The Update Communications Wizard is displayed. Use the Wizard to review and update the communication settings. When you click Finish, GAS-Guard View 2.0 updates the host’s communication settings.

To verify monitor communications, click Check Communications… on the Action menu for this tab. This command will attempt to contact the monitor and retrieve basic information about the monitor. After the command completes (or fails), a message box displays the outcome of the test.

Menu Commands This section provides an overview of the menu commands available in GAS-Guard View 2.0.


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File Menu

File New…

This menu item displays the New File Creation wizard to begin the creation of a new file. Since each transformer asset and its monitor are represented in a single file, this operation is used to add new assets and monitors to your GAS-Guard View 2.0 installation.

After the initial screen, the wizard displays the Monitor Information page shown in Figure 17.

Figure 17. Monitor Information page.

After entry of the required information, the wizard displays the Select File page. A default filename is composed from the last folder in which you located a file combined with the site and asset name you specified. If you have not previously located a file using GAS-Guard View 2.0, the location will default to your My Documents folder.

You may use the keyboard to change any part of the path or use the Browse… button to select a different folder in which to create the file.

The wizard then presents the Connection Type page. This page allows you to select the monitor’s communications type from a range of supported alternatives. When you click the Next button, a communications configuration page specific to the selected communications type is displayed.


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If you selected LAN communication, for example, the configuration page supports entry of a LAN (Ethernet) address. If you selected modem communications, the configuration page supports entry of phone number, communications port, and related information.

After configuring communications, clicking the Next button will display a textual summary of the information collected by the wizard. When the Finish button is clicked, the new file is created and added to the navigator. It will remain in the navigator even if you exit and restart GAS-Guard View 2.0. To remove an asset and its associated monitor from the navigator, click Close… in the File menu.

File Open…

This item is used to open an existing file. It presents a standard Open File dialog. After the file is opened successfully, it is added to the navigator. It will remain in the navigator even if you exit and restart GAS-Guard View 2.0. To remove an asset and its associated monitor from the navigator, use File Close….

File Close…

This item is used to close (remove from display) one or more files. The files must have previously been added to the navigator via File New… or File Open…. Closing the file only removes the file from view. The file’s contents are not altered and the file is not deleted.

File Archive…

This item is used to reduce the size of large files while preserving their data. The Choose

Archive Date dialog is displayed. Use this dialog to set the boundary date. When you click OK, a standard file selection dialog is displayed. After you choose an archive file name and location and click OK, all monitor data older than the boundary date is removed from the primary data file and placed in the archive. Since archived data is no longer present in the data file, it is no longer displayed.

If you wish to review archived data at a later date, click Open in the File menu and select the archive file using the Open File dialog box.

Archiving your data is optional. GAS-Guard View 2.0 will function correctly even if all data ever downloaded is allowed to accumulate in the primary data file.

File Export…

Selecting this item displays a File Save dialog that allows the export of transformer data. The export file will contain the data for the date range currently selected in the End Date and Range controls in the application toolbar.

Use this command to make data available to other application programs, e.g. Microsoft Office Excel. Exports may be created at any time. Exporting data does not remove it from the data file: the data continues to be displayed by GAS-Guard View 2.0 after you export it.

Data may be exported in one of two formats:

Comma-separated value (.CSV): files in this textual format may be loaded directly by Microsoft Excel and many other applications.


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TOA4: this textual file format is directly compatible with Transformer Oil Analyst version 4 (TOA-4) software from Delta-X Research.

File Print…

This item allows the contents of the viewing pane to be printed. A standard printer dialog is displayed. You may change print settings defined by your printer, if desired, and then click OK to print the viewing pane contents.

This item is unavailable (“grayed out”) if there is nothing to print.

File Print Preview

A standard Print Preview dialog is displayed. The contents of the viewing pane may be printed from within the preview using the controls at the top.

This item is unavailable (“grayed out”) if there is nothing to print.

File Exit

This item closes the application.

Action Menu Some of the contents of the Action menu are determined by the selection in the navigation pane and the visible (currently selected) tab. This section describes each possible action and identifies the selection type and tab which must be visible for the action to be available in the menu.

The following menu items are available in the Action menu regardless of the selection or current tab.

Action Select Modem

This menu item opens the Select Modem dialog box. The dialog allows you to select the TAPI modem used to communicate with Siemens model GAS-Guard 3 and GAS-Guard 8 monitors.

Note: the modem selected using this dialog box affects communication with Siemens model GAS-Guard 3 and GAS-Guard 8 monitors only. When

communicating with Serveron TrueGas monitors, the COM port selected on the Configure Modem page of the Update Communications dialog

determines the modem used to contact the monitor.

The Select Modem dialog box displays a dropdown list containing all properly-configured TAPI modems. If your modem is not displayed in the list, click Configure TAPI Modem to display the Add/Remove Hardware Wizard. Follow the prompts to configure your modem. For more information, see Configuring Modems later in this manual.


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Action Send Diagnostic Data…

This item displays the Send Diagnostic Data dialog box. It is designed to help you obtain support from Serveron Customer Service should your monitor ever require it. In general, you should contact Serveron Customer Service for guidance before using this command.

After querying whether to continue, GAS-Guard View 2.0 will begin generation of an informational file about the monitor. The informational file includes everything in the monitor’s data file. By default, GAS-Guard View 2.0 attempts to contact the monitor (using the configured communication path) to obtain additional service-related information. If a connection to the monitor cannot be established, this additional data is not included in the informational file. You can limit the duration of this connection or choose not to connect using the controls in the dialog box.

GAS-Guard View 2.0 will prompt for a file in which to save the diagnostic data. After you select a file and click OK, GAS-Guard View 2.0 will contact the monitor and obtain diagnostic information (unless you chose not to do so) and then copy the current data file into the diagnostic file.

After saving the diagnostic file, GAS-Guard View 2.0 will create an email message using your default email client (Microsoft Office Outlook, Outlook Express, Mozilla Thunderbird, etc.) The generated email message will appear on your screen for review.

You must attach the informational file to the generated email message using the commands provided by your email client. Instructions for locating the file appear within the generated email message itself.

Note: GAS-Guard View 2.0 only prepares data for transmission to Serveron. GAS-Guard View 2.0 will never, under any circumstances, send data of any kind to Serveron. You must send the email that was generated in GAS-Guard View 2.0, like you would any other email, if you wish to communicate the diagnostic information to Serveron.

The remaining menu items in this section are specific to the selection in the navigation pane and the current tab. Example: the Rename Company item appears in the Action menu when you select a Company in the navigation pane and then display the Status tab.

Action Rename Company… (Company selected, Status tab)

This command displays the Rename Company dialog box which allows the entry of a new name for the currently selected company. When you click OK, one or more files are updated to reflect the change and both the navigation and viewing panes are redrawn.

Action Rename Site… (Site selected, Status tab)

This command displays the Rename Site dialog box which allows the entry of a new name for the currently selected site. When you click OK, one or more files are updated to reflect the change and both the navigation and viewing panes are redrawn.


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Action Rename Asset… (Transformer asset selected, Status tab)

This command displays the Rename Asset dialog box which allows the entry of a new name for the currently selected asset. When you click OK, the file is updated to reflect the change and both the navigation and viewing panes are redrawn.

Action Poll Now (Transformer asset selected, Status tab)

Causes GAS-Guard View 2.0 to connect to the selected asset’s transformer monitor and download all data. The connection attempt uses the current communications settings, which are displayed on the Communications tab when the monitor icon is selected.

Action Enter DGA… (Transformer asset selected, Gas in Oil tab)

Displays the Enter DGA Data dialog box, which supports entry of DGA data for display on the Gas in Oil graph. Enter the values from your manual DGA into the cells of the empty row and adjust the date as appropriate. If you need to add additional rows, click the Add Row button to add a new empty row. When you are satisfied, click OK to save your entries.

If you discover an error in a DGA entry, use the dialog box to change the value displayed in the cell and then click OK. To delete a manual DGA, open the dialog box. Click the area to the left of the date and time to highlight the entire row, click the Delete button, and then click OK to update the file and graph.

Action Start Sample Run (Transformer asset selected, Gas in Oil tab)

After confirming your choice, this command commands the transformer monitor to immediately start a sample run. Since sample runs are scheduled automatically by the monitor, use of this command is rarely required.

Note: to adjust the monitor’s sampling schedule, click the monitor icon in the navigation pane, then click the Sampling tab, and finally click Update



defined.

Action Update Limits (Transformer asset selected, Limits tab)

Displays the Update Limits dialog box, which supports changes to the gas in oil caution and alarm limit values. For Siemens model GAS-Guard 8 and GAS-Guard 3 monitors, the dialog supports both level and rate of change alarms; for Serveron TrueGas monitors, only level alarms are supported.

When the OK button is clicked, GAS-Guard View 2.0 immediately contacts the monitor to update the limit values.


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Action Start Verification Run (Transformer asset selected, Verification Data tab)

After confirming your choice, this command commands the transformer monitor to immediately start a verification run. Since verification runs are scheduled automatically by the monitor, use of this command is rarely required.

Note: to adjust the monitor’s verification schedule, click the monitor icon in the navigation pane, then click the Sampling tab, and finally click Update



defined.

Action Start Calibration Run (Transformer asset selected, Verification Data tab)

After confirming your choice, this command commands the transformer monitor to immediately start a calibration run. A calibration run takes 30 minutes to 1 hour depending the model of transformer monitor you have installed.

Note: Siemens monitors contain an auto-calibration feature. Manual calibration runs should only be performed by trained Customer Service

personnel.

Action Change Monitor Password… (Transformer asset selected, Status tab)

This command is intended to ensure that only a single approved installation of GAS-Guard View 2.0 software may access the transformer monitor.

Note: changing the password is intended to block access to the selected transformer monitor by other computers running GAS-Guard View 2.0. The

new password is set in the monitor and stored securely on the local computer. After completing this command, GAS-Guard View 2.0 will be able to poll data or access monitor data and settings from the local computer only.

GAS-Guard View 2.0 first offers the opportunity to cancel the operation. If you choose to continue, GAS-Guard View 2.0 displays a dialog box supporting entry of the new password. When you click OK on this dialog box , GAS-Guard View 2.0 securely stores the password in the host compter. GAS-Guard View 2.0 then displays the Poller Activity dialog and sets the new password in the monitor.


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Action Set Monitor Date and Time (Transformer asset selected, Status tab)

This command sets the transformer monitor’s internal date and time to match the local computer. If the monitor is a Siemens model GAS-Guard 8 or GAS-Guard 3, the time is converted to Universal Coordinated Time (UTC) before being sent to the monitor.

Action View Log… (Transformer asset selected, Status tab)

This command displays recent activity by the polling/dialing subsystem (“Poller”). For more information about the Poller, see Theory of Operations later in this manual.

Action Sample Hourly (Monitor selected, Sampling tab)

Note: this command is available for Siemens model GAS-Guard 8 and GAS-Guard 3 transformer monitors only. Serveron TrueGas monitors do not

support hourly sampling.

Causes GAS-Guard View 2.0 to connect to the transformer monitor and establish a temporary sampling schedule within the monitor. The temporary schedule continues for 24 hours and specifies that sample runs should be performed once per hour.

After the 24 hour period elapses, the monitor reverts to the schedule that was in effect when the Sample Hourly command was given. If you wish to continue hourly sampling, you may issue the command again to enable hourly sampling for another 24 hour period.

The Sample Hourly command is intended to allow you to temporarily accelerate sampling when additional online DGA data is critical, e.g. when a transformer is experiencing a gassing event or other unusual condition.

Note: by increasing the number of sample runs, this command increases the monitor’s consumption of helium carrier gas. Excessive use of this command may require replacement of the helium cylinder more frequently than stated

in the Siemens Transformer Monitor product documentation.

The Sample Hourly command also interacts with the automatic scheduled polling feature of GAS-Guard View 2.0. If the monitor that is sampling hourly is also configured for automatically scheduled polling, the Poller component of GAS-Guard View 2.0 will begin polling it at an accelerated rate (hourly) in order to make the data available to you.

Under certain conditions, the Siemens transformer monitor may begin sampling at an accelerated (hourly) rate without any input from you. This form of accelerated sampling occurs when a previously configured Rate of Change (ROC) gas alarm limit is violated within the monitor. ROC accelerated sample will not occur unless you configure Rate of Change alarm limits,. If this form of accelerated sampling does occur at your installation, the Poller component of GAS-Guard View 2.0 will notice after several hours and begin polling at an accelerated rate in order to make the data available to you.


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A monitor that is performing hourly samples due to a ROC alarm will cease performing accelerated runs and return to its previous schedule approximately 24 hours after the ROC alarm condition is cleared. If ROC does not return to normal on its own, you can clear the condition by increasing the ROC alarm limit value or disabling the alarm for that gas. For more information, see Action Update Limits (Transformer asset selected, Limits tab) below.

Action Check Communications (Monitor selected, Communications tab)

This command allows you to check communications by performing a lightweight poll of the monitor without switching tabs. The Poller Activity dialog is displayed just as with Poll

Now. Unlike the Poll Now operation, GAS-Guard View 2.0 will not attempt to download data from the monitor. Instead, it will update control information (alarm levels, sampling schedule, etc) and then terminate the connection. After communication is complete (or fails), a message box displays the outcome of the test.

Action Update Communications (Monitor selected, Communications tab)

This command displays the Update Communications Wizard, allowing all communication settings for the selected transformer monitor to be reviewed and optionally updated.

For more information about the Update Communications Wizard, see Configuring

Communications later in this document.

View Menu

View Refresh (F5)

This command updates the Navigator and all tabs with the latest data.

View Auto Refresh

Enables or disables the automatic refresh feature. If the menu item is checked, GAS-Guard View 2.0 will automatically refresh the display with the latest data approximately once per hour. Each automatic refresh is equivalent to manually selecting View Refresh or pressing F5.

If the menu item is not checked, automatic refresh will not occur.

View Navigator

This command makes the Navigator visible. It is useful if the navigation pane has been hidden using the small close box at upper right of the pane.

Help Menu

Help User’s Manual

Opens this document.


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Help Frequently Asked Questions

Displays the Frequently Asked Questions (FAQ) about GAS-Guard View 2.0.

Help Release Notes

Displays the Release Notes.

Help Licensing

This menu item raises the Licensing dialog. All tasks associated with obtaining, installing and assigning licenses (except assigning polling licenses) are performed using this dialog box. These tasks are described in Installing and Using Licenses in the Using GAS-Guard

View 2.0 section of this manual.

The Licensing dialog box has three tabs.

Keys tab. This tab is used to obtain your machine ID, which must be provided to Serveron when you request a license. Use the Copy to Clipboard button to copy your machine ID and then paste it into the license request email as described under Installing and Using Licenses.

The Keys tab is also used to install licenses you receive from Serveron. After receiving your license via email and saving the license file attachment, click the Browse… button on the Keys tab to open the Serveron license key file. When you click OK, GAS-Guard View 2.0 attempts to install the license.

Finally, the Keys tab displays the license keys you have currently installed. To display the details of an installed license, click the license to select it and then click Details.

Polling tab. This tab displays the number of polling license you have available. Your available licenses are maintained in a pool managed internally by GAS-Guard View 2.0 as described under Installing and Using Licenses. The same value is displayed when you open the Update Automatic Polling Status dialog (Polling tab, Action menu, Update

Automatic Polling Status).

Polling licenses are installed by browsing from the Keys tab, and assigned to monitors using the Update Automatic Polling Status dialog as described in the Company Specific Tabs section.

Diagnostics tab. This tab is used to assign Diagnostics Package licenses to individual monitor serial numbers. Siemens monitors that have not been assigned Diagnostics licenses are shown in the left box. To assign a license, click to select the monitor and then click Assign… Since a diagnostic license cannot be reassigned, you will be prompted to confirm. Carefully check your selection and then click OK. The selected serial number is removed from the left box and displayed in the right box.

The newly-assigned license will not take effect until the next time GAS-Guard View 2.0 polls the monitor. At that time, encrypted licensing information will be stored in the host data file. Any GAS-Guard View 2.0 installation that opens the file will discover the licensing information and enable the diagnostic features.


