Power Transformer Erection Manual

DOC.
NO HHIS-WZ-TE-100(09)
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SHIPMENT, STORAGE AND ERECTION

OF
OIL-IMMERSED TRANSFORMER
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SHIPMENT, STORAGE AND ERECTION HHIS-WZ-TE-100 (09)
VDIHW\#
SUHFDXWLRQ #
IMPORTANT MESSAGES
z Before attempting to install and operate this equipment, read this manual carefully
to obtain important information regarding safety, handling, installation and
maintenance procedures.
z Signal words such as DANGER, WARNING, CAUTION, NOTICE and Safety

instruction.
z Such words are used to alert the reader that sections so marked contain important
safety information that must be carefully reviewed to assure safe and efficient
inspection of this equipment.
Indicates an imminently hazardous situation, which, if not avoided,

will result in death or serious injury.
Indicates a potentially hazardous situation, which if not avoided,

could result in death or serious injury.
Indicates a potentially hazardous situation, which, if not avoided, may

result in minor injury or property damage.
Provides helpful information.
QUALIFIED OPERATORS ONLY
z Only qualified personnel are authorized to install, inspect, operate and serivce his
equipment according to all applicable codes and established safety practices.
z The manual is written for a qualified person or a person who has knowledge of the
transformer. When handling the equipment, please read the manual carefully and
understand the contents and follow the instruction of the qualified person.
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z A qualified person must:

1) Carefully read this entire instruction manual.
2) Be skilled in the installation, construction or operation of the equipment and be aware of

the hazards involved.
3) Be trained and authorized to safety energize, de-energize, clear, ground, lockout and
tag circuits in accordance with established safety practices.
4) Be trained and authorized to perform the service, maintenance or repair of this

equipment.
5) Be trained in the proper care and use of protective equipment such as rubber
gloves, hardhat, safety glasses, face shield, nonflammable clothing, etc., in
accordance with established practices.
6) Be trained in rending first aid.
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CONTENTS
1. GENERAL ………………6
2. SAFETY REGULATIONS ……………… 7

2.1 General ……………… 7
2.2 In installation ……………… 7
2.3 Safety ……………… 9
3. SHIPMENT ……………… 11
3.1 Main transformer ……………… 11
3.2 Bushing ……………… 11
3.3 Detail parts ..……………. 12
3.4 Impact recorder: If requested ……………… 12
3.5 Handling ……………… 12
3.6 Equipment of dry air or nitrogen gas for Transportation ……………… 15
3.6.1 Check of equipment
3.6.2 Operation of equipment
3.6.3 Replacement of empty gas bottle
4. INSPECTION OF THE EQUIPMENT AFTER DELIVERY ……………… 18

4.1 Document ……………… 18
4.2 Main tank ……………… 18
4.2.1 External Inspection
4.2.2 Impact recorder (If provided)
4.2.3 The gas pressure and dew point of transformer
4.2.4 Internal Inspection
4.3 Accessories ……………… 21
4.4 Checklist of transformer after delivery ……………… 22
5. STORAGE TRANSFORMER PRIOR TO ENERGIZATION ……………… 23

5.1 General ……………… 23
5.2 Gas used for filling the tank ……………… 23
5.3 Preparations for Storage ……………… 23
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5.4 Temporary storage of a transformer in dry nitrogen gas or dry air ……………… 24
5.5 Storage of transformer in oil ……………… 24
5.5.1 Completely assembled
5.5.2 Without Assembly
5.6 Accessories & Detail parts ……………… 26
6. TRANSFORMER INSTALLATION ……………… 27

6.1 General ……………… 27
6.2 Caution for transformer installation ……………… 27
6.2.1 Work in the tank
6.2.2 Weather
6.2.3 Clothing
6.2.4 Pressure Relief
6.2.5 Handling
6.2.6 Lifting and accessories
6.2.7 Fastening with bolts and nuts
6.2.8 Transformer oil
6.3 Installation procedure of the transformer ……………… 29
6.4 Preparation for installation ……………… 30
6.4.1 Arrangement of a location for its installation
6.4.2 Equipment and tools for installation works
6.5 Setting up ……………… 32
6.6 Internal inspection ……………… 33
6.7 Assembling the transformer ……………… 33
6.7.1 Cooling equipment
6.7.2 Piping
6.7.3 Bushing
6.7.4 Other accessories
6.7.5 Wiring
6.7.6 Gas monitor
6.7.7 Bushing Current Transformer
6.7.8 Grounding
6.7.9 Connection of terminal lug
6.8 Complete oil filling ……………… 44
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6.8.1 Cautions for vacuuming and oil filling

6.8.2 Draining the insulation oil while filling with nitrogen gas
6.8.3 Installation
6.8.4 Valve operation
6.8.5 Vacuum treatment
6.8.6 Oil filling
6.9 Moisture content verification ……………… 51
6.10 Oil level adjustment ……………… 56
6.11 Touch-up painting ……………… 57
6.11.1 Outdoor transformer
6.11.2 Indoor transformer
6.12 Spill prevention control and countermeasures plans ……………… 58
6.12.1 Spill prevention plan for transformer
6.12.2 Spill cleanup procedures
6.12.3 Personnel safety procedures
7. SITE TEST ……………… 61

7.1 Insulation resistance measurement ……………… 61
7.2 Polarity and phase rotation ……………… 62
7.3 Turn ratio test ……………… 64
7.4 Insulation power test ……………… 65
7.5 Applied potential test ……………… 65
7.6 Resistance measurement ……………… 65
7.7 Oil test ……………… 66
7.8 Bushing Current Transformer Test ……………… 67
7.9 Test of alarm devices and control units ……………… 67
7.10 Leakage test of transformer ……………… 67
7.11 Operational test of other equipment ……………… 67
7.12 Valve check ……………… 67
7.13 Visual inspection ……………… 67
8. ENERGIZATION ……………… 68
9. FACTORY REPAIR PROCEDURE (CONTACT POINT) ……………… 68
10. SUMMARY OF THE STORAGE METHOD OF THE LARGE POWER TRANSFORMER
……………… 69
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1. GENERAL
These instruction manuals are intended as a guide to the installation and maintenance of
our transformer. Every man who works on the receiving, installation, storage, commissioning
and maintenance of a power transformer should be constantly aware of what he should and
should not do to protect the quality and reliability of the transformer. When installed and
commissioned with care, transformers usually require less maintenance than any other kind
of electrical power apparatus. A regular program of inspection should be established and
consistently carried out. The frequency of such inspections being determined by the
conditions under which the transformers operate. For example, a transformer operating
under arduous conditions requires more maintenance than one operating under light-load
conditions. Similarly, atmospheric pollution, temperature, humidity and altitude all affect the
transformer. Therefore, the inspection and maintenance routine is a matter for local
consideration. But all of possible contingencies, which may arise during installation and
maintenance, and all details and variations of this equipment do not purport to be covered
by these instruction manuals. If further information is required by purchaser regarding his
particular installation or maintenance of his equipment, HYUNDAI HEAVY INDUSTRIES CO.,
LTD. would furnish sufficient information willingly.
Before dealing with transformer, one must read and remember these manuals
especially section 2. SAFETY REGULATIONS!
Not following these instructions may cause personal injury or property damage.
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2. SAFETY REGULATIONS
2.1 General
Safety regulations are intended to alert personnel who are in charge possible personal injury,
death or property damage. One must avoid improper working mentioned in this manual.
Safety levels are defined in three levels as follows in this manual. These have mark or are
printed in bold characters.
Extreme hazardous working that can cause severe personal injury, death or
property damage.
Hazardous or unsafe working that has possibility of injury, death or property

damage.
Unsafe or improper working, which can result in minor personal injury or property
damage.
All safety regulations with the symbol have to be strictly observed to prevent person related
hazard or property damage. Each person–operator or who is in charge of transformer – has
to read and aware of these regulations.
The whole part of section 2 is related with safety. These instructions must be obeyed during
working on the transformer.
2.2 In installation
1) Supports for Climbing

External valves, piping and miscellaneous fittings must not be used for climbing or support
because they will not support a human’s weight and are not safe for climbing. Use ladders
when climbing.
2) Lifting and jacking

Lifting and jacking must be done using the proper lifting lugs and jacking pads. Many of
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the eyes and surfaces are not suitable for lifting or jacking and will not support the
transformer weight. See the transformer outline drawing supplied with the transformer for
correct location of these operations. Injury to personnel and damage to the transformer can
result if improper fittings are used.
When lifting and skidding unit, be certain that the hooks, jacks and ropes are
secured not to fall down or slip out of position. Failing to do this can cause
severe personal injury or equipment damage.
3) Grounding
The transformer tank must be grounded at all times. Windings must be grounded except
when electrical tests are being made. Bushings (after installation) must be grounded. All oil
handling equipment and vacuum pumps must be grounded. Maintain equipment grounds
for six hours after oil filling. All test equipment must be properly grounded. Disregarding
any of the above can result in static discharges injuring personnel and damaging the
transformer.
4) Transformer Internal Pressure

Do not open any covers or fittings unless zero gauge pressure exists inside the unit.
Failure to relieve the pressure could cause the part being removed to become a hazardous
flying object. Always relieve internal pressure slowly through valves.
5) Transformer Internal Atmosphere

Do not enter the transformer or breathe the internal atmosphere unless the oxygen content
of the gas inside the transformer is 19.5%௥24%. Oxygen content less than this can cause
drowsiness, injury or death. Transformers shipped in gas are not safe to enter. Always
check the oxygen content. Whenever anyone is inside the tank, other personnel must be
near the manhole on the cover.
6) Electrical Testing
High turn ratios can transform very small input voltages into dangerous output voltages.
Never touch any leads or bushings with test equipment energized.
7) Fire Extinguishers
Fire extinguishers should be available for emergency use. One should be available on top
of the transformer when work is being done inside the tank. Smoking must not be permitted
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on top or inside of the transformer or in the vicinity of the oil handling equipment.
The use of a fire extinguisher inside the transformer will usually severely damage
or ruin transformer insulation.
8) Care on Transformer Cover

Extreme caution must be used when walking on the cover of a transformer because the
cover may be slippery due to an oil film.
9) Condenser Bushings
Caution must be used when grounding bushings because they may retain electrical charge
after transformers have been disconnected from external circuits.
2.3 Safety
1) Working near Energized Transformer

Never climb on any part of a transformer while it is energized. Injury or death can occur
from electrical discharges.
2) Liquid Level
Do not open any valves or plugs on the transformer or any of its accessories while the
transformer is energized because the liquid level could drop below the minimum level. (The
gas or oil sampling valves are the only exception.) An internal flashover may occur if the oil
is allowed to drop below the minimum oil level.
3) Control Circuits
The control circuits, inside and outside the control cabinet, utilize voltages that can be
dangerous to personnel. Caution must be used when operating any of the switches or
breakers. If work on the circuits is necessary, the power supply must be shut off.
4) Cooling Equipment
When the transformer is energized, the proper cooling equipment must be in operation. If
not, dangerous pressures can occur inside the transformer and possibly result in injury to
personnel. Multiple pieces of protection equipment prevent the situation described from
becoming dangerous while in operation.
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5) Jacking
When unloading the transformer or placing it in position, make sure the jack lugs or places
designated for jacking on the outline drawing are used when jacking the unit. The use of
jacks on any other part of the transformer may require costly repairs.
6) Pulling Eyes
Always pull the transformer with pulling eyes supplied on the unit. Check the outline
drawings for the proper fittings to use.
7) Current Transformers
The secondary of any current transformer not connected in auxiliary circuits must be
short-circuited and grounded.
8) Electrical Grounding
The transformer tank must be solidly grounded.
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3. SHIPMENT (and Transportation)
3.1 Main Transformer

