AC DC EMU Maintenance Manual (Siemens PDF)

CAMTECH/E/13-14/MM AC-DC EMU/1.0 1 CHAPTER 5 TRACTION TRANSFORMER 5.1 TRACTION TRANSFORMER The transformer is designed for a nominal rating of 1250...

CAMTECH/E/13-14/MM AC-DC EMU/1.0 1 CHAPTER 5 TRACTION TRANSFORMER 5.1 TRACTION TRANSFORMER The transformer is designed for a nominal rating of 1250 kVA. It consists of a primary winding and 2 secondary windings. Therefore, 625 kVA is available at each secondary. This corresponds to a secondary side nominal current of 731 A at a secondary voltage of 855 Volt (22.5 kV mains voltage). The transformer is cooled with a total of 530 litres of oil. Traction Transformer Fitted Under Slung 5.2 TECHNICAL DATA Manufacturer : ABB Secheron SA Type : LOT1250, Oil Immersed transformer Identification No : XCH000000-AUC Nominal Line Voltage : 25 kV (19 to 27.5 kV) Line voltage min (2s < t < 10min) : 16.5 kV Line Voltage max (2s < t < 5 min) : 30 kV Frequency : 50 Hz (46 to 54 Hz) Installation point : Under slung Dimensions (length x width x height) : App. 2800 x 2000 x 850 mm Total weight, including oil : App. 3.3 t Cooling : ODAF- mineral oil cooled Installation point : Under slung Maintenance Manual for AC-DC EMU (Siemens) Chapter 5 2 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Technical data Primary Side Rated power : 1250 kVA Nominal primary Voltage : 22.5 kV Rated current voltage : 58 A at 22.5 kV Technical data Traction Winding Number : 2 Rated power : 625 kVA Secondary Voltage : 855 V Standard current per winding : 731 A at 855 V (prim. 22.5 kV) Leakage inductance : 1.465 mH  10% related to the secondary Transformation ratio : 26.32: 1 Resistance :  50 m - Related to secondary side Magnetisation Current : 0.17 A ± 30% , Under 22.5 kV Efficiency : 96% Cooling surface area : 4.37 m2 Turns Ratio : 26.294 Total Oil Volume at 20° C : 560 dm3 Winding Details HV Winding Traction Winding No of windings 1 2 Conductor Material Copper Copper No of parallel conductors 1 per HV Coil associate to 2 on each traction traction winding, 2 Coils winding in parallel Total X-section 8.74 mm2 128.35 mm2 Rated current at 22.5 kV 55.55 A 731 A 2 Current Density 6.4 A/ mm 5.69 A/ mm2 Number of layers 18 layer winding 6 layer winding Winding Resistance (DC) at 9.135Ω 15.4 mΩ 85° C No of Turns 2682 102 Chapter 5 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 3 5.3 MAJOR COMPONENTS OF TRANFORMER Maintenance Manual for AC-DC EMU (Siemens) Chapter 5 4 CAMTECH/E/13-14/MM AC-DC EMU/1.0 5.3.1 Transformer oil pump Flow-well Oil Pump for transformer is glandless Mono-bloc Centrifugal type suitable for circulating the oil. The pump has inline suction and delivery flanges. The pump-set is driven by 3 Phase, 50 Hz, 415 V AC supply. General specifications: Motor H.P. 3 Discharge in LPM 700 Total Head in Meters 10.8 Mtrs (0.9 bar) Speed 2850 RPM Class of Insulation `H' Suction X Delivery 80 x 80 mm Total Weight 39 Kgs. Type 1530 Fabricant FLOWWELL PUMPS & METERS 5.3.2 Air Dryer (Breather) The transformer is equipped with two air driers. One is to dry the air in the oil expansion tank. The second one (smaller) is to dry the air in the bushing box. The upper and lower parts of air drier consist of compact casting in aluminium alloy and the transparent hose, which contains the salts (Silica-gel) and it is protected by a stainless steel cylinder drilled in such a way as to allow the visual control of salts. The air sucked into the transformer (due to thermal contractions of oil mass) passes through these drier. In the lower part there is a closing system which prevents the contact between air and salts. This closing system allows the air passage in the two directions (inlet and outlet) only when there is a pressure difference between the inside and the outside of the transformer. Silica-gel air dries are transparent tanks