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Help Install Sample Files

Displays the Install Sample Files dialog box which allows the sample files to be copied to a folder of your choice. The function of this menu item is identical to the Install Sample Files button on the Welcome screen.

Help About Siemens Client

This item displays the About Box, which shows the detailed version number of GAS-Guard View 2.0 and a link to Siemens’s world wide web page.

Using the Duval Triangle The Duval Triangle is a feature of the Diagnostics Package, which requires a separate license from Serveron. For information on how to enable the Diagnostics package, please see Installing and Using Licenses.

To access the Triangle, select a Transformer asset in the navigation pane and then click the Duval Triangle tab in the viewing pane. If no license is found, the background will be displayed but data points will not.

Overview The Duval Triangle is an analytical tool developed by Dr. Michel Duval of IREQ (Hydro Quebec), Canada. The Triangle presents DGA (dissolved gas analysis) results in a graphical form by sorting them according to a list of faults as codified by IEC Publication 60599, "Mineral oil-impregnated electrical equipment in service- Guide to the interpretation of dissolved and free gases analysis," March 1999.

The Triangle and IEC Publication 60599 are analysis tools meant to be used as an aid for diagnosing the source of combustible gases in transformer coolant oil. The Triangle should not be regarded as the “final word” for such diagnosis but as a tool to be used by an informed expert for the purpose of evaluating the health of a transformer.

The Duval Triangle task is shown in Figure 18.


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Figure 18. Duval Triangle task.

Interpretation of regions The Triangle is broken into seven (7) polygonal regions, labeled T1, T2, T3, D1, D2, DT, and PD. The regions labeled with a T indicate probable thermal faults, with increasing numbers indicating higher temperatures. The regions labeled with a D indicate probable discharge faults, with increasing numbers corresponding to more energetic discharges. The region labeled DT indicates a probable mixture of thermal and discharge faults. Finally, the small region at the apex labeled PD indicates a probable partial discharge (also known as corona) condition.

Specifically, each region is to be interpreted as specified in IEC Publication 60599:

T1 - Thermal faults not exceeding 300°C

T2 - Thermal faults exceeding 300°C but not exceeding 700°C

T3 - Thermal faults exceeding 700°C

D1 - Discharges of low energy

D2 - Discharges of high energy


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PD - Partial Discharges

The DT region indicates a probable combination of thermal and discharge faults. It is not discussed in IEC 60599.

Interpretation of the Triangle Each of the Triangle's three sides forms an axis with a range of 0 to 100%. The Triangle's base is the acetylene (C2H2) axis. The left side is the methane (CH4) axis. The right side is the ethylene (C2H4) axis.

Use of the Triangle begins with a dissolved gas measurement (such as one obtained every few hours from the Siemens on-line transformer monitor) that includes acetylene, methane, and ethylene values. The values of the three gases are then normalized to total 100%.

Example: A DGA result might show acetylene at 10 parts per million (PPM), methane at 20 PPM, and ethylene at 20 PPM. The normalized values for these three gases at these concentrations are 20% acetylene, 40% methane, and 40% ethylene.

A single data point is plotted at the intersection of the three normalized values by drawing lines across the triangle from each of the appropriate normalized values on the axes. These lines are always drawn parallel to some axis of the graphic, as indicated by the dotted white lines.

Multiple data points The advent of on-line DGA data provided by the Siemens transformer monitor provides new opportunities for use of the Triangle. In particular, the wealth of data provided by the Siemens monitor can be used to quickly assess the health of a transformer by viewing values in the Triangle over a specific range of dates, allowing one to correlate specific fault conditions with transformer loading or extraneous events.

The End Date and Range controls in the application tool bar determine the range of interest for plotting points on the Duval Triangle. The Duval Triangle displays all meaningful samples shown on the corresponding Trend Graph. The relative age of DGA samples are indicated using pale yellow for the oldest to bright yellow, pale orange, and bright orange for the most recent samples. The latest sample plotted in the Triangle is distinguished using an X marker contained in a circle. In addition, dotted lines normal to the three graph axes are shown on the graph, for the most recent data point only.

Summary The Duval Triangle analysis tool, integrated with Siemens's industry-leading On-Line Transformer Monitor and turnkey asset monitoring services, offers breakthrough capabilities for transformer asset management.


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Using the Rogers Ratio Viewer The Rogers Ratio Viewer is a feature of the GAS-Guard View 2.0 Diagnostics Package, which requires a separate license from Serveron. For information on how to enable the Diagnostics package, please see Installing and Using Licenses.

To access the Viewer, select a Transformer asset in the navigation pane and then click the Gas in Oil tab in the viewing pane. Then click the Rogers Ratio Viewer button in the Graph toolbar (see Graph Toolbar in the section Using the Graphs). If no license is available, clicking the toolbar button will display a dialog box instructing you to contact Siemens or your Siemens representative to obtain one.

Note: the Rogers Ratios (also known as Basic Gas Ratios) are based on five measured gases: H2, CH4, C2H2, C2H4, and C2H6. The Siemens model GAS-Guard 3 online transformer gas monitor measures CH4, C2H2, and C2H4, but does not measure H2 or C2H6. For this reason, Rogers Ratios

cannot be computed from data gathered using a GAS-Guard 3.

When the asset selected in the Navigation Pane is monitored by a GAS-Guard 3, the Rogers Ratio button does not appear in the graph toolbar.

Siemens recommends use of the Duval Triangle to assess transformer gas in oil data gathered with a GAS-Guard 3 monitor.

Introduction The Rogers Ratio Viewer is displayed using a button on the Graph toolbar as described above. The Viewer is a separate component that displays in its own window. If the Viewer is not installed or cannot be executed, the button itself is not shown on the Graph toolbar.

The Rogers Ratios Viewer uses Microsoft DirectX® version 9, a graphical software toolset. Some video adapters and video device drivers do not support DirectX version 9. The Viewer requires a video display with 32-bit color (24-bit RGB plus alpha). This mode may be referred to as “high color” or “true color” and is sometimes erroneously labeled as “24-bit color”. Most video adapters built since 2001 can support the Viewer.

Functional Overview Dissolved gas ratios (known as Rogers Ratios in IEEE Standard PC57.104 D11d and Basic Gas Ratios in International Standard IEC-60599) are a tool for the interpretation of Dissolved Gas Analysis (DGA) results. The Ratios present DGA results in graphical form by organizing them according to a list of faults as codified in an IEC Standard and an IEEE Draft Standard. These documents are IEC Publication 60599, "Mineral oil-impregnated electrical equipment in service - Guide to the interpretation of dissolved and free gases analysis," March 1999, and draft IEEE Publication PC57.104 D11d, “Draft Guide for the Interpretation of Gases in Oil Immersed Transformers”, April 21 2004. Note that this latter document is an unapproved IEEE standards draft, subject to change.

Both specifications define the ratios as follows:


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CH4 / H2

C2H2 / C2H4

C2H4 / C2H6

The Ratios and respective standards are intended as diagnostic aids for DGA interpretation. The Ratios should therefore not be regarded as the "final word" for such diagnosis but rather as a tool to be used by an informed expert for evaluating the health of a transformer.

The advantages of these ratio tools are that they are quantitative and independent of transformer oil volume. However, these and other ratio methods can produce incorrect interpretations or none at all. Therefore, they should be used in conjunction with other diagnostic tools such as the Duval Triangle. The value of on-line monitoring is that these diagnostic tools can be utilized over time to enable a comprehensive condition-based asset management program.

The Rogers Ratio Viewer is shown in Figure 19.

Figure 19. Rogers Ratio Viewer

The advent of on-line DGA data provided by the Siemens On-Line Transformer Monitor provides new opportunities for use of the Ratios. In particular, the wealth of data provided by the On-Line Transformer Monitor can be used to quickly assess the health of a


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transformer by viewing ratio values over a specific range of dates, allowing one to correlate specific fault conditions with transformer loading or extraneous events.

Selecting an End Date and Range for the Trend Graph determines the range of interest for plotting points in the Ratio Viewer. The Ratio Viewer displays all meaningful samples shown on the corresponding Trend Graph. The relative age of DGA samples are indicated using pale yellow for the oldest to bright yellow, pale orange, and bright orange for the most recent samples. The latest sample plotted in the Viewer is distinguished using a solid red color. In addition, dotted lines normal to the three graph axes are shown on the graph, for the most recent data point only.

Interpretation of Regions The Viewer displays ratios in a three-dimensional volume containing several rectangular solid regions, labeled T1, T2, T3, D1, D2, PD, and OK. Note that the region labeled PD

appears only in the IEC-60599 ratio definitions while the region labeled OK appears only in the IEEE PC57.104 D11d ratio definitions.

The regions labeled with a T indicate probable thermal faults, with increasing numbers indicating higher temperatures. The regions labeled with a D indicate probable discharge faults, with increasing numbers corresponding to discharges that are more energetic. The region labeled PD indicates a probable partial discharge (also known as corona) condition, while the region labeled OK indicates a presumed absence of faults.

The IEEE PC57.104 D11d and IEC-60599 specifications generally agree on the following detailed region definitions:

OK - Normal Unit

IEEE PC57.104 D11d names this region Case 0. IEC-60599 does not define this region.

PD - Partial Discharges

IEC-60599 defines this region, while IEEE PC57.104 does not.

D1 - Discharges of low energy

This region is named Case 1 in IEEE PC57.104 D11d.

D2 - Discharges of high energy

This region is named Case 2 in IEEE PC57.104 D11d. The extent of this region differs slightly between the IEC-60599 and IEEE PC57.104 D11d definitions.

T1 - Low temperature thermal faults not exceeding 300°C


T2 - Thermal faults exceeding 300°C but not exceeding 700°C


T3 - Thermal faults exceeding 700°C



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Interpreting the Graphical View Each of the Viewer’s three axes is logarithmic with conceptually unlimited range. The "front" axis shows an increasing ratio of Methane (CH4) to Hydrogen (H2), referred to as R1 in the text below. The "up" axis shows an increasing ratio of Acetylene (C2H2) to Ethylene (C2H4), referred to as R2. The "right" axis shows an increasing ratio of Ethylene (C2H4) to Ethane (C2H6), referred to as R3.

Use of the Viewer begins with a dissolved gas measurement (such as one obtained every few hours from the Siemens On-Line Transformer Monitor) that includes nonzero ethylene, ethane, and hydrogen values expressed in Parts per Million (PPM). The three ratios are then computed. The resulting values determine the location of a point in 3D-space for display by the Viewer.

Mathematically speaking, a ratio value is not defined if its denominator is zero. Therefore, a sample containing a hydrogen (H2) value of 0.0 PPM causes R1 to be undefined. Likewise, a sample with an ethylene (C2H4) value of 0.0 PPM causes R2 to be undefined and an ethane (C2H6) value of 0.0 PPM causes R3 to be undefined.

When one or more of the ratios is undefined, the three values R1, R2 and R3 do not determine a point in 3D-space and the Viewer cannot plot the sample. The Viewer displays a count of samples that could not be plotted in the upper left corner of the display window. The count is labeled Zero denominator.

As noted above, each axis has conceptually unlimited range. The Viewer is capable of displaying ratio values between 0.01 and 100.0. If a value of R1, R2 or R3 lies outside the range from 0.01 to 100.0, an out of range marker is displayed. The marker appears as a small ring with an arrow through it.

The graphical view can be rotated, zoomed and panned using the arrow keys, shift-arrow keys, and control-arrow keys respectively. The display can be cleared and the points re-plotted in time sequence by pressing the Backspace key. For more information, press F1 while the Viewer is active to raise the Help window. In the Help window, press Show Key

Help... to display the complete command list for the Viewer.

Summary The Rogers Ratio Viewer analysis tool, integrated with Siemens's industry-leading On-Line Transformer Monitor and turnkey asset monitoring services, offers breakthrough capabilities for transformer asset management.


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Maintaining GAS-Guard View 2.0 Installations

This chapter provides additional detail about GAS-Guard View 2.0 and discusses important aspects of GAS-Guard View 2.0 installations.

Configuring Communications

Introduction The physical connection type is selected or updated using the Connection Type page of the Wizard. The Wizard is displayed when creating a new monitored asset (File New… menu item) or when updating communications to an existing monitor (Action Update

Communications… menu item on the Communications tab, which is available when a monitor is selected in the navigation pane).

The Connection Type page is shown in Figure 20.

Figure 20. Connection Type page.

After the connection type is selected and the Next button is pressed, a page specific to the connection type’s configuration requirements is presented. The following sections describe the supported connection types and their configuration options.


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Local Area Network (LAN) Direct monitor communication via Ethernet LAN is supported for Siemens model GAS-Guard 8 and GAS-Guard 3 monitors. The Next button leads to the Configure LAN Connection page. When LAN is selected, only a single configuration item, the network (Ethernet) address of the monitor, need be supplied.

Telephone Modem Plain old telephone system (POTS) and cellular modems are supported for both TrueGas and GAS-Guard family monitors. Configuration data for the modem is entered on the Configure Modem Connection page. Five items are required to configure a modem connection:

The phone number, also called the dial string. The dial string may include commas to introduce delays into the dialing sequence. It may also include codes to temporarily disable PBX functionality; in the example, the code *71 represents a typical command to disable the Call Waiting feature. GAS-Guard View 2.0 also supports a send/expect protocol for arbitrarily complex interactions with the modem. This protocol is enabled by the caret (^) character, which can only be entered after checking the Allow advanced dial string checkbox. The send/expect protocol is described in the section Advanced Dialing Strings.

The modem setup string. This string contains modem initialization commands that should be in effect at all times. The default modem setup string is also described in the section Configuring

Modems, below.

The COM port to which the modem is attached (TrueGas monitors only). The number of the COM port on the local computer. This value does not apply to Siemens model GAS-Guard 3 and GAS-Guard 8 monitors and is not displayed for them. To select the modem used to communicate with your model GAS-Guard 3 or GAS-Guard 8 monitors, please click Select Modem in the Action menu.

The baud rate which should be used. The baud rate at which the port should be used. GAS-Guard View 2.0 uses Modbus for direct serial/radio connection to Serveron TrueGas monitors only. For TrueGas monitors, the Modbus address of the monitor must be specified. The default Modbus address is 17.


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RS-232 Direct RS-232 connectivity is supported for both TrueGas and GAS-Guard family monitors. Three items are required to configure a direct connection:

The COM port to which the cable is attached. The number of the COM port on the local computer.

The baud rate which should be used. The baud rate at which the port should be used.

The Modbus address of the monitor (Serveron TrueGas monitors only) GAS-Guard View 2.0 uses Modbus for direct serial connection to Serveron TrueGas monitors only. For TrueGas monitors, the Modbus address of the monitor must be specified. The default Modbus address is 17.

RS-232 with radio (FreeWave®) GAS-Guard View 2.0 supports a direct serial connection to a short-range radio link, e.g. FreeWave from FreeWave Technologies. Four items are required to configure a direct-to-radio connection:

The COM port to which the cable is attached. The number of the COM port on the local computer.


The unit address of the slave radio. This value is a configuration parameter of the FreeWave.

The Modbus address of the monitor (Serveron TrueGas monitors only) GAS-Guard View 2.0 uses Modbus for direct serial/radio connection to Serveron TrueGas monitors only. For TrueGas monitors, the Modbus address of the monitor must be specified. The default Modbus address is 17.


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Telephone Modem with radio (FreeWave®) GAS-Guard View 2.0 supports a modem connection to a short-range radio link, e.g. FreeWave from FreeWave Technologies. Six items are required to configure a modem-to-radio connection:

The phone number, also called the dial string. The dial string may include commas to introduce delays into the dialing sequence. It may also include codes to temporarily disable PBX functionality; in the example, the code *71 represents a typical command to disable the Call Waiting feature. GAS-Guard View 2.0 also supports a send/expect protocol for arbitrarily complex interactions with the modem. This protocol is enabled by the caret (^) character, which can only be entered after checking the Allow advanced dial string checkbox. The send/expect protocol is described in the section Advanced Dialing Strings.

The modem setup string. This string contains modem initialization commands that should be in effect at all times. The default modem setup string is also described in the section Configuring

Modems, below.

The COM port to which the modem is attached (TrueGas monitors only). The number of the COM port on the local computer. This value does not apply to Siemens model GAS-Guard 3 and GAS-Guard 8 monitors and is not displayed for them. To select the modem used to communicate with your model GAS-Guard 3 or GAS-Guard 8 monitors, please click Select Modem in the Action menu.


