ABB VUBB Installation And Commissioning Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Industrial Equipment
  5. VUBB
  6. Installation and commissioning manual
ABB VUBB Installation And Commissioning Manual

ABB VUBB Installation And Commissioning Manual

Vacuum on-load tap-changers
Hide thumbs Also See for VUBB:
Table of Contents

Advertisement

Quick Links

Download this manual
1ZSC000562-AAK EN, REV. 2, 2019-07-03
Vacuum on-load tap-changers, type VUBB
Installation and commissioning guide

Advertisement

Table of Contents
loading

Related Manuals for ABB VUBB

Summary of Contents for ABB VUBB

  • Page 1 1ZSC000562-AAK EN, REV. 2, 2019-07-03 Vacuum on-load tap-changers, type VUBB Installation and commissioning guide...
  • Page 2 The information contained in this document may be subject to change without prior warning and should not be considered as binding on ABB AB’s behalf. ABB AB accepts no liability for any errors that may appear in this document. ABB AB is not liable for any damage resulting from the incorrect interpretation of this document.

  • Page 3: Table Of Contents

    Contents Safety Levels of safety risks ................................... 5 Hazardous working situations ..............................6 Safety precautions..................................6   Product description Design ......................................7   Delivery Incoming inspection..................................9 Transportation ..................................... 9 Storage ......................................9 Lifting ......................................10 3.4.1 Lifting the transport box ............................. 10 3.4.2 Lifting the tap-changer out of the transport box......................
  • Page 4   Oil-filling Preparations ....................................53 Oil-filling with the atmospheric process ............................54 Oil-filling with the vacuum process .............................. 57   Electrical connection and testing Connection of the operational circuits ............................61 Testing of the electrical connections............................62 8.2.1 Testing of BUE2................................. 62 8.2.2 Testing of BUL2 .................................

  • Page 5: Safety

    1 Safety 1.1 Levels of safety risks Throughout the manual, various types of safety risks are indicated. The most serious level on this scale provides a warning about serious personal injury or possible death, or major damage to a product, if the instructions are not observed.

  • Page 6: Hazardous Working Situations

    1.2 Hazardous working situations Hazard Action Working close to high voltage. Disconnect all plant power. Ground all objects at the workplace. If work must be done close to live plant components, make sure that the safety distance is in compliance with the applicable safety regulations.

  • Page 7: Product Description

    2 Product description 2.1 Design Overview The VUBB on-load tap-changer features an in-tank design. The motor-drive mechanism is attached to the side of the transformer tank, and connected to the tap-changer by drive shafts and a bevel gear. Vertical driveshaft...
  • Page 8 Protection devices and accessories The standard IEC 60214-1 requires that at least one protection device is supplied with the tap-changer. Protection devices must detect all faults related to the tap-changer as quickly as possible. Protection devices operate when they detect high temperatures, high pressure pulses or high oil-flows caused by an internal failure in the tap-changer.

  • Page 9: Delivery

    Make sure that all items have been delivered, refer to the packing list. • Carefully inspect the tap-changer for shipping damage. If damage is found, submit the following to ABB: • A damage report with photos of the damaged parts.

  • Page 10: Lifting

    Forklift lifting points Type Weights Transport box Tap-changer Total weight VUBB 30 kg 280 kg 310 kg Procedure Make sure that the crane is approved for lifting the total weight of the transport box and tap-changer. Refer to the packing list.

  • Page 11: Lifting The Tap-Changer Out Of The Transport Box

    3.4.2 Lifting the tap-changer out of the transport box Procedure Make sure that the crane is approved for lifting the weight of the tap-changer. Refer to the net weight on the packing list. Remove the cover (1) and the sides (2) of the transport box.
  • Page 12 Lower the bottom of the tap-changer down onto a soft bedding (5). Remove one soft lifting sling (4). Lift the tap-changer to the vertical position. Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...
  • Page 13 Put supports under the tap-changer, or attach a safety cable from the ceiling to a lifting eye (3). DANGER! If the tap-changer tips, it could cause death or injury to personnel. End of instruction Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...
  • Page 14 Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...

  • Page 15: Installation In The Transformer

    4 Installation in the transformer 4.1 Tools Tool Part number Note Air pump with pressure gauge and Pressure range 0-250 kPa, hose hose connection with internal thread R 1/8”. Standard set of open-end Up to 18 mm. wrenches Standard set of socket wrenches Up to 18 mm.

