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How to install Oil-Immersed Transformers properly?
Release time:
Jul 10,2025
Source:
Oil-immersed transformers are the backbone of power systems. Incorrect installation can lead to:
30%+ reduction in operational lifespan
Increased risk of oil leaks, fires, or explosions
Costly downtime and maintenance
Follow this IEC/IEEE-compliant guide to achieve optimal performance and safety.
Phase 1: Pre-Installation Preparation
✅ Critical Site Requirements
Foundation: 150mm reinforced concrete base with 1.5x transformer footprint
Clearances: ≥1.5m ventilation space around all sides (per NFPA 70)
Environmental Control: Humidity <85%, ambient temperature -25°C to +40°C
⚠️ Tools & Safety Checklist
| Equipment | Specification |
|---|---|
| Lifting Gear | Capacity ≥ 1.25x transformer weight |
| Insulation Tester | 5kV Megohmmeter |
| Oil Filtration Unit | 3µm filtration accuracy |
| PPE | Arc-flash suits, insulated gloves |
Phase 2: Rigging & Positioning
▶️ Lifting Protocol (Key to Avoid Structural Damage)
Attachment Points: Use ONLY manufacturer-provided lifting lugs
Angle Control: Maintain <30° cable angle during hoisting
Landing Procedure:
Place on anti-vibration pads (≥10mm thickness)
Verify levelness: ≤2mm/m tolerance using laser level
Phase 3: Electrical Connections - IEC 60076 Standards
| Connection Type | Torque Value | Protection Method |
|---|---|---|
| HV Bushings | Per nameplate ±10% | Silicone grease coating |
| LV Terminals | 50-60 N·m | Weatherproof boots |
| Grounding | 25mm² copper cable | Double-bolt compression lugs |
Pro Tip: Apply contact resistance tester after termination (value ≤10µΩ)
Phase 4: Oil Management - ASTM D3481
🔬 Oil Processing Flow
New Oil Delivery → Filtration (72hrs @ 60°C) → Dielectric Test (>50kV/2.5mm gap) → Vacuum Filling (<0.5mbar residual pressure)
📊 Oil Parameters Table
| Parameter | Acceptable Range | Test Method |
|---|---|---|
| Breakdown Voltage | ≥60 kV | IEC 60156 |
| Water Content | ≤15 ppm | ASTM D1533 |
| Acidity | ≤0.03 mg KOH/g | IEC 62021 |
Phase 5: Commissioning Tests
Essential Verification Sequence:
Insulation Resistance: HV-LV/Ground >1000 MΩ @ 40°C (IEC 60270)
Turns Ratio Test: ±0.5% of rated value
Winding Resistance: ±2% phase balance
DGA Baseline: Capture initial dissolved gas values
Critical: First energization at ≤33% load for 24hr thermal monitoring
Phase 6: Operational Safety Systems
⚠️ Mandatory Functional Checks
Pressure Relief Valve: Trip test @ 0.85 bar(g)
Buchholz Relay: Simulate gas accumulation alarm
OTI/WTI: Calibrate top oil/winding temperature indicators
Sudden Pressure Relay: Verify 5ms response time
Long-Term Maintenance Routine
| Interval | Key Actions |
|---|---|
| Daily | Visual oil level check, load recording |
| Quarterly | IR thermography scan of connections |
| Annually | DGA + Furan testing (IEC 60599) |
| 5 Years | Full oil reconditioning |
Why Trust AISITE Transformers?
✓ 15 Years Production Experience - and our products have been exported to over 50 countries and regions
✓ Certified Safety
✓ Technical Support - Access our professionals via the following ways:
📧 Email: [sale@aisite-ast.com]
📞 Phone/Whatsapp: [+86 15896663407]
🌐 Website: [https://www.aisite-ast.com/]
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