The unit address of the slave radio. This value is a configuration parameter of the FreeWave.

The Modbus address of the monitor (Serveron TrueGas monitors only) GAS-Guard View 2.0 uses Modbus for direct serial/radio connection to Serveron TrueGas monitors only. For TrueGas monitors, the Modbus address of the monitor must be specified. The default Modbus address is 17.


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Configuring Modems

Modem Initialization Before sending any dial string to the modem, GAS-Guard View 2.0 will transmit the modem setup string. The default modem setup string is at v1 e0 q0 &d2 x4. This setup string is needed to configure the modem in your PC for proper communication with GAS-Guard View 2.0.

at indicates the start of a modem command string.

v1 tells the modem to send responses that contain alphabetical codes rather than numeric codes.

e0 turns echo off.

q0 quiets or suppresses response codes from your modem.

&d2 sets the modem to do the following when Data Terminal Ready (DTR) is lost:

hang up

turn off auto answer

return to command mode

x4 sets the modem to display at least these response codes:

extended response set

dial tone

busy signal detection

Below are general definitions of the Hayes-compatible commands being used in the example. Your specific modem may require commands in addition to or instead of those shown in this example. Refer to the documentation that came with your modem for more information.

vN - Displays result codes in short form (numbers) or long form (test).

N = 0: send numeric responses

N = 1: send word responses (default).

eN - Turns the command echo feature on or off.

N = 0: command echo off

N = 1: command echo on (default).

qN - Displays or suppresses (quiets) result codes

N = 0: displays codes (default).

N = 1: suppresses codes.

&dN - Controls data terminal ready (DTR) transition

0 = ignore DTR signal


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1 = return to command mode when after losing DTR

2 = hang up, turn off auto answer, and return to command mode after losing DTR (default)

3 = reset after losing DTR

xN - Determines which result codes will be displayed following modem operations

N = 0: Basic response set, blind dialing

N = 1: extended response set, blind dialing

N = 2: extended response set, dial tone detection

N = 3: extended response set, blind dialing, and busy signal detection

N = 4: extended response set, dial tone, and busy signal detection (default).

Advanced Dialing Strings

Overview

Occasionally, nonstandard communications configurations may require that you exercise direct control over interaction between the host computer running GAS-Guard View 2.0 and the modem (or modem-compatible) device.

GAS-Guard View 2.0 supports this unusual but important requirement through advanced

dial strings. An advanced dial string is any string containing the caret (^, usually shift-6 on U.S. English keyboards).

Since the presence of caret characters significantly changes the behavior of the dial string, GAS-Guard View 2.0 prevents you from entering them by default. To enter an advanced dial string containing carets, you must first check the Allow advanced dial string checkbox. The box is found just below the Phone Number on the Configure Modem Connection page of the New File Creation (or Update Communications) wizard. After checking the box, you may type the advanced dial string in the Phone Number text box.

Send/Expect Protocol

The caret character is used to define a send/expect protocol between the computer running GAS-Guard View 2.0 and the modem (or modem-like device) attached to the selected COM port. Carets in properly-formed advanced dial strings always come in pairs. The first member of the pair defines a block of text that GAS-Guard View 2.0 will send to the modem. The second caret defines the response to expect from the modem-like device. Further interactions may be specified by entering a third caret with a send sequence, a matching fourth caret defining an expected response, etc. In principle there is no limit to the length of the send/expect sequence that may be defined.

Example: the advanced dial string

ÂTÔKÂTDT5551212^CONNECTEDÂTÔKÂTDT7^CHANNEL 7

Would be executed as follows:


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1. GAS-Guard View 2.0 opens the COM port and then transmits the string AT to the port.

2. GAS-Guard View 2.0 collects response lines from the port until the pattern OK is found.

3. GAS-Guard View 2.0 sends the string ATDT5551212 to the port.

4. GAS-Guard View 2.0 collects response lines until the pattern CONNECTED is found.

5. GAS-Guard View 2.0 transmits the string AT to the port.

6. GAS-Guard View 2.0 collects response lines until the pattern OK is found.

7. GAS-Guard View 2.0 transmits the string ATDT7 to the port.

8. GAS-Guard View 2.0 collects response lines until the pattern CHANNEL 7 is found.

At this point, GAS-Guard View 2.0 assumes it is connected to the Siemens transformer monitor and begins communication with the monitor.

Each time GAS-Guard View 2.0 transmits a character sequence to the port, it begins interpreting response lines. It continues to collect response lines until the expected response is found or a timeout occurs. The timeout is relatively long (3 minutes). If the timeout occurs, GAS-Guard View 2.0 reports that it was unable to connect to the monitor.

Configuring TAPI Modems GAS-Guard View 2.0 uses TAPI, a feature of Microsoft Windows, to access the modem when communicating with Siemens Model GAS-Guard 8 and GAS-Guard 3 (TMx) monitors. Use of TAPI requires that your analog modem be properly installed as a TAPI

modem. If you plan to communicate with GAS-Guard monitors using analog modem(s), you must ensure your modem is properly installed and configured for use by TAPI.

Note: if you do not use modem(s) to communicate with Siemens GAS-Guard monitors, this section does not apply to your installation.

To select the TAPI modem, click Select Modem in the Action menu to display the Select

Modem dialog box. The dialog box contains a dropdown list containing all properly-configured TAPI modems. If your modem does not appear in the list, click Configure TAPI

Modem to display the Add/Remove Hardware wizard. Follow the prompts in the wizard to configure your modem.

If your modem does not appear in the dropdown list after you complete the Add/Remove Hardware wizard, the following information may be helpful.

To determine whether your analog modem is properly installed for use by TAPI, click Settings in your Start menu, open the Control Panel, and then double-click Phone and

Modem Options. In the Phone and Modem Options applet, select the Modems tab. Verify that your modem (example: MultiTech MT5600ZDX Play & Play) is shown in the list. If it


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is not, click the Add... button and use the wizard to properly install and configure your modem for use by TAPI.

GAS-Guard View 2.0 will automatically create a phonebook entry named Siemens to manage your modem. If you system does not have a properly configured TAPI modem, GAS-Guard View 2.0 may fail to bind or may logically bind to a nonfunctional device such as the printer port. If your modem is configured for TAPI but you are unable to connect to your GAS-Guard monitor using it, click Settings in your Start menu and then click Network Connections. Right-click and delete the Siemens entry in the list. Ensure your modem is properly installed for use by TAPI as described above and then restart your computer.

When your computer is ready, start GAS-Guard View 2.0 and try the connection again. You may then view your Network Connections and verify that the Siemens entry has been recreated.

Troubleshooting

Corrupt or Invalid Files

Overview

GAS-Guard View 2.0 stores data in structured textual files with the extension .TGH. These files are informally referred to as TGH files.1 Although they are textual, TGH files have an internal structure that must be preserved to allow GAS-Guard View 2.0 to correctly process of the file. If the internal structure of a TGH file is not correct, GAS-Guard View 2.0 will report that the file is corrupt or invalid. This section describes steps that may be taken to recover most or all of the data in this unusual case.

Note: Siemens recommends that you create a backup copy of any .TGH file before attempting any of the actions described below. Siemens strongly

discourages the examination or modification of TGH files using programs other than GAS-Guard View 2.0 except when absolutely required.

File Structure

TGH files consist of a series of sections. Each section consists of a single header line followed by content lines. The header consists of the section name, e.g. Serial, enclosed in angle brackets < and >.

TGH files may be examined and modified using any textual file editor, e.g. Microsoft Notepad. Examination of a TGH file that has been populated with data will show that the file’s sections fall into two loose groups, header sections and data sections.

1 The acronym TGH stands for Transformer Gas History.


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Each header section contains a collection of key=value pairs. The keys are often but not always numeric. The values include communications configuration, metadata (e.g. company, site and asset names), and monitor configuration (alarm limits, schedules, etc.)

Each data section contains an ordered collection of date-time=value,value,… lines. Each line in a data section must begin with a date and time. The definition of the values within the line varies from one section to another.

An example of a .TGH file is shown below.


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<Comment>

DO NOT EDIT THIS MACHINE-GENERATED FILE

<Info>

2=TGE-D998201

20=Siemens Demo

21=Serveron Stories

22=#11 GSU (11-3-2003 for 1 week)

35=0

<Serial>

Address=ModBus,17

CommPort=

Command=

Modem=

Phone=

Settings=

<Setup>

Interval=

<Sensors>

PartitionType=UseCustom

StdTemp=60

TankWallSensor=0

<Tasks>

Alarms=

Clock=

Schedule=

<Sched>

1=

2=

3=

4=

5=

<Alarms>

00=133.0,200.0

01=380.0,400.0

02=0.0,0.0

03=468.0,524.0

04=323.0,498.0

05=3230.0,4980.0

06=443.0,480.0

07=150.0,222.0

08=6.0,8.0

09=0.0,0.0

10=-1.0,-1.0

11=-1.0,-1.0

12=-1.0,-1.0

13=0.0,0.0

14=0.0,0.0

15=0.0,0.0

16=0.0,0.0

17=0.0,0.0

18=0.0,0.0

19=0.0,0.0

20=0.0,0.0

21=0.0,0.0

22=0.0,0.0

23=0.0,0.0

24=0.0,0.0

25=0.0,0.0

26=0.0,0.0

27=0.0,0.0

28=0.0,0.0

29=0.0,0.0

30=0.0,0.0

<PPM Data>

2003/10/27 00:00=0,6.2,197.1,0.0,0.7,35.9,139.8,1.3,1.0,0.0,0.0,0.0,0.0,0.0

2003/10/27 04:00=0,6.0,196.5,0.0,0.7,38.0,156.5,1.2,1.0,0.0,0.0,0.0,0.0,0.0

2003/10/27 08:00=0,6.0,197.2,0.0,0.8,40.6,162.3,1.3,1.0,0.0,0.0,0.0,0.0,0.0

<Sensors Data>

2003/10/27 00:00=0,0.0,0.0,16.4,30.0,5.7,0.0,23.9,26.0,37.4,60.0,35.0,8.2

2003/10/27 04:00=0,0.0,0.0,12.1,30.0,5.7,0.0,21.8,26.3,37.6,60.0,35.0,8.2


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2003/10/27 08:00=0,0.0,0.0,16.5,30.0,5.7,0.0,22.9,26.1,37.5,60.0,35.0,8.2

<Retention Data>

2003/10/27 00:00=0,182.0,323.0,0.0,1171.0,2196.0,776.0,1153.0,976.0,0.0,0.0,0.0

2003/10/27 04:00=0,182.0,323.0,0.0,1167.0,2193.0,776.0,1160.0,977.0,0.0,0.0,0.0

2003/10/27 08:00=0,183.0,324.0,0.0,1171.0,2194.0,776.0,1157.0,977.0,0.0,0.0,0.0

<Extractor Data>

2003/10/27 00:00=0,31.2,1.9,14.8,15.5,27.3,0.0,35.0,28.7,29.1,25.9,0.0,0.0,0.0

2003/10/27 04:00=0,28.7,1.9,15.9,16.5,27.3,0.0,32.9,26.4,29.4,26.1,0.0,0.0,0.0

2003/10/27 08:00=0,30.7,2.0,15.3,16.2,26.5,0.0,33.2,27.2,29.8,26.1,0.0,0.0,0.0

TGH files are locale-invariant: the file contents do not change regardless of the current locale. This allows files written on any locale (e.g. Asian or European Windows) to be read and correctly interpreted on any other locale (e.g. U.S. English or Brazilian Portuguese Windows). User-entered textual data, e.g. the company name, is stored in UTF-8, a variable-length encoding for the Unicode® character set.

Causes of File Corruption

Common causes of file corruption include:

Missing or invalid serial number. The value of key 02 in the <Info> section must be a valid serial number. If the <Info> section does not exist, or key 02 is not present, or the value is not a valid Siemens serial number, the file will be reported as corrupt or invalid.

Broken or incomplete line(s). Each line in each data section must begin with a valid date and time. GAS-Guard View 2.0 accepts a wide range of date and time formats.

The following conditions will not cause the file to be reported as corrupt or invalid, but may result in unexpected behavior:

Nonstandard section names. File sections with unrecognized headers are preserved when the file is modified but are otherwise ignored. They do not cause the file to be reported as corrupt or invalid.

Nan or Inf values. Like almost all contemporary software, GAS-Guard View 2.0 represents floating-point data in conformance with IEEE standard 754. IEEE-754 includes representations for values that are Not a Number (NaN) as well as positive or negative infinity (Inf). These values may appear in floating point value fields as the literal strings Nan or Inf. These values are read and processed by GAS-Guard View 2.0 according to the normal rules of IEEE-754 arithmetic; they do not cause the file to be reported as corrupt or invalid.

For more information, please consult the IEEE standard.

Repairing Damaged Files

Begin by checking for the serial number key (02) in the <Info> section. If the key is present and valid, scan all data sections for data lines that do not begin with a date and time. You may discover one or more lines with unexpected line breaks. If you find such line(s), use Notepad or a similar text-editing program to merge the split line or delete the badly formed lines completely. After making one or more corrections save the file and use File Open… in GAS-Guard View 2.0 to see if the file can now be read.

As noted above, customer textual data is encoded in UTF-8. UTF-8 is a variable-length encoding of the 16-bit Unicode character set. If your TGH file contains characters with code


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points that lie outside the ISO Latin-1 256 character subset, the editor program you select must be capable of handling the variable-length UTF-8 encoding format.

If these steps do not correct the problem, please contact Siemens or your Siemens representative.

Menu Items Unavailable (“Grayed Out”) Menu items are unavailable (“grayed out”) if the operation they represent is not meaningful or cannot be performed. For example, GAS-Guard View 2.0 makes the File Close… menu item unavailable when the navigation pane contains no files.

If numerous menu items are unavailable (grayed out), check the status information lower right corner of the GAS-Guard View 2.0 window. Many menu items require interaction with the GAS-Guard View 2.0 Poller component. If your GAS-Guard View 2.0 installation configuration is Viewer Only, the status bar will display Poller: None and these menu items are unavailable. They include File New, Help Licensing, and most of the contents of the Action menu.

If your installation configuration is Standalone or Server, the indicator at the lower right corner of the main GAS-Guard View 2.0 window should say Busy or Idle. If it says None, the Viewer and Poller components of GAS-Guard View 2.0 are not communicating correctly. For more information about GAS-Guard View’s components, please see the Theory of Operations section below.

Theory of Operations

Overview

Note: this section assumes general knowledge of Microsoft Windows system administration. Understanding the concepts presented here is not required

to make successful use of the GAS-Guard View 2.0 software.

GAS-Guard View 2.0 is composed of two components, the Viewer and the Poller. These components are separate programs.

The Viewer is the application you see and interact with. The Poller works “behind the scenes”, communicating with your Siemens monitor(s) and saving the data they gather in files. The Viewer is always installed and appears in your Start menu under Programs Siemens GAS-Guard View 2.0

Installation of the Poller depends on the installation configuration you selected.


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If the Installation Configuration is…

Then the Poller component is…

Viewer Only Not installed – not present.

Standalone Installed as an ordinary program with a shortcut in every user’s Startup folder.

Server Installed as a Windows Service requiring separate login credentials that you must specify during installation.

For more information about installation configurations, see the section Choosing an

Installation Configuration near the beginning of this manual.

GAS-Guard View 2.0 stores company, site, and asset names, the communications configuration, and information gathered from the monitor in structured text files with the extension .TGH (“TGH files”). This file-based design provides data portability and serves to segregate the data by monitor. GAS-Guard View 2.0 retains compatibility with files created using GAS-Guard View version 1.6.2 or earlier.

Note: files created or modified by GAS-Guard View 2.0 are incompatible with GAS-Guard View version 1.6.2 (or earlier) and TM MultiView. If your

site includes multiple installations of GAS-Guard View, all users should upgrade earlier versions to GAS-Guard View 2.0.

In addition to information stored in TGH files, both the Viewer and the Poller store information in the Registry. The Viewer saves the content of the Navigation pane so it can be restored each time you reopen the Viewer. The Poller saves licensing information and the contents of the Polling tab there.