  • Page 16: Consumables

    4.2 Consumables Use an approved grease or grease with equivalent properties. Item Brand Part number Note GULF-718 EP Gulf For ball bearings. Mobilgrease 28 Mobil 11714014-407 Lubricates and protects metals against corrosion. Protects rubber. Does not react with transformer oil. Aero Shell Grease 22 Shell Rags for cleaning...
  • Page 17 Install the gasket in the groove (3) in the transformer cover. NOTE! The gasket is not included in the tap-changer delivery. Attach lifting chains (4) to the lifting eyes, and lift the tap-changer. CAUTION! Make sure that the angle between the lifting chains (4) is less than 90°.
  • Page 18 Turn the tap-changer as necessary to make installation of drive shaft and pipes possible. Please refer to the transformer manufacturer´s documentation. NOTE! The bevel gear (1) must be within the limits (9). Remove the lifting chains from the lifting eyes. Install the washers and nuts on the stud bolts (1), and tighten the nuts.

  • Page 19: Installation On The Yoke

    4.3.2 Installation on the yoke Overview The tap-changer is made for both cover-mounting and yoke-mounting. This procedure describes yoke-mounting. Procedure Remove the bolts (1), and then remove the top cover (2). CAUTION! Carefully lift the top cover straight up. The shaft for the bevel gear can bend if the top cover is not lifted straight up.
  • Page 20 Install the gude pins (7) in the flange. NOTE! The guide pins are delivered with the tap-changer. Make sure that the holes (6) in the yoke fits the guide pins. NOTE! The guide pins are Ø 7 mm. Put the tap-changer on the yoke. Turn the tap-changer as necessary, to make installation of drive shaft and pipes possible.

  • Page 21: Connection Of Conductors To The Terminals

    4.4 Connection of conductors to the terminals Procedure Connect all conductors (2) to the tap-changer terminals. Refer to the connection diagram. CAUTION! Make sure that there is no tension in the conductors (2). If the conductors (2) are in tension at installation, they will cause the terminals on the tap-changer to break when the transformer is in operation.

  • Page 22: Installation Of The Top Flange, Yoke-Mounting

    4.5 Installation of the top flange, yoke-mounting Prerequisite This procedure can be started after the active part with tap-changer has been installed in the transformer tank. Procedure Lower the active part into the transformer tank. Put the transformer-tank cover on the transformer tank. Install the O-ring (10).
  • Page 23 Put the top flange (5) in position. Attach the lifting chains to the four lifting eyes (6). Lift the tap-changer (10) until it touches the top flange (5). Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...
  • Page 24 Install the top flange (5): Install the bolts (4), spring washers and plain washers. Tighten the bolts (4) in a crosswise sequence. Torque 24 Nm Install the nuts (8) and plain washers. Torque 84 Nm ± 10 % Install the top cover (2), and then install the bolts (1).

  • Page 25: Transformer Ratio Measurement

    4.6 Transformer ratio measurement Procedure Remove the cover (1). Record the position (2) of the tap-changer. Attach the hand crank to the bevel gear. Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...
  • Page 26 Operate the tap-changer through the entire operating range, in both the LOWER and RAISE directions. • One clockwise turn of the hand crank switches between two taps in the RAISE direction. • One counter clockwise turn of the hand crank switches between two taps in the LOWER direction.
  • Page 27 Install the cover (1). End of instruction Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...
  • Page 28 Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...

  • Page 29: Drying

    5 Drying 5.1 Preparations Procedure Remove the bolts (2), and then the top cover (1). CAUTION! Carefully lift the top cover straight up. The shaft for the bevel gear can bend if the top cover is not lifted straight up. CAUTION! Do not drop bolts or other small parts into the tap-changer.

  • Page 30: Drying Processes

    5.2 Drying processes 5.2.1 Overview Dry the tap-changer with the transformer as a unit. The unit can be dried one of with these two processes: • Vapor phase process • Alternating hot air and vacuum process CAUTION! Do not operate the tap-changers mechanism after the drying process has started. Operation of the mechanism without lubrication will cause damage to the tap-changer.

  • Page 31: After Drying

    Procedure Open the bottom valve. The valve can be accessed from both the top and the bottom: • Top access: turn the bottom valve (1) with the bottom valve key. • Bottom access: turn the bottom valve (2) with a hex key. CAUTION! Use only the bottom valve key.
  • Page 32 Install the O-ring (3). Install the top cover (1) and then the bolts (2). CAUTION! Carefully lower the top cover straight down. The shaft for the bevel gear can bend if the top cover is not lowered straight down. CAUTION! Do not drop bolts or other small parts into the tap-changer.

