PowerIT Transformers and Reactors

VACUUM OIL FILLING ON SITE

Table of Content

1 GENERAL----------------------------------------------------------------------------------------------------------------------------------------------- 2
2 NECESSARY EQUIPMENT------------------------------------------------------------------------------------------------------------------------ 2
3 VACUUM TREATMENT WITH FINAL LEAK TEST ------------------------------------------------------------------------------------------ 3
4 PROCESSING THE OIL BEFORE FILLING --------------------------------------------------------------------------------------------------- 4
5 FILLING PROCEDURE FOR THE MAIN TANK ---------------------------------------------------------------------------------------------- 4
5.1 Filling from the tank lower filtering valve---------------------------------------------------------------------------------------------------- 4
5.2 Oil filling of on-load tap changer -------------------------------------------------------------------------------------------------------------- 6
6 CIRCULATION OF OIL IN THE MAIN TRANSFORMER TANK -------------------------------------------------------------------------- 6
6.1 Oil circulation procedure------------------------------------------------------------------------------------------------------------------------ 6
7 FILLING OF SEPARATE COOLERS ------------------------------------------------------------------------------------------------------------ 7
8 IMPREGNATION TIME BEFORE ENERGIZING --------------------------------------------------------------------------------------------- 7
9 ADDITIONAL DRYING PROCEDURE ON SITE---------------------------------------------------------------------------------------------- 7
10 RE-FILLING AFTER INTERRUPTED PROCEDURES-------------------------------------------------------------------------------------- 7
11 APPENDIX : CONVERSION OF UNITS -------------------------------------------------------------------------------------------------------- 7
12 REVISION----------------------------------------------------------------------------------------------------------------------------------------------- 7
1 General

This Product Information applies to oil filling of transformers shipped without oil in dry-gas. New transformers are
normally designed for oil filling under vacuum. Although the transformer tank is specified to be vacuum-proof, there
may be components that are not vacuum proof, which require certain precautions (insulating barriers between tap-
changer compartments and the main tank, parts of the cooling equipment and oil conservators). Check the Instruction
Manual and look out for warning signs. In case of doubt, check with the ABB representative.
.

2 Necessary Equipment
A high vacuum degassing unit with oil filter and thermostatically controlled heaters for the oil is required. The filter
equipment must be able to treat oil to fulfill the requirements in instruction 1ZBA4601-213.
Observe especially:

! The filter equipment should be capable of reducing water content in the oil to not above 10 ppm (at 50 –80
degrees C) and dissolved gas content to not above 0.2 percent.
The filter shall remove particles bigger than 5 micrometers.
The filter shall have a capacity not less than 2000 liters/hour
The filter shall raise the temperature of the outgoing oil to at least 60 but not more than 80 °C. For 80 degree
it is necessary to use condensers in the vacuum system.
3
! A vacuum pump with adequate capacity (example 250 m / hour for evacuation of the tank down to below 0.1
kPa (about 0.75 Torr).

! A vacuum gauge with a reading range covering the interval 0.02 - 1 kPa (0.15 - 7.5 Torr). If a mercury gauge
is used, a trap must be provided which will prevent mercury from entering the transformer.

! Vacuum proof oil hoses, valves and fittings for connections between transformer tank, filter, and storage
tanks. The "filter valves" on the tank that are to be used.. (See transformer Outline drawing)

! Transparent vacuum proof plastic tubing for the connection of instruments and for use as an oil level indicator
during filling.

! Storage tanks for oil (provided with desiccant breather).

In addition the following instrumentation may be needed during the operation

! Oil Tester for measuring dielectric breakdown strength of the oil before filling, and dry, clean oil sampling cans
or bottles.

! Thermometers.

! Also a cold trap for checking moisture extraction from the tank may be used (when drying is performed)

! When filling at low temperatures, special equipment is needed (blankets, heaters)

Rev. No: Page No:

Prepared By: W. Klein Date: 1998-04-30
Approved By: Anders Lindroth Rev. Date: 2003-08-11 G Page 2 of 8
TrafoStar Title:
Applicability: Lang: en
Document No. Vacuum Oil Filling on Site
1ZBA4601-215
3 Vacuum treatment with final Leak test
Before The Vacuum Oil filling Process a final leaks test of the complete transformer with its cooling equipment must be
done.