Viewer Component The Viewer provides the entire user interface to GAS-Guard View 2.0. The Viewer opens TGH files in order to read and display their contents; it is incapable of updating or modifying TGH file contents in any way. All operations that update or modify file data involve the Poller This includes operations that do not involve Siemens monitors, such as entering DGA data and creating annotations. Since these operations require the cooperation of the Poller, they are not available to users with Viewer Only installation configurations.

Poller Component The Poller is responsible for all monitor communication and updates to data files, but does not offer a user interface. Since the Poller has no user interface of its own, it must rely on the Viewer to provide one.

The Viewer and Poller often interact as client and server, although neither one requires the presence of the other. The Viewer may be installed without the Poller (Viewer Only


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installation configuration). The Poller runs whenever you are logged in (Standalone configuration) or continuously (Server configuration).

The Viewer communicates with the Poller using TCP/IP. The Poller listens on port 8011. The Poller accepts connections only from a single Viewer on the same computer (localhost). This feature is hardwired in the code. Restricting incoming connections to localhost addresses network security concerns associated with the use of TCP.

If you run firewall software locally on the PC, you may be required to configure the firewall to allow the Poller to listen locally on port 8011. As noted above, this should not raise security concerns because the Poller will only accept connections originating from the same computer on which it is running. GAS-Guard View 2.0 does not offer any network service(s) available from off-host.


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Serveron Corporation

3305 NW Aloclek Drive

Hillsboro, OR 97124 USA

www.serveron.com

Corporate Office: (800) 880-2552

Technical Support: (866) 273-7763

E-mail: [email protected]


All rights reserved.

POWEROHM RESISTOR, INC.

5713 13TH

STREET

KATY, TX 77493

INSTALLATION AND MAINTENANCE

INSTRUCTIONS

FOR

NEUTRAL GROUNDING RESISTORS

IMPORTANT: READ INSTRUCTIONS

THROUGHLY BEFORE UNPACKING

1

INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR POWEROHM NEUTRAL GROUNDING RESISTORS

TABLE OF CONTENTS SHIPPING AND RECEIVING

2

INSTALLATION

3

INSPECTION

4

NEUTRAL CONNECTION

5

GROUND CONNECTION

6

ACCESSORIES

7

MAINTENANCE STORAGE

8

9

2

SHIPPING

After the final inspection, Powerohm Neutral Grounding Resistors are securely fastened, in an upright position, onto a wooden skid. In some cases, additional bracing and/or banding is added to insure a safe shipment. The units are then completely wrapped with plastic to protect the finish and keep the outer surface free of dirt and moisture. Depending on certain criteria, units are shipped either "open" or crated. All crates are constructed with 1" thick lumber. The finished package is easily handled with a forklift or hand truck. All crates are clearly marked with the correct shipping information and requested customer marks. A copy of the packing list is securely fastened to the package in clear view. NOTE: Each unit is provided with a copy of the certified test report (the originals are kept on file at the factory). Normally, all crates are loaded by forklift into the enclosed van of a common carrier. At this point, it is the responsibility of the carrier to provide proper handling to the destination.

RECEIVING Upon receipt, the crated unit should be unloaded and inspected immediately to insure that proper handling was practiced during transit. Report any apparent damage to the crate that could have harmed the contents. NOTE: Great care is taken to properly package your resistor, therefore, it is recommended that the unit remains crated until it reaches the job site. All packaged neutral grounding resistors are suitable for prolonged storage. Always store the unit in the upright position (as shipped). Setting the crate on its side or top will likely cause damage to the resistor. Avoid stacking anything on top of the crate.

3

INSTALLATION

When ready for installation at the jobsite, uncrate the resistor using care not to damage the enclosure finish and/or external bushings. Next, remove the bolts which fasten the resistor enclosure to the skid. It is recommended that a hoisting device be used to lift the unit with the aid of the eyebolts on the top of the enclosure. When using the eyebolts provided with Powerohm Resistors Inc. neutral grounding resistors located at the top of the enclosure, lifting must incorporate use of a spreading device to ensure a safe lift. Not utilizing a spreader while lifting the unit causes the eyebolts to be pulled at various angles resulting in roof damage. See examples below:

CORRECT NOT CORRECT

For units without eyebolts or if a hoisting device is not available, a forklift can be used, provided the forks rest against the top of the mounting channels located on the bottom of the enclosure. Avoid resting the forks against the screened center. NOTE: Do not remove the enclosure covers before lifting the resistor unit. Powerohm Neutral Grounding Resistors can be mounted on a concrete pad, support stand or directly on top of the transformer (if the units size and weight will permit). Always mount the unit in the upright position. The unit should be bolted to the mounting surface using the 5/8" diameter holes provided at each corner of the mounting channels. Expansion type anchors are recommended for concrete pad mounting. If the enclosure has an elevating stand, secure the stand to it's mounting surface before mounting the enclosure. Never lift the enclosure with the elevating stand attached. NOTE: The enclosure should always be securely grounded to prevent a shock hazard to personnel or wildlife.

4

INSPECTION

After the resistor has been securely mounted, remove the front cover (the front cover can be identified by the Powerohm nameplate). Note: If the unit has external bushings mounted on the front cover, remove the back cover only. When installing the front or back cover, DO NOT EXCEED 20 IN.-LBS WHEN TIGHTENING THE 1/4-20 COVER HARDWARE (exceeding this torque value will damage the 1/4-20 threaded inserts). After removing the cover, remove all packing material and banding, if any, used to support the insulators and resistor banks during shipment. NOTE: Failure to remove packing material from the inside of the enclosure may result in fire hazard and/or resistor failure. With the packing material removed, carefully inspect the inside of the unit for broken insulators, bushings and other parts that may have been damaged during shipment. NOTE: If any damaged parts are found, contact the factory immediately. Energizing the unit may damage the resistor and create a shock hazard to personnel. Finally, check all electrical connections to ensure tightness.

5

NEUTRAL CONNECTION

The neutral lead from the transformer or generator may be connected one of three ways depending upon the specific design (refer to the supplied drawing for terminal location): 1. The connection is made directly to a top or side mounted entrance bushing.

The bushing may have an eyebolt connector (accepts bare cable), a copper stud connector (requires customer supplied lug) or a NEMA two or four hole pad type connector (requires customer supplied lug).

2. The connection is made directly to an internal terminal via rigid conduit

entering from the bottom through enclosure knockouts. The terminal consists of a firmly supported stainless steel conductor (normally a Nema 2-hole pad). Cable termination will require a customer supplied compression type lug (that accepts up to 4/0 cable). The neutral terminal is tagged for easy identification. Location and termination of the conduit is the customer's responsibility.

3. The connection is made directly to the primary terminal of the current

transformer which is mounted inside the enclosure. This terminal will be tagged "neutral" and requires a customer supplied lug and bolt. The other primary terminal of the current transformer has been factory wired to the resistive element. The neutral lead usually enters from the bottom through conduit. Sometimes the current transformer is factory wired to a top mounted entrance bushing in which case the connection is the same as the first example above.

NOTE: The factory supplied drawing identifies the neutral and ground connection. In all cases, the neutral terminal is tagged for easy identification and the proper connection is shown schematically on the drawing. Check all electrical connections to ensure tightness.

6

GROUND CONNECTION

The ground lead from the resistive element to ground may be connected one of two ways: 1. The connection is made directly to a top or side mounted entrance bushing.

The bushing may have an eyebolt connector (accepts bare cable), a copper stud connector (requires customer supplied lug) or a NEMA two or four hole pad type connector (also requires customer supplied lug).

2. The connection is made directly to an internal terminal via rigid conduit

entering from the bottom through enclosure knockouts. The terminal consists of a firmly supported stainless steel conductor (normally a Nema 2-hole pad). Cable termination will require a customer supplied compression type lug (that accepts up to 4/0 cable). The ground terminal is tagged for easy identification. Location and termination of the conduit is the customer's responsibility. Please note if a window type current transformer is present the ground cable must pass through the window of the current transformer and connect to the ground terminal (as identified above).

NOTE: The factory supplied drawing identifies the neutral and ground connection. In all cases, the ground connection is tagged for easy identification and the proper connection is shown schematically on the drawing. Check all electrical connections to ensure tightness.

7

ACCESSORIES

Neutral grounding resistors may come equipped with accessories such as ground fault sensing devices. If applicable please follow the instructions below when connecting this type of equipment.

1. If a sensing resistor is present both neutral and ground terminals come pre-wired by the factory. However signal leads must be field wired to the appropriate terminals on the ground fault monitoring device (see owner’s manual). 2. If a current transformer is present the ground cable must pass through

the window of the current transformer and connect to the ground terminal (as identified in step 2 of the ground connection section). In addition, the current transformer secondaries (X1 and X2) must be field wired to the appropriate terminals on the ground fault monitoring device (see owner’s manual).

NOTE: The factory supplied drawing identifies these connections. In all cases, both the neutral and ground connections are tagged for easy identification and proper connection is shown schematically on the drawing.

Check all electrical connections to ensure tightness.

8

MAINTENANCE

Normally, no maintenance is necessary on a neutral grounding resistor. However, periodic inspections for damage are needed to ensure that the resistor is still capable of protecting the system. Damage may occur from lightning, storms, earthquakes, wildlife, overloads or extended service life. Basically, it is necessary to ensure that the resistive element has not burned open and that the element (including the incoming bushing) is still properly isolated from ground. The following procedure is recommended for periodic field inspections. 1. De-energize the system being grounded and break the connection between

the system neutral and the grounding resistor. An isolation switch is some times available to break this connection. These precautions are recommended to prevent a shock hazard to maintenance personnel and to prevent the system from being operated without proper grounding.

2. Remove the front cover (which is on the same side as the nameplate) and the

rear cover. This will allow for a visual inspection of all internal components. 3. Carefully check for cracked insulators or bushings. A Meggar or Hi-Pot test is

the most reliable method of ensuring that the porcelain insulation is still providing the necessary electrical isolation.

4. Check the resistive element for continuity. An ohmmeter reading made

between the neutral and the ground side of the resistor should be within 10% of the nameplate value. If the resistance of the element is more than 15% off from the nameplate value, the resistors should be replaced.

5. Check all internal connections for tightness. Check wiring for signs of damage

from heat or overloads. 6. Check the enclosure for signs of damage from weather or rodents. Replace all

covers removed during inspection and check the mounting bolts for tightness.

9

STORAGE 1. If the unit is to be unused or stored for any length of time indoors, cover the

unit to prevent buildup of dirt. If stored outdoors, do not cover with plastic that may create condensation and enclosure corrosion or staining.

2. There is no special preparation for the unit. 3. Storage temperatures should remain -40C to 70C (-40F to 158F).

This document remains the sole property of JF Hillebrand Group AG and is to be used by the employees of Trans Ocean Bulk Logistics, JF Hillebrand, their appointed agents and customers. Issuance outside of these entities must first be

authorised by Trans Ocean Technical Department.

Discharge Manual

Covers VinBulk and RhinoBulk

Author

Justin Smith

Date 1st November 2013

© 2013 Trans Ocean/JF Hillebrand

www.transoceanbulk.com

www.jfhillebrand.com

http://www.transoceanbulk.com/

http://www.jfhillebrand.com/

Discharge manual Page 2 of 4 www.transoceanbulk.com

Any questions regarding any aspect of this manual or the equipment required should be referred to the nearest Trans Ocean Technical Representative. Revision and Issue Listing The final issue on the list will be considered as the current version of the document.

Revision Date Description A 14th Aug 2012 Original issue B 1st Nov 2013 New format and combined VinBulk and RhinoBulk versions

Checklist A multilingual checklist is attached to the PDF version of this manual

Equipment requirements • The flexitank valve connection is a 3” (DN80) male Camlock. A female Camlock

connector will therefore be required. • A strap or stand will be required to support the hose during discharge to avoid

excessive stress on the valve/elbow assembly. • The flexitank cannot be pressurised to assist discharge and therefore a suitable pump

will be required. It is recommended that advice always be sought from a Trans Ocean technical representative before proceeding. This is important due to the potential variations in discharge sites.


1. Container Positioning & Safety a) Park container/chassis in a stable position b) Apply ALL vehicle and chassis parking brakes. c) Turn off vehicle engine and remove keys from ignition. d) Ground/Earth container via suitable conductive media. e) Secure chassis wheels with front and back chocks.

f)

A slope (<5°) to the rear will assist discharge of the flexitank although this is not essential.

NOTE: These safety procedures MUST be completed before discharge can commence. These should be considered the minimum steps and any additional requirements for a particular facility should be followed accordingly. 2. Discharge a) Check container number corresponds with all relevant documentation. b) Check customs seal is intact and that number corresponds to relevant documentation

c)

Check valve condition. Valve should be locked in closed position with cap in place.

d)

Remove cap and connect hose. Hose should be supported to avoid excess strain on valve/ elbow assembly.

e)

Open valve and ensure locking pin is engaged when ready to begin discharge.


f)

Flexitank will collapse as discharge continues.

g)

Hose support may require adjustment throughout discharge.

h)

After discharge is complete close valves and replace cap.

4



10.4 List of Brochures

1) Operating Instruction for OLTC MR GERMANY Leaflet

2) Installation and Maintenance Instructions of Temperature Indicators (WTI/OTI) perfect control make.

Leaflet

3) Transformer Temperature Indicator (WTI/OTI) Leaflet

4) Tech. Specification on Temperature Detector (RTD System) Perfect Control Make.

Leaflet

5) Pressure Equalizing Between OLTC & tank T005-0497

6) Plate Valve Assembly T010-0497

7) Gas and Oil Actuated Relay T016-0497

8) Silica gel Breather T020-0799

9) Magnetic oil level gauge T025-0497

10) Gas Collecting Device T029-0897

11) Constant Oil Pressure System (COPS) Conservator T034-0201

12) Long Term Storage of Gas Filled Main Unit & Accessories

T035-0998

On-load tap-changer VACUTAP® VR I HD

Operating Instructions

On-load tap-changer VACUTAP® VM

Technical Data

© All rights reserved by Maschinenfabrik Reinhausen

Copying and distribution of this document and the utilization and communication of its contents are strictly prohibited unless expressly authorized.

Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

The product may have been modified after this document went to press.

We expressly reserve the right to make changes to the technical data, the design or the scope of delivery.

The information provided and the arrangements agreed during processing of the relevant quotations and orders are generally binding.

The original operating instructions were drawn up in German.

