instruction manual whl rupture disk

Shenzhen Huadian Electricity Fire Prevention Ltd. Ver:121010 0

FMD

(Rupture Disk Type)

Instruction Manual for

Installation and Commissioning

LC Number/Date: IM2BDG0003712 / 120918 HS Code: 8419.5000

by

Shenzhen Huadian Electricity Fire Prevention Ltd.


Content 1 Introduction 1.1 FMD Principle: Explosion Prevention, Fire Prevention, and Fire Extinction 1.2 Characteristics & Functions 1.3 Application Scopes 1.4 Working Conditions 2 Structure and Major Components 2.1 Technical Data and Parameters 2.2 Major Components Characteristics 3 Ordering Information 3.1 Ordering Procedures & Requirements 3.2 Scope of Supply 3.3 Transformer Manufacturer 3.4 Substation or Power Plant Contractor 4 Installation 4.1 Ground Construction Preparation 4.2 Shutter 4.3 Oil Installation Valve 4.4 N2 Installation Valve 4.5 Fire Detectors 4.6 Fire Cabinet 4.7 Pipes between Transformer and Fire Cabinet 4.8 Control Cabinet 4.9 Cable Layout and Connection 5 Commissioning 5.1 Testing Procedure 5.2 Mechanics 5.3 Electrics 6 Operation 6.1 Basic Requirements 6.2 Instruction before Normal Operation 6.3 Activation during Normal Operation 6.4 After Activation 7 Maintenance 7.1 Regular Inspection and Maintenance 7.2 Periodical Inspection and Maintenance 7.3 Device Reset 7.4 Replace the Loss Products 7.5 Common Fault and Eliminating Methods 7.6 Announcements 8 Statement


T2 T2+0.2ST1 T00 1

T32

T43

T54 Time

0.55 AB C

Without PRV

1.0

1.5

D

Pressure

PRV Activating Level

F

FMD Activating Level

With PRV and without FMD

E

Transformer Explosion Region

Transformer Maximum Pressure

With PRV and FMD

Nitrogen Injection Begings

1 Introduction Blast or fire of oil-immersed transformers generally results from a break down of insulation. It may be caused by over-current, over-voltage, earthing, or short-circuit. If the insulator is decayed and the oil is moistened or decomposed, the level of insulation drops. Once it exceeds a limit to cause an electric arc, the oil in the transformer can be decomposed rapidly. Then, many different kinds of ignitable gases are produced as well as the limit of the oil tank pressure is exceeded. As a result, the body of the transformer or on load tap changer can be broken. Once the high temperature oil or gas expel out of the transformer and ignite with nature gas, fire spreads onto the transformer and the floor. The fire is even worse if the oil continuously delivers to the tank. 1.1 FMD Principle: Explosion Prevention, Fire Prevention, and Fire Extinction

Transformers are the most expensive and important equipment in power plants and substations, and oil-immersed transformers are among the most popular type in the current power industry. Because the body of this transformer contains many flammable substances, explosion and fire can be easily caused. As a result, the adjacent equipment is damaged, electricity is shut down, and economy is momentous loss. Therefore, special attention must be paid to protect the transformer. It often focuses on the matter of transformer parameters, but the increasing level of oil pressure due to break down of insulation is ignored.

Curve of Pressures under Different Condition during Transformer Failure

T0: Insulation breaks down and appears at time zero

T1: PRV activation time (under set value) (Point A)

T2: FMD activation time (Point B)

T2+0.2s: FMD start-up time. Oil drains and pressure releases (Point C)

T3: Time for transformer to explode if PRV inactivates (Point D)

T4: Time for transformer to explode due to insufficient pressure released by PRV (Point E)

T5: FMD Nitrogen injection activates (Point F)


If the transformer is not working properly, an enormous of flammable gases is created in the oil tank. Hence, the gas relay closes and the electric breaker switches off. At this moment, the internal pressure of transformer increases due to the thermal inertia. Once the pressure exceeds rupture disk activating level, FMD system is automatically and instantly operated. Consequently, the drain oil valve opens to draw off oil in order to relieve the pressure inside the tank and prevent any explosion and fire.