Pressure relief devices shall be assembled before application of vacuum and oil filling.

The conservators are not always vacuum proof this is indicated in the Oil Level Indicator Plate and in
drawings. See instruction 1ZBA4601-218 or -219 If the conservator is not vacuum proof the valve between the
conservator and the main tank shall be closed and the drain valve of the conservator opened.

If the valve between main tank and conservator is not vacuum proof, the connection between tank and conservator
shall be disconnected and the connection to the tank shall be blanked off.

If the conservator is vacuum proof and has the added rubber membrane option, care must be taken when pulling
vacuum. Special attention shall be given to maintaining the same pressure on both sides of the rubber membrane.
See Instruction in 1ZBA4601-219 and the specific instruction leaflets.

Cooling equipment may be tested and oil filled separately.

Note: Closed compartments of on-load tap-changers may have to be treated according to special instructions for the
tap-changer model supplied, see specific instruction leaflets.

The leak integrity test procedure will be as follows:

1) Connect the vacuum gauge to a suitable valve on the tank. A compound gauge (vacuum over-pressure gauge)
shall be connected to the highest possible point of the cover or to the Bucholz relay for any transformer with a
conservator, which is not evacuated. This will allow a complete filling of oil to zero pressure before opening the
connection to the conservator.

2) Connect the vacuum pump to a valve on the transformer cover or to the conservator if a vacuum proof
conservator is available and used for oil filling.

3) Evacuate the tank until the pressure is below 0.3 kPa (about 2.3 Torr)

4) Shut the valve to the pump and wait for an hour, then take a first pressure reading. This reading is called P1 .

5) Take a second pressure reading 30 minutes later. This reading is called P2.

6) Note the total quantity of oil required, according to the rating plate, and express as a volume, V, in m3.

The formula for calculating leakage when time between readings is τ :

(P2 -P1) x V =L
τ
The maximum permitted leakage is 20 mbar x liters /second. Continued readings at successive 30 min intervals may
be taken to confirm the result.
Maximum permitted Leakage at different Volumes and measuring time 0.5 and 1 hours can be found in Figure 1.

If the leak test is successful, the pumping shall continue, until the pressure has reached to 0.13 kPa (1 Torr). The
vacuum shall then be hold for the time given in Table 2 before the oil filling starts.

If the specified vacuum cannot be reached check first the vacuum pumps, if they works correct there is leaks in the
transformer system, which must be located and corrected (see previous section).

Rev. No: Page No:

Prepared By: W. Klein Date: 1998-04-30
Approved By: Anders Lindroth Rev. Date: 2003-08-11 G Page 3 of 8
TrafoStar Title:
Applicability: Lang: en
Document No. Vacuum Oil Filling on Site
1ZBA4601-215
 Figure 1 Leak Rate

Max allowed pressure increase at Leak rate 20 MbarL/sec.

2.40
2.20
2.00
Pressure increase mbar

1.80
1.60
1.40
30 minutes
1.20 60 minutes
1.00
0.80
0.60
0.40
0.20
0.00
0
0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 00
0
00
0
00
0
00
0
10 20 30 40 50 60 70 80 90 10
0
11
0
12
0
13
0

Tank Oil Volume

Table 2 Vacuum hold times.

Nominal system voltage Vacuum treatment time
1)
[kV] < 0.13 kPa hours
≤ 69 12
> 69 < 325 24
≥ 325 36

1) For low temperatures (active part below 10 ºC) steps have to be taken to heat
the active part and / or prolong the vacuum time.

4 Processing the oil before filling

The oil tanker or holding tank, all hoses, pumping equipment, valves and filters must be for the exclusive use of the
transformer oil or have been meticulously cleaned and rinsed. Failure to ensure pristine oil and equipment puts at risk
the viability of the transformer operation. For specification and handling of oil se instruction 1ZBA4601-213

Precautions in Cold Weather

The final processing of the transformer is more difficult when ambient temperatures are low. The water vapor pressure
of the residual surface moisture of the insulation becomes very low, and vacuum has less drying effect. Covering the
transformer with tarps and heating the tank walls with air jet gas heaters must be done. This pre-heating should be
done prior to vacuum.