Table of contents

© Maschinenfabrik Reinhausen 2010 2332907/00 EN VACUTAP® VM 3

Table of contents

1 General / Technical Data ............................................................ 11

1.1 On-load tap-changer designations..........................................................11

1.2 Technical data for VACUTAP® VM ........................................................12

1.2.1 Technical data for VACUTAP® VM I ..................................................................121.2.2 Technical data for VACUTAP® VM II .................................................................131.2.3 Technical data for VACUTAP® VM III ................................................................141.2.4 Step capacity diagram VM..................................................................................15

1.3 Rated insulation level..............................................................................17

1.4 Rated withstand voltages........................................................................17

1.4.1 Rated withstand voltages of the internal on-load tap-changer insulation (with the exception of VACUTAP® VM 300) ......................................................19

1.4.2 Rated withstand voltages of the internal on-load tap-changer insulation for VACUTAP® VM 300...........................................................................................20

1.4.3 VM rated withstand voltages – multiple coarse change-over selector ..............22

2 Special designs........................................................................... 23

2.1 Parallel bridges for parallel connections .................................................23

2.2 On-load tap-changer VACUTAP® VM 650 Y...VM I 1503 with multiple coarse change-over selector (up to maximum of 5 coarse tap connections)............................................................................................24

2.3 Two-pole on-load tap-changer VACUTAP® VM II 302/352/502/602 ......24

2.4 On-load tap-changer VACUTAP® VM III 350 Y...VM I 1503 for linear voltage adjustment, up to a maximum of 34 operating positions ............24

3 Appendix ..................................................................................... 25

3.1 Dimensional drawings/connection diagrams...........................................25

3.1.1 VACUTAP® VM III 300 Y-0/W/G (898038) ........................................................253.1.2 VACUTAP® VM II 302-0/W/G (898039).............................................................263.1.3 VACUTAP® VM I 301-0/W/G (898040)..............................................................273.1.4 VACUTAP® VM III 350/500/650 Y-0/W/G (746219) ..........................................283.1.5 VACUTAP® VM II 352/502/652-0/W/G (746220)...............................................29

Table of contents

4 VACUTAP® VM 2332907/00 EN © Maschinenfabrik Reinhausen 2010

3.1.6 VACUTAP® VM II 351/501/651-0/W/G (746221)............................................... 303.1.7 VACUTAP® VM I 802/1002-0/W/G (746222)..................................................... 313.1.8 VACUTAP® VM I 1203/1503-0/W/G (746223)................................................... 323.1.9 VACUTAP® VM III K-0/W/G (746224) ............................................................... 333.1.10 VACUTAP® VM III 650 Y with multiple coarse change-over selector (746226) 343.1.11 VACUTAP® VM I 601 with multiple coarse change-over selector (746227)...... 353.1.12 VACUTAP® VM I 802/1002 with multiple coarse change-over selector

(746228) ............................................................................................................. 363.1.13 VACUTAP® VM I 1203/1503 with multiple coarse change-over selector

(746229) ............................................................................................................. 373.1.14 VACUTAP® VM III 300 tie-in resistors without potential switch (898695).......... 383.1.15 VACUTAP® VM III 300 tie-in resistors without potential switch (898694).......... 393.1.16 VACUTAP® VM III 300 tie-in resistors without potential switch (898693).......... 403.1.17 VACUTAP® VM III Y tie-in resistors with/without potential switch (898692)...... 413.1.18 VACUTAP® VM II tie-in resistors with/without potential switch (898691) .......... 423.1.19 VACUTAP® VM I tie-in resistors with/without potential switch (898690) ........... 433.1.20 VACUTAP® VM I 351...1503, tie-in resistor cylinder with potential switch

without tie-in resistors (898804) ......................................................................... 443.1.21 VACUTAP® VM 300 – installation drawing of centrical drive (765192) ............ 453.1.22 VACUTAP® VM – installation drawing of centrical drive (746230) ................... 463.1.23 VACUTAP® VM – on-load tap-changer head, centrical drive (893899) ........... 483.1.24 VACUTAP® VM – variants of on-load tap-changer head (720026) .................. 493.1.25 VACUTAP® VM – swivel range of gear unit (720027) ..................................... 503.1.26 VACUTAP® VM – screenings on oil compartment contacts (730336) ............. 513.1.27 VACUTAP® VM 300 – tap selector cross-sections (898041) ........................... 523.1.28 VACUTAP® VM 300 – arrangement of contacts on tap selector

(blanks, 891114)................................................................................................. 533.1.29 VACUTAP® VM – arrangement of contacts on tap selector, tap selector

division 10...22 (898013) .................................................................................... 543.1.30 VACUTAP® VM – installation position of tap selector connection contacts

(890477) ............................................................................................................. 553.1.31 VACUTAP® VM – connecting leads 3W, 1G, 3G (723590) ............................. 563.1.32 VACUTAP® VM – screenings on fine tap selector and change-over selector

(730335) ............................................................................................................. 573.1.33 VACUTAP® VM 802/803/1203/1503 – bridges to parallel connection of tap

selector connection contacts (899598)............................................................... 583.1.34 VACUTAP® VM – horizontal drive shaft, centrical drive (893896) ................... 593.1.35 VACUTAP® VM III 350/500/650 Y – arrangement of tap selectors (891107) .. 603.1.36 VACUTAP® VM I 351/501/651 – arrangement of tap selectors (891108) ........ 613.1.37 VACUTAP® VM I 1503 – arrangement of tap selectors (891109) .................... 623.1.38 VACUTAP® VM I 802/1002 – arrangement of tap selectors (891110) ............. 633.1.39 VACUTAP® VM, supporting flange, special design for bell-type tank installation

for Um up to 300 kV (896762) ............................................................................ 64

Table of contents


3.1.40 VACUTAP® VM – flange for pressure relief valve (895168) ............................653.1.41 VACUTAP® VM – tap selector base with additional screening, reversing

change-over selector design (893934) ...............................................................663.1.42 VACUTAP® VM – tap selector base with additional screening, coarse tap

connection design (893935) ...............................................................................673.1.43 VACUTAP® VM – tap selector base with through hole D20 and D13

(725649) .............................................................................................................68

3.2 VACUTAP® VM 300 – overview of on-load tap-changer designs (765835)..................................................................................................69

3.3 VACUTAP® VM – overview of on-load tap-changer designs (899740) 70

3.4 Overview of basic connection diagrams with tap selector connection contacts designated in accordance with MR standard (890616) ............71

3.5 Connection diagram (contacts designated in accordance with MR standard).................................................................................................74

3.5.1 VACUTAP® VM III 300 Y, basic connection diagram 10 19 1 W (2414642) .....743.5.2 VACUTAP® VM III 300 Y, basic connection diagram 10 19 3 W (2414644)......753.5.3 VACUTAP® VM III 300 Y, basic connection diagram 14 27 1 G (2414648) ......763.5.4 VACUTAP® VM III 300 Y, basic connection diagram 14 27 3 G (2414649) ......773.5.5 VACUTAP® VM III 350/500/650 Y, basic connection diagram 10 19 1 W

(2414658) ...........................................................................................................783.5.6 VACUTAP® VM III 350/500/650 Y, basic connection diagram 10 19 3 W

(2414670) ...........................................................................................................793.5.7 VACUTAP® VM I 802/1002, basic connection diagram 14 27 1 G (2414631)...803.5.8 VACUTAP® VM I 1203/1503, basic connection diagram 18 35 1 W

(2414636) ...........................................................................................................813.5.9 VACUTAP® VM I 802/1002, basic connection diagram 16 79 1 G, multiple

coarse change-over selector design (2407535) .................................................82

4 MR worldwide.............................................................................. 83

List of figures


List of figures

Figure 1 Step capacities (rated step voltage Ui, rated through-current Iu) .....15

Figure 2 Step capacities (rated step voltage Ui, rated through-current Iu) .....16

Figure 3 Rated withstand voltages ................................................................18

Figure 4 On-load tap-changer combination VM I 351/VM II 352(a – VM I 351, b – VM II 352) for delta connection .......................23

List of tables


List of tables

Table 1 Technical data for VACUTAP® VM I ......................................................12

Table 2 Technical data for VACUTAP® VM II .....................................................13

Table 3 Technical data for VACUTAP® VM III ....................................................14

Table 4 Rated insulation level..............................................................................17

Table 5 Rated withstand voltages of the internal on-load tap-changer insulation (with the exception of VACUTAP® VM 300)...........................................19

Table 6 Rated withstand voltages of the internal on-load tap-changer insulation for VACUTAP® VM 300..........................................................................20

Table 7 Available connections (also available as 3 W, 3 G) ................................21

Table 8 On-load tap-changer VACUTAP® VM with multiple coarse change-over selector, rated withstand voltages of the internal on-load tap-changer insulation.................................................................................................22

1 General / Technical Data



1.1 On-load tap-changer designationsExample: VM III 650 Y - 72.5 / C - 10 19 1W R

Basic connec-tion diagram

Type VACUTAP® VM VM

Number of phases 1 phase I2 phases II3 phases III

Ium (in A) VM I, VM II, VM III 300VM I, VM II, VM III 350VM I, VM II, VM III 500VM I, VM II, VM III 650VM I 802VM I 1002VM I 1203VM I 1503

Number of parallel main switching contacts

1 (3-phase Y) 01 (1-phase) 12 (1-phase) 23 (1-phase) 3

Applications For use with neutral point only Y

Um (in kV) VM 72.5VM 123VM 170VM 245VM 300

Tap selector size BCD

not with multiple coarse change-over selector

DE

Number of maximum operat-ing positions without change-over selector

10 1012 1214 1416 1618 1822 22

Number of maximum operat-ing positions with change-over selector (reversing change-over selector or coarse tap selector)1)

10 1912 2314 2716 3118 35

Number of maximum operat-ing positions with multiple coarse change-over selector

10 5912 7114 8316 9518 107

Mid-positions 0 mid-positions (without change-over selector)

0

1 mid-position 13 mid-positions 3

Change-over selector Reversing change-over selector WCoarse tap connection G

Tie-in measures Tie-in resistor RPotential switch SPotential switch with tie-in resistor P

1) 300 amp variants with a maximum of 27 operating positions available



1.2 Technical data for VACUTAP® VM

1.2.1 Technical data for VACUTAP® VM I

On-load tap-changer VM I 301 302 351 501 651 802 803 1002 1203 1503

Number of phases and application 1 1 1 1 1 1 1 1 1 1

Maximum rated through current Ium (in A) 300 300 350 500 650 800 800 1000 1200 1500

Rated short-time current (in kA) 4 4 4.2 5 6.5 8 8 10 12 15

Rated duration of short-circuits (in s) 3 3 3 3 3 3 3 3 3 3

Rated peak withstand current (in kA) 10 10 10.5 12.5 16.25 20 20 25 30 37.5

Maximum rated step voltage Uim (in V)1) 3300 3300 3300 3300 3300 3300 3300 3300 3300 3300

Step capacity (PStN, in kVA) 990 990 1155 1625 1625 2640 2640 3300 3500 3500

Rated frequency (in Hz) 50...60

Operating positions Without change-over selector: maximum 18With change-over selector: maximum 352)

With multiple coarse change-over selector: maximum 1072)

Oil compartment Pressure-tight up to 0.3 bar permanent differential pressure (test pressure 0.6 bar), head and cover of the diverter switch oil compartment are

vacuum-proof.Temperature range The on-load tap-changer VACUTAP® VM can be operated in the rated load

range at surrounding oil temperatures of between -25 ° and +105 °C and with overload up to +115 °C in accordance with IEC 60214-1. For details of operation under Arctic conditions, please refer to the General Technical

Data TD 61.Dimensions Weight, displacement volume and oil content of the diverter switch oil

compartment are shown in the relevant dimension drawings.

Table 1 Technical data for VACUTAP® VM I

1) The maximum rated step voltage may be exceeded by 10 % due to overexcitation of the transformer if the step capacity is limited to its rated value.




1.2.2 Technical data for VACUTAP® VM II

On-load tap-changer VM II 302 352 502 652

Number of phases and application 2 2 2 2

Maximum rated through current Ium (in A) 300 350 500 650

Rated short-time current (in kA) 4 4.2 5 6.5

Rated duration of short-circuits (in s) 3 3 3 3

Rated peak withstand current (in kA) 10 10.5 12.5 16.25

Maximum rated step voltage Uim (in V)1) 3300 3300 3300 3300

Step capacity (PStN, in kVA) 990 1155 1625 1625







Data for TD 61.Dimensions Weight, displacement volume and oil content of the diverter switch oil


Table 2 Technical data for VACUTAP® VM II





1.2.3 Technical data for VACUTAP® VM III

On-load tap-changer VM III 300 Y 350 Y 500 Y 650 Y

Number of phases and application 3 3 3 3

Maximum rated through current Ium (in A) 300 350 500 650

Rated short-time current (in kA) 4 4.2 5 6.5

Rated duration of short-circuits (in s) 3 3 3 3

Rated peak withstand current (in kA) 10 10.5 12.5 16.25

Maximum rated step voltage Uim (in V)1) 3300 3300 3300 3300

Step capacity (PStN, in kVA) 990 1155 1625 1625







Data for TD 61.Dimensions Weight, displacement volume and oil content of the diverter switch oil


Table 3 Technical data for VACUTAP® VM III





1.2.4 Step capacity diagram VM

1.2.4.1 Step capacity diagram for network application

Figure 1 Step capacities (rated step voltage Ui, rated through-current Iu)

i

u

Rat

ed s

tep

volta

ge U

i (V)

Rated through current Iu (A)



1.2.4.2 Step capacity diagram for autoclave application

Figure 2 Step capacities (rated step voltage Ui, rated through-current Iu)

Rat

ed s

tep

volta

ge U

i (V)

Rated through current Iu (A)

i



1.3 Rated insulation level

1.4 Rated withstand voltages

Figure 3 shows diagrams of the voltage stress present on the tap winding of the three primary basic connections of three-pole on-load tap-changers and single-pole on-load tap-changers.

When selecting the on-load tap-changer, you must check that the highest stress on the tap selector does not exceed the related rated withstand voltages.

Rated insulation level For all on-load tap-changer variants

Highest voltage for equipment Um (in kV)1 72.5 123 170 245 3002)

Highest operating voltage Ub (phase-phase) on on-load tap-changer (kV)

55 79 145 170 245

Rated lightning impulse withstand voltage (in kV, 1.2/50 µs)

350 550 750 1050 1050

Rated switching impulse voltage (in kV) 850 850

Rated short-duration power frequency withstand voltage (in kV, 50 Hz, 1 min.)

140 230 325 460 460

Table 4 Rated insulation level

1) In accordance with IEC 60214-1, chapter 3.57: highest effective value for phase-to-phase voltage in a three-phase system for which an on-load tap-changer is designed with respect to its insulation.

2) 300 A variants with a maximum of 245 KV available.



Figure 3 Rated withstand voltages

a0 = Between selected and preselected tap on the diverter switch and tap selector.

a1 = Between tap selector contacts of the winding of one tap position (connected or not connected)

a = Between beginning and end of a tapped winding and, with respect to a coarse winding, between beginning and end of a coarse winding.Note for coarse tap selector connection (-) position of the change-over selector:When stressed with impulse voltage, the permissible withstand voltage "a" must be adhered to between the end of a coarse tap winding connected with the K fine tap selector contact and the fine tap selector contact at the end of the tapped winding of the same phase.

b = Between the fine tap selector contacts of different phases and between change-over selector contacts of different phases, which are connected with the beginning/end of a tapped winding or with a fine tap selector contact.

f = Between diverter switch output terminal and ground

Additionally for coarse tapping arrangement in (+) position of the change-over selector:

c1 = From one (-) change-over selector contact to take-off lead of the same phase.

c2 = Between (-) change-over selector contacts of different phases.

without change-over selector with reversing change-over selector

with coarse change-over with coarse change-over

CAUTIONAdhere to maximum rated light-ning impulse withstand voltage stress on a0 in mid-position.

selector in (+) position selector in (-) position



1.4.1 Rated withstand voltages of the internal on-load tap-changer insulation (with the exception of VACUTAP® VM 300)

The tap selector size (ID letters B, C, D, DE, E) characterizes the internal insulation of the tap selector, whose rated withstand voltages must be matched to the requirements of the transformer winding.

The admissible maximum operating voltage on the individual tap selector distances corresponds to half the value of the above mentioned rated short-duration power frequency withstand voltages.