of salts of silicon chemically pure, with cobalt indicator or without cobalt. Silicagel has the purpose to absorb the air humidity signaling the reached degree of saturation by change of colour: With cobalt Without cobalt BLUE = completely dry ORANGE = completely dry PINK = =completely saturated COLORLESS = completely saturated Chapter 5 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 5 The salts contained in the dehumidifier can be taken off and regenerated by heating them at 120-150°C until they get their original colour again. When more than the half of silicagel is became pink (or colorless) (water satured) it has to be fully changed or regenerated. 5.3.3 Heat Exchanger (Radiator) The aim of the cooling system is to transfer the electrical losses created within the transformer to the outside air. Two fans provide the necessary airflow to cool down the circulating oil through the cooler. The oil is pushed through the cooler by the circulating pump. 5.3.4 High Voltage Bushing ( HT terminal) The main insulation of the HV bushing, Elastimold 750 S, 18/30kV is a core of solid insulation with condenser layers for field control. The plug is particularly characterized by its space saving construction and simple assembly and disassembly. The external cone of execution for the plug connection is always protected by a cap when the plug is not attached. Before the HV plug is connected, the cone of bushing must be cleaned. No foreign bodies may be gotten jammed. While the plug is connected, it should make certain that no air is included. 5.3.5 Earth Terminal 5.3.6 Butterfly Valves (Drain & Filling cock) This valve is built with a aluminium casing. Sealing is realized with NBR gasket. The valve is equipped with a locking plate that indicated also the position (open or close). To operate the valve use a 19mm wrench. To lock the valve use M6 bolt or cadenas diameter 6 mm. Maintenance Manual for AC-DC EMU (Siemens) Chapter 5 6 CAMTECH/E/13-14/MM AC-DC EMU/1.0 5.3.7 Ball valve The ball valve is built in stainless steel with PTFE gasket. It is fixed by 4 screws M10 to the tank. The exit is closed by a 1"1/4 plug. The operating arm is fixed to the tank to insure the closed position 5.3.8 Marshaling Box (Low voltage terminal) The connection box is IP67 box equipped with IP 68 cable gland. All electrical devices are connected in the connection box to terminal blocks. ADO terminal block provided to avoid wire stripping and to have good safety and reliability. The main point for ABB terminal blocks are: Elimination of conductor preparation risks No retightening Vibration resistant Corrosion resistant A tool which guarantees a safe connection Procedures simplification 5.3.9 Name Plate 5.3.10 Suspension Arrangement The transformer is fixed under the coach body using rubber dampers. The rubber dampers are mounted to the transformer suspension arms by ABB Rubber dampers are chosen for their properties to limit the transmission of vibration from the transformer to the coach body and to absorb part of choc that coach body can transmit to the transformer. The arrangement also allows compensate flatness default, Chapter 5 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 7 5.3.11 Bellow (Flexible Coupling) Bellow made from ductile metallic materials allows misalignment and thermal expansion of piping. The basic element, which is a thin-walled cylindrical tube, is formed into parallel corrugations with hydraulic or mechanical pressure. The bellows are protected against object projection (stones etc.) with stainless plates placed in the exposed side around the bellows. 5.3.12 Thermometer Sensor The thermometer sensor is composed of 2 platinum resistance thermometers PT100. The sensor is placed in oil. The thermometer sensor is used to measure the oil temperature in the transformer. The sensor is screwed in a pocket, and it is possible to change the sensor without oil draining. For a good heat transmission, the pocket is filled with oil. Enough space is keep free of oil to allow dilatation. 