Meanwhile, the shutter under transformer conservator is activated. The oil supply from the oil conservator to the transformer body is automatically cut off. The oil level is prevented to continuously increase and to causes more serious fire. After draining oil for 3-20 seconds, injected nitrogen through the bottom of transformer body stirs the oil, compulsively cools down failure points and oil temperature, isolates oxygen with a protection layer. Fire prevention and extinction is achieved when the oil temperature drops below a flash-point (135-150) and a burn-point (165-190). It means fire can be prevented before it happens, and fire can be extinct if it is happening. After the nitrogen gas is continuously injected for 45 minutes, the large amount nitrogen gas sufficiently cools down the transformer, extinguishes fire, and prevents any re-combustion. 1.2 Characteristics & Functions 1.2.1 Functions z Prevent transformer explosion and fire z Extinguish transformer fire z Cool down transformer oil 1.2.2 Characteristics z State-of-the-art concept: Rapidly drain oil to prevent explosion and inject nitrogen to prevent and extinct fire. z Excellent performance: Utilize fast valve to drain oil within milliseconds with the technique from the national defense. z Fast response: Once a fault signal is detected from the transformer, the oil is drained within milliseconds in order to release pressure and to avoid explosion. The nitrogen gas is injected after 3s in order to mix and cool down the oil, to reduce the concentration of flammable gases, to isolate oxygen gas, and to extinct fire. z High reliability: Utilize the principle of logic signal to prevent any improper or unnecessary activity to the system and to provide a more flexible system. z High efficiency: Able to inject nitrogen gas continuously for more than 31 min to completely cool down the transformer oil as well as prevent and extinguish fire. z Reduce pollution: No environmental pollution due to the characteristic of nitrogen gas in FMD. Extinguish fire without water is an advantage to the lack of the water area.


z Feasibility: Easy to install and maintain for either new or existing transformers. z Reasonable investment: Minor price compare to other traditional transformer fire extinction systems, such as water spraying systems and CO2 spraying systems. z Patent Right: National Patent Number 02225196.0. z FMD has been tested by National Fixed Fire Extinction System Fire-proof Quality Center. 1.3 Application Scopes

FMD is for both new or existing high power oil-immersed transformers and can be used in large capacity power plants, such as hydroelectric plants; in electric grid substations, such as unmanned, indoor, or underground; in the area where are cold or dry and where the space are limited. 1.4 Working Conditions 1.4.1 Working Environment: Control Cabinet (indoor): z Max Temperature: 45 z Min Temperature: 0 z Relative Humidity:95% (20 ) Fire Cabinet: z Max Temperature: 60 z Min Temperature: -40 z Relative Humidity:95% (20 ) 1.4.2 Operation Power Supply: z Control Cabinet: DC 110V 0.5A (Require 5A for Operation) z Fire Cabinet: AC 220V 2A (Dehumidify Heater Power Supply)


2 Structure and Major Components

1. Shutter 2. Fire Detector 3. Rupture Disk 4. N2 Injection Pipe 5. Oil Draining Pipe

6. N2 Control Device 7. Fire Cabinet 8. Oil Draining Valve 9. N2 Cylinder 10. N2 installation valve

2.1 Technical Data and Parameters Fire Extinction Medium: 99.99% Nitrogen Purity; N2 Cylinder Volume: 2 X 40L; N2 Cylinder Pressure: 13~15MPa; Depressurized N2 Outlet Pressure: 0.6 MPa; Oil Draining Activation Time:


200

80 160

8hole18

22.522.5

z Send Signal: DC220V 0.25A; z Exterior Dimension: (diameter X length)

200X200 (mm); z Interior Diameter: 80; z Bolt Connection: 160, 8-hole18; z Weight: 6.3kg.

2.2.2 Fire (Temperature) Detector: A high-strength or easy-melted alloy probe is equipped in the fire detector which activated at 13010. This detector is installed on the top of a transformer where the fire is easily ignited, such as beside bushings or an on load tap changer (OLTC). An electric signal will be sent when fire is detected. The alloy probe has to be replaced after a fire incident. z Send Signal: DC 220V 0.5A z Dimension (lengthwidthheight): 18010040(mm) z Weight: 0.6kg

Fire Detector

2.2.3 Fire Cabinet: It can rapidly evacuate oil and injects nitrogen gas after a signal is received from the control box. This operation can be automatically or manually switched on. This cabinet should be installed beside the transformer at a distance of 3 to 8 meters. If fire cabinet is located at outdoor, a dehumidify heater should be used and installed inside the cabinet. z Exterior Dimension (lengthwidthheight): 10006002050mm z Weight: 420kg


N2 and Oil Pipes between Fire Cabinet & Transformer Control Box and Fire Cabinet

2.2.4 Control Cabinet and Control Box: 2.2.4.1 Control Cabinet: Control Cabinet can be installed up to 3 Control Box and is located in the substation main control room. z Exterior Dimension (lengthwidthheight): 8006002260mm z Weight: 180kg 2.2.4.2 Control Box: The brain of the whole FMD system is Control Box, which is installed in Control Cabinet and powered up by DC220V 5A. z Exterior Dimension (lengthwidthheight): 480480355(mm) z Weight: 10kg 2.2.5 Oil Draining Pipe and N2 Injection Pipe: Connecting the transformer tank and Fire Cabinet, the pipes should be zincified and are used as channels to drain oil and inject nitrogen gas. Exhaust faucet should be installed on 90-degree elbows closed to Fire Cabinet to release gas after oil filled during installation. z Oil Pipe: DN100 z N2 Pipe: DN25 2.2.6 Rupture Disk Rupture Disk is installed in the terminal port between Transformer, OLTC, and Bushing. An electric signal will be delivered to FMD control box after Rupture Disk Device activates. Rupture Disk has to be replaced manually after being used.