Insulation distances

Tap selector size B

Tap selector size C

Tap selector size D

Tap selector size DE

kV1.2/ 50 µs

kV50 Hz1 min

kV1.2/50 µs

kV50 Hz1 min

kV1.2/50 µs

kV50 Hz1 min

kV1.2/50 µs

kV50 Hz1 min

a0 Power-frequency voltage test (50 Hz/1 min): 20 kV 50 Hz 1 min;Response voltage with 1 mA leakage current: 35 kV 1.2/50 µs;3 kA residual voltage (= lightning impulse protection level): 56 kV 1.2/50 µs with ZnO

a1 150 30 150 30 150 30 150 30

a 265 50 350 82 490 105 550 120

b1) 265 50 350 82 490 146 550 160

c1 485 143 545 178 590 208 660 230

c21) 495 150 550 182 590 225 660 250

Table 5 Rated withstand voltages of the internal on-load tap-changer insulation (with the exception of VACUTAP® VM 300)

1) Insulation distance omitted for single-pole on-load tap-changers



1.4.2 Rated withstand voltages of the internal on-load tap-changer insulation for VACUTAP® VM 300



VM III 300 Y VM I 301

kV 1.2/ 50 µs kV, 50 Hz, 1 min kV 1.2/ 50 µs kV, 50 Hz, 1 min

a0 Power-frequency voltage test (50 Hz/1 min): 20 kV 50 Hz 1 min;Response voltage with 1 mA leakage current: 35 kV 1.2/50 µs;3 kA residual voltage (= lightning impulse protection level): 56 kV 1.2/50 µs with ZnO

a 300 70 300 70

b 300 70 - -

c1 400 120 400 120

c2 400 120 - -

Table 6 Rated withstand voltages of the internal on-load tap-changer insulation for VACUTAP® VM 300



without change-over selector

with reversing change-over selector

with coarse change-over selector

Connection Tap selector size



10050 B/C/D/DE 10071W B/C/D/DE 10071G B/C/D/DE




10090 B/C/D/DE 12111W B/C 12111G B/C

10100 B/C/D/DE 14111W D/DE 14111G D/DE

12110 B/C/D/DE 14121W B/C 14121G B/C

12120 B/C/D/DE 14131W B/C 14131G B/C

14130 B/C/D/DE 16121W D/DE 16121G D/DE

14140 B/C/D/DE 16131W D/DE 16131G D/DE


16160 B/C/D/DE 16151W B/C 16151G B/C

18170 B/C/D/DE 18151W D/DE 18151G D/DE

18180 B/C/D/DE 18161W B/C 18161G B/C

22190 B/C/D/DE 18171W B/C 18171G B/C


22210 B/C 12231W B/C/D/DE 12231G B/C/D/DE

22220 B/C 14271W B/C/D/DE 14271G B/C/D/DE

16311W B/C/D/DE 16311G B/C/D/DE

18351W B/C/D/DE 18351G B/C/D/DE

Table 7 Available connections (also available as 3 W, 3 G)



1.4.3 VM rated withstand voltages – multiple coarse change-over selector


a0 = Between selected and preselected tap on the diverter switch and tap selector

a1 = Between tap selector contacts of the winding of one tap position (connected or not connected)

a = Between beginning and end of a tapped winding and also between the connected K contact and any points of the tapped winding of the same phase

b = Between the tap selector contacts of different phases and between the connected K contact of one phase and any points of the tapped winding of another phase

c1 = Between any coarse tappings of one phase to the diverter switch terminal of the same phase

c2 = Between identically-named, unconnected coarse tappings of different phases

d1 = Between connected and adjacent coarse tap contacts in one phase

d2 = Between unconnected, adjacent coarse tap contacts in one phase

d3 = Between beginning and end of all coarse tap connections of one phase

f = Between diverter switch output terminal and ground


Tap selector size B Tap selector size C Tap selector size D

kV1.2/ 50 µs

kV50 Hz, 1 min

kV1.2/50 µs

kV50 Hz, 1 min

kV1.2/50 µs

kV50 Hz, 1 min

a0 Power-frequency voltage test (50 Hz/60 s): 20 kV 50 Hz 1 min;Response voltage with 1 mA leakage current: 35 kV 1.2/50 µs;3 kA residual voltage (= lightning impulse protection level): 56 kV 1.2/50 µs with ZnO

a1 150 30 150 30 150 30

a 265 50 350 82 450 105

b1) 265 50 350 82 450 146

c1 455 127 525 165 590 210

c21) 455 127 525 165 590 215

d1 265 50 350 82 450 105

d2 350 82 450 105 450 105

d3 350 82 450 105 490 120

Table 8 On-load tap-changer VACUTAP® VM with multiple coarse change-over selector, rated withstand voltages of the internal on-load tap-changer insulation

1) Insulation distance omitted for single-pole on-load tap-changers

2 Special designs


2 Special designs

2.1 Parallel bridges for parallel connections

Current division on the connection contacts of 2 tap selector planes only for on-load tap-changers VACUTAP® VM I 802 (803)/1002 and of 3 tap selector planes only for on-load tap-changers VACUTAP® VM I 1203/1503, see .Chapter 3.1.33

Parallel bridges on the tap selector terminals are mandatory if the tap winding has been wound in two or more branches and each of these branch taps is con-nected to the terminals of the tap selector.

This measure reliably prevents the following:

On-load tap-changer combination for delta connection

The on-load tap-changers can also be used with the single-phase on-load tap-changer VM I 351 as a two column on-load tap-changer combination VM I 351/VM II 352 for adjusting the voltage of transformer windings in a delta connection (analogous to VM I 501/VM II 502 and VM I 651/VM II 652).

The tap windings should correspond to those in Figure 4.

a) Introduction of circulating currents into the current paths of tap selector and diverter switch

b) Commutating arc on movable tap selector contact bridges

c) Overvoltage between adjacent tap selector connection contacts connected in parallel

Figure 4 On-load tap-changer combination VM I 351/VM II 352(a – VM I 351, b – VM II 352) for delta connection

2 Special designs


2.2 On-load tap-changer VACUTAP® VM 650 Y...VM I 1503 with multiple coarse change-over selector (up to maximum of 5 coarse tap connections)

Extremely fine voltage adjustment requires a great number of operating posi-tions which sometimes can only be achieved with a multiple coarse tapping arrangement.

For instance, 107 operating positions can be obtained by using a 5-tap coarse winding and a tapped winding with 18 taps.

The multiple coarse change-over selector is attached to both sides of the tap selector.

The on-load tap-changers are available (on request) for Um = 72.5 up to max. 300 kV and for 2 to 5 coarse taps (tap selector sizes B and C) or 2 and 3 coarse tap connections (tap selector size D).

2.3 Two-pole on-load tap-changer VACUTAP® VM II 302/352/502/602

On-load tap-changer VM II 302/352/502/602 can be supplied as a two-pole on-load tap-changer for single-phase center point tap-change operations with the same technical data as on-load tap-changers VM III 350 Y, VM III 500 Y and/or VM III 650 Y (see dimensional drawings, Chapter 3).

2.4 On-load tap-changer VACUTAP® VM III 350 Y...VM I 1503 for linear voltage adjustment, up to a maximum of 34 operating positions

The high number of operating positions without change-over selector is achieved by doubling the tap selector contact planes compared with the stan-dard design (requires a larger installation length).

The on-load tap-changers are available for Um = 72.5...300 kV and several tap selector sizes (rated withstand voltages and dimensional drawings on request).

3 Appendix


3 Appendix

3.1 Dimensional drawings/connection diagrams

3.1.1 VACUTAP® VM III 300 Y-0/W/G (898038)

3 Appendix


3.1.2 VACUTAP® VM II 302-0/W/G (898039)

3 Appendix


3.1.3 VACUTAP® VM I 301-0/W/G (898040)

3 Appendix


3.1.4 VACUTAP® VM III 350/500/650 Y-0/W/G (746219)

3 Appendix


3.1.5 VACUTAP® VM II 352/502/652-0/W/G (746220)

3 Appendix


3.1.6 VACUTAP® VM II 351/501/651-0/W/G (746221)

3 Appendix


3.1.7 VACUTAP® VM I 802/1002-0/W/G (746222)

3 Appendix


3.1.8 VACUTAP® VM I 1203/1503-0/W/G (746223)

3 Appendix


3.1.9 VACUTAP® VM III K-0/W/G (746224)

3 Appendix


3.1.10 VACUTAP® VM III 650 Y with multiple coarse change-over selector (746226)

3 Appendix


3.1.11 VACUTAP® VM I 601 with multiple coarse change-over selector (746227)

3 Appendix


3.1.12 VACUTAP® VM I 802/1002 with multiple coarse change-over selector (746228)

3 Appendix


3.1.13 VACUTAP® VM I 1203/1503 with multiple coarse change-over selector (746229)

3 Appendix


3.1.14 VACUTAP® VM III 300 tie-in resistors without potential switch (898695)

3 Appendix



3 Appendix


3.1.17 VACUTAP® VM III Y tie-in resistors with/without potential switch (898692)

3 Appendix


3.1.18 VACUTAP® VM II tie-in resistors with/without potential switch (898691)

3 Appendix


3.1.19 VACUTAP® VM I tie-in resistors with/without potential switch (898690)

3 Appendix


3.1.20 VACUTAP® VM I 351...1503, tie-in resistor cylinder with potential switch without tie-in resistors (898804)

3 Appendix


3.1.21 VACUTAP® VM 300 – installation drawing of centrical drive (765192)

3 Appendix


3.1.22 VACUTAP® VM – installation drawing of centrical drive (746230)

3 Appendix


VACUTAP® VM – installation drawing of centrical drive (746230)

3 Appendix


3.1.23 VACUTAP® VM – on-load tap-changer head, centrical drive (893899)

3 Appendix


3.1.24 VACUTAP® VM – variants of on-load tap-changer head (720026)

3 Appendix


3.1.25 VACUTAP® VM – swivel range of gear unit (720027)

3 Appendix


3.1.26 VACUTAP® VM – screenings on oil compartment contacts (730336)

3 Appendix


3.1.27 VACUTAP® VM 300 – tap selector cross-sections (898041)

3 Appendix


3.1.28 VACUTAP® VM 300 – arrangement of contacts on tap selector (blanks, 891114)

3 Appendix


3.1.29 VACUTAP® VM – arrangement of contacts on tap selector, tap selector division 10...22 (898013)

3 Appendix


3.1.30 VACUTAP® VM – installation position of tap selector connection contacts (890477)

3 Appendix


3.1.31 VACUTAP® VM – connecting leads 3W, 1G, 3G (723590)

3 Appendix


3.1.32 VACUTAP® VM – screenings on fine tap selector and change-over selector (730335)

3 Appendix


3.1.33 VACUTAP® VM 802/803/1203/1503 – bridges to parallel connection of tap selector connection contacts (899598)

3 Appendix


3.1.34 VACUTAP® VM – horizontal drive shaft, centrical drive (893896)

3 Appendix


3.1.35 VACUTAP® VM III 350/500/650 Y – arrangement of tap selectors (891107)

3 Appendix


3.1.36 VACUTAP® VM I 351/501/651 – arrangement of tap selectors (891108)

3 Appendix


3.1.37 VACUTAP® VM I 1503 – arrangement of tap selectors (891109)

3 Appendix


3.1.38 VACUTAP® VM I 802/1002 – arrangement of tap selectors (891110)

3 Appendix


3.1.39 VACUTAP® VM, supporting flange, special design for bell-type tank installation for Um up to 300 kV (896762)

3 Appendix


3.1.40 VACUTAP® VM – flange for pressure relief valve (895168)

3 Appendix


3.1.41 VACUTAP® VM – tap selector base with additional screening, reversing change-over selector design (893934)

3 Appendix


3.1.42 VACUTAP® VM – tap selector base with additional screening, coarse tap connection design (893935)

3 Appendix


3.1.43 VACUTAP® VM – tap selector base with through hole D20 and D13 (725649)

3 Appendix


3.2 VACUTAP® VM 300 – overview of on-load tap-changer designs (765835)

3 Appendix


3.3 VACUTAP® VM – overview of on-load tap-changer designs (899740)

3 Appendix


3.4 Overview of basic connection diagrams with tap selector connection contacts designated in accordance with MR standard (890616)

3 Appendix


Overview of basic connection diagrams with tap selector connection contacts designated in accordance with MR standard (890616)

3 Appendix


3.5 Connection diagram (contacts designated in accordance with MR standard)

3.5.1 VACUTAP® VM III 300 Y, basic connection diagram 10 19 1 W (2414642)

3 Appendix


3.5.2 VACUTAP® VM III 300 Y, basic connection diagram 10 19 3 W (2414644)

3 Appendix


3.5.3 VACUTAP® VM III 300 Y, basic connection diagram 14 27 1 G (2414648)

3 Appendix


3.5.4 VACUTAP® VM III 300 Y, basic connection diagram 14 27 3 G (2414649)

3 Appendix


3.5.5 VACUTAP® VM III 350/500/650 Y, basic connection diagram 10 19 1 W (2414658)

3 Appendix


3.5.6 VACUTAP® VM III 350/500/650 Y, basic connection diagram 10 19 3 W (2414670)

3 Appendix


3.5.7 VACUTAP® VM I 802/1002, basic connection diagram 14 27 1 G (2414631)

3 Appendix


3.5.8 VACUTAP® VM I 1203/1503, basic connection diagram 18 35 1 W (2414636)

3 Appendix


3.5.9 VACUTAP® VM I 802/1002, basic connection diagram 16 79 1 G, multiple coarse change-over selector design (2407535)

4 MR worldwide


4 MR worldwide

Australia Reinhausen Australia Pty. Ltd. Ground Floor 6-10 Geeves Avenue Rockdale N. S. W. 2216 Phone: +61 2 9556 2133 Fax: +61 2 9597 1339 E-Mail: [email protected]

Italy Reinhausen Italia S.r.l. Via Alserio, 16 20159 Milano Phone: +39 02 6943471 Fax: +39 02 69434766 E-Mail: [email protected]

Russian Federation OOO MR Naberezhnaya Akademika Tupoleva 15, Bld. 2 ("Tupolev Plaza") 105005 Moscow Tel. +7 495 980 89 67 Fax. +7 495 980 89 67 E-Mail: [email protected]

Brazil MR do Brasil Indústria Mecánica Ltda. Av. Elias Yazbek, 465 CEP: 06803-000 Embu - São Paulo Phone: +55 11 4785 2150 Fax: +55 11 4785 2185 E-Mail: [email protected]

Japan MR Japan Corporation German Industry Park 1-18-2 Hakusan, Midori-ku Yokohama 226-0006 Phone: +81 45 929 5728 Fax: +81 45 929 5741

South Africa Reinhausen South Africa (Pty) Ltd. No. 15, Third Street, Booysens Reserve Johannesburg Phone: +27 11 8352077 Fax: +27 11 8353806 E-Mail: [email protected]

Canada Reinhausen Canada Inc. 1010 Sherbrooke West, Suite 1800 Montréal, Québec H3A 2R7, Canada Phone: +1 514 286 1075 Fax: +1 514 286 0520 Mobile: +49 170 7807 696 E-Mail: [email protected]

Luxembourg Reinhausen Luxembourg S.A. 72, Rue de Prés L-7333 Steinsel Phone: +352 27 3347 1 Fax: +352 27 3347 99 E-Mail: [email protected]

South Korea Reinhausen Korea Ltd. Baek Sang Bldg. Room No. 1500 197-28, Kwanhun-Dong, Chongro-Ku Seoul 110-718, Korea Phone: +82 2 767 4909 Fax: +82 2 736 0049 E-Mail: [email protected]

India Easun-MR Tap Changers Ltd. 612, CTH Road Tiruninravur, Chennai 602 024 Phone: +91 44 26300883 Fax: +91 44 26390881 E-Mail: [email protected]

Malaysia Reinhausen Asia-Pacific Sdn. Bhd Level 11 Chulan Tower No. 3 Jalan Conlay 50450 Kuala Lumpur Phone: +60 3 2142 6481 Fax: +60 3 2142 6422 E-Mail: [email protected]

U.S.A. Reinhausen Manufacturing Inc. 2549 North 9th Avenue Humboldt, TN 38343 Phone: +1 731 784 7681 Fax: +1 731 784 7682 E-Mail: [email protected]

Iran Iran Transfo After Sales Services Co. Zanjan, Industrial Township No. 1 (Aliabad) Corner of Morad Str. Postal Code 4533144551 E-Mail: [email protected]

P.R.C. (China) MR China Ltd. (MRT)

360 4E

200120 86 21 61634588 86 21 61634582

[email protected] [email protected]

United Arab Emirates Reinhausen Middle East FZE Dubai Airport Freezone Building Phase 6, 3rd floor, Office No. 6EB 341 Dubai Phone: +971 4 6091828 Fax: +971 4 6091829 E-Mail: [email protected]

2332907/00 EN • 11/10 • F0248500

Answers for energy.

TMDS™ Smart MonitorSolutions for transformer life-cycle management

TMDS™ Smart Monitor Selecting a transformer monitoring solution is a critical step in achieving your company’s Smart Grid asset management strategy. Siemens TMDS™ Smart Monitor is a self-contained, expert system combining multiple IEEE/ANSI-accepted engineering models with advanced rule-based logic, far exceeding existing monitoring concepts. TMDS™ Smart Monitor turns transformer monitoring data into actionable information by translating combustible dissolved gas, bushing capacitance deviation, moisture and other sensor measured data into diagnostic and prognostic messaging.

The TMDS™ Smart Monitor provides alarming using models that work with rule-based logic, derived from accepted IEEE/ANSI guidelines. Alarm messaging includes maintenance support and suggested loading recommendations should TMDS™ classify the observed deviation as severe enough that it may result in the damage or potential failure of the transformer.