5.3.13. Pressure Relief Valve The pressure relief valve (or over pressure valve) limit the pressure in the transformer tank. The valve open when the pressure over-pass 0.8 bar. When the valve operates it causes a central rod to protrude from the protective casing commuting immediately the switch and giving an electrical and visual signal. When the over-pressure falls down, a spring closes the valve. But the signal returns to its initial position only by manually pushing inwards. 5.3.14 Oil Level Indicator The oil level indicator is located at the expansion tank. The indicator shows the height of the oil level. The minimum and maximum Oil levels are displayed and also the oil level when the oil is 30°C. The transformer is filled 100% with oil. The expansion of the oil is taken up by the expansion tank, which is connected to the transformer. The expansion tank is installed on the side of the transformer. The min. mark is corresponding to an oil temperature of -20°C and max. mark is corresponding to an oil temperature of +120°C. Maintenance Manual for AC-DC EMU (Siemens) Chapter 5 8 CAMTECH/E/13-14/MM AC-DC EMU/1.0 5.3.15 Oi1 level detector The oil level detector measures minimum level in the expansion tank using floats. If the oil level becomes too low, the oil level detector switches and the transformer has to de-energized. 5.3.16 Oi1 flow sensor The flow sensor detects a minimum oil flow. A paddle moves related to flow volume and actuates a micro-switch. 5.4 NEW OIL CHARACTERISTICS: Requested Value Typical Value Density at 20° C 1.0 kg/dm3(Max) 0.876 kg/dm3 Kinematic Viscosity at 40 35 mm2/s (Max) 7.6 mm2/s Flash Point Min 250° C 144° C Pour Point Max -45° C -63° C Water content Max 200 mg/kg < 20 mg/kg Neutralisation Value Max 0.03 mg KOH/g < 0.01 mg KOH/g Total Acidity Max 0.3 mg KOH/g 0.04 mg KOH/g Total Sludge Max 0.05 %/mass < 0.02 %/mass Break Down voltage Min 45 kV 40-60 kV >70 kv after treatment Dissipation Factor at 90° C, 50 Hz Max 0.03 < 0.001 DC Resistivity at 90° C Min 2 G Ωm 5 G Ωm Dissolved Gas Analysis Sr. No Gas Limit value in ppm ( Max) 1 CO2 12000 2 CO 1000 3 H2 400 4 CH4 (Methane) 200 5 C2H6 (Ethane) 200 6 C2H4(Ethylene) 300 7 C2H2(Acetylene) 30 Chapter 5 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 9 5.5 TRANSFORMER OIL COOLING CIRCUIT Heat exchanger Oil pump Transformer Figure: Cooling circuit diagram Cooling System: Make : Type : Aluminium Plate Exchanger Oil Volume : 20 litre Case : Steel Thermal data : Air inlet Temperature : 50° C Air outlet Temperature: 77.7° C Oil inlet Temperature : 85° C Oil outlet Temperature: 81.9° C Oil flow : 655 lpm Fan Data: Numbers: 2 Type: Entry from Front, Exit to the bottom. Power consumption at rated capacity: 2 X 2.2 kVA (3.2 A) Motor Data: Make: ABB Type: HX100 LB1004/2 Voltage: 3 Phase, 415 V Low Speed High Speed Starting Current/ Torque 450%/160% (4P) 600%/200% (2P) Continuous Rating 0.4 kW 1.6 kW Speed 1405 2825 Power Factor/ Slip 0.83/6.3% 0.92/5.8% Maintenance Manual for AC-DC EMU (Siemens) Chapter 5 10 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Monitoring System Equipment Type Make Limit Pressure Relief Valve T3(DN80) Sukrut 0.8 bar Thermometer sensor Double PT100 Altop Oil Level Indicator Float arm Sukrut Oil Level Detector Nivofix RW1016PVK Honsberg (EU) Oil Flow Detector UB1025HM Honsberg (EU) Current Transformer Siemens Maintenance Check List: 1. DGA : As specified above 2. Winding Resistance : HV Winding : 9.135Ω TR Winding : 15.4 mΩ 3. Insulation resistance : Voltage Time Admissible Value at 20 ° C 30 seconds > 100 MΩ 1000V 60 seconds > 150 MΩ Chapter 5 Maintenance Manual for AC DC EMU (Siemens)