  • Page 33: Final Assembly

    6 Final assembly 6.1 Installation of the motor-drive mechanism Overview For information about installation of the motor-drive on the transformer tank, please refer to documentation from the transformer manufacturer. Procedure Install the consoles on the transformer tank, refer to documentation from the transformer manufacturer.
  • Page 34 Measure the length (K1) between the spherical shaft-ends. Calculate the drive-shaft length and subtract 6 mm from the length K1. Cut the drive shaft to length (K1 - 6 mm). Remove burrs and loose material from the drive shaft. Calculate the correct length (LB1) for the protection tubes, refer to the table. Example: if the length of K1 is 390 mm, then LB1 is = (390 +210) / 2 = 600 / 2 = 300 mm.
  • Page 35 Put the protection tubes together with the slotted ends (5) outwards. Put the hose clamps (6) on the protection tubes. NOTE! Do not tighten the hose clamps (6). Apply grease to the spherical shaft ends (7) and the unpainted surfaces on the bevel gears. Install two coupling halves (3) on one side of the drive shaft.
  • Page 36 Install the drive shaft. Put the protection tube (8) on the drive shaft. Install the coupling halves (3) to one bevel gear. Tighten the two outer hex screws (2). Torque 10 Nm Tighten the four hex screws (2). Torque 10 Nm Install two coupling halves (4) on the drive shaft, turned 90°...
  • Page 37 Tighten the two outer hex screws (2). Torque 10 Nm Tighten the four hex screws (2). Torque 10 Nm Make sure that the axial play is less than 2 mm. If the axial play is more than 2 mm: Loosen the hex screws (2). Move the coupling halves outwards (9).
  • Page 38 Move the protection tubes (8) apart, and tighten the hose clamps (6). CAUTION! Make sure that the slots (9) point down. This will keep rainwater out of the protection tubes. Put the adhesive caution plate around the protection tube. CAUTION! Do not step on the horizontal drive shaft.
  • Page 39 Measure the length (K2) between the spherical shaft-ends. Calculate the drive shaft length and subtract 6 mm from the length K2. Cut the drive shaft to length (K2 - 6 mm). Remove burrs and loose material from the drive shaft. Calculate the correct length (LB2) for the protection tubes, refer to the table.
  • Page 40 Put the protection tubes together with the slotted ends (5) outward. Put the hose clamps (6) on the protection tubes. NOTE! Do not tighten the hose clamps (6). Remove the two bolts in the multi-hole coupling flange. 11 Multi-hole coupling flange, BUL2 12 Multi-hole coupling flange, BUE2 Apply grease to the spherical shaft ends (7) and the unpainted surfaces on the bevel gears.
  • Page 41 Install two coupling halves (3) on one side of the drive shaft. Tighten the hex screws (2) with your fingers. Install the drive shaft. Put the protection tube (8) on the drive shaft. Install the coupling halves (3) to one bevel gear.
  • Page 42 Install two coupling halves (4) on the drive shaft, turned 90° perpendicular to the first pair of coupling halves (3). Tighten the hex screws (2) with your fingers. Tighten the two outer hex screws (2). Torque 10 Nm Tighten the four hex screws (2). Torque 10 Nm Installation and commissioning guide...
  • Page 43 Make sure that the axial play is less than 2 mm. If the axial play is more than 2 mm: Loosen the hex screws (2). Move the coupling halves outwards (9). Tighten the hex screws (2). Torque 10 Nm Move the protection tubes (8) apart, and tighten the hose clamps (6).

  • Page 44: Synchronization Of The Motor-Drive

    6.3 Synchronization of the motor-drive 6.3.1 Synchronization of BUL2 Procedure Open the door (1). Open the inner panel (2). Inspect the brake assembly and make sure that the motor-drive mechanism is in the correct position. NOTE! The brake assembly is at position (3). NOTE! The correct position is when the roller is centered in the notch (4).
  • Page 45 If the roller is not in the correct position: Put the hand crank (6) on the shaft end (5). Turn the hand crank (6) until the roller is in the correct position (4), at the center of the notch. NOTE! One complete switching operation takes 11.5 ±...

  • Page 46: Synchronization Of Bue2

    6.3.2 Synchronization of BUE2 Procedure Open the door (1). Open the inner panel (2). Inspect the brake assembly make sure that the motor-drive mechanism is in the correct position. NOTE! The brake assembly is at position (3). NOTE! The correct position is when the brake is centered on the red line (4).