Additionally the TMDS™ Smart Monitor can perform cooling system control functions by initiating staged cooling to optimize transformer operating temperatures.

The Siemens TMDS™ Smart Monitor advantages include the following:

Best-in-class transformer monitoring and diagnostic system

Advanced detection of abnormal conditions

Supports customer preferences in transformer sensing technologies

Automatically detects bad sensor data to avoid false diagnosis

Configurable for legacy transformers

PI Historian and SCADA system interface

Can be integrated with Siemens TMDS™ to support a centralized asset management strategy.

Comprehensive data requires powerful

analytical tools

7

Select from a suite of analysis applications. The following Siemens specialist models are provided with TMDS™ Smart Monitor:

Bushing relative capacitance deviationEvaluation of bushing insulation condition

Insulation moistureEvaluation of oil moisture condition and estimated moisture in paper

ThermalHot spot evaluation by ANSI, IEC and Siemens proprietary methods

Ageing and life expectancyEvaluation of relative loss of life and relative ageing by ANSI, IEC or ABNT methods

Cooling system monitoring Evaluation of proper cooling system operation by monitoring the load current of the fan groups and oil or water flow (depending on the cooling system)

Conservator oil volumeProvides advanced notification of conservator oil volume before reaching lowest acceptable level

Cooling system controlControls the cooling system by calculating the future hot spot as a function of the current loading, executing periodical cooling groups exercise

Dissolved gas-in-oilEvaluation of limit values of gas generation in oil (depending on sensors installed, may include methane, ethylene, acetylene, ethane, carbon dioxide, hydrogen, oxygen and carbon monoxide). Analysis and indication of incipient faults using the Duval triangle method

LTC monitoringEvaluation of position indication, contact wear calculation and torque for comparison with learned values.

Duval’s analysis was performed. In case gas formation shows stability, no further action is recommended. TMDS will re-assess Duval’s analysis within 24 hours. Region of Duval’s Triangle = T2 - Thermal Fault, 200(degrees) C < T < 700 (degrees) C. Reduce load by 25 percent and re-assess transformer behavior. In case it persists, must undertake immediate internal inspection to establish cause of fault.

TMDS™ Smart Monitor delivers decision support to the right personnel in the context of actionable information.

Siemens provides a comprehensive

suite of transformer life-cycle

management solutions specifically

designed to meet your needs.

TMDS™ Smart Monitor

TMDS™ Smart Monitor supports a distributed diagnostic strategy where responsibility for responding to alarms and providing diagnostic expertise is regionally distributed. Field teams are self-sufficient in assessing asset condition, performing tests and arriving at corrective actions to be taken.

Siemens’ answers for transformer

monitoring

TMDS™

TMDS™ supports a central diagnostic strategy where responsibility for fleet-wide asset analysis and budget preparation is centralized. Field teams are typically dispatched by central maintenance or asset management groups.

Differences in functionality and architecture between TMDS™ and TMDS™ Smart Monitor

TMDS™ TMDS™ Smart Monitor

Provides monitoring and diagnostics for transformers in one or across multiple substations

X Stand alone monitor for single transformer

Provides advanced detection of abnormal conditions

X X

Supports customer preference in sensing technologies

X X

Automatically detects bad sensor data to avoid false diagnosis

X X

Provides maintenance support and loading recommendations to address abnormal operation

X X

Provides overview of possible consequences (prognostics) if current trend or parameter deviation continues

X X

Location of historical data and diagnostic information

Central TMDS™ engineering server Smart Monitor flash memory

Access to data and diagnostic information Active monitoring remotely via customer intranet

Active monitoring via Smart Monitor touch screen or remotely via Smart

Monitor Web server

Cooling system control X X

Creates and monitors statistical definition for multiple parameters

X

Performs correlation between multiple parameters and across multiple transformers

X

Variables monitored, depending on sensors installed, include: 1. Winding temperature

2. Top and bottom oil temperatures

3. Ambient temperature

4. Load current

5. Fan motor current

6. Oil flow (pump motor)

7. Moisture in oil

Aquaoil

Vaisala

8. Dissolved gas in oil

Multi-gas Serveron TM8

Siemens GAS-Guard 8

Kelman MULTITRANS

Single-gas Calisto

Hydran

9. Bushing condition

Doble IDD

HSP

10. LTC monitoring

11. Oil level

9

9

9

2

3

2

5

6

7810

11

1

4

Actionable information

Delivers statistically relevant abnormal operating data and alarm conditions

Provides maintenance support to address abnormal operation

Suggests loading recommendations through the adaptation of models using actual field condition assessment data.

Sensing technology agnostic

Due to the large availability of sensors in the market, TMDS™ Smart Monitor is designed to support data acquisition from different manufacturers’ sensors.

Supports customer preference in transformer sensing technologies

Allows customer to incorporate appropriate sensing technology based upon transformer importance.

Self diagnostic

TMDS™ Smart Monitor automatically detects bad sensor data to avoid false diagnosis.

The TMDS™ Smart Monitor can easily be

installed on new or legacy transformers

from any manufacturer utilizing existing

sensors

Configurable for legacy transformers

Legacy transformers are unique in that they each have a specific operational history. Siemens TMDS™ Smart Monitor allows condition assessment data to be incorporated into the configuration of alarms and recommended loading to take into account the operational history of the transformer.

Features include:

Active monitoring via TMDS™ Smart Monitor’s local 12” touch screen or laptop connection and passive monitoring remotely via built-in Web server

Historical and diagnostic information that can be downloaded directly from the TMDS™ Smart Monitor and is also buffered up to 12 months

DNP 3.0/Modbus communication options are available for SCADA-type communications.

www.usa.siemens.com/energy

Published by and copyright © 2010:Siemens AGEnergy SectorFreyeslebenstrasse 191058 Erlangen, Germany

Siemens Energy, Inc.7000 Siemens RoadWendell, NC 27591

For more information, contact+1 (800) 347-6659www.usa.siemens.com/energy

Siemens Canada Limited1550 Appleby LineBurlington, Ontario, Canada+1 (905) 315-6868

Order No. E50001-F730-A155-X-76US Printed in USABU 20099151385997F 01101

All rights reserved. Trademarks mentioned in this document are the property of Siemens AG, its affiliates, or their respective owners.

Subject to change without prior notice. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract.

Answers for energy.

GAS-Guard® 8 Online dissolved gas analysis sensor

Throughout your system there are transform-ers that are vital to the reliability of your grid - generator step-up transformers, large transmission transformers and critical substation transformers. Based on historical installation rates, the average transformer age is 40 years. However, age itself is not a cause of failure. As transformers age, they endure various stresses that can contribute to a variety of failure mechanisms. Appropriate online DGA monitoring and diagnostic tools can help utilities lower maintenance costs, extend transformer useful life and avoid unplanned failures.

Gas chromatography (GC) has long been the accepted standard for the measurement of dissolved gas levels in transformer oil. The GAS-Guard® 8 brings the DGA laboratory to your transformer with its rugged, closed-loop gas chromatograph.

Dissolved gas analysis (DGA)

Dissolved gas analysis is the single-most

comprehensive tool for transformer

condition assessment

Key benefits include:

Field-based, fully automated DGA requires no manual oil sampling or remote lab testing

Use of the only measurement method specified for all DGA standards worldwide (IEE, IEC, ASTM)

Built-in self calibration system traceable to NIST standards executes weekly tests for performance confirmation

Accurate and timely DGA results improve the ability to protect transformer against fault damage

Time-date stamped test results allow correlation between real events and measured conditions

Data generated by the Gas-Guard 8 can be used to support condition-based maintenance programs.

Many transformer failures can be prevented through analysis of DGA data supporting the diagnosis of developing abnormal conditions.

Comprehensive data requires powerful analytical tools

The software package included with the GAS-Guard® 8 sensor allows the user to graphically display continuous gas evolution for each of the eight critical fault gases and as well as moisture, load and ambient temperature.

Online diagnostic tools

The software package also allows the user to trace changes in fault severity over time through dynamic plots created using the Duval Triangle and Rogers Ratios analysis tools.

Online DGA data populating diagnostic tools deliver new insights. This displays Rogers Ratios (IEEE PC57.104.D11d) and basic gas ratios (IEC 60599-1999-03).

The Duval Triangle (IEC 60599-199-03) provides a diagnostic outcome for combinations of three fault gases.

SITRAM® GAS-Guard 8: Facts and figures

Moisture-in-oil and oil temperature option

Parameter Accuracy5 Range

Moisture-in-oil ±2% 0 – 100% RS6

<10% of reading for oil temperature >30° C

0 to 807 ppm

<18% of reading for oil temperature <30° C

0 to 807 ppm

Oil temperature ±0.1° C (typ.) -40° C to +180° C5 Includes nonlinearity and repeatability6 Relative saturation7 Upper range limited to saturation

Environmental specifications

Operating temperature –50° C to + 55° C

Cold-start temperature –20° C

Operating humidity 5% to 95%, RH noncondensing

Oil inlet pressure 0 to 45 psi, to 3 bar

Storage temperature –40° C to +75° C

Storage humidity 5% to 95%, RH noncondensing

Physical specifications and weights

Height 22.0 in (55.9 cm)

Width 20.0 in (50.8 cm)

Depth 11.2 in (28.4 cm)

Weight 65 lb (29.5 kg)

Enclosure rating IP 66, NEMA 4

Packaged dimensions 26.4 in x 26.4 in x 15.9 in (67 cm x 67 cm x 40.3 cm)

Shipping weight (monitor only) 70 lb (31.8 kg)

Certifications/standards

Electromagnetic compatibility

Specification Test method

EN 61326 Class A: 2002 EN 61326: 2002 radiated emissions, 2002 conducted emissions

EN 61000-3-2: 2000 EN 61000-3-2: 2000 current harmonics

EN 61000-3-3: 2001 EN 61000-3-3: 2001 voltage fluctuations

EN 61326 Annex A: 2002 IEC 61000-4-2: 2001 ESD

IEC 61000-4-3: 2002 radiated immunity against HF field

IEC 61000-4-4: 2004 EFT

IEC 61000-4-5: 2001 surge

IEC 61000-4-6: 2004 conducted RF immunity

IEC 61000-4-8: 2001 magnetic field immunity

IEC 61000-4-11: 2004 voltage dips and interrupts

Safety

IEC 61010-1, IEC 61010-2-81

UL 61010-1 (2nd Edition), UL 60950-1 Clause 6.4

CSA-C22.2 No. 61010-1-04

Input power requirements

Voltage 115 VAC or 230 VAC ±15%

Frequency 50/60 Hz

Current 6 A maximum at 115 V

3 A maximum at 230 V

Total dissolved gases

True total dissolved combustible gas (TDCG) output is available(∑H2, CO, CH4, C2H2, C2H4, C2H6 in PPM).

Each gas is measured at 100% of detected level.

Total hydrocarbons (THC) output is available (∑CH4, C2H2, C2H4, C2H6 in PPM).

Each gas is measured at 100% of detected level.

Gas analysis

Oil sampling is continuous and gas analysis intervals are user-selectable from 2 hours to 12 hours (Default: 4 hours).

All data is time-date stamped.

Up to two years of data stored in memory.

Automatic schedule acceleration when rate of change alarm limit exceeded (Default: 1hour).

System performs periodic autocalibration to NIST8 traceable gas standard.8 National Institute of Standards and Technology

Alarms

For each individual gas measured:

Two individually programmable caution and alarm settings for level (ppm) as well as rate of change (ppm/day)

Freely programmable relay contact for gas alarm or service event

One relay contact for self-monitoring of power supply.

Communications options

Standard physical layer interfaces include RS-232, RS-485, Ethernet(10/100Base-TX), V.92 internal POTS modem.

Optional physical layer interfaces include cellular modem, Ethernet(100Base-FX), wireless radio.

Three 4-20 mA inputs and one RS-232 port available to connect to optional devices.

Protocols supported: TCP/IP, DNP3, Modbus RTU and ASCII, OPC

External sensors

Current sensor for load-dependent gas development

Ambient temperature

Moisture in oil and oil temperature

The Siemens GAS-Guard 8 sensor provides a complete online dissolved gas analysis.

Through chromatography, the GAS-Guard 8 generates individual measurements of eight critical fault gases found in transformer oil. Accuracy is commensurate with traditional lab results. The sensor continually collects oil samples as often as every two hours. The GAS-Guard 8 can also measure moisture in the oil, oil temperature and ambient tempera-ture. DGA results and other measurement data are time-date stamped and can thus be correlated to transformer load.

The Siemens GAS-Guard® 8 provides accurate and repeatable measurement of eight (8) critical fault gases

Gas Accuracy1 Repeatability2 Range3

Hydrogen H2 +/- 5% or +/- 2 ppm <2% 2-3,000 ppm

Oxygen O2 +/- 5% or +30 / - 0 ppm <1% 30-5,000 ppm

Methane CH4 +/- 5% or +/- 10 ppm <1% 10-5,000 ppm

Carbon Monoxide CO +/- 5% or +/- 3 ppm <1% 3-10,000 ppm

Carbon Dioxide CO2 +/- 5% or +/- 5 ppm <1% 5-30,000 ppm

Ethylene C2H4 +/- 5% or +/- 3 ppm <1% 3-5,000 ppm

Ethane C2H6 +/- 5% or +/- 5 ppm <1% 5-5,000 ppm

Acetylene C2H2 +/- 5% or +/- 1 ppm <2% 1-3,000 ppm

NOTES: All specifications are independent of oil temperature and gas pressure level.1 Percent of ppm - whichever is greater2 At gas calibration level3 Gas-in-oil

DGA tolerances of the GAS-Guard 8

Graphical representation of GAS-Guard 8 connected to the transformer tank.

www.usa.siemens.com/energy

Published by and copyright © 2010:Siemens AGEnergy SectorFreyeslebenstrasse 191058 Erlangen, Germany

Siemens Energy, Inc.7000 Siemens RoadWendell, NC 27591

For more information, please contact:Telephone: +1 (919) 365-2200Toll-free: +1 (800) 347-6659

Siemens Canada Limited1550 Appleby LineBurlington, Ontario, CanadaL7L 6X7+1 (905) 315-6868

Order No. E50001-F730-A110-X-4A00Printed in USATD 2009212142519480F BR 0110.5

All rights reserved. Trademarks mentioned in this document are the property of Siemens AG, its affiliates, or their respective owners.

Subject to change without prior notice. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract.

Type NR Neutral Grounding Resistors

Powerohm Type NR Neutral Grounding Resistors are usedin industrial power systems for resistance grounding of wye-connected generators and transformers. A neutral ground-ing resistor limits the fault current to a value which issufficient enough to operate protective relays, yet preventunwanted fault damage.

N

G

Neutral GroundingResistorR

CTTo Protective

Relay

Transformer or GeneratorSecondary

Neutral Grounding Resistor Schematic

RESISTORS, INC.POWEROHM Ω 5713 13th Street

Katy, Texas 77493Phone: (281) 391-6800, Fax: (281) 391-6810

Please visit our website at www.powerohm.com

Neutral grounding resistors are rated in line-to-neutralvoltage (system voltage divided by 1.732), initial faultcurrent and maximum time on. Powerohm neutral ground-ing resistors are designed to dissipate the required amountof energy and not exceed the temperature limitations ofIEEE Standard 32-1972. As defined in this publication,the time and temperature ratings for neutral groundingresistors are as follows:

Short time: Short time ratings are 10 and 60 seconds.Since short time rated resistors can only withstand ratedcurrent for short periods of time, they are usually used withfault clearing relays. The short time temperature rise forthe resistive element is 760°C.

Extended time: A time on rating greater than ten minuteswhich permits temperature rise of resistive elements tobecome constant, but limited to an average not more than90 days per year. The extended temperature rise for theresistive element is 610°C.

Continuous: Capable of withstanding rated current foran indefinite period of time. The continuous temperaturerise for the resistive element is 385°C.

All units are factory tested in accordance with IEEE Stan-dard 32-1972, specifically Sections 10.1.4 and 10.3.2. Theprocedure includes a resistance measurement test to verifythat the tolerance is within + 10%, and an applied potentialtest. A copy of the test report is included with each shippedunit.