Before shipping, the transformer is carefully filled and pressurized with dry air (or nitrogen
by requirement) to minimize the likelihood of condensation or moisture entering the tank.
Transformers will be shipped in one of the following conditions:
1) The smaller transformers are shipped with the accessories mounted and completely
filled with oil, when shipping clearance and weights permit.
2) With the tank filled with oil to a level to cover the windings, the space above the oil is
filled with dry nitrogen or dry air. Before leaving the factory, the transformer tank is filled
with dry nitrogen or dry air to a pressure of 2.0 PSI (0.14kg/᎚) at about 25ఁ and is
tested for leakage. A pressure gauge and bleeder is fitted to enable tank pressure to be
monitored.
3) The tank is completely drained of oil and filled with dry air or nitrogen under pressure
2PSI. During transit, however, a certain amount of oil may be extracted from the core
and windings. An equipment (Fig 3-2) is installed during the transportation to maintain
gas pressure inside transformer tank.
4) All valves should be closed and the blind covers or caps are attached to valves to
prevent oil / air leakage during transportation.
3.2 Bushing
The bushings often have to be removed from the transformer for shipment. This is
necessary to meet shipping clearances and to avoid shipping damage to the bushings. The
bushing leads will be supported by temporary shipping braces which are an integral part of
the blind flange cover or by the tank braces. The bushing leads must be disconnected from
these temporary braces before the blind flange covers are removed.
The bushing leads, lead connections and coils can be severely damaged if you
attempt to remove the covers without first disconnecting the shipping supports.
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3.3 Detail Parts

All fittings are shipped mounted in place when possible. Detachable cooling equipment is
removed for shipment. Packing list indicates the parts that are to be removed for shipment.
Those fittings subject to damage during transporting are packed in wooden crates of
suitable size and type in accordance with the maker’s export standard.
3.4 Impact Recorder: If requested

An impact recorder is mounted on the transformer. See the operating manual of impact
recorder.
3.5 Handling
Transformers must be handled in the normal up-right position. The angle between ropes
must be below 60 degree for lifting the transformer main body with crane. Lifting lugs or
eyes are provided for crane lifting. When the transformer is lifted, all of the correct hooks or
eyes, per the outline drawing must be used. The lifting angle and size of wire ropes to be
used for lifting the transformer must be determined in accordance with the relevant standard.
Similarly, jacking pads are provided for lifting the transformer with jacks. All such pads must
be used when the transformer is to be jacked.
Never attempt to lift the transformer by using any part of the transformer other
than the correct fittings provided for the purpose.
1) Unloading at the port

Transformer shipped by boat from Korea will be unloaded at the main port of destination by
cranes etc. Such unloading works should be executed by skilled works and it is desirable
that a representative of the customer should be present during unloading operations.
Take care against the following

(1) Contact of transformer against a quay
(2) Contact of transformer against a ground
(3) Check nitrogen gas pressure positive or not.
Use a steel wire rope having sufficient strength to lift the transformer and
accessories to prevent dropping. Not doing this may cause severe injury, death or
equipment damage.
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2) Inland loading
Transformer is transported to site by trailer or by other means. It is undesirable to give
severe shock to the transformer during transportation. The speed of the transport car
(trailer etc.) should be regulated according to the condition of the road surface.
The normal speed is as follows.

(1) Complete paved road : Less than 50km/h
(2) Insufficient pave road : Less than 30km/h
(3) Unpaved road : Less than 10km/h
But, when the transformer is transported by rail, there is no problem while the train is
running, however attention should be paid to preventing shock during loading and unloading
work. It is undesirable to incline the transformer too much.
The angle of slope should be less than 10ᇈas shown FIG. 3-1. It is desirable to
install an impact recorder on the cargo or the transformer itself.
ᇪ : Less than 10ᇈ
[ FIG. 3-1 ]
3) Detail parts
(1) By cranes
a) Put guide ropes on boxes to prevent swings.
b) Observe hanging position marks on boxes when hanging up.
c) Do not give shocks especially on porcelains of bushings and surge arresters.
(2) By freight car or truck.

a) Fix boxes on freight car or truck not to give damage.
b) Observe care marks on boxes when handling.
c) Do not give shocks especially on porcelains of bushings and surge arresters.
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z The accessories should be transported and stored according to the following care marks,
which are printed on the boxes.
MARK MARK
DESCRIPTION DESCRIPTION
PRINTED PRINTED
THIS MARK INDICATES
THIS MARK INDICATES
THAT THE TOP SIDE
THE SLINGING
MUST ALWAYS BE
POSITION
FACING UPWARDS.
THIS MARK INDICATES
THIS MARK INDICATES
THAT THE CONTACTS
THE POSITION AT
ARE FRAGILE AND
WHICH THE WEIGHT OF
THE PACKAGE MUST
THE CONTENTS IS
BE KEPT FREE FROM
BALANCED
SHOCKS.
THIS MARK INDICATES THIS MARK INDICATES
THAT THE PACKAGE THAT THE PACKAGE
MUST BE KEPT AWAY MUST BE STORED
FROM WATER. INDOORS.
THIS MARK INDICATES
THAT HAZARDOUS OR
POISONOUS OBJECTS
ARE CONTAINED
3.6 Equipment of dry air or dry nitrogen gas for transportation.
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If transformer tank is transported filled with nitrogen gas, nitrogen gas cylinder is supplied
instead of dry air cylinder.
ᐭࣜ Joint connection by connecting valve

ᐮࣜ 1 ST pressure reducing
1.1 1 ST pressure gauge (0~200 Ꭰ /᎚ )
1.2 2nd pressure gauge (0௥ 30 Ꭰ /᎚ )
ᐯࣜ 2nd pressure reducing valve
ᐰࣜ Low pressure gauge (0௥1.0 Ꭰ/᎚)
ᐱࣜ Pressure relief valve (0.3 Ꭰ/᎚)
ᐲࣜ Coupling
ᐳࣜ Case
ᐴ ࣜCylinder
ᐵ ࣜCylinder valve
௴ FIG 3-2 ௵ Schematic diagram of equipment (typical)
3.6.1 Check of equipment

When transformer arrival at site, check of the value of equipment (P1, P2, P3)
P1 : ᆚ14 Ꭰ/᎚
P2 : 3.5~5 Ꭰ/᎚
P3 : 0.035~0.35 Ꭰ/᎚
3.6.2 Operation of equipment

The schematic arrangement is shown in FIG 3-2.
1) Close the connecting valve. ࣜᐭ
2) Disconnect coupling to transformer ( ᐲ ).
࣯ࣥ Check the remained gas by checking the pressure on 2.1

after opening cylinder valve. ࣜᐵࣜ
4) Adjust 1st reducing valve ᐮ until Item 2 nd pressure gauge 2.2 shows 3.5 Ꭰ/᎚.
5) Cover the couplingᐲ outlet with hand and adjust 2nd pressure reducing valve ᐯ until
low pressure gauge ᐰ shows should be 0.35 Ꭰ/᎚ or about (0.5 psi).
6) Adjust the 2nd pressure reducing valve ᐯ that low pressure gauge ᐰ shows 0 Ꭰ/᎚
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and 0.035 Ꭰ/᎚ when close and open the coupling ᐲ inlet with hand repeatedly.
7) If low pressure gauge ᐰ shows different value above procedure must be repeated.
8) If low pressure gauge ᐰ shows 0.035 Ꭰ/᎚ connect the pipe line to the connecting
valve ᐭ. After opening the connecting valve ᐭ transformer inside is filled with gas with
pressure 0.035 Ꭰ/᎚ automatically.
9) Inside pressure of transformer is changed 0.035௥0.35 Ꭰ/᎚(0.5~5 psi) according to the

variation of ambient temperature. (If inside pressure of transformer is less than
0.035 Ꭰ/᎚, according to low ambient temperature or leakage, nitrogen gas or dry air
flows into transformer from cylinder.)
10) If shows the leakage of dry air or nitrogen gas that the pressure inside cylinder is
rapidly reduced. In this case, leakage test must be carried out at expected points
(Example: connecting point, gasket, welding point, etc.)
11) air pressure or nitrogen pressure should be maintained in accordance with FIG.4-1
during transportation and storage.
3.6.3 Replacement of empty gas bottle (Refer to FIG. 3-2)

The gas bottle (cylinder) must be exchanged according to below procedure when the
internal pressure is less than approximately 14 Ꭰ/᎚.
1) Remove the cover plate from the case ᐳ.
2) Close the valve ᐵ.
3) Close the 1st pressure-reducing valve ᐮ. (Turn locking screw (2) in an anti-clock wise
direction)
4) Loosen cap nut of the gas pipe on the valve of the cylinder to be replaced.
5) Loosen the cylinder holder, exchange the cylinder and fix it.
6) Remove the protective cap from the head of the new cylinder and fix the gas pipe to
cylinder valve using cap nut.
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7) Slowly open cylinder valve ᐵ
8) Slowly open 1st pressure reducing valve ᐮ until 2nd pressure gauge 2.2 shows
3.5 Ꭰ/᎚.
9) Fill nitrogen gas after adjusting the low pressure gauge on 0.03௥0.04 Ꭰ/᎚ by opening
2nd pressure reducing valve slowly.
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4. INSPECTION OF THE EQUIPMENT AFTER DELIVERY
4.1 Document
Shipping documents, outline and wiring drawings, instruction leaflets and other relevant
documents furnished with the transformer must be available for use during inspection.
Immediately after delivery to site, all equipment must be examined for possible transport
damage. If any damage or oil leakage is discovered at the site management, the receiving
inspection check sheet (Refer to section 4.4) must be completed by the transportation
company, the transport insurer and customer’s representative, for each unit and informed to
HYUNDAI HEAVY INDUSTRIES CO., LTD. (HHI), in order to maintain the warranty.
4.2 Main tank

Check the external damaged of the main tank, such as deformation, break-down, missing
parts, etc.
4.2.1 External Inspection

Any external evidence of damage or evidence indicating the possibility of hidden damage
must be reported to the carrier’s representative and to a HHI representative before
unloading the transformer. Take pictures of external damage. The customer must assume all
responsibility for unloading damaged transformers. The external inspection prior to
unloading the transformer should include all of the following.
1) Are all tie rods undamaged and nuts tight?
2) Is all blocking tight and in good condition?
3) Is there any evidence of load shifting in transit?
4) Are there indications of external damage such as broken glass on gauges, broken
welds on flanges?
5) Is the paint finish damaged?
6) Are all fittings which were shipped attached still in place and undamaged (see the outline
or outside assembly drawings)?
7) Is there any evidence of oil leakage (units shipped in oil)?
8) Is there either positive pressure or vacuum in the tank (Refer to 4.2.3)?
9) Are any porcelains chipped or otherwise damaged?
10) Is oil level in bushings normal?
11) Does the impact recorder tape indicate higher impacts
(If attached on the tank, refer to 4.2.2)?
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4.2.2 Impact recorder (If provided)

If the indication of an impact has been recorded over the following values, carry out the
special internal inspection as early as possible and must be informed to HHI.
- Lateral (X AXIS) :2G
- Longitudinal (Y AXIS) :3G
- Vertical (Z AXIS) :2G
4.2.3 The gas pressure and dew point of transformer