Rupture Disk


Once the pressure in transformer exceeds the blasting value of the rupture disk, it breaks itself automatically and FMD system is automatically and instantly operated. Consequently, the drain oil valve opens to draw off oil in order to relieve the pressure inside the tank and prevent any explosion and fire. Note that the position of exhaust faucet must be installed vertically facing on the sky for the purpose to evacuate the air.

Structure of Rupture Disk Set 1. DN100 Flange 2. Rupture Disk 3. Oil Resisted Rubber Washers 4. Elastic Pipe (Absorber) 5. Gate Valve 6. Exhaust Faucet

Structure of Rupture Disk Set

2.2.7 Cables: 2.2.7.1 Heat-resisted Cable: It must be heat-resisted cable for delivering signals from Fire Detectors to the transformer terminal box. 2.2.7.2 Control Cables: They are used for the connections between control box, relay protection cabinet, control panel, and fire prevention cabinet. The type and layout of these cables are listed in the project design diagram. 2.2.7.3 AC Power Supply Cable: It is used for the heater inside of Fire Cabinet to heating up and dehumidify inside of Fire Cabinet. Its power (AC220V 150W) should be supplied directly from the transformer terminal box.


3 Ordering Information 3.1 Ordering Procedures & Requirements FMD explosion prevention, fire prevention, fire extinction equipment of transformer is highly recommended based on project demonstrations and technical economic comparisons.

The construction investor may directly sign a contract with the FMD manufacturer or agent and provides the following information of the transformer(s): the type, capacity, and quantity; the manufacturer; the contract number; the location to install and the name of user; and the company who designs the power plant or substation. 3.2 Scope of Supply Please check the following table for the major and exterior component of each set of FMD. Note that all components are depended on the real case of the transformer and the on-site location, and the supply of FMD does not include any valve, pipe, or cables. Please consult with the FMD manufacturer or agent for more information.

No. Name and Specification Qty Remark

1 Control Cabinet (Rupture Disk Type for Tank and OLTC Protection)

1 set

2 Fire Cabinet (Rupture Disk Type for Tank and OLTC Protection)

1 set

3 N2 Tee One Way Valve (DN25) (on Top of Fire Cabinet) 1 pc 4 Rupture Disk Set for Tank (Including Decompression Chamber) 1 pc 5 Bracket for Rupture Disk on Tank 1 set TX 6 Rupture Disk Set for OLTC 1 pc 7 Shutter (DN80) 1 pc 8 Nitrogen Cylinders 2 bottles 9 Fire Detector 6 pc 10 Rain Cover for Fire Detector 6 pc 11 Heat-resisted Control Cable for Fire Detectors21.5 30-40 m LOCAL 12 Steel Cable Sheath for Heat-resisted Control Cable 30-40 m LOCAL 13 Bracket for Fire Detector on Tank 6 pc TX 14 Power and Control Cable 1 set LOCAL 15 Oil Installation Valve (Stainless Knife Gate Valve DN100) 2 pc TX 16 Blind Plate for Oil Installation Valve 2 pc TX 17 Three-ways Tee Pipe (For lifting up PRV on OLTC) 1 pc TX 18 N2 Installation Valve (Ball Valve DN25) 3 to 5 pc TX 19 Blind Plate for N2 Installation Valve 3 to 5 pc TX 20 Bracket for Oil and N2 Pipes 1 set LOCAL 21 4" Elastic Pipe (DN100) with Flange 1 pc LOCAL


22 4Zincified Steel Pipe (DN100) > 13 m LOCAL

23 490Zincified Steel Elbow Pipe (DN100) with Flange and Exhaust Faucet

1 set LOCAL

24 490 Zincified Steel Elbow Pipe (DN100) with Flange > 2 pc LOCAL 25 4Zincified Steel Tee Pipe (DN100) with Flange 1 set LOCAL 26 4Flange > 10 pc LOCAL 27 M1670 (Nickle Bolt and Nut with Flat and Elastic Nut) > 40 pc LOCAL 28 4Gasket (Nitrile-butadiene Rubber) > 10 pc LOCAL 29 1Zincified Steel Pipe (DN25) > 25 m LOCAL

30 190Zincified Steel Elbow Pipe (DN25) with Flange and Exhaust Faucet

1 set LOCAL

31 190 Zincified Steel Elbow Pipe (DN25) with Flange > 8 pc LOCAL 32 1Zincified Steel Tee Pipe (DN25) with Flange > 3 set LOCAL 33 1Flange > 24 pc LOCAL 34 M1260 (Nickle Bolt and Nut with Flat and Elastic Nut) > 96 pc LOCAL 35 1Gasket (Nitrile-butadiene Rubber) > 24 pc LOCAL 36 Red Paint for Fire Prevention 1 set LOCAL