  • Page 47: Installation Of The Oil Conservator

    Make sure that the position indicators (7) and (8) show the same position. CAUTION! If the position indicators show different positions, failure of the transformer can occur. Install the two bolts in the multi-hole coupling flange (11). End of instruction 6.4 Installation of the oil conservator Procedure Remove the transport cover (1) from flange (C).
  • Page 48 Make sure that the flange of the oil valve fits the tap-changer. NOTE! Dimensions of the O-ring (3). Install the oil valve (5), with the O-ring (3). Install the pipe (2) on the oil valve (5). CAUTION! Make sure that the O-ring (3) is not damaged, and is correctly installed.

  • Page 49: Installation Of The Oil Tap

    End of instruction 6.5 Installation of the oil tap Overview An oil tap must be installed för sampling of transformer oil in the tap-changer. ABB does not supply the oil tap. Procedure Remove the transport cover (1). NOTE! Keep the nuts and the O-ring.
  • Page 50 Make sure that the flange of the oil-tap pipe fits the tap-changer. NOTE! Dimensions of the O-ring (3). Install the pipe (2) to the oil-tap, with the O-ring (3). CAUTION! Make sure that the O-ring (3) is not damaged, and is correctly installed. NOTE! 24 Nm Install the oil-tap (4) at a convenient hight above...

  • Page 51: Installation Of Protection Devices

    6.6 Installation of protection devices Overview For the installtion of protection devices, please refer to Accessories and protection devices for on-load tap-changers, 1ZSC000562-AAD. Refer to the packing list for the configuration of protection devices. Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...
  • Page 52 Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...

  • Page 53: Oil-Filling

    7 Oil-filling 7.1 Preparations Overview The transformer can be oil-filled with one of with these two processes: • Atmospheric oil-filling process • Vacuum oil-filling process The tap-changer cylinder can withstand a vacuum on one side and atmospheric pressure on the other side. The transformer-oil quality The oil volume of the tap-changer is approximately 300 liter.

  • Page 54: Oil-Filling With The Atmospheric Process

    Ambient temperature Oil-level in oil conservator If the ambient temperature is 20 °C, fill transformer oil to the center of the scale. If the ambient temperature is over 20 °C, add 10 % of transformer oil on the scale for every 10 °C. If the ambient temperature is under 20 °C, remove 10 % of transformer oil on the scale for every 10 °C.
  • Page 55 Open the valve (2) between the tap-changer and the oil-conservator. Remove the breathing device (4) from the tap-changer's oil-conservator. Connect the oil pump (5) to the oil-valve (3). Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...
  • Page 56 Open the oil-valve (3). Start the oil pump, and fill the tap-changer to the correct oil-level. Monitor the oil-level indicator on the oil-conservator NOTE! Refer to The correct oil-level, page 53. Close the oil-valve (3). Disconnect the oil pump. Install the breathing device (4). Make sure that there are no leaks.

  • Page 57: Oil-Filling With The Vacuum Process

    7.3 Oil-filling with the vacuum process Procedure Make sure that the oil conservators are approved for vacuum. Connect both oil conservators with a pipe (1). Open the valve (2) between the tap-changer and the oil conservator. Connect the oil pump (5) to the oil valve (3). Installation and commissioning guide 1ZSC000562-AAK EN, REV.
  • Page 58 Close the oil valve (3). Connect the vacuum equipment to the transformer. Start the vacuum equipment. NOTE! The vacuum is drawn from the tap-changer because it is connected to the transformer. When the vacuum is sufficient, open the oil valve (3) on the tap-changer.
  • Page 59 Disconnect the pipe (1) between the oil conservators. Install the breathing device (4) on the oil conservator on the tap-changer. Make sure that there are no leaks. End of instruction Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...
  • Page 60 Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...

  • Page 61: Electrical Connection And Testing

    8 Electrical connection and testing 8.1 Connection of the operational circuits Procedure Put a flexible cable (1) between the grounding stud on the tap-changer and a grounding point in the transformer. Put a flexible cable (1) between the grounding stud on the motor drive and a grounding point in the transformer.