1) Check the gas pressure and dew point inside transformer tank after receiving the
transformer.
2) It is desirable to maintain constant pressure of gas inside transformer tank. The gas
pressure is changed in proportion to the temperature. The permissible pressure difference
due to temperature change is shown in FIG. 4-1. If the gas pressure in the tank is above
zero, it may be assumed that the tank seal is still effective. If the gas pressure is zero or
negative, the possibility exists that moisture may have entered the tank and HHI should be
notified.
3) Dew point of dry air;

(1) If the dew point check and humidity content is below 0.7% and/or kept as close as
possible to the value as measured at the factory, it may be assumed that the
transformer has not been contaminated with air or moisture in transit.
(2) If the dew point check and humidity content is above 2%, drying should be performed
according to the method of clause 6.9 and HHI should be notified.
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௴ FIG. 4-1 ௵ Temperature difference versus pressure difference graph
Note:
“Temperature difference” signifies gas temperature at the time of arrival at site minus gas
temperature at dispatch. “Press. Difference” means the gas pressure at the time of arrival at
site minus gas pressure at dispatch.
Example:
- Temperature when dispatched 15ఁ
- Measured temp. at site 25ఁ
- Temp. difference +10ఁ
- Pressure when dispatched 0.06kg/᎚
- Measured press. at site 0.1kg/᎚
- Press. difference 0.04kg/᎚
When the gas pressure measured agrees with the value on the graph of FIG. 4-1, it says
that the gas in the tank did not leak during transportation.
4.2.4 Internal Inspection

A preliminary internal inspection is normally not required unless suspected shipping damage
is involved. The principle objective of the internal inspection is to locate any damage, which
might have occurred in shipment. Particular attention should be paid to leads, tap changers,
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current transformers, and the insulation and lead support structure. Temporary shipping
braces should be removed after the transformer is placed on its foundation.
If damage is observed, the following test may be made as part of the internal inspection.
1) A ratio test on all windings and tap positions.
2) A megger test of insulation resistance of each winding to all other windings and ground
and from all windings to ground should be made with the windings. These readings
should be comparable with the measurements made at the factory.
Do not enter the transformer until the inside gas is replaced by dry air when
transformer has been shipped with nitrogen. Oxygen content inside transformer
must be at least 19.5% ௥ 24% before entering for internal inspection. Oxygen
content less than 19.5% may cause drowsiness, injury or death.
Always check that the inside pressure of the transformer is zero before opening
the manhole/hand-hole cover.
4.3 Accessories
All accessories and detail parts should be checked against the packing list to make certain
that there are no shortages. The crates and boxes should be carefully examined for
evidence of damage. In making examinations of any parts or crates for shipping damage,
check carefully for evidence of moisture entrance and for damage to the moisture barriers or
waterproof wrappings. Accessories and detail parts must be placed in a location, which will
minimize exposure to weather and the possibility of damage and loss. If the transformer is
not to be installed immediately, the parts must be stored in accordance with section 5.
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4.4 Checklist of transformer after delivery

REFERENCE : SERIAL No. :
INSTALLATION PROJECT No. :
TRANSFORMER SPECIFICATION :
DATE : SIGNATURE :
1. TRANSPORT
- With oil above the cover ( )
- With oil …………. ᎖ below the cover ( )
- Without oil and filled with gas ( )
2. GAS GAUGE PRESSURE IN THE TANK.
- Kg/᎚ or psi ( )
- None ( )
3. GAS GAUGE PRESSURE IN CYLINDER

- kg/᎚ or psi ( )
4. IMPACT RECORDER 5. TANK DAMAGED

- Not provided ( ) - No ( )
- Provided ( ) - Yes (notified to) ( )
- Recorded severe impacts ( )
6. PAINT FINISH 7. ACCESSORIES
- Not damaged ( ) - Proper quantity provided ( )
- Slightly damaged ( ) - Incomplete and damaged ( )
- Heavily damaged ( )
8. TRANSFORMER OIL 9. OIL TREATMENT PLANT
- Proper quantity provided ( ) - Required ( )
- Insufficient quantity ( ) - Not required ( )
- Drum damaged ( ) - Provided 1/hour ( )
- Will be obtain from ( )
10. INSTALLATION TOOLS
- Proper quantity provided ( )
- Not provided ( )
- Not required ( )
- Will be obtain from ( )
11. HHI COMMISSIONING ENGINEER 12. COMMISSIONING
- Will be carried out by ( )
- Will be requested ( )
- Will be carried out by HHI ( )
- Will not be requested ( )
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5. STORAGE TRANSFORMER PRIOR TO ENERGIZATION
5.1 General
Some smaller transformers are dispatched with an oil preservation system mounted and
completely filled with oil when shipping clearance and weights permit. If dispatch takes
place without conservator, the tank is not completely filled with oil, but with an approx.
250mm height of gas-cushion, due to the changes in volume, which takes place by
temperature variations and as a protection against absorption of moisture. In special cases,
shipment takes place without any oil, in the case, the transformer is filled with dried dry air
(or nitrogen gas by requirement). A transformer may be stored in dry gas or oil. The storage
period begins the day the transformer is received. If the transformer must be stored beyond
6 months, the preferred method is storage in oil.
When the transformer is filled with nitrogen gas, a well visible notice should be
affixed to the tank wall or case of FIG 3–2.
5.2 Gas used for filling the tank

- Dry air : Dried and above 99.95% purity
- Nitrogen : Dried and above 99.90% purity
5.3 Preparations for Storage

Before the transformer is prepared for storage, the inspections outlined in section 4 should
be made. The works carried out and the result should be demonstrated in checklist (section
4.4). If it turns out that the standards given in these instructions are not met, the necessary
repairs should be made prior to storage. Transformers and accessories can be stored if the
following conditions are prepared.
1) The area on which the transformer is placed must be adequately stable and protected
against water flowing underneath.
2) Oil leakage must be prevented from having any adverse effect on the surroundings.
3) Provision must be made for adequate protection against oil and gas losses and for
continuous monitoring with indication to immediately attract attention.
4) Moisture must be prevented from entering the tank or the transformer oil by replacing
gas cylinders in changing time or by providing and servicing dehydrating breathers.
5) Suitable weather protection (shed, roof) must be provided to prevent condensation
forming in the fittings. If required, use dehydrating silicagel in bags for the individual
- 23 -
‫ٻ‬
items of equipment.
6) Adequately protect the packing of the accessories against rotting.
7) Tank must be protected against corrosion and mechanical damage.
8) Transformers stored outside a fenced area should be secured and barricaded.
5.4 Temporary storage of a transformer in dry air or nitrogen gas

If the transformer cannot be installed immediately upon arrival, and oil filling is impractical,
it is possible to store the transformer under a positive dry air pressure upto six months from
the day the transformer is received. The transformer must be placed on a solid, level
foundation in the storage area. Ground the tank and any bushings that are mounted. The
storage of transformers in gas requires positive assurance that the gas pressure is
continuously maintained. The use of dry inert-gas pressure equipment is recommended. The
inert-gas pressure equipment must be installed within one week after the transformer has
been delivered. If the transformer is not equipped for inert-gas pressure, temporary pipe
connections can be made using the upper filter press or vacuum filling connections. After
installing the inert-gas pressure equipment with a full cylinder of dry air, carry out the
pressure test of transformer for four hours at 5 psi gauge pressure to check the tank for
leaks. And the 2 psi(0.14kg/᎚) at ambient temperature, transformer should be pressured
inside tank during storage.
Transformer gas pressure and cylinder pressure should be recorded every day the first two
weeks. These readings should preferably be taken at approximately the same time every
day and the time and temperature also noted on the log.
After two weeks of daily logging with stable conditions, the frequency of pressure readings
may be reduced to once a week. An accurate log of the pressure readings is required; it may
be the determining factor in any decisions that may have to be made on further drying of the
insulation. Use the procedure from section 6 for installing the transformer. When vacuum
filling with oil, increase the vacuum period prior to oil filling by one hour for each month of
storage. To prevent condensation forming, the control cabinet and motor drive unit with
heater should be connected to a power supply unit.
5.5 Long tern storage of transformer in oil

5.5.1 Long term storage for more than one year
If the transformer must be stored for more than one year, complete assembly and vacuum
filling with oil per section 6 is recommended.
If these operations can all be completed, the transformer will then be ready for service at
any time, providing it receives the same inspection and maintenance during storage as a
transformer in service. The oil preservation system must be in operation. Run the fans and
pumps each month for 30 minutes.
- 24 -
‫ٻ‬
Do not operate the fans and pumps if the temperature is below -15 degree C. An accurate
log of inspection and maintenance data is required: This must be reviewed by the user prior
to energizing the transformer. If the data is questionable, contact HYUNDAI HEAVY
INDUSTRIES CO., LTD. At the end of the storage period, samples of oil must be drawn from
the bottom of the transformer and from the tap changer compartments and tested for
electrical strength, power factor, and water content. Make megger and power factor tests
and compare with factory test values. If all test results are satisfactory, the transformer may
be energized. To prevent condensation forming, the control cabinet with heater should be
connected to a power supply unit.
5.5.2 Long term storage for more than 6 months

If the transformer cannot be completely assembled and storage from 6 months to 12 months
is anticipated, the oil preservation system should be assembled on transformer tank and
transformer should be filled with oil according to clause 6.9. Oil level must be checked daily
for the first two weeks. After two weeks the oil level must be checked once a week. The
transformer should be completely assembled and filled with oil at vacuum condition
according to section 6. If the transformer uses the sealed oil preservation system or the oil
preservation system is conservator type and is not going to install before storage, a positive
internal pressure must be maintained. If the conservator cannot be mounted, temporary pipe
connections should be made. Fill oil in the transformer at vacuum condition until the oil
level is approx. 250mm from the cover. Break the vacuum with dry air. After installing the oil
preservation system, pressure test the transformer for four hours at 5psi gauge pressure.
Oil leakage inspection should be carried out. And the 2 psi(0.14kg/᎚) at ambient
temperature, transformer should be pressured inside tank during storage. Transformer gas
pressure and cylinder pressure should be recorded every day for the first two weeks. These
readings should preferably be taken at approximately the same time every day and the time
and temperature also noted on the log. After two weeks of daily logging with stable
conditions, the frequency of pressure readings may be reduced to once a week. An accurate
log of the pressure readings is required; it may be the determining factor in any decisions
that may have to be made on further drying of the insulation.
At the end of the storage period, the records of pressure readings must be reviewed to
make certain that positive pressure was maintained. Also, oil samples should be drawn from
the bottom of the transformer and tested for electrical strength, power factor and water
content to insure that moisture has not entered the transformer. If all tests are satisfactory,
assemble transformer per section 6. To prevent condensation forming, the control cabinet
and motor drive units with heater should be connected to a power supply unit.
- 25 -
‫ٻ‬
5.6 Accessories & Detail parts