ELECTRICAL TESTS

Resistor Assembly: The resistor coils consist of a stainlesssteel edgewound element wound around a ceramic coresupported on a through-rod. Glazed insulators are attachedto each end of the coils and fastened to a heavy gage,corrosion resistant frame. The unit is designed to permit theexpansion of supporting rods when submitted to high oper-ating temperatures. Resistor elements are joined by stain-less steel connectors, which are welded in place, to form apositive electrical path.

Safety Enclosure: Our resistor assemblies are availablewith grounded safety enclosures to protect personnel andwildlife from harm. Screened and louvered enclosures areavailable in a variety of finishes including painted, powdercoated, mill galvanized, hot-dipped galvanized, aluminumand stainless steel.

Options: A number of additional options are availableincluding entrance bushings, current transformers, elevat-ing stands and disconnect switches.

BASIC CONSTRUCTION

DESIGN REQUIREMENTS

APPLICATION Neutral Grounding Resistor

CATALOGNUMBER

INITIALAMPS

RESIS-TANCE A

NR1390-100-10NR1390-200-10NR1390-300-10NR1390-400-10NR1390-500-10NR1390-600-10NR1390-800-10NR1390-1000-10




2400 VOLTS LINE-TO-NEUTRAL (4160 VOLT SYSTEM)

1390 VOLTS LINE-TO-NEUTRAL (2400 VOLT SYSTEM)3030303030303030

3030303030303636

3636363636365454

5454545454548484

APPROX.WEIGHT

280290300310320340350360

380390400410420430490500

550560570580590600680700

820830840850870880950990

B C

3838383838383838

3838383838383838

3838383838384444

4444444444444444

3838383838383838

3838383838383838

3838383838385454

5454545454545454

100200300400500600800

1000

100200300400500600800

1000

100200300400500600800

1000

100200300400500600800

1000



10 SECOND TIME RATINGS

NR1390-15-ENR1390-25-ENR1390-50-E

NR2400-15-ENR2400-25-ENR2400-50-E

NR4160-15-ENR4160-25-ENR4160-50-E

152550

152550

152550

383838

383854

545454

320370420

450550850

900950

1400



303036

363654

545454

383838

383844

444484

13.906.954.633.482.782.321.741.39

24.0012.008.006.004.804.003.002.40

41.6020.8013.8710.408.326.935.204.16

80.0040.0026.7020.0016.0013.3010.008.00

EXTENDED TIME RATINGS


92.755.627.8

160.096.048.0

227.3166.483.2

RATINGS: The following table contains information on the mostcommon size units, other variations are available.

DIMENSIONS: The dimensions listed in thetable are in inches. Information subject tochange without notice.

The above drawing details a typical neutralgrounding resistor with enclosure. Units areavailable with screened or louvered coverson front and back. All units normally havesolid tops and sides and a perforated bottom.

TO ORDER A NEUTRAL GROUNDING RE-SISTOR NOT LISTED IN THE TABLE,SPECIFY THE FOLLOWING:1. Line-to-neutral voltage.2. Initial fault current.3. Maximum time on.4. Special requirements or options.

Ratings & Dimensions of Standard Size Units

FRONT VIEW

Neutral Bushing

GroundTerminal

A

C

B

RIGHT SIDE VIEW

Generator Neutral Grounding Resistors

BASIC CONSTRUCTION

Powerohm offers high resistance grounding equipment forwye connected generators. Our equipment is normallydesigned to limit the line-to-ground fault current to below 15amps for generators rated up to 14,400 volts. These units willprovide a high resistance neutral during a fault condition,while allowing the system to operate as an ungroundedsystem during normal operating conditions. The configura-tion basically consists of a dry-type single-phase trans-former with a resistor connected across the secondary. Theprimary of the transformer is then connected between thewye point of the generator and ground.

Powerohm generator grounding equipment is normally sup-plied with the transformer and resistor installed in a commonenclosure. Continuous rated units are usually compartmen-talized to separate the resistor assembly from the trans-former which is subject to overheating. Units do not normallyinclude any relaying or control circuitry, but do offer thetransformer secondary wired to a terminal block installed inan external junction box.

APPLICATION

Transformer: For continuous time ratings, the transformermust be capable of withstanding rated current for an indefi-nite period of time; therefore, the KVA rating of the groundingtransformer is equal to the rated line-to-neutral voltage timesthe desired neutral current. For a short-time rating, the KVArating of a grounding transformer will be smaller because theunit is designed to carry its rated current for a limited time.

Resistor Assembly: The resistance value is calculated bydividing the secondary voltage by the rated current neces-sary to obtain the desired fault current on the primary.Resistor elements are selected to best meet the current andvoltage requirements of the system. A typical assemblyincludes all stainless steel elements, bus bars andterminals.


ELECTRICAL TESTS

Safety Enclosure: Our grounding assemblies are availablein grounded NEMA 1 or NEMA 3R safety enclosures,complete with nearly any finish including mill galvanized,power coated, hot dipped galvanized after fabrication, alumi-num or stainless steel.

Options: A number of additional options are available,including entrance bushings, current transformers, elevat-ing stands, and disconnect switches.

Generator Neutral Grounding Resistor

WYE-CONNECTEDGENERATOR

GROUNDINGTRANSFORMER

TO PROTECTIVERELAY

G

N

R

The best way to resistance ground a power system is toobtain the system neutral through a generator or trans-former with a wye-connected winding. However, a systemneutral may not be available, particularly in many older lowvoltage systems and a significant number of existingmedium voltage systems. To avoid the high cost of replacinga source transformer, an existing delta-connected systemcan be grounded using a zigzag transformer to form anartificial neutral, then connecting a resistor between thenewly created wye-point and ground.

A zigzag transformer has no secondary winding, and isdesigned to provide a low-impedance path for the zero-sequence currents to flow. During a line-to-ground faultcondition, the zero sequence currents can flow into theground at the point of the fault, and back through the neutralof the grounding transformer. The impedance of the zigzagtransformer to balanced three-phase voltages is relativelyhigh, therefore, when there is no fault on the system, only asmall magnetizing current flows in the windings. A zigzaggrounding transformer provides a stable neutral point whichmakes possible its use for grounding an otherwise isolatedneutral system.

A zigzag transformer with a resistance ground is normallydesigned for a short time rating of 10 to 60 seconds.Consequently, the grounding transformer is much smaller insize than an ordinary continuously rated transformer withthe same rating. For short time ratings, the short timetemperature rise for the resistive element is 760°C.


ELECTRICAL TESTS

Transformer: For a short time rating, the groundingtransformer is designed to carry its rated current for a limitedtime, consequently the unit is ordinarily much smaller,physically, than an ordinary three-phase transformer for thesame rated kVA.

Resistor Assembly: The resistance value is calculated bydividing the line-to-neutral voltage by the rated neutralcurrent. Resistor elements are selected to best meet theshort time current rating and voltage requirements of thesystem. A typical assembly includes all stainless steelelements, bus bars and terminals.

Safety Enclosure: Our grounding assemblies are availablein grounded NEMA 1 or NEMA 3R safety enclosures,complete with nearly any finish, including mill galvanized,power coated, hot dipped galvanized after fabrication, alumi-num, or stainless steel.

Options: A number of additional options are availableincluding entrance bushings, current transformers, elevat-ing stands and disconnect switches.

BASIC CONSTRUCTION

APPLICATION

24 HOUR EMERGENCY SERVICE (800) 838-4694

Resistance Grounding with a Zigzag Transformer

G

R RESISTOR

ZIGZAGTRANSFORMER

TO UNGROUNDED 3-PHASE LOAD

TO UNGROUNDED 3-PHASE VOLTAGE

SOURCE

Zigzag Grounding Transformer with Resistor

Powerohm's Type ER and ERB Edgewound Resistors canbe used for any AC or DC power application. Units are mostcommonly used for VFD braking, motor control, load banksand neutral grounding applications.

The Type ER and ERB resistors are suitable for continuousduty applications where low resistance and high current arerequired. The high element mass allows these units towithstand high current, intermittent duty applications. Thischaracteristic, combined with the high-temperature ceramicinsulation, makes the edgewound ideal for neutral groundingapplications, which reach temperatures as high as 800°C.

APPLICATION

ELECTRICAL CHARACTERISTICSVOLTAGE INSULATION: A standard Type ER and ERBresistor is insulated for up to 1000 volts. Standard enclo-sures are insulated for up to 1000 volts and by adding furtherstages of insulation, an assembly of units can be used forapplications exceeding 15 kV.

RESISTANCE TOLERANCE: + 10% for all units; as low as+ 3% if required.

COEFFICIENT OF RESISTIVITY: Resistance values willincrease as the element temperature rises. Expect anapproximate increase of 5% in resistance after the unitreaches an operating temperature of 375°C above ambient.Contact the factory for more specific information if needed.

AMBIENT TEMPERATURE: Standard ratings are based onmaximum ambient temperatures of 40°C. Derate currentrating 95% for 50°C ambient, 90% for 75°C ambient, and85% for 100°C ambient.

EFFECTS OF ALTITUDE: The published electrical ratingsare applicable for altitudes of 6000 feet or less. Contact thefactory for deration factors above 6000 feet.

Powerohm offers a complete selection of standard size coilson the following page. These coils cover a wide range ofresistance and current values. Numerous variations areavailable for special applications or replacement of othermanufacturers. Powerohm can match the electrical ratingsof any edgewound product available. Please contact thefactory for assistance.

CUSTOM DESIGNS

OPTIONS

BASIC CONSTRUCTIONPowerohm's Type ER and ERB resistors are lightweight,heavy-duty units consisting of a non-corrodible, high qualitystainless steel alloy. The ribbon-like element is wound onedge in the form of a helix, and then spun onto a ceramiccore. Type ER resistors are supported by a threaded rodpassing through the center of the ceramic core. Type ERBresistors are supported by a mounting bar which is slottedat either end. Fixed terminations are made by weldingstainless steel tabs to either end of the element, or at variouspoints for multiple connections. This unit includes fixedterminals, through-rods, through-bars, hardware and stain-less steel element.

Our ceramic insulating cores are manufactured in-house tomaintain total control over production and quality standards.Powerohm is the only domestic resistor manufacturer withthis added advantage.

POWEROHMRESISTORS, INC.Ω 5713 13th Street

Katy, Texas 77493Phone: (281) 391-6800, Fax: (281) 391-6810

Please visit our website at www.powerohm.com

Type ER and ERB Edgewound Resistors - 16 to 100 Amps

Type ER Edgewound Resistor

COIL SIZES: Type ER and ERB resistors are available in(6) standard lengths, all having the same, approximatediameter of 2 inches. Wattage values vary from 400 to 2300watts per coil. These units are available in (15) differentcurrent ratings ranging from 16 to 100 amps continuous, andresistance values between 6.2 and .06 ohms, respectively.

ADJUSTABLE TERMINALS: Adjustable terminals, whichcan be clamped to the element, are available for certain sizeunits; add "-A" to the part number.

ENCLOSURES: Powerohm Type ER resistors can bepackaged in our standard line of enclosures. See theEnclosure Catalog Section for details.

Type ER Electrical Ratings & Coils Dimensions

CONTINUOUSAMP RATING

1.90

1.70

1.30

1.20

.89

.69

.49

.43

.35

.27

.25

.19

.15

.12

.07

.06

4.10

3.50

2.7

2.4

1.85

1.44

1.02

.90

.73

.56

.52

.40

.32

.26

.15

.13

5.10

4.40

3.5

3.1

2.3

1.81

1.29

1.13

.92

.70

.65

.51

.40

.33

.19

.16

7.20

6.20

4.90

4.3

3.3

2.6

1.82

1.60

1.30

.99

.92

.72

.57

.46

.27

.23

6.20

5.30

4.2

3.7

2.8

2.2

1.55

1.37

1.11

.85

.78

.62

.48

.39

.23

.20

15

16

18

20

23

26

29

32

36

40

45

50

60

70

85

100

LENGTH 2 LENGTH 3 LENGTH 4 LENGTH 5 LENGTH 6 LENGTH 7

RESISTANCE IN OHMS

Amp RatingRATINGS: The continuous current ratings are based on a 375°C temperature rise. The resistance values are measuredat 25°C and have a + 10% tolerance.

3.00

2.60

2.0

1.80

1.37

1.06

.75

.66

.54

.41

.38

.30

.23

.19

.11

.10

ELECTRICAL RATINGS OF STANDARD SIZE COILS

TYPE ER DIMENSIONS: The coil dimensions are for standardsize units. Coil and threaded rod length can be varied percustomer request. All units have the same approximate diam-eter of 2 inches. Units are furnished with 5/16"-18 through rodsand terminal hardware. 6-1/8

9-1/8

12-1/8

15-1/8

18-1/8

21-1/8

LENGTH A B C

9-3/8

12-3/8

15-3/8

18-3/8

21-3/8

24-3/8

2

3

4

5

6

7

STANDARD COIL DIMENSIONS

7

10

13

16

19

22

SPECIFY PART NUMBERS AS FOLLOWS: ER or ERB __ - __ .Length

For example, the part number of a Type ER, 50amp, 0.51 ohm coil is ER5-50.

FRONT VIEW SIDE VIEW

C

A

3

3/8 DIA.

B

TYPE ERB EDGEWOUND: Type ERB bar-mounted edgewounds areavailable with the same electrical ratings as the Type ER edgewounds. Allunits have the same approximate diameter of 2 inches. Units are furnishedwith a through-bar and terminal hardware.

LENGTH A B

9-1/4

12-1/4

15-1/4

18-1/4

21-1/4

24-1/4

2

3

4

5

6

7

STANDARD COIL DIMENSIONS

7-7/8

10-7/8

13-7/8

16-7/8

19-7/8

22-7/8

Type ERB Coil Dimensions & Tap Options TYPE ERB (BAR-MOUNT) EDGEWOUND DIMENSIONS

ADDITIONAL TAPS

SPECIFY PART NUMBERS AS FOLLOWS: -

Number of Taps

Spacing (See Table)

For example, the part number of a TypeER, 50 amp, 0.51 ohm coil with 2 taps at1/3 spacing is ER5-50-2C. See below foradditional part number examples.

Part Number

ADDITIONAL TAPS & SPACING CHART

FRACTIONALSPACING

SUFFIXLETTER

1/21/31/41/5

1/61/71/81/9

1/101/111/121/13

1/141/151/161/17

BCDE

FGHJ

KLMN

PRST

(5 TAP @ 1/6 SPACING)ER3-50-5F

Type ER resistors are furnished with two stainless steel terminals at either end of the ceramic core. Additional fixedtaps consist of a stainless steel terminal welded in place at various intervals. Numerous tap configurations areavailable, but limited to a spacing no closer than 1-1/4 inches.

ER3-50-1D(1 TAP @ 1/4 SPACING)

Other examples of ER Edgewound Resistorswith additional taps.

B


A

(2) 17/32SLOTS

1-1/4

3/8 DIA.

3

Type ER Mounting Bracket Options & Dimensions

24 HOUR EMERGENCY SERVICE (800) 838-4694

SPECIFY PART NUMBERS AS FOLLOWS: ER - .

Part Number

Bracket Identification

For example, the part number of a Type ER, 50amp, 0.51 ohm coil mounted on B1 Brackets is1ER5-50-B1. Standard assemblies of 2 or morecoils include series jumpers. Add "-N" to eliminatejumpers and "-P" for parallel jumpers.

B1 BRACKET ASSEMBLY OPTIONS & DIMENSIONS



STANDARD BRACKET DIMENSIONS DIMENSION SIZE 2 SIZE 3 SIZE 4 SIZE 5 SIZE 6 SIZE 7

A 9 12 15 18 21 24

B 8 11 14 17 20 23

Type ER Edgewound Resistors are available fully assembled on open-style brackets. This open-style construction consistof resistors installed on mill galvanized brackets complete with all hardware and stainless steel bus bars.

Number of Coils in Assembly

0.00

0

000W

P00

00

0.00

0

000W

P00

00

1.23

1

500W

P11

026

7/16 DIA.

A

B

3-1/2

2

5/16 HARDWARE


7/16 DIA.

B

6

3-1/4

5/16 HARDWARE


A

7/16 DIA.

A

B 3-1/4

5/16 HARDWARE

9


ET10412+O&M+MANUAL+ENGLISH_25.04.15

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