In modern power systems, dry-type transformers serve as core equipment, performing critical tasks such as voltage conversion and power distribution. They are widely used in factories, commercial complexes, high-rise buildings, and other similar settings. Proper installation and commissioning not only form the cornerstone for ensuring the safe, efficient, and stable operation of dry-type transformers but also act as the key to enabling transformers to play a central role in the entire power system. Below, we will delve into the full process of dry-type transformer installation and commissioning, and comprehensively explore how to maintain transformers in optimal operating conditions at all times.
I. Pre-Transformer Installation: Meticulous Preparation to Lay the Foundation for Transformer Operation
(1) Transformer Equipment Inspection: Multi-Dimensional Checks to Ensure Transformer Quality
- Appearance Inspection:
Carefully examine the outer casing of the dry-type transformer to ensure no dents or collision marks exist—such defects may indicate damage to internal components. Meanwhile, the insulating paint on the surface of transformer windings must remain intact, with no peeling or cracking. This is critical for the transformer’s insulation performance and directly impacts its safe operation. Additionally, verify the transformer’s nameplate data (including model, capacity, rated voltage, and connection group) to ensure it fully matches actual requirements and design specifications, preventing operational failures caused by parameter mismatches.
- Transformer Accessory Inspection:
Conduct a thorough check of accessories attached to the dry-type transformer, such as temperature controllers, cooling fans, and protective enclosures. Ensure the temperature controller probe is undamaged, cooling fan blades are free from deformation, fan motors operate normally, and the protective enclosure’s dimensions align with the transformer’s mounting holes. This ensures seamless compatibility between accessories and the transformer, safeguarding subsequent operation.
- Transformer Insulation Testing:
Use an insulation resistance tester (megohmmeter) to measure the insulation resistance of the dry-type transformer’s high-voltage and low-voltage windings. For dry-type transformers with a voltage rating of 10kV or below:
- The insulation resistance of the high-voltage winding to the low-voltage winding and ground should not be less than 300MΩ;
- The insulation resistance of the low-voltage winding to ground should not be less than 100MΩ.
If the transformer’s insulation resistance fails to meet standards, promptly perform drying treatment or investigate the cause of insulation damage to avoid malfunctions triggered by insulation issues.
(2) Transformer Installation Site Preparation: Creating a Suitable Environment to Support Transformer Operation
- Site Cleaning:
Keep the transformer installation site flat, clean, and free of debris and standing water. For indoor installations, ensure adequate ventilation and fully functional doors/windows to meet the transformer’s heat dissipation and protection needs during operation, thus creating a favorable operating environment.
- Transformer Foundation Construction:
Construct a concrete foundation tailored to the dry-type transformer’s size and weight. Key requirements include:
- Foundation flatness error controlled within ±5mm;
- Foundation dimensions 100–150mm larger than each side of the transformer base;
- Foundation height determined based on on-site conditions (to ensure the transformer body is elevated above the ground, facilitating ventilation and flood prevention);
- Precisely reserved mounting bolt holes, with a deviation of no more than ±5mm, ensuring stable installation.
- Safety Measures for Transformer Installation:
Place prominent safety warning signs (e.g., “DANGER—HIGH VOLTAGE”) at the installation site. Prepare fire-fighting equipment such as dry powder extinguishers and carbon dioxide extinguishers to prevent fire accidents. Additionally, ensure unobstructed access at the site to facilitate equipment transportation and personnel movement, ensuring smooth progress of installation work.
II. During Transformer Installation: Standardized Operations to Ensure Stable Transformer Operation
(1) Transformer Handling and Positioning: Stable Handling and Accurate Placement
Select an appropriate handling method (e.g., using lifting equipment) based on the dry-type transformer’s size and weight. During handling:
- Exercise extreme caution to avoid collisions or severe vibrations that could damage internal components;
- Ensure the transformer is transported smoothly to the designated installation location.
(2) Transformer Fixed Installation: Secure Foundation to Guarantee Operational Safety
Install the dry-type transformer vertically and accurately on the foundation, ensuring the foundation is sturdy and has sufficient load-bearing capacity to support it. Based on the transformer’s size and load requirements, choose a suitable fixing method (e.g., bolt fastening or welding) to ensure it remains stable and does not shift during operation—preventing safety hazards caused by displacement.
(3) Transformer Wiring Connection: Correct Wiring to Ensure Unobstructed Circuits
① Transformer Main Wiring Connection
- Before wiring, confirm that the power supply and load match the transformer’s rated voltage and rated capacity (to avoid damage due to voltage or capacity mismatches);
- Select cables with appropriate specifications, cross-sectional area, and insulation performance;
- Ensure secure and reliable wiring to prevent short circuits or open circuits, safeguarding the normal operation of the transformer circuit.