When accessories are not mounted immediately after the transformer is received, they must
be given care to protect them from damage or loss during storage. The following general
instructions and the more detailed instructions given in instruction leaflets for the
accessories, when furnished, must be followed. In the event of conflict between this manual
and instruction leaflets for the individual accessory, the latter shall take precedence. The
box, containing details as shipped should be stored indoor and in a dry and clean place. The
box contains internal connections, gaskets, internal bushing connectors, tape insulations,
paint, control panel, relay, etc. as specified on the detail packing list.
The radiators and coolers, cooling fans, bushings should be stored indoors or in a
weatherproof shed. Also the transformer oil is preferably to be stored indoors same as the
accessories. However, where the oil is stored outdoors, place drums on square timbers so
that the plugs are to be the same level as shown on FIG. 5-1.
௴ FIG. 5-1 ௵
Do not open any parcels, just for checking, until the material is actually needed in
the process of assembly.
- 26 -
‫ٻ‬
6. TRANSFORMER INSTALLATION
6.1 General
Carry out the installation work as far as possible in sequence with this instruction and in
accordance with the complete outline drawing. The smaller transformer, with output ratings
up to 2000KVA and insulation levels up to 30KV is generally delivered as complete
assembly condition for easy installation at the site.
Transformers that were shipped with a low oil level or without oil should be filled with oil
within 4 weeks of their arrival at site if the nitrogen gas or dry air filling becomes ineffective.
At this time the conservator, piping, buchholz relay and dehydrating breather must be fitted.
There are two procedures for installing and oil filling a transformer.
6.2 Caution for transformer installation

6.2.1 Work in the tank
When opening the transformer tank, care must be taken to prevent moisture or dirt entering
the transformer or moisture condensing in the transformer. If wet air enters the transformer,
it may be cooled by the tank wall below its dew point and condensed, so it will reduce
dielectric strength of the transformer. If internal working or inspection is required, nitrogen
gas should be discharged by vacuuming and dry air with 99.95% purity must be filled. Dry
air should be supplied through hand hole during working or inspection. Care especially must
be taken not to drop tools or foreign substances. It is recommended that tools used in the
tank be tied to worker with a cord. When the work in the tank is completed, the inside of the
tank should be inspected. For inside cleaning, the dry, clean and lint-free cloths should be
used.
Do not enter any transformer until the gas in the tank is replaced by dry air.
Oxygen content inside transformer must be at least 19.5%௥24% before entering
for inside inspection. The oxygen content must always be checked. Oxygen
Only installed manholes or hand-holes should be opened to prevent

contamination. Cover all other openings with dry, clean, pressboard or plastic.
This will prevent wet air from coming into the unit.
- 27 -
‫ٻ‬
6.2.2 Weather
a. Do not open or leave opened during periods of rain or during rapidly changing weather
conditions, unless the opening is completely protected from the weather through a double
door lock.
b. The number of openings and the exposure time should be kept to a minimum especially of
the ambient humidity exceeds 60%
6.2.3 Clothing
Never enter a transformer with dirty or wet clothing. Clean cloth and shoe covers or nitric
rubber overshoes must be worn.
6.2.4 Pressure Relief

Do not open any cover or fittings unless zero gauge pressure exists inside the transformer.
Always relieve internal pressures slowly through valve.
Failure to relieve pressure could cause the part being removed to become a
hazardous flying object.
6.2.5 Handling
Lifting lugs are located on the upper part of the transformer wall for lifting the transformer.
Lifting eyes or lugs are provided on the tank cover for untanking the core and coil assembly.
The transformer assembled completely and filled with oil may be lifted with either the wire
rope and/or the lifting beam. When the transformer is skidded, moved on rollers or jacked up,
take care not to injure the base. The jack pad is also provided for jacking the transformer
and the jacks should be placed under the jacking pad.
When lifting and skidding unit, be certain that the hooks, jacks and ropes are
secured not to fall down or slip out of position. Failing to do this can cause
severe personal injury or equipment damage.
6.2.6 Lifting and accessories

Position and direction of the accessories and other parts should be according to the outline
drawing or assembly drawing of the transformer. Before fitting them, read the instructions
completely. Mishandling will result in damage to the accessories.
- 28 -
‫ٻ‬
6.2.7 Fastening with bolts and nuts

Each bolt and nut should be screwed rigidly. But in order to avoid the bolts and nuts broken,
take care not to over tighten. Please refer to [Table 6-3].
6.2.8 Transformer oil

The transformer oil should be of high quality and handled with much care in installing
because it influences the life of the transformer and is very sensitive to contamination, so
that tanks, pumps, pipes and hoses in which the oil is shipped or handled must be clean and
free from the moisture and other contamination.
Transformer oil is supplied in drums; Refer to Table 6-1. Extent of sampling.
Transformer oil is delivered in tank trailers; Take two samples from each separate tank
compartment.
Most of the properties of insulating oil are affected by impurities, particularly water. Care
must be taken in order to avoid contamination of the oil-samples.
All equipment used in obtaining samples and the sample container should be cleaned and
dried.
The test of dielectric strength, power factor and water content must be carried out. if
possible Regarding the characteristics of oil, please refer to below standard and the actual
characteristics of supplied oil are shown on test report.
KSC 2301 ASTM D1040 IEC 296 JIS C2320 BS 148
[Table 6-1] Extent of sampling per 1 Transformer

No of drums No of drums of No of drums No of drums of
delivered sampled delivered sampled
1 – 50 2 1 – 200 4
1 - 100 3 1 – 400 5
Note : If the insulation oil delivery with storage tank, in case the insulation oil should be
sampling for each storage tank.
6.3 Installation procedure of the transformer

The installation procedure of the transformer is as follows:
1) Prepare erection equipment, temporary facilities and check the base leveling.
2) Set main body on base and check a chart of impact recorder.
3) Measure dew point, insulation resistance of core, general inspection and unpacking.
4) Assemble radiator bank. (If provided)
5) FILL with DRY AIR inside transformer tank.
- 29 -
‫ٻ‬
6) Assemble radiator bank upper pipe and lower pipe. (If provided)
7) Assemble radiators.
9) Assemble bushing housing.
10) Mount LV & Neutral bushing.
11) Mount HV bushing.
12) Assemble cooling fans.
13) Fit accessories.
14) Wire for electric system
15) Do grounding work.
16) Evacuate the transformer.
17) Fill with oil. (Please, refer to note)
18) Adjust oil level.
19) Run a leakage test.
20) Run site test
21) Do touch-up painting.
22) Clean of site.
* Note; If the transformer is delivered with oil to level to cover the windings, drain the total
oil in the tank before complete oil filling, and fill with oil under vacuum according to clause
6.8.2. If it is impossible at site condition the working should be proceeded according to
clause 6.9.
6.4 Preparation for installation

6.4.1 Arrangement of a location for its installation
Concrete foundation, anchor, etc. must be completed at the location for installation and the
exact installation position must also be determined prior to the arrival of transformers. The
foundation for installation should be made so as to be exactly horizontal. The anchor bolts
should also be prepared prior to the setting up of transformers. If the wheels are provided,
check the rail gauge to be sure it is correct.
6.4.2 Equipment and tools for installation works.

The equipment, material and tools listed in table 6-2are recommended for installing and
assembling the transformer. They should be prepared before the transformer arrives.
௴Table 6-2 List of equipment and tools (Typical)
DESIGNATION Q’TY DESCRIPTION REMARKS
1) Carrying and 1 Mobile crane (More than 20 ton) Lifting/Assembly

Lifting equipment 1set Sling wire (More than 6m) Assembly
- 30 -
‫ٻ‬
4 Shackle (More than 1ton) Assembly
1 Chain block (1 ton) Assembly
1set Winch Carrying
1set Roller (Steel tube or wood) Carrying
4 Jack Jacking for main tank
1set Manila ropes (5m, 20m) Lifting

1 Electric welding machine Working
1 Oxygen welding machine Working
1set Manila ropes (More than 2tons) Lifting
Oil storage tank
1set (Volume: 110% of total oil) Oil storage
Oil processing equipment (More than

1 Oil treatment
100 lt/min)
Oil purifier
1 (More than 4000 lt/hour) Oil treatment
Vacuum pump
1 (Ultimate vacuum : min0.05x10 -2 mm Evacuation
HG)
Pirawl gauge
2) Filling with oil 1 Evacuation
(Range : 0.01௥ 10 ᎖ HG)
Oil tester (80KV, including test cup for
1 storaging) Oil dielectric strength
1 Nitrogen gas or Dry air (-50୅ G GP Leak test

Rubber hose, pipes, necessary Evacuation and
1set adapters, flanges, valves, etc. oil filling
5 Drum Working
Inside inspection & under
5-25 Dry air cylinder
installation
Torque wrench
2set Assembly
(250, 600, 1000 & 2000 kg-cm)
Spanners
2set Assembly
(8mm, 13mm, 22mm, 30mm, etc.)
2set Adjustable wrenches (250) Assembly

3) General tools
1set Screw driver (plus and minus) Assembly
1 Gas cutting machine Assembly
2 Lamp Assembly
2LT Thinner or alcohol Assembly
- 31 -
‫ٻ‬

Normal cleaning cloth (5kg),
1set Assembly
Special cleaning cloth (20m)
2sets Paint brush (1inch, 2inchs) Assembly
2 Tent for protecting rain (5mx10m) Assembly
1 Multi-tester Testing
1 A.C. voltmeter Ratio test
1 Megger (1000V) Insulation resistance

4) Test equipment Battery (More than 6V)
1 Polarity of B.C.T
Wires, knife switch short clip etc.
> 20m Wire (3Pለ3.5 ᎙ ) Testing
> 20m Wire (1Pለ2.0 ᎙ ) Testing
1 Dew point test min -60୅ Testing
Note : The processing equipment above should be capable to reduce water content in
the oil below 10ppm and the dissolved content up to or below 0.5%.
The test voltage on the windings must be less than 1,000 volts, when the
transformer is not filled with oil.
6.5 Setting up
Install the transformer at the specified location at the site. Take care not to incline the
transformer too much, and prevent the transformer from the shock during such installation
work. The foundation of the transformer should be able to withstand the load and the
vibration of earthquake. To adjust the perpendicular alignment of the transformer, use the
centerline marking at the transformer tank. If not perpendicular, insert thin iron plates at an
appropriate point to adjust it perpendicularly. Fixing of the transformer, install it with
attached anchor bolts at the correct position and then fix the anchor bolts with cement. After
a few days, when the cement is sufficiently hard, again clamp the anchor bolts. When
installing a transformer with rollers or wheels, lock two of the rollers. Locking devices are
only available from the works on special order; they are usually made by the customer.
6.6 Internal inspection

The checking points are:
1) Condition of lead
2) Bracing, clamping and blocking of leads
- 32 -
‫ٻ‬
3) Connections
4) Tap changer
5) Core and coil, it has not moved during transit
6) Core & Clamp grounding, this should be checked with a megger when the ground straps
have been removed.
7) Bushing C.T (If possible)
8) Check that the bushing lead set without being too close to ground or other points of
different potential.
Do not enter the transformer until the inside gas is replaced by dry air when
transformer has been shipped with nitrogen. Oxygen content inside transformer
must be at least 19.5% ௥ 24% before entering for internal inspection. Oxygen
Always check that the inside pressure of the transformer is zero before opening
the manhole/hand-hole cover.
6.7 Assembling the transformer

The assembling procedure should be so planned that opening-up of the tank and cooling
system components are reduced to the minimum. The final oil filling of the transformer and
cooling system should be carried out as soon as possible, to reduce the possibility of
condensation. Dry air should be supplied inside the transformer during assembling
according to Clause 6.3.
The suggested sequence of assembly for a standard transformer is as follows:

1) Erect cooling equipment and all pipe work not necessitating the unsealing of the main
tank.
2) Unseal main tank and complete bushing erection and connect pipes.
3) Complete the final oil filling of the transformer. See the final oil filling of transformer.
- 33 -
‫ٻ‬
Do not open or leave opened during periods of rain or during rapidly changing
weather conditions, unless the opening is completely protected from the weather
through a double door lock.
Do not attempt to install the transformer if it is raining.
The number of openings and the exposure time should be kept to a minimum especially of
the ambient humidity exceeds 60%
During installation, all such equipment as cooling system, should be checked, as blanking
plates are removed; ensure that they are clean and free from moisture. Any items showing
signs of moisture must be cleaned and dried before installation. When installation is being
carried out on top of the transformer to avoid danger of anything falling into the transformer
tank, all loose articles should be removed from the workers pockets.
Also tools used for fitting the detail parts of the transformer should be anchored by cords so
that they can be easily removed if dropped into the tank.
All accessory arrangements are given in outline drawing.
(1) During the process of bolting, the torque must be evenly and uniformly distributed
according to [table 6-3].
(2) If Nitrile cork gasket is applied for outside flange, gasket should be compressed to
approx. 70% of its original thickness. (For example, the original thickness of Nitrile cork
gasket is 10 mm, compressed value is 3mm and the distance between metal surfaces is
7mm.)
All accessory arrangements are given in outline drawing.
[Table 6-3] Torque of bolt
INSIDE(BUS:BAR,BUSHING TERMINAL)
BRASS OR COPPER BOLT A2-70 OR S45C BOLT
SIZE kgf-cm N-m lb-ft SIZE Kgf-cm N-m lb-ft
M8 102 10 7.5 M8 163 16 11.8
M10 160 16 12.0 M10 336 33 24.3
M12 204 20 15.0 M12 581 57 42
M16 280 28 21.0 M16 1479 145 106.8
- 34 -
‫ٻ‬
BUSHING MOUNTING (Material: Stainless steel)

WITHOUT FLANGE WITH FLANGE
SIZE
kgf-cm N-m lb-ft kgf-cm N-m lb-ft
M10 163 16 12 - - -
M12 286 28 21 286 28 21
M16 367 36 27 408 40 29.48
M20 - - - 510 50 36.86
M24 - - - 710 70.4 50
M30 - - - 1010 100 71
M36 - - - 1420 140 99.4
OUTSIDE (HEX BOLT + HEX NUT)

Material STAINLESS STEEL(A2-70) STEEL(S45C 8.8)
SIZE kgf-cm N-m lb-ft Kgf-cm N-M F-P
M8 163 16 11.8 183 18 13.2

M10 336 33 24.3 367 36 26.5
M12 581 57 42 642 63 46.4
M16 1479 145 106.8 1581 155 114.2
M20 2856 280 206.3 3111 305 224.7
M24 4947 485 357.4 5406 530 390.6
M30 9894 970 714.8 10761 1055 777.5
M36 17238 1690 1245.5 18768 1840 1356
OUTSIDE (HEX BOLT OR STUD BOLT + TAPPED)

Material STAINLESS STEEL BOLT(A2-70) STEEL BOLT(s45c 8.8)
SIZE kgf-cm N-m lb-ft Kgf-cm N-M F-P
M8 71.4 7 5.1 81.6 8 5.8

M10 153 15 11.0 173.4 17 12.5
M12 255 25 18.4 306 30 22.1
M16 663 65 47.9 765 75 55.2
M20 1326 130 95.8 1530 150 110.5
M24 2295 225 165.8 2601 255 187.9
M30 4590 450 331.6 5253 515 379.5
M36 8007 785 578.5 9180 900 663.3
z Tolerance : ᇹ10%
- 35 -
‫ٻ‬
6.7.1 Cooling equipment

Radiators or any of the various types of coolers shipped as detail items with transformers to
be assembled at the final location must be thoroughly inspected prior to assembly to be
certain that no water or foreign material is in the oil space. Avoid opening the equipment
when it is at a lower temperature than the ambient air in order to prevent condensation. If
there is any evidence of moisture, the equipment must be thoroughly dried either by blowing
hot air through or by flushing with hot oil. Flushing out the cooling equipment thoroughly
with hot oil is recommended.
The radiators or coolers should be installed on the transformer the same day they are
opened and not permitted to stand exposed after opening for inspection or flushing. All
cooling equipment should be installed prior to final oil filling. Radiator valves should be
closed during installation of cooling equipment. Immediately prior to final vacuum treatment
and oil filling, open all cooling equipment valves.
1) Fitting of radiator
The radiators are shipped separately. The blank covers are attached to the flange of
radiator to prevent moisture. Radiator valve is located on each radiator connection so that
any individual radiator may be removed in time of necessity without lowering the oil level of
the transformer tank. The radiator should be handled carefully to prevent bending or
puncturing the panels. The position number is stamped on the header of each radiator and
this should be matched with the position number stamped on the flange on the main tank
side. Fit the radiator according to the following procedures.
(1) Hoist the radiator from the ground, and pay attention not to damage other radiators
with the hoisting tools.
(2) Remove the blind cover and gasket on the radiator.
(3) Inspect inside of the radiator visually.
(4) Clean the fitting flange surface of the radiator.
(5) Remove the blank cover and gasket on the radiator valve of the transformer.
(6) Clean the flange surface of the radiator valve.
(7) Apply bonding cement to all sealing faces.
(8) Hoist the radiator by crane and pull the radiator by hand, incline it and drain the
residual oil inside the radiator (See FIG. 6-1). (If needed)
(9) Line up the upper and lower flanges.
(10) Match the radiator valve and flange surface of the radiator and clamp then by nuts.
(11) Clamp the pair of nuts located diagonally one after another in order to clamp evenly.
(12) Mount all the radiators in the above procedure.
- 36 -
‫ٻ‬
Before mounting the next radiator, check the paint and touch up any spots that
have been damaged.
OR
௴FIG. 6-1௵ Incline and drain residual oil
1. Radiator valve
2. Cap
3. Gasket
4. Blind cover
5. Stud bolts and Nuts
[FIG. 6-2] Radiator valve and blind cover
- 37 -
‫ٻ‬
1. Cap
2. Radiator valve
3. Gasket
4. Radiator head pipe
5. Lifting and interlocking lug
6. Air vent plug
7. Panel type radiator
8. Transformer tank wall
9. Bolts and nuts
10. Panel supporting bar
11. Interlocking and
Fan supporting lug
12. Oil drain plug
௴FIG. 6-3௵Radiator assembly
The radiator can be attached to the transformer tank by using crane as FIG 6-4.
1. Transformer tank
2. Radiator
3. Crane
௴FIG. 6-4௵ Assembly of radiator
- 38 -
‫ٻ‬
2) Operation of radiator valve

(1) Remove the protective cap located on the top of the valve.
(2) Turn the valve stem with a spanner to desired direction.
(3) Attach the cap and bolt it.
It is desirable to change gasket with new one every time the cap is removed.
[ Close ] [ Open ]
[Fig. 6.5] Valve Cap
3) Cooling fan (if provided)
Before fitting the fans, check that the impellers rotate freely by pushing with hand. Mount
the fans on the brackets welded to the bottom of the radiator. There are vent plugs
screwed to the motor housing. Open the bottom plug and close top/side plugs to prevent
inlet water at installed position. More detail is shown on the catalogue of fan.
6.7.2 Piping
For shipment, ex-works pipes are fitted with blank flanges. When removing the blank flanges,
listen for a hissing noise of nitrogen filling. If there is no hissing noise, flush the pipes with
oil. If in exceptional cases, it is necessary to weld pipes on site, remove any heavy oil
deposits and leave both pipe ends open (fire hazard). Do welding work at a location where a
jet of flame will do no harm and also keep a fire extinguisher handy. Light hammer blows on
the outside will dislodge any possible rust deposits or welding scale.
If necessary, clean with a steel wire tube brush, blow out with a jet of compressed air and
flush with oil, circulating through a conditioning plant. Do not clean with a cloth as fibers
might get left behind if the inner surface is rough. Welding on oil-carrying pipes or in the
proximity of oil-filled vessels is very hazardous and should only be carried out by skilled
men from HHI. When fitting the piping ensure that the pipe from the transformer tank to the
oil conservator has an incline between the tank and the Buchholz relay. The pipes of the
cooling system must have a vent at the highest point. Make tight all flanges with gaskets. In
case of pipeline with several parts, assemble all parts of pipeline with gaskets and make
tight all flanges with same torque.
- 39 -
‫ٻ‬
1. Main conservator 10. Separating plate

2. OLTC conservator (If provided) 11. Oil level indicator (If provided)
3. Air release flange 12. Drain valve (If provided)
4. Oil level indicator 13. Protective relay (If provided)
5. Drain valve 14. Lifting lugs
6. Buchholz relay 15. Connection valve (If provided)
7. Connection valve 16. Breather flange (If provided)
8. Breather connection flange 17. Equalizing valve
9. Mounting supports 18. Equalizing valve
௴FIG. 6-6௵ Typical arrangement of conservator
6.7.3 Bushing
Bushings should be installed lastly to minimize the possibility of their being damaged while
installing other parts. Care should be taken in unpacking the bushing package to avoid
damage of the porcelain.
Before fitting the bushings clean the porcelain and the live part thoroughly. Bushings
should be mounted on their locations as shown in outline drawing. Make connections to both
ends of the bushings in such a manner that strain is avoided. When heavy bus-bars are
connected to bushing, flexible connections should be used to prevent damage that might
possibly result from expansion and contraction due to temperature changes. In case of oil to
SF6 type and oil-to-oil type bushing, it is essential that the bushing is protected from the
- 40 -
‫ٻ‬
ingress of moisture. Therefore put the bushing on outside into a barrier sheet, add the
necessary quantity of desiccant and fasten the bag with scotch tape to flange. Bushing
should be installed on the transformer according to the instruction of bushing itself. Be sure
that all connections are tight to prevent local heat of the terminal. When the bushings are
installed on the transformer, change a gasket with new one for the fitting seat. The flange
should be fixed uniformly by nuts in such manner as shown in FIG. 6-7. Throughout the
work, worker should not use the gloves and tools-monkey wrench, spanner, etc., unless they
are tied to the worker with hempen strings to prevent them being dropped into the
transformer tank. All bushings must be grounded for safety after installation.
Each pair of stud bolt 1-1, 2-2 and 3-3 should be tightened
with nuts at the same time in order to fix the flange
uniformly.
௴FIG. 6-7௵ Bushing fitting flange

Before handling and installing the bushing, read the separately attached instruction manual
in which described the bushing handling manner such as unpacking, cleaning and lifting.
6.7.4 Other accessories

Other accessories should be mounted on their location as shown in outline drawing.
Before handling and mounting the other accessories, read the separately attached
instruction manual. They must be inspected, cleaned and tested on their contacts before
installation. Check insulation oil inside the pockets for temperature indicator. If not, fill in
insulation oil in the pockets.
6.7.5 Wiring
The accessories and equipment which are removed for transport purpose, should be
connected by the associate wires or cables with identification ferrules after reassembling at
site. Usually control cables for indication, signaling, fan and tap changer motor are
connected to terminal cubicles as shown on the control drawings.
6.7.6 Gas monitor

The oil gas monitor instruction book provides assembly instructions. After the oil filling
- 41 -
‫ٻ‬
process, open the valve and bleed the sensor as directed in the instruction book. It is
mandatory to read the manufacturer oil gas monitor manual for its installation and
operation.
6.7.7 Bushing Current Transformers

Check ratios, lead continuity and polarity at the terminal points in the control panel.
An energized current transformer is dangerous if the secondary is an open circuit.