  • Page 62: Testing Of The Electrical Connections

    8.2 Testing of the electrical connections 8.2.1 Testing of BUE2 Procedure Remove the cover (1). Make sure that the position indicators (7) and (8) show the same position. CAUTION! If the position indicators show different positions, catastrophic failure of the transformer can occur.
  • Page 63 Operate the motor drive mechanism to the position (7) in the middle of the range. Turn the control selector switch S1 to position local. Turn the control switch S2 to operate the tap-changer in the raise direction. NOTE! If the phase sequence is incorrect (from the three-phase electrical supply), then the motor-drive mechanism will move in the lower direction.
  • Page 64 Make sure that the red mark (4) on the brake disc aligns with the red mark on the brake pad. If it does not stop with the red lines (4) aligned, then refer to the maintenance guide Motor-drive mechanisms, types BUE and BUL2 1ZSC000498-ABH.

  • Page 65: Testing Of Bul2

    8.2.2 Testing of BUL2 Procedure Remove the cover (1). Make sure that the position indicators (7) and (8) show the same position. CAUTION! If the position indicators show different positions, catastrophic failure of the transformer can occur. Operate the tap-changer with the hand crank, and count the number of turns from the exact position until the tap-changer operates.
  • Page 66 Operate the motor drive mechanism to the position (7) in the middle of the range. Turn the control selector switch S1 to position local. Turn the control switch S2 to operate the tap-changer in the raise direction. NOTE! If the phase sequence is incorrect (from the three-phase electrical supply), then the motor-drive mechanism will move in the lower direction.

  • Page 67: Testing Of The Protection Devices

    Make sure that the center of the notch (4) in the cam disc stops within ±2 mm of the center of the roller. If it does not stop at the center of the notch (4), then refer to the maintenance guide Motor-drive mechanisms, types BUE and BUL2 1ZSC000498-ABH.
  • Page 68 Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...

  • Page 69: Preparations For Transportation To Site

    9 Preparations for transportation to site 9.1 General Overview • The tap-changer can be transported with the transformer as a single unit. • If the transformer is transported filled with transformer oil, then the tap-changer must also be filled. • Remove as few parts as necessary.
  • Page 70 Procedure, with the oil conservator removed Remove the cover (1). DANGER! Make sure that hoses and equipment is correctly grounded. Unsatisfactorily grounded equipment can cause explosive gases to ignite. Explosive gases are generated during normal operation of the transformer. Put a hose into the center hole (2) of the cover, and connect it to an oil pump.

  • Page 71: Transportation Without Transformer Oil In The Transformer

    Remove the hose, and install the cover (1). Torque 10 Nm End of instruction 9.3 Transportation without transformer oil in the transformer Overview The tap-changer must be drained from transformer oil, if the transformer is drained. Procedure Drain the transformer oil from the tap-changer. CAUTION! Do not transport the tap-changer filled with transformer oil if the transformer oil has been drained from the transformer.
  • Page 72 Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...

  • Page 73: Commissioning At Site

    10 Commissioning at site 10.1 Installation of the removed parts Overview Refer to the report from the preparations of the transformer before transportation to the site. Procedure Remove all transport covers. Install all parts that where removed for transportation. Refer to the markings made to each part. NOTE! It is important that all parts are correctly installed, and in the same position as when they were removed.
  • Page 74 Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...

  • Page 75: Spare Parts

    11 Spare parts 11.1 Summary Please contact ABB Components for spare parts and special tools. Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...
  • Page 76 Installation and commissioning guide 1ZSC000562-AAK EN, REV. 2, 2019-07-03...

  • Page 77: Disposal And Enviromental Information

    12.2 Disposal and recycling ABB strives to minimize the product's impact on the environment throughout its entire life cycle. Technical and product development focuses on environmental aspects. The ecocycle approach is striven for, and consideration is taken to the materials' environmental impact and recycling alternatives.
  • Page 78 Oils and greases Before disposal of the tap-changer, oil, grease and similar products must be removed and sent to an approved environmental waste treatment plant or recycling plant. By utilizing gravimetric forces, oil waste can be separated into oil, water and a range of contaminants. In many cases, the oil can then be reused. As an alternative, the energy content in oil can be recovered through combustion at a plant designed for the purpose.

  • Page 79: References

    13 References 13.1 Summary • Technical guide Vacuum on-load tap-changers, type VUBB, 1ZSC000562-AAJ. • Technical guide Motor-drive mechanism, type BUE 2, 1ZSE 5483-104. • Technical guide Motor-drive mechanism, type BUL, 1ZSC000562-ABD. • Maintenance guide Motor-drive mechanisms, types BUE and BUL2 1ZSC000498-ABH.
  • Page 80 ABB AB, Components SE-771 80 Ludvika, Sweden www.abb.com/transformercomponents © Copyright 2019 ABB, All rights reserved. Specifications subject to change without notice.

Table of Contents