② Transformer Control Wiring Connection
After completing the main wiring, connect the transformer’s relay control wiring. This ensures accurate transmission of control signals, enabling effective control and protection of the transformer and facilitating timely handling of abnormal conditions.
(4) Transformer Cooling System Connection: Ensuring Heat Dissipation to Maintain Stable Operation
Dry-type transformers rely on fans or blades for heat dissipation, making the correct connection of the cooling system critical. During installation:
- Ensure unobstructed ventilation in the cooling system, with no foreign objects blocking cooling channels;
- After connection, conduct a test run of the cooling system to verify its normal operation—this guarantees efficient heat dissipation for the transformer, preventing overheating (caused by poor heat dissipation) that could reduce its service life and operational stability.
III. Post-Transformer Installation: Rigorous Testing to Ensure Error-Free Transformer Operation
(1) Transformer Insulation Testing: Dual Detection to Validate Insulation Performance
① Transformer DC High-Voltage Power Test
Use a DC high-voltage power supply to further test the insulation performance of the dry-type transformer’s windings and insulating materials. This step evaluates whether the insulation meets equipment requirements and application standards, providing insulation assurance for safe operation.
② Transformer Insulation Resistance Retest
Re-measure the insulation resistance of the dry-type transformer and compare the results with pre-installation data. This confirms that the insulation performance remains unaffected during installation, ensures the transformer can operate safely, and prevents damage to its insulation structure during installation.
(2) Transformer Commissioning and Testing: Multi-Parameter Detection to Ensure Stable Operation
① Transformer Electrical Parameter Testing
Comprehensively test the dry-type transformer’s electrical parameters, including voltage, current, and power factor. Analyze these data to:
- Assess the transformer’s operating status;
- Verify whether it operates stably under rated load;
- Make necessary adjustments based on test results, ensuring the transformer maintains optimal operating parameters at all times.
② Transformer Operation Monitoring
During the dry-type transformer’s trial operation, closely monitor key parameters such as:
- Transformer temperature;
- Ambient humidity;
- Transformer insulation status.
If abnormalities occur (e.g., sudden temperature spikes or decreased insulation performance), promptly investigate and resolve the issue to ensure safe and stable operation, preventing fault escalation that could disrupt normal use.
IV. Transformer Safety Assurance: Full-Process Protection to Ensure Uninterrupted Operation
(1) Adhering to Transformer Standards and Specifications
Strictly follow relevant installation and operation standards, as well as the installation and user manuals provided by the transformer manufacturer. Ensure every step of installation and commissioning complies with specifications, guaranteeing high-quality installation.
(2) Transformer Operator Training and Protection
- Ensure operators have extensive experience in transformer installation and operation, and have received professional training to familiarize themselves with the transformer’s performance and operational requirements;
- Require operators to wear personal protective equipment (e.g., work caps, insulating gloves, and insulating shoes) during operation;
- Enforce strict adherence to safe operating procedures to prevent electric shock and avoid transformer damage caused by improper operation.
(3) Transformer Power-Off Operation
Before conducting any installation, maintenance, or overhaul work, always cut off the transformer’s power supply. This prevents safety accidents caused by misoperation and protects the safety of personnel and equipment.
(4) Installing Transformer Warning Signs
Place clear safety warning signs around the transformer to restrict unauthorized personnel from approaching. This avoids electric shock accidents caused by accidental contact by non-staff, creating a safe operating environment.
(5) Regular Transformer Maintenance and Testing
- Perform regular electrical tests and insulation tests on dry-type transformers to ensure their electrical and insulation performance remains in normal condition;
- Regularly clean the transformer’s casing and insulating materials to remove dust and debris from the surface—this maintains proper heat dissipation and insulation, extends the transformer’s service life, and enables it to stably serve the power system long-term.
Conclusion
The installation and commissioning of dry-type transformers is a systematic and rigorous process, where every step directly impacts the transformer’s ability to operate safely, stably, and efficiently. Only by:
- Conducting meticulous preparations before installation;
- Implementing standardized operations during installation;
- Performing rigorous testing after installation;
- Providing full-process safety assurance;
Can we ensure the transformer consistently maintains optimal operating conditions and provides a solid foundation for a reliable power supply in the power system? Only in this way can we fully leverage the core role of transformers in the power system, meet society’s continuous demand for electricity, and drive the stable development of various industries.
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