Death or serious injury can result from contact with the terminals.
The short-circuiting devices must be connected to the appropriate terminals in the
control panel if there is no load connected to the transformer.
6.7.8 Grounding
1) Step-down transformer
Transformer have two ground pads diagonally opposite each other on the tank.
Also separated construction from transformer tank must be connected ground wire. All
components and parts (Terminal boxes, control panels, cooling fans, bushing, pump etc.)
which are not welded to the transformer tank should be earthed to the tank. The parts
which are connected with gasket must be earthed to the transformer tank in accordance
with [Table 6-4].
[ Table 6-4 ] Specification of earthing wire for step-down transformer

Min. cross section
Part for earthing Remarks
of ground wire (᎙)
A ground wire must be
Transformer tank *360
connected to only one of them.
Connected
Separated Instruction
to grounded (Radiator, etc.) *360 Separately grounded
wire Surge arrester
*180 Separately grounded
Surge counter
Parts are not welded
360 Earthed to transformer tank
to tank
Connected Earthed to transformer tank
to TR. tank (But the separated circuit from
Control panel 360
case must beseparately
grounded)
* If requested by customer, the cross section of ground wire can be changed.
- 42 -
‫ٻ‬
6.7.9 Connection of terminal lug

Use the same material to prevent electro-chemical corrosion for bushing terminal, connector
and connecting cable. If different material and aluminum terminal are used, connection work
must be proceed by below method.
1) TERMINALS AND CONDUCTORS IN ALUMINUM ALLOYS

Bare aluminium protects itself by forming a thin oxidation layer on its surface. This
phenomenon has a detrimental effect on the contact surfaces of aluminum alloy conductors
because the oxidized layer is a good electric insulator. Therefore the oxidized layer must
be removed from connection surfaces of aluminum alloy conductors and its regeneration
must be avoided. When installing conductors in aluminum alloys the contact surfaces are to
be treated as follows:
- Clean the contact surface with a steel brush

- Coat the contact surface with contact grease (ES241-300-303)
- Brush the contact surface with the steel brush, without removing the contact grease
- Wipe off the contact grease with cloth, so that a thin layer remains
- Install the conductor
2) CONNECTION OF CONDUCTORS AND TERMINALS IN ALUMINIUM ALLOYS TO

THOSE IN COPPER OR COPPER ALLOYS
In the case of connection of aluminum alloy conductors and terminals to copper or copper
alloy conductors particular care must be taken to prevent electro-chemical corrosion. To
avoid corrosion of the copper surfaces the contact surfaces are often provided with a
galvanic coating.
When assembling conductor connections attention should be given to the following:

- The surface of the aluminum part should be considerably larger than that of the copper
conductors
- Between the contact surfaces aluminum-copper a CUPAL-sheet (cu-plated aluminum
sheet) should be inserted, which is protruding some millimeters on all edges.
During installation the following steps should be carried out:

- Remove dirt and grease by cleaning the contact surfaces, the conductor and the
CUPAL-sheet
- Coat with contact grease
- Brush off the oxidation layer with steel brush, without removing the contact grease
Note: Surfaces with a galvanic coating are not to be brushed with steel brush but are
- 43 -
‫ٻ‬
only to be cleaned.
- Wipe off contact grease with cloth, leaving a thin layer.
- Install conductor.
-
6.7.10 Hydran 201R gas monitor or AMS-500 gas monitor.
1) If the sensor is supplied separately from transformer tank, the sensor should be
mounted after filling tank.
2) If the sensor is supplied assembled on transformer tank, the connection valves should
be close during the vacuum and oil filling.
3) Air should be vented by drain plug after opening the connection valves.
4) Before handling and installing the gas monitor, read the attached instruction manual.
-
6.8 Complete oil filling
6.8.1 Cautions for vacuuming and oil filling.

1) When opening drums of oil, care should be taken to prevent moisture from condensing
within them. It is preferable that filling is done when humidity is low. Drums should be
opened only at the time when the oil is needed. Before filling the oil, take sample from
the drums or tank trailer according to clause 6.2.8 and test the dielectric strength and
water content. Please refer to [Table 6-6, 6-7].
2) The oil filling apparatus should be clean and free from moisture. Care should be taken to
prevent moisture from being introduced into the oil through oil line.
3) Do not energize the transformer when vacuuming and filling oil.
4) Before exhausting air from the transformer, close the connection valves of sudden
pressure relay.
6.8.2 Draining the insulating oil while filling with dry air (Shipment with low oil level)
After all accessories except the dehydrating breather (this should be installed after the
completion of oil filling) have been installed, drain off the total quantity of insulating oil from
the transformer in order to eliminate foreign matter, dust, etc. in the oil as well as any which
may have been absorbed. Supply dry air into the transformer to displace insulating oil, then
to drain off the oil. Do not allow the transformer internal pressure to become negative.
Sealing pressure of dry air should be form 0.05௥0.2kg/᎚.
* If the insulation oil of transformer which was filled at factory is good condition and it is
- 44 -
‫ٻ‬
difficult to drain off the total quantity of insulation oil from the transformer tank, two times of
total oil circulation should be performed in order to eliminate foreign matter, dust, etc.
according to section 6.9
6.8.3 Installation
The transformer should be assembled completely. To prevent the moist air from being
entered the transformer during installation, all openings should be re-closed as quickly as
possible. All separate oil compartments must be interconnected by pipes or other means at
the top. If these pipes are permanently installed, all their shut off devices (valves etc.) must
be opened so that there is a uniform pressure in all these compartments during evacuation.
The vacuum line is connected to the flange of the upper filtering valve.
The vacuum in the tank should be checked continuously with a vacuum gauge, which is
fitted on the conservator or tank cover from the evacuating connection as far as possible.
When the transformer is being filled with oil, the gauge should be protected against the
ingress of oil by a suitable shut off valve.
6.8.4 Valve operation

The typical oil filling arrangement is shown on Table 6-5. The oil compartment of on load tap
changer and air seal cell type conservator must be pulled vacuum at the same time by
means of opening equalizing valve.
Before raising vacuum, check whether the equalizing valves and connection valves are open,
and all openings such as oil filling holes, air relief plugs, hand-holes etc. are completely
closed. For valve operation, refer to table 6-5.
- 45 -
‫ٻ‬
Vacuuming and oil filling procedure for Conservator type Transformer (Rubber cell type)
1. Connection for the vacuuming and oil filling

Equalizing v/v (1") 3
Equalizing v/v (1")

Tem porary v/v
15 2 Rubber cell
Rubber cell Tube
Pressure gauge
Vacuum gauge
connection
to check
Conservator gauge
indication
8
V-P
Insulation oil Temporary v/v

12
9
Temp.
14 Oil drain v/v (1")
v/v
Nitrogen
Conservator connection v/v (3")

for Conservator Vacuum
4 5 Pump
1 Vacuum v/v (4")

Transparent tube
(to check oil level)
Insulation oil Oil inlet
6 10
Oil filling &
filtering v/v (2")
Silicagel Radiator
breather 7
Transformer Oil
filtering
13 unit
Oil outlet direction
11
Oil sampling v/v with transparent tube
Oil drain v/v (2")
(to check oil level and gauge indication)
2. Vacuuming process
1.
1. Check dew
Check dewpoint
pointprior to vacuuming
prior (Refer to
to vacuuming fig 6-9to
(Refer & 6-10 in the&instruction
fig 6-10 manual).
6-11 in the instruction manual)
2. Make connection
Make connection as shown
as shown above.above. Equip temporary
Equip temporary valves (v/vvalves(v/v8.9&12)and connect
8, 9 & 12) and connect vacuum vacuum
hoses (dotted hoses(dotted
line). line)
3.
3. Check the equipment/vacuum apparatus while
Check the equipment/vacuum apparatus while v/v 9 is closed. v/v9 is closed.
4. Open v/v 1through 9 and start vacuuming.
4.
5.
Open v/v 1 through 9 and start vacuuming.
Record vacuum level (torr) and ambient temperature every hour.
5.
6. Record leak
Check vacuum in level (torr) and ambient
the transformer tanktemperature
when the every hour.reaches 1 torr
vacuum
6. Check leak in the transformer
1) Close v/v 1,2 & 3tank when
then the vacuum
inspect reachesvacuum
and record 1 torr. after around 30 minutes.
2)
1) The
Closepressure
v/v 1, 2 & should drop and
3 then inspect drastically reaching
record vacuum after100uHg
around 15orminutes.
below
3) Vacuum reading should be lower than around table 6-8
2) Vacuum reading should be lower than around 300 mmHg.
7. Maintain required vacuum level for required period (Refer to table 6-7 in the instruction manual)
7. Maintain required vacuum level for required period (Refer to table 6-7 in the instruction manual).
3. Oil filling process

1. Test oil prior to oil filling (Refer to table 6-8 in the instruction manual).
2. Fill the oil if the oil is OK.
1) To check oil level, connect v/v 13 and v/v 14 with transparent tube and open the valves.
3. Open v/v 10 and fill the oil through upper filling v/v (v/v 10) by oil filtering unit.
4. When the oil level reaches around 200 mm below tank cover, close v/v 1 and continue filling through v/v 10 while vacuuming through v/v 2 & 3.
1) Oil level can be checked through temporarily connected transparent tube.
5. Stop filling when the oil level gauge on the conservator indicates around 5. This indication depends on oil temperature.
6. Continue vacuuming for two hours to remove remaining bubbles while v/v 2 & 3 are opened.
7. After two hours vacuuming, close v/v 2, 3, & 10.
8. Release vacuum by supplying nitrogen gas or dry air through v/v 12 slowly.
1) Make sure v/v 2, & 3 are closed before supplying nitrogen gas.
9. When the pressure inside of the conservator reaches "0" then prepare for oil circulation.
1) Remove vacuum gauge, nitrogen bottle and v/v 8 & 12, then connect breather. Remove the oil cup under the breather.
10. Open the v/v 10 & 11 then start filtering. Two times of total oil volume circulation should be done.
11. Check conservator air bag.
1) Remove breather and connect pressure gauge, nitrogen bottle and v/v 8 & 12.
2) Fill nitrogen gas through v/v 8 & 12 at a pressure of 2 psi.
3) To release air inside of the conservator, open the flange 15 slowly. If oil flow out, close the flange.
4) Remove pressure gauge, nitrogen bottle and v/v 8 & 12, then connect breather.
12. Adjust oil level when oil temperature reaches ambient temperature.
1) Refer to oil level curve.
Note: To check proper operation of the oil level gauge, close v/v 14, disconnect tube from it and straight up the end of the tube to the conservator top.
Compare oil level indication with oil level inside the tube.
- 46 -
‫ٻ‬
6.8.5 Vacuum treatment

When all preparation for continuous oil filling have been made, evacuate the transformer
according to the specification in table 6-5. If the specified vacuum can not be obtained, all
the equipment used for this process should be checked for leakage. Repair the leak.
The evacuation time starts when the necessary vacuum is obtained. If the vacuum
deteriorates, the counting of the time must be restarted.
Vacuum conditions;
1) If the temperature of core and coil (ambient temperature) is below 50F (10ఁ), the
moisture released from the air will condense on these parts and will be absorbed into the
paper insulation. To avoid this hazard, the core and coil should be heated by filling the
tank with warm oil. Please refer to clause 6.9.
2) Do not attempt to establish vacuum if it is raining. If the unit leaks, moisture will be
drawn in. But once it has been started, vacuum work should be continued even if it rains
during the work.
௴Table 6-5௵ Valve operation (typical)