37 Three-ways Electric Ball Valve (DN25) (Optional if OLTC with Filter)

1 set OPTIONAL

38 Oil Gases Separation Tank (Optional for Oil Storage) 1 set OPTIONAL

Note: z Items with LOCAL in the table are not supplied with FMD. Buyer should purchase and

install locally with the on-site contractor. z Items with TX in the table are not supplied with FMD. Buyer should purchase and install

with the transformer manufacturer. z Items with OPTIONAL in Appendix 2 are not standard component of FMD. Buyer should

purchase as optional order. z Number of items on this appendix might vary depending on the transformers. More

detailed should be found in the technical drawing.

3.3 Transformer Manufacturer 3.3.1 The transformer manufacturer should contact the FMD manufacturer or agent (the seller) immediately if the transformer is going to be equipped with FMD. 3.3.2 Submit the pressure values in both normal and designed explosion condition for the transformer tank; the type and activation pressure value of the pressure relieve valve. 3.3.3 Submit detailed diagrams (from top, side, and front) of the transformer and its layout of oil pipes. 3.3.4 Before connecting the oil pipe from the transformer to the FMD fire cabinet, drill a 110mm hole on an approved location at the side and close to the top of the transformer and weld a pipe (DN100) with a flange and a (butterfly valve) oil installation valve sealed by a blind flange. 3.3.5 Before connecting the N2 pipe from the transformer to the FMD fire cabinet, drill 2 to 6 hole on approved locations at the side and close to the bottom of the transformer and weld a pipe (DN25) with a flange and a (ball valve) N2 installation valve sealed by a blind flange.


3.3.6 Reserved DC220V power supply with 6A breaker from the transformer terminal box for the FMD heater that is in the FMD fire cabinet. 3.3.7 Install the FMD shutter between the oil conservator and gas relay and its related parts with provided installation diagrams from the FMD manufacturer or agent. 3.3.8 Install the brackets for the FMD fire detectors on the top of the transformer. 3.4 Substation or Power Plant Contractor 3.4.1 Design a location and direction of the FMD cabinet. The distance must be in between 3 to 8m from the transformer tank. 3.4.2 Design a fundamental diagram for the pipes of FMD with the FMD manufacturer or agent. 3.4.3 Provide the required signals for FMD including: breaker tripping, over gas concentration protection, and pressure relief valve (PRV) activation. 3.4.4 Provide DC110V 5A power supply from the main control room where the FMD control cabinet will be located. 3.4.5 (Optional) Reserve space on the control panel in the main control room to display the conditional signals of FMD system from the FMD control cabinet 3.4.6 Design all cables for the connections and distributions of FMD including: quantities, lengths, and types with the FMD manufacturer or agent. The following is general cable connection layout. 3.4.7 Provide AC 220V 2A 150W power supply for the FMD heater located in the FMD fire cabinet. 3.4.8 Reserved the required signals for Control Cabinet including: Public, Control Box Power Supply Loss, Fire Detector Activation, FMD System ActivationTransformer Over Pressure, the Signal of Shutter Activation, N2 Low Pressure and Oil Leakage. 3.4.9 FMD manufacturer shall provide following diagrams: Fire Cabinet and its ground base drawing; FMD Cable layout installation drawing; Cable connection drawing; Terminal connection drawing; Cable specification table. .

Cable Connection Layout


4 Installation This manual comes with the shipment of FMD and should be kept in a specific area. Each component should be checked one by one right after the package of the shipment is opened. This manual should be read carefully before the installation. Supervisors from FMD manufacturer or agent with local technical engineers should be appointed to instruct the installation. 4.1 Ground Construction Preparation 4.1.1 Oil Storage Container for FMD: An underground oil storage container made by steel is highly recommended for the purpose to collect the drained oil from the FMD fire cabinet during a transformer accident. The capacity of container should be able to store 30% of the transformer oil. And this steel container should pre-bury a DN150 steel pipe to connect through the base to the FMD fire cabinet. If the storage container is on the ground, please to inform us in advance. The connections of oil-drained pipe (on fire cabinet) and storage container should be done by the user.

Ground Base of Fire Cabinet 4.1.2 Fire Cabinet Ground Base: The engineers who design power plant or substation should first confirm the location of the fire prevention cabinet and then design a construction diagram for the base of the fire prevention cabinet with its detail drawing and scheme provided by the FMD manufacturer or agent.

The base should pre-bury a DN150 steel pipe for draining oil and two DN50 pipes for connecting cables into the FMD fire cabinet.