5 Filling procedure for the main tank

The preferred method of filling is to feed oil from the storage tank through the filter for heating and degassing, and then
into the transformer tank through the lower oil-filling valve. If preferred the tank can be filled through the upper valve but
in this case the transformer must be prepared for this procedure at manufacturing, please consult the documentation or
the ABB representative. Filling of conservators see also 1ZBA4601-218 and 1ZBA4601-219.

5.1 Filling from the tank lower filtering valve

1) A vacuum proof plastic tube may be connected to valves at the top and bottom for use as an oil level indicator.
See Figure 2

Rev. No: Page No:

Prepared By: W. Klein Date: 1998-04-30
Approved By: Anders Lindroth Rev. Date: 2003-08-11 G Page 4 of 8
TrafoStar Title:
Applicability: Lang: en
Document No. Vacuum Oil Filling on Site
1ZBA4601-215
 Vacuum is pulled on the transformer tank continuously (0.13 kPa - 1 Torr) and oil is filled through a valve at the
lower part of the transformer tank.
The oil filling speed has to be controlled to always maintain the vacuum below
0.13 kPa (1 Torr).

Note : During oil filling, there must be kept permanently a positive pressure in the hose before the lower
valve.

2) For transformers without a conservator and for transformers with a vacuum proof conservator evacuated, the oil is
filled up until the oil level gauge indicates the proper level. Observe that the oil gauge will show normal level for oil
at 25 °C. See Product Information for Oil Conservators 1ZBA4601-218
The oil level has to be corrected for the oil temperature..

For transformers with a conservator not evacuated, fill oil until the oil level is closely below the tank cover. Close
the valve to the vacuum pump to avoid oil to come into the pump. Continue the oil filling slowly observing the
compound gauge and fill until the pressure is close to zero. Stop the oil filling, open the valve to the conservator
and close the conservator drain valve.
For conservators with rubber membrane air cell bag, See Product Information for Oil Conservators
1ZBA4601-219

3) Bleed the bushing turrets and porcelain bushings.

4) For Sealed Tank Designs, fill to the correct oil level as indicated and then pressurize with the appropriate dry gas
blanket to the required pressure.

c o m po und g a uge

va c uum g aug e
tra nsparent hose for level
monitoring

Buchholz
rela y
va c uum
va c uum filter p ump
stora ge
ta nk

c o m po und g a uge right

before fill valve

Figure 2 Oil filling from lower filter valve.

Rev. No: Page No:

Prepared By: W. Klein Date: 1998-04-30
Approved By: Anders Lindroth Rev. Date: 2003-08-11 G Page 5 of 8
TrafoStar Title:
Applicability: Lang: en
Document No. Vacuum Oil Filling on Site
1ZBA4601-215
 5.2 Oil filling of on-load tap changer
On-load tap changers shall be filled in accordance with their respective instructions either simultaneously with the main
tank or separately. Separate tap changer compartments with partition walls of insulating board may need to be
evacuated together with the main tank. These walls are not always vacuum proof with full oil pressure head on the
transformer side.

6 Circulation of oil in the main transformer tank

When the main tank with the core and coils has been filled under vacuum, the insulation system should be virtually free
of trapped gas bubbles. As an additional precaution to ensure total impregnation, the oil in the tank may continue to be
circulated through the filter. Figure 3. Regardless if oil circulation is applied or not, the unit shall not be energized for
some time period to allow the oil to completely soak into the insulation to facilitate total impregnation. The time before
energization is based on the system voltage of the transformer. The specified impregnation time is given in Table 2.
The impregnation time includes the oil circulation time.

Vacuum filter

Figure 3. Oil circulation.

6.1 Oil circulation procedure

1) The transformer is connected to the filter in a loop through the upper and lower filter valves. The direction of
circulation shall be from the filter to the transformer at the top and from the bottom of the transformer to the filter.

2) The temperature of the oil from the filter to the transformer shall be 60 to 80 °C.