Oil filling
In Each oil
No TR. Associated In service of
Description evacuation compartmen
. oil compartment TR.
(FIG. 6-8) t separately
(FIG. 6-8)
(FIG. 6-9)
Air release vent
1 Closed Closed Closed Closed
for main conservator
Equalizing valve
2 Opened Opened Closed Closed
3 Drain valve for OLTC conservator Closed Closed Closed Closed
Connection valve
4 Opened Opened Opened Opened
for OLTC conservator
5 Connection valve for breather Opened Opened Opened Opened
6 Drain valve for main conservator Closed Closed Opened Closed
7 Connection valve for breather Opened Opened Opened Opened

Connection valve
8 Opened Opened Closed Opened
9 Drain valve for OLTC Closed Closed Opened Closed
Equalizing valve
10 between OLTC and tank Opened Opened Opened Closed
(if provided)
Connection valve Opened Opened Opened
11 Opened
between cable box and tank (if needed) (if needed) (if needed)
- 47 -
‫ٻ‬
12 Oil filling valve Closed Closed Opened Closed
13 Oil filtering valve Opened Opened Closed Closed
14 Radiator valve Opened Opened Closed Opened
15 Drain valve for tank Closed Closed Closed Closed
16 Oil sampling valve or cock Closed Closed Closed Closed
A. Vacuum pump
B. Protective relay
C. Buchholz relay
D. Radiator
E. Oil treatment plant
F. Oil storage tank
G. Pump
H. OLTC Conservator
I. Air seal cell Conservator
J. OLTC
K. Cable box
L. Vacuum gauge
௴FIG. 6-8௵Connection of oil and vacuum pipes for filling the transformer
and the associated oil compartments with oil (typical)
A. Breather
B. Protective relay
C. Buchholz relay
D. Radiator
E. OLTC Conservator
F. Air seal cell Conservator
G. OLTC
H. Cable box
I. Breather
௴FIG. 6-9௵Connections for filling separate compartments with oil from the conservator
(typical)
- 48 -
‫ٻ‬
6.8.6 Oil filling

1) Check the valve operation as shown on table 6-5.
2) Preparations for oil filling should be made during evacuation. The oil to be filled into the
tank must be satisfied as following conditions.
Table 6-6 Test limits for new mineral insulating oil received
In new equipment, below 260kV, prior to energization
Value for voltage class
Test and method
ᆙࣲࣵधऒ >69-<230kV
a
Dielectric strength ,
ASTM D1816-97,
kV minimum,
1 mm gap b : 25 30
b
2 mm gap : 45 52
Dissipation factor(power factor),
ASTM D924-99el,
25ఁ , % maximum: 0.05 0.05
100ఁ ࣨ% maximum: 0.40 0.40
Interfacial tension,
ASTM D971-99a,
mN/m minimum: 38 38
Color,
ASTM D1500-98,
ASTM units maximum: 1.0 1.0
Visual examination,
ASTM D1524-94(1999): Bright and clear Bright and clear
Visual examination,
ASTM D974-02,
mg KOH/g maximum 0.015 c 0.015 c
Water Content,
ASTM D1533-00,
d
mg/kg maximum : 20 10
Oxidation inhibitor content when specified,
ASTM D2668-96,
Typeዜ फथनࣨࣜ࣡ࣜऩझऴथऩऱऩࣶࣜ - 0.08
ऐवबडዜ फथनࣨࣜ࣡ࣜऩथपथऩऱऩࣶࣜ - 0.0
ऐवबडዝ फथनࣨࣜ࣡ࣜऩझऴथऩऱऩࣶࣜ 0.3 0.3
ऐवबडዝ फथनࣨࣜ࣡ࣜऩथपथऩऱऩࣶࣜ >0.08 >0.08
ऐफरझनࣜठथययफनलडठࣜणझयࣜࣽएऐउࣜऀࣰࣱ࣮ࣩ࣭ࣩࣵ࣬ࣤࣵࣵࣴࣥ 2.0% 1.0%
a
Oil dielectric testing in accordance with ASTM D877-00 has been replaced by ASTM D1816-97 in Table 2.See
5.2.1
b
Alternate measurements of 0.04 in and 0.08 in respectively for gaps.
c
This value is more stringent than the ASTM D3487-00 requirement.
d
Equivalent measurement is parts per million,ppm
- 49 -
‫ٻ‬
Table 6-7 Test limits for new mineral insulating oil processed for equipment,
230kV class and above, prior to energization
Value for voltage class

Test and method
ᆚ230kV-<345kV 345kV and above
Dielectric strength,
ASTM D1816-97,
kV minimum,
1 mm gap a : 32 35
a
2 mm gap : 55 60
Dissipation factor(power factor),
ASTM D924-99el,
25ఁ, % maximum 0.05 0.05
100ఁࣨ% maximum 0.30 0.30
Interfacial tension,
ASTM D971-99a,
mN/m minimum: 38 38
Color,
ASTM D1500-98,
ASTM units maximum: 1.0 0.5
Visual examination,
ASTM D1524-94(1999): Bright and clear Bright and clear
Neutralization number(acidity),
ASTM D974-02,
mg KOH/g maximum: 0.015 b 0.015 b
Water content,
ASTM D1533-00,
mg/kg maximum 10 10
Total dissolved gas, 1.0%
1.0%
ASTM D2945-90(1998):
a
Alternate measurements of 0.04 in and 0.08 in respectively for gaps.
b
This value is more stringent than the ASTM D3487-00 requirement.
c
This value should be obtained from a sample collected 24 to 48 h after the transformer is
filled and applies only to transformers with diaphragm conservator systems.
d
Equivalent measurement is parts per million,ppm
- 50 -
‫ٻ‬
** If not satisfied, the oil must be degassed and dried by circulating method. Refer to
section 6-9 “Moisture content verification”.
3) When the oil meets the specified requirements and evacuation time is over (maintain the
vacuum for above one hour after the required vacuum has been obtained). The oil is filled
into the transformer tank from the storage tank through the oil purifier plant. The filling
speed should be adjusted so that the vacuum in the transformer tank is maintained during
oil filling. HHI recommends that maximum rate of oil filling is 6000 liter per hour and the
oil temperature must be 40௥60ఁ.
4) After oil filling, two-time total oil volume circulation is recommended continuously to
perform through a vacuum oil treatment in order to eliminate foreign matter, dust,
remaining moisture, dissolved gases etc. However, if the oil characteristics meet to
requirement, it is not necessary.
5) The conservator should be filled to such an extent that the oil levels correspond to 5ఁ
higher than the actual oil temperature.
6) After oil filling, the vacuum is maintained for two hours and then released with nitrogen
gas. This causes a slight drop in the oil level as a result of the tank contraction
decreasing. To prevent the oil level dropping below the tank cover, refill the tank with oil.
(If needed.)
7) Take a sample of the oil from sampling valve and measure the dielectric strength. This
mean value should be higher than the value on table 6-6 or 6-7. If it is not, the oil must be
degassed and dried (Refer to section 6-9).
8)The rest periods described in the table 6-8 must be remained before the transformer is
energized in order to establish proper impregnation of the solid insulating material free
from partial discharge and then adjust the oil level. Check for oil leaks after completion of
oil filling. And they should be vented-trapped air by the method of clause 7) or 8)
6.9 Moisture content verification

The dew point must be measured 24hours after completing the leak test to allow moisture
equilibrium to occur inside the unit. This reading is necessary to calculate the moisture
content of the transformer. This only applied when the insulation temperature is above
10 ୅UGpGGGGGGXW୅G GGGGGGGYLUG
{GGGGGGGGGGGG
- 51 -
‫ٻ‬
Method 1 – Circulating hot oil. This method is very slow and not as effective as the
vacuum methods
- Method 2 – Short-circuited windings (oil-filled), vacuum (without oil). A low value of
residual moisture can be obtained by this method.
- Method 3 – High vacuum. This method is used with and without heat. Heat increases the
efficiency and decreases the drying time required. It is the method generally used for
large MVA units, for high voltage, and for reduced insulation classes.
- Method 4 – Hot air. The method is not as effective as the vacuum methods.
Example) Method 1(100 to 230kV)
1) Prior to adding for circulation, a vacuum of 0.35torr or less, shall be applied for 48
hours.
2) Hot oil should be circulated from the top of the unit at a point remote from the vacuum
connection, and with the use of a splash plate, to the bottom drain valve.
3) The amount of oil may be added depends on the height of the major insulation system
(core & winding) in the tank. The insulation (core & winding) should not be covered with
oil during the dryout process. It is recommended that the oil may be used within 20 ~ 30
percent of total oil volume.
4) Oil should enter the top of the unit at no more than 80 degree C (176 F) and should be
circulated to maintain an exit temperature of 60 degreeC (140 F).
5) When the temperature of inside tank (measured by oil temperature indicator) is 30 to 40
degree C, the hot oil circulation will be finished.
6) The oil is drained totally with dry air or N2 gas.
7) The oil filling is starting according to clause 6.8.6 oil filling. The required vacuum value
and time is Hot oil circulation level.
The heat flow should be directed so that it does not splash on bushing porcelain. It is
possible to break bushing porcelain with thermal shock.
When tested values are higher than the value on table 6-6 or 6-7 the circulating of oil is
finished.
- 52 -
‫ٻ‬
௴Table 6-8௵Vacuum Treatment and oil filling requirements after complete assembly
Min. time for holding Humidity content of Waiting period
the vacuum after insulation, determined between
Highest Required vacuum during
reaching the required by dew point after releasing the
Voltage final filling
vacuum during final complete assembly and vacuum and
filling before evacuation (*) putting in service
(kV) Amb.temp Torr Hours (Percentage) Hours

> 30 ᆙ 1.0
4 <0.5
ᆙ 30 ᆙ ࣱ࣬࣪ࣳ
> 30 ᆙ 0.75
12 ᆙ 1.5
Up to ᆙ 30 ᆙ 0.5
16
72.5 > 30 ᆙ ࣱ࣬࣪
16 > 1.5 to ᆙ 2.0
ᆙ 30 ᆙ ࣰࣱ࣬࣪
> 30 ᆙ ࣰࣱ࣬࣪
24 > 2.0
ᆙ 30 ᆙ ࣰ࣬࣪
> 30 ᆙ ࣱ࣬࣪ࣳ
12 <0.5
ᆙ 30 ᆙ ࣱ࣬࣪
> 30 ᆙ 0.5
24 ᆙ 1.2
100 to ᆙ 30 ᆙ 0.45
36
230 kV > 30 ᆙ ࣰࣱ࣬࣪
36 > 1.2 to ᆙ 2.0
ᆙ 30 ᆙ ࣰ࣬࣪
> 30 ᆙ ࣰ࣬࣪
48 > 2.0
ᆙ 30 ᆙ ࣱ࣯࣬࣪
> 30 ᆙ 0.5
12 <0.5
ᆙ 30 ᆙ 0.45
> 30 ᆙ 0.45
24 ᆙ 1.2
245 to ᆙ 30 ᆙ 0.4
500 kV > 30 ᆙ 0.4

36 > 1.2 to ᆙ 2.0
ᆙ 30 ᆙ 0.35
> 30 ᆙ 0.35
48 > 2.0
ᆙ 30 ᆙ 0.3
48
> 30 ᆙ 0.45
24` <0.5
ᆙ 30 ᆙ 0.4
> 30 ᆙ 0.4
36 ᆙ 1.2
Over ᆙ 30 ᆙ 0.35
500 > 30 ᆙ 0.35