The buried oil pipe should be connected directly or through an isolated channel to the oil storage container. The scatter pipe should not be connected to the oil container at the bottom of the transformer. The following diagrams are the structure of ground base and bottom of the FMD fire cabinet.

4.2 Shutter Shutter should be installed horizontally between the oil conservator (on the top of transformer)

7070

0

475


and the gas relay. An elastic pipe can be added if it is necessary. All connections between flanges must be fixed with oil resisting rubber washers. PLEASE PAY ATTENTION ON THE DIRECTION OF THE SHUTTER THAT THE ARROW ON THE SHUTTER SHOULD BE POINTING TO THE TRANSFORMER TANK (NOT THE OIL CONSERVATOR). And also note that the condition of shutter (open or close) is depended on the flux of the oil. Therefore, the handle on the shutter must be held and fixed to the Always Open position manually during filling oil to avoid automatically turning the shutter to the close position. Once the valve of the shutter closes, a signal will be sent to the FMD control box as a result the shutter indicator and alarm on.

Shutter in between Oil Conservator and Gas Relay 4.3 Oil Installation Valve The transformer manufacturer should drill a hole with a diameter of 108mm that is located at a side of transformer tank and 200-250mm from the top. Joint the hole with a DN100 steel pipe (with a flange at the other end). This oil installation valve is a stainless knife gate valve installed between the flange and a blind flange in the transformer factory. i

Oil Installation Valve on Transformer Tank and OLTC Left: Before Rupture Disk and Oil Pipe Connection Right: After Rupture Disk and Oil Pipe Connection


4.4 N2 Installation Valve

The transformer manufacturer should drill holes close to the bottom of the transformer. The holes should be connected with the N2 installation valves (ball valves).

N2 Installation Valve with N2 Pipe

4.5 Fire Detectors Fire detectors should be mounted on the top of transformer evenly or the key area where fire can be easily detected. The easy-melted alloy probe of the detector should face downward. The transformer manufacturer should weld the brackets for the detectors in advance. Welding for the brackets should be done and designed with the transformer manufacturer. All Brackets welded on the top of transformer and should be covered with anticorrosive paint twice and red paint once. Fire Detectors should be installed horizontally and fixed with M4 bolts with the brackets. Cables for Fire Detectors must be heat-resisted. These Cables should be separated into 2 pairs. Each pair should be paralleled to half of Fire Detectors (as seen in the following diagrams) and connected to the transformer terminal box. The joint area for cables should be sealed completely.

Fire Detector with Heat-resisted Cable


4.6 Fire Cabinet 1. DN100 Flange (Optional)

2. High Pressure Pipe

3. N2 Cylinder Pressure Meter

4. N2 Cylinder Valve

5. Massive Regulator

6. N2 Control Device

7. Oil-Gas Separator

8. DN25 Tee.One Way Valve

9. DN100 Flange

10. Temperature and Humidity Controller

11. Oil Leak Tester

12. Oil Draining Valve

13. Screen for Checking

14. Heater

15. Base of Fire Cabinet (Optional)

Structure of Fire Cabinet

4.6.1 Fire Cabinet Body: This cabinet that is the core of the whole FMD system is necessary to have a steady installation and should fix with M10 bolts and a gasket nut on the pre-designed ground base. Stick oil-drained pipe (DN100) into a steel oil pipe (DN150) which is pre-buried into the ground 4.6.2 N2 Cylinder The cylinder is an outsourcing with its manufacturer product certificate and injected with 13 to 15MPa 99.99% pure nitrogen. For installation, two cylinders should be first fixed with metal hoops inside of the fire cabinet. Then connect each high pressure pie between the N2 cylinder valves and N2 pipe system respectively. All connections must be sealed to avoid any gas leakage. Do not adjust the N2 control device because it must be pre-adjusted in FMD manufacturer. Before FMD commissioning, the N2 cylinder valves must be closed. 4.6.3 N2 Control Device: The N2 Control Device is first installed in FMD manufacturer in a Safety Condition . Once FMD is activated, the N2 Control Device must be replaced. 4.6.4 Oil-Gas Separator: This oil-gas separator is already adjusted and installed in FMD manufacturer. Users are not required to work anything if FMD is newly installed. If FMD is activated or during maintenance, close all N2 installation valve and the oil-gas separator must be replaced with a new one.


4.6.5 Oil Draining Valve Installation (No Work Done Required): It is connected to oil pipes with flanges with preset close condition. This valve is opened automatically with a signal from the control box only if FMD is activated or during simulation test. Signal indicator on the control box represents the conditions of the valve. The valve can only be closed manually. The isolation or position of the valve can be inspected through the screen.