3) The circulation shall proceed until a volume of oil has passed through the loop corresponding to 2 times the
total oil volume in the tank. (At freezing ambient temperature the circulation time is increased: circulate 3 times the
volume at temperature down to minus 20°C, increase to 4 times below that temperature).

Rev. No: Page No:

Prepared By: W. Klein Date: 1998-04-30
Approved By: Anders Lindroth Rev. Date: 2003-08-11 G Page 6 of 8
TrafoStar Title:
Applicability: Lang: en
Document No. Vacuum Oil Filling on Site
1ZBA4601-215
7 Filling of separate coolers

Separate, vacuum proof cooler banks, suspended on the tank or pedestal mounted, may be left alone and shut off from
the tank during the main filling procedure. They are then filled separately, after proper vacuum leak checks as
performed on the main tank.
They should be filled with clean, degassed oil through the vacuum filter.

8 Impregnation time before ENERGIZING

Regardless if oil circulation is applied or not, the unit shall not be energized for some time see Table 2 before the
transformer may be energized, the specified impregnation time must be met or exceeded,
The impregnation time is graded according to the system voltage level and an oil temperature of at least 60 Deg during
oil filling.

Table 2 Impregnation time.

Nominal System Voltage Impregnation time (hours)

< 150 kV 12
≥ 150 < 325 kV 48
≥325 kV 96

9 Additional drying procedure on site

If, the dryness of the insulation system is not satisfactory at the time of final oil filling, then it may be necessary to
perform an additional drying cycle on site. This may be accomplished using the equipment available for the vacuum oil
filling process. This procedure should not proceed without conferring with ABB representatives and requires ABB
approval.

10 Re-filling after INTERRUPTED procedures

If the oil filling procedure is interrupted by equipment failure or for any other reason, or if the oil level has to be lowered
in the tank after filling for corrective actions, then the following rules are to be observed.

If the oil level is above the coil assembly, so that no cellulose insulation is exposed above the oil surface, the tank may
be filled up again with de-gassed oil.

If cellulose insulation has been exposed, complete re-filling has to be carried out. The oil is first removed from the tank.
The tightness is again checked under vacuum, and filling of the tank with core and coils is repeated, as described
above.

Note. Pulling vacuum above the oil level when the oil has absorbed gas (air) is not recommended. Gas bubbles are
formed in the oil and may be trapped in the insulation system. Such bubbles may take a long time to be absorbed by
the oil and may cause dielectric failures.

11 Appendix : Conversion of units

1 ton = 1000 kilograms = 2 200 lbs
1 m3 = 1000 litres = 260 US gallons = 220 Imp gallon
1 kPa (kilo-Pascal) = 10 millibar = 7.5 Torr (mm of mercury)
2
1 atmosphere = 0.1 MPa (mega-Pascal) = 1.02 kp/cm = 14.5 psi
1 litre of transformer oil weights 0.89 kg.

12 Revision
A: 2001-02
B: 2001-09 Pg 2 (1)
C: 2002-05 Pg 7 (8.1.1); Pg 8 (fig 2)
D: 2003-01-02 new Form
E: 2003-05-30 It-format
F: 2003-06-02 Pg 2 (fig 2)
G: 2003-08-11 Revised

Rev. No: Page No:

Prepared By: W. Klein Date: 1998-04-30
Approved By: Anders Lindroth Rev. Date: 2003-08-11 G Page 7 of 8
TrafoStar Title:
Applicability: Lang: en
Document No. Vacuum Oil Filling on Site
1ZBA4601-215
 DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF,

OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY
SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS
DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on our
experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED
TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be
consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR

PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY
NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort
(including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or
power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in
the use of existing power facilities, or claims against the user by its customers resulting from the use of the
information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should comunicated to:
ABB Power Transformers acording to contact list in Aspect Viewer

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Rev. No: Page No:

Prepared By: W. Klein Date: 1998-04-30
Approved By: Anders Lindroth Rev. Date: 2003-08-11 G Page 8 of 8
TrafoStar Title:
Applicability: Lang: en
Document No. Vacuum Oil Filling on Site
1ZBA4601-215