Cad Drawing of Oil Draining Valve Picture of Oil Draining Valve

4.6.7 Heater (No Work Done Required): Consisting of a control device and a heater, it is installed at the lower right corner of the fire cabinet. This heater requires an external power supply AC220 (not from the FMD control box) connected to the terminal port of the cabinet. The power supply could be obtained directly from the transformer terminal box if available. In order to operate the components in the fire cabinet normally in a suitable temperature, this heater is on automatically if the temperature drops below 5 and off if the temperature exceeds 15. The heater is also on automatically if the humidity exceeds 85%RH5%RH. 4.7 Pipes Between Transformer and Fire Cabinet 4.7.1 Oil Pipe: 4.7.1.1 The size of oil pipe should be DN100 or DN150. The structure of this pipe includes the oil installation valve from the transformer tank, a elastic pipe (optional) for more flexible connection purpose, a horizontal oil pipe, a 90 elbow welded with a exhaust faucet, and a vertical oil pipe to the top of fire cabinet. 4.7.1.2 The welding process should be done by a technician who has experience of welding

To R 1/2 Low Pressure Pipe

FMD Oil-Gas Separator


pressure vessel. The welding must ensure no leakage and neatly. 4.7.1.3 Before the oil pipe is installed, all dust and rust must be removed and the pipe should be rinsed two times by the transformer oil. After welding, the whole oil pipe should be painted with a primary layer of anti-rust material and the surface layer of red color. 4.7.1.4 All flanges must connect with oil-resisted rubber gaskets or type-O washer. They should be evenly tightened with bolts in order to ensure no leakage. 4.7.1.5. The horizontal pipe should be ascended (2% higher on the fire cabinet side than the transformer side) in order to release air from the exhaust faucet. The horizontal pipe should be supported its weight with adequate brackets. 4.7.2 N2 Pipe: 4.7.2.1 The pipe should be DN25. Depending on the condition of location, its connection can be used with flange or direct welding, and the pipe should be supported and fixed with some angle iron and pipe nipper. 4.7.2.2 The welding process should be done by a technician who has experience of welding pressure vessel. The welding must ensure no leakage and neatly. 4.7.2.3 Before the oil pipe is installed, all dust and rust must be removed and the pipe should be rinsed two times by the transformer oil. Pressure within the pipe should be up to 0.15 MPa for 2 hours to ensure no leakage. After welding, the whole oil pipe should be painted with a primary layer of anti-rust material and the surface layer of red color. 4.7.2.4 Flanges are connected to oil-resisted rubber gaskets or type-O washer. They should be evenly tightened with bolts in order to ensure no leakage. 4.7.2.5 The horizontal pipe should be ascended 2% lower on the fire cabinet side than the transformer side. 4.7.2.6 Oil pipe can be connected to the oil gases separator; DN25 valve should be added at the bottom of the connection pipes for the purpose to evacuate oil in the tank and pipes. 4.8 Control Cabinet It is a high-quality standard control cabinet installed in a reserved area (must be indoor) in the main control room by M10 bolts. Each standard cabinet can be installed with three FMD control boxes and one FMD UPS. 4.9 Cable Layout and Connection The transformer manufacturer should reserve terminals in the transformer terminal box that connect signals from the fire detectors, shutter, pressure relief valve, gas relay and AC power supply for the heater. Cables should precisely follow the designed circuit diagram and layout to be connected. The cables in the terminal should be clearly labeled for the purpose of testing and inspecting. Fire detectors should connect with the heat-resisted cables.


5 Commissioning

Supervisor from FMD manufacturer or agent with local technical engineers should be appointed for the on-site commissioning with FMD Testing Report. After approving and signing by corresponding department, FMD can be operated in a normal condition. 5.1 Testing Procedure

The oil installation valve and N2 installation valve on the transformer should be closed before any testing. Then follow 5.2 and 5.3. 5.2 Mechanics 1. Inspect all connections flanges. They should be installed with tightened bolts and airproof

gaskets (washers). 2. Close and open all valves respectively with . Inspect each valve including its open-close

conditions and output signals. 3. All on and off conditions should be corresponding to their actions. 4. N2 cylinder should be mounted tightly. High pressure pipe should be twisted tightly. Open the

N2 cylinder valve to inspect the pressure and density of the gas on the gauge. Inspect the isolation on the N2 control device. DO NOT CONNECT ANY ELECTRICAL SIGNAL TO ANY TERMINAL AT THIS MOMENT.

5. Dehumidify heater, Depressurized N2 valve and Oil-gases separator have pre-adjusted in FMD manufacturer.

6. Please also refer to FIG 5.1 to 5.4. 5.3 Electrics 1. Make sure all cable or wires are connected correctly. Check with the schematic diagrams and

terminal layouts. 2. Make sure the fire detectors and their heat-resisted cable and the other control cables are laid

and connected correctly. 3. Make sure the voltage of power supplies DC110V in the control box and AC220V in the fire

cabinet are in corresponding voltage levels. Make sure the breaker protection of power supplies works promptly

4. Use 500V Meg Ohm Meter to make sure the resistance of insulator is more than 20Mohm for each terminal of the control box.

5. Make sure all operation signals are functioned properly with FMD Test Report. They should all be tested at their respective terminals.

6. Please also refer to FIG 5.1 to 5.4.


FIG 5.1 FIG 5.2

FIG 5.3 FIG 5.4


6 Operation 6.1 Basic Requirements Before operating, please read and understand this manual. If there is any question, please contact and consult with the FMD manufacturer or its authorized agent. 6.2 Instruction before Normal Operation First, follow 5.2 to inspect the FMD system. Then, follow the procedure below: 6.2.1 In the control box, turn the operation condition switch to Stop and the activation condition switch to Automatic. Then, unplug the keys and keep them by a specified person. 6.2.2 Open the exhaust faucet halfway to release gas from the N2 pipe. THE FAUCET MUST BE OPENED VERY SLOWLY IN ORDER TO AVOID CLOSING THE VALVE OF THE SHUTTER. There will be some oil and gas mixture at the beginning. Until there is only ejecting oil with no gas, tighten the faucet. 6.2.3 Oil draining valve should be closed. 6.2.4 The shutter should always be in a normal condition if FMD is working normally. If the shutter is close, turn the shutter handle counter clockwise to the normal position. 6.2.5 Connect modified wires to the terminal box of the fire cabinet (make sure there is no voltage on the terminal.)

6.2.6 Open two N2 cylinder valves. 6.2.7 If it is necessary, connect the power supply for the heater in the fire cabinet (AC220 150W). 6.2.8 Connect power supply (DC110V) to the control box. Turn the operation condition switch to Normal and the activation condition switch to Automatic. 6.2.9 Operating procedures finish without any alarms on. 6.2.10 Please also refer to FIG 5.1 to 5.4. 6.3 Activation during Normal Operation 6.3.1 If the activation condition is at Automatic position and the transformer has an accident, I-type signal (High Gas + Transformer Overpressure + Breaker Tripping) should be received and FMD will automatically start-up to prevent explosion and fire. If the transformer is on fire, II-type signal (High Gas + Fire Detector + Breaker Tripping) should be received and FMD will


automatically start up to extinguish fire. 6.3.2 When a fire is obviously around or on the transformer and the breaker tripping signal is received, the user can turn the activation switch to Manual position and press Manual Start Up Confirm Button on the control box to manually activate FMD. FMD can be started-up from a certain distance to extinguish fire.

FMD will continuously inject N2 for more than 45 min to cool down the oil and the fault portion inside the transformer in order to avoid re-ignition. Please also refer to FIG 5.1 to 5.4.

6.4 After Activation Once FMD injects N2 and drains oil to and from the transformer, the following must be replaced

z Oil-gas separator z Fire detectors and its damaged control cables if the transformer was on fire. z N2 control device z Rupture Disk

Recharge N2 cylinder to FMD required pressure with 99.9% purity nitrogen gas, and follow the procedures from 5.1 to 5.3 and 6.2 to re-operate the FMD system. Please also refer to FIG 5.1 to 5.4. For more information about the replacement, please contact the FMD manufacturer.


7 Maintenance In order to ensure the reliability of FMD system to protect the transformer, FMD system have to be inspected for maintenance in a certain periodWhen maintenance, user must rigorously follow the instruction below. If improper operation or misoperation, the user responsible for the consequences. The whole FMD system must be inspected at least every 3 years. And all maintenance records should be saved. The procedures and details for FMD maintenance are listed in FMD Periodic Maintenance and Inspection. Please contact the FMD manufacturer or agent for any maintenance service and spare component. Please also refer to FIG 5.1 to 5.4. 7.1 Regular Inspection and Maintenance 7.1.1 Inspect the pressure of the N2 Cylinder every week. When the pressure of N2 cylinder is below 11.7MPa, a signal will be sent to the FMD control box, as a result, the N2 low pressure indicator and alarm on.

z Record the interior temperature of the FMD Fire Cabinet, date, and time in the specified data sheet by a specified supervisor.

z The pressure of N2 cylinder must be above 8 MPa (20). z When the pressure of N2 cylinder drops below 8 MPa, recharge N2 cylinder to

FMD required pressure with 13 to 15MPa 99.99% purity nitrogen gas (20) 7.1.2 Inspect the oil pipe, N2 pipe, flange, exhaust faucet and fast oil draining every week. 7.1.3Inspect N2 cylinder, massive regulator, N2 injection pipe, maintenance valve, fast oil draining valve, operating mechanism, N2 control device and oil-gas separator every month. Make sure that all of them work properly. 7.1.4 Inspect the power supply of control cabinet, indicator and alarm every month. 7.2 Periodical Inspection and Maintenance 7.2.1 During transformer maintenance: 7.2.2 Close the gate valve and close N2 installation valve. 7.2.3 Inspect the power supply of fire Cabinet and control cabinet, signal lights and alarm every moth. 7.2.4 Unscrew the fire detectors, its switch is activated. A signal will be sent to the FMD control box as a result the fire detectors activation indicator is on. When the fire detectors return the normal position, the fire detectors activation indicator is off. 7.2.5 Inspect the electric performance of breaker tripping, transformer over pressure, transformer over pressure, shutter and gas over concentration in control cabinet. Short the terminal, the corresponding indicator is on. Make sure their wire connections are not loosened. 7.2.6 Open Pressure Relief Valve on Rupture Disk Device to avoid the changes of pressure and temperature, close the gate valve and N2 installation valve during with transformer maintenance or the inspection of transformer oil. After maintenance and inspection, close Pressure Relief Valve and open the gate valve and N2 installation valve. And follow the procedures from 5.1 to 5.3 and 6.2 to re-operate the FMD system.


7.2.9 During the annual power cut off of the transformer maintenance, inspect all airproof washers and Type-O ring for the connection of flanges to avoid any oil leakage. If there is any damage, replace a new one immediately. 7.2.10 Inspect the brackets and the pipes annually. Make sure they are fastened tightly.

7.3 Device Reset z Electric reset: Remove the wires of simulation signals. z Remove the short wires. z Mechanical reset: Follow the operation procedures.

7.4 Replace the Loss Products 7.4.1Replace the loss product in normal

1. High Pressure Pipes should be replaced with new pipes at least every 3 years or during with transformer maintenance.

2. Oil-gas separator should be replaced with new one at least every 3 years or during with transformer maintenance.

3. N2 control device should be replaced with new one at least every 3 years or during with transformer maintenance.

4. Rupture Disk device should be replaced with new one at least every 3 years or during with transformer maintenance.

5. Prepare N2 cylinder with FMD required pressure with 99.99% purity nitrogen gas, when the pressure of recharge N2 cylinder drops below11.7Mpa. Recharge the N2 cylinder or replace, when N2 cylinder drops below 8 MPa. z Close the valve of N2 cylinder, and remove the high pressure pipe. Recharge N2

cylinder to FMD required pressure with 99.9% purity nitrogen gas. z After N2 is recharged, fix the N2 cylinder like before. Then open the valve of the N2

cylinder, the pressure should be back to normal. And inspect any leakage. 7.4.2 Replace the loss products after activation

z Oil-gas separator z N2 control device z Fire detectors and its damaged control cables if the transformer was on fire. z Recharge N2 cylinder to FMD required pressure with 99.9% purity nitrogen gas. z Rupture disk device

7.5 Common Fault and Eliminating Methods

Common fault Reason Eliminating Methods Leakage of pipe The flanges are not tighten, or gaskets are aging

Tighten every flanges or change the broken gasket.

The connectors from N2 cylinder to N2 control device are not tightened. Tighten every connector. N2 Cylinder Low Pressure The high pressure pipe is aging. Replace the high pressure pipe. The connector is not tighten. Tighten the connectors Leakage of

Oil-gas separator Leakage on the oil-gas separator. Replace the oil-gas separator


Short ciruit inside of detectot box caused by aging or not fastened tightly. Fire Detector alarms on Detector is broken or aging.

Tighten the connectors or replace the detector.

The flow rate is so fast when extraction the transformer oil Shutter activation The flow rate is so fast when oil conservator replenish the oil to the tank

Turn the shutter handle counter clockwise to the normal position. Follow the operation procedures in 4.2.

7.6 Announcements 1. The maintenance procedures must strictly accord to the maintenance instructions; 2. Before FMD commissioning, the N2 cylinder valves must be closed; 3. Before FMD commissioning, do not connect lead wires of electric actuator; 4. Once the alarm on when commissioning, first to make sure the fault category. Then press the

alarm off buttoneliminate alarm. After eliminating fault, to re-operate the FMD system according to the steps.

5. When maintenance the transformer, the FMD system must be run out. After maintenance FMD is back into normal working condition.

6. If there any liquid in Oil Leak Tester, check the liquid is oil or water to judge the rupture disk is or isn't leakage.

7. If encounter problems do not operate without authorization, lest damage the device. Please consultation technical personnel of our company.


8 Statement The registered patents and the interpretation rights of FMD are belong to Shenzhen Huadian Electricity Fire Prevention Ltd. All copyrights are reserved. If there is any new modification in this manual, the information will not be individually notified. For more updated information about FMD, please contact Shenzhen Huadian Electricity Fire Prevention Ltd frequently. Shenzhen Huadian Electricity Fire Prevention Ltd. Address: 7/F Block C Donjiaotou Industrial Zone, Shekou, Shenzhen, China 518067 Tel: +86 755 26868025 Fax: +86 755 26815766 Email: [email protected] Web site: http://www.whl.com.cn

instruction manual whl rupture disk

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