60 > 1.2 to ᆙ 2.0
ᆙ 30 ᆙ 0.3
> 30 ᆙ 0.3
72 > 2.0
ᆙ 30 ᆙ 0.25
- 53 -
‫ٻ‬
* The humidity content of insulation must be allowed to remain in the transformer for at least
24 hours after reaching the final pressure of about 3 psi prior to obtaining Dew point.
** These minimum times should be increased by 1 hour for each eight hours that the
transformer was open during the installation
133
VAPOR PRESSURE
[FIG 6-10] Conversion from dew point or frost point to vapor pressure
- 54 -
‫ٻ‬
[FIG 6-11] Moisture equilibrium chart

(with moisture content in percent of dry weight of insulation)
- 55 -
‫ٻ‬
௴FIG. 6-12௵Oil container connected to oil treatment plant and drum.
6.10 Oil level adjustment (Typical)

For filling the conservator, the oil level must be set to the fixed mark. This level must then
be corrected in accordance with the temperature of the oil in the transformer by adding or
draining a certain quantity determined by calculation. The correction quantity is calculated
as follows. In case of air seal cell conservator oil level must be corrected in accordance with
oil level-temperature curve.
G
'V u r u 'T
g
- చV(dm 3 or LT) : Correction quantity to be added or drained depending on whether the
temperature of liquid in the transformer is above or below the valve marked
on the oil level indicator.
- G(kg) : Weight of oil in the transformer shown on the nameplate
3
- g (kg/dm ) : Density of expansion of transformer oil (= 0.88௥0.9)
-1
- r(K ) : Coefficient of expansion of transformer oil (= 0.78x10 -3 )
- ᇎT(K) : Difference between oil temperature set on the oil level indicator
When the calculation results in a correction quantity of ᇎV ᆙ5(dm 3 ), a correction need not
be made.
Example
- Weight of oil in transformer (G) = 40,000kg
- Temperature of oil in transformer = +25ఁ
- Mark on oil level indicator = +20ఁ
- Difference (ᇎT) = 5K
- 56 -
‫ٻ‬
§ 40,000 · 3
'V ¨ ¸ u 0.78 u 10 u 5 180
© 0.88 ¹
Therefore, 180 litters oil must be added from the +25ఁ mark onwards.
6.11 Touch-up painting.

After all assembly work and inspections have been finished, check the transformer whether
there are any faults and defects such as oil leakage, bolts loosening etc. If it is no problem,
the parts which are transported and assembled should be touch-up painted finally.
6.11.1 Outdoor transformer

1) Remove perfectly rust and peeled paint by sandpaper or steel wire brush.
2) All surfaces to be painted shall be clean with waste cloth and compressed air.
3) After that, the surface should be dried by wind or air blowing.
4) The primary paint must be coated, because it is anticorrosive paint, and it should be
coated by air spray gun or brush, the mixing ratio of primer – base: hardener = 4:1 (by
volume)
5) After previous coating was dried sufficiently, the finish paint should be coated by air
spray gun or brush the mixing ratio of final paint – base: hardener = 2 : 1 (by volume),
but should be added a little thinner in order to spray.
6) Several thin coatings is more effective than one thick coating.
7) In case of bolt connecting point, primer is painted with heavy thickness and then finish
coating should be done.
8) After the final coating is finished, it must be dried for 2 hours at 25 degree C.
9) Repair work on touch up painting should be carried out only in dry weather. The
temperature must be at least 5 degree C. Surfaces damp from dew must not be painted.
6.11.2 Indoor transformer

Method of recoating is same as the outdoor service. A volatile and inflammable solvent
should not be used for paint as its volatile matter that remains in the room may cause fire.
- 57 -
‫ٻ‬
6.12 Spill prevention control and countermeasures plans
6.12.1 Spill prevention plan for transformer

1) Transformer should be using insulating oil between core and coil, earthing parts in tank,
in order to get good insulation effect. Characteristics of insulating oil ASTM D3487. In
this case, the operator of oil handling equipment should keep a request of HHI manual
for installation. Especially, operator should take care to avoid environmental-pollution
due to spill and leak through process of below stage. After required preparations are
made, assemblies of transformer begin.
2) Residual oil in radiator and manifolds will be drained and stored in drums according to
HHI assembly manual per HE-648, clause 6.8.2 cooling equipment. Any left-over oil will
be treated by qualified local company.
3) Any oil hose connections between tanker, oil handling equipment, and transformer tank
will be wrapped in oil absorbent material. A bucket will be placed underneath hose joining
connections. Extra care should be taken to ensure hoses are adequately connected.
4) Before beginning repair of transformer oil sampling valve, the side of inspection door will
be removed and oil level checked. After draining any necessary oil, repair as previously
outlined.
6.12.2 Spill cleanup procedures:

1) Land spill – no potential of liquid (oil) reaching surface waters.
(1) Stop the leak by taking any necessary or appropriate action.
(2) Cleanup the contaminated area by removing earth or surface material to a depth of 10
inches. The removed soil or ground material, damaged transformer, rags and absorbent
pads should be disposed of in approved labeled drums. All visible signs of the spill must
be removed. Removal of additional four inches may be necessary depending on the
severity of the spill.
(3) Any vehicle or equipment contaminated due to a spill should be decontaminated by
swabbing surfaces with a solvent such as kerosene or biodegradable solvent. The
cleaning rags or pads should be discarded in the approved drums. Do not rinse or clean
the vehicle with water or soap until it has been properly decontaminated as described
above. Do not move the vehicle from the scene until it is been properly decontaminated.
(4)If the spill is on ground paved with asphalt, the contaminated asphalt should be
removed. If the spill is on ground paved with concrete (e.g. roadside curb or footpath),
the surface should be thoroughly cleaned by swabbing the surface with an organic
- 58 -
‫ٻ‬
solvent like kerosene or biodegradable cleaner using the double wash/double rinse
method. The used cleaning solvent and used swabs shall be properly disposed of in
approved drums.
(5) The contaminated liquid and solid waste shall be deposited in approved labeled drums.
2) Land spill – with potential of liquid (oil) reaching surface water.

(1) Stop the leak by taking necessary and appropriate action.
(2) Immediately contain the spill by trechning1 damming, or any other means at hand to
prevent liquid (oil) from reaching surface water. Use absorbent pads or some other
absorbent material to remove as much of the contamination as possible from the
affected area. Prevent the spill from getting into a sewer, open drain or wetlands.
(3) Once the spill has been confined to land, follow the procedure as described under
“Spill on land with no potential of its reaching surface water”.
3) The spill is on surface water or has reached surface water.

(1) Stop the leak by taking necessary and appropriate action.
(2) If practical, immediately confine the spilled materials and prevent further spillage from
reaching surface water.
(3) Seek the help of a commercial spill response contractor if necessary.
4) Spill on land and/or surface water under inclement weather.

(1) Spill incidents must be considered emergencies, and containment and cleanup
activities must be initiated immediately.
(2) Follow the appropriate procedures as described previously.
6.12.3 Personnel Safety procedures:

Employees assigned to spill cleanup shall wear following personal protective clothing.
1)Protective clothing shall be worn during cleanup.

Protective plastic gloves shall be worn under leatherwork gloves to protect hands.
2)Safety glasses with side shields, a face shield or goggles shall be worn while handing oil.
3)After handling oil, the hands especially the skin, which has come in contact with oil, shall
be first washed with waterless soap, and wiped with disposable towels. Cleaning
materials shall be properly disposed of with other contaminated wastes. Washing with
warm water and soap, especially before eating, smoking, or using toilet facilities should
follow this.
- 59 -
‫ٻ‬
4)In case of spillage on personal clothing, the clothing should be removed as soon as
possible, the skin washed, and the clothing properly marked and placed in sealed
containers/drums for disposal. Employees should immediately wash as previously
outlined.
- 60 -
‫ٻ‬
7. SITE TEST
The site tests are performed upon each transformer after field assembly. Since it is
impractical to duplicate all factory tests at the site, a few selected tests can be performed.
The recommended tests are as follows. The site test result must be kept at site because the
result is helpful for operation and maintenance.
1) Insulation resistance measurement. 2) Polarity and phase relation
3) Turns ratio test 4) Insulation power factor (if possible)
5) Applied potential test (if possible) 6) Resistance measurement
7) Oil test 8) BCT test
9) Test of alarm devices and control units 10) Leakage test of transformer.
11) Operational test of other equipments 12) Valve check & Visual inspection
7.1 Insulation resistance measurement

1) Transformer body
The winding insulation resistance test, which is often referred to as a megger test, is the
measure of the quality of the insulation within a transformer. Insulation resistance
measurement are made between each winding and all other windings and ground by means
of a megger of more than 1000V. Winding should never be left floating for this test. Since
the values of insulation resistance vary with temperature, all measurements are corrected to
20ఁ for comparison purposes. FIG. 7-1 can be used as a guide to the values of insulation
resistance, which are acceptable.
௴FIG. 7-1௵ Oil-immersed transformer: insulation resistance at 20ఁ
- 61 -
‫ٻ‬
The measured insulation resistance at the ambient temperature of the transformer is

corrected to 20ఁ by multiplying the measured value by the correction factor (Refer to table
7-1) corresponding to the ambient temperature.
௴Table 7-1௵Temperature corrections for insulation resistance test

Transformer Transformer
Correction factor Correction factor
Temperature ఁ Temperature ఁ
95 89.0 35 2.5
90 65.0 30 1.8
85 49.0 25 1.3
80 36.2 20 1.0
75 26.8 15 0.73
70 20.0 10 0.54
65 14.8 5 0.40
60 11.0 0 0.30
55 8.1 -5 0.22
50 6.0 -10 0.15
45 4.5 -15 0.12
40 3.3
1) Accessories and wiring

Measure insulation resistance between two terminals of terminal box and between each
terminal and earth from terminal to terminal and record insulation resistance value and
temperature. In the case of bushing CT, be sure to measure insulation resistance between
two CTs in addition to insulation resistance between each CT and earth. At a temperature
of 20ఁ more than 100 Ꮓ is required.
7.2 Polarity and phase rotation

Perform the polarity and phase relationship test at the rated tap.
1) To polarity test
V1 > V2 : Subtractive
V1 < V2 : Additive
2) To check phase relationship

The check is made by connecting H1 to X1 and applying a three phase voltage to H1, H2
and H3 and then measuring the voltage between the indicated points and comparing them
- 62 -
‫ٻ‬
via the FIG 7-2.

DIAGRAM FOR CHECK
ANGULAR DISPLACEMENT CHECK MEASUREMENTS
MEASUREMENT
CONNECT H1 TO X1
MEASURE H2-X2,
H3-X2, H1-H2,
GROUP 1 H2-X3, H3-X3
ANGULAR
DISPLACEMENT VOLTAGE RELATIONS
0 DEGREES (1) H2-X3 ౓ H3-X2
(2) H2-X2 < H1-H2
(3) H2-X2 < H2-X3
(4) H2-X2 ౓ H3-X3
CONNECT H1 TO X1
MEASURE H3-X2,
H3-X3, H1-H3,
GROUP 2 H2-X2, H2-X3
ANGULAR
DISPLACEMENT VOLTAGE RELATIONS
30 DEGREES (1) H3-X2 ౓ H3-X3
THREE-PHASE TRANSFORMER WITH TAPS (2) H3-X2 < H1-H3
(3) H2-X2 < H2-X3
(4) H2-X2 < H1-H3
[ FIG 7-2 ]
- 63 -
‫ٻ‬
7.3 Turn ratio test

The ratio test is a means by which the turns ins the high voltage winding are compared with
the turns in the low voltage winding to insure the proper voltage transformation. For use in
the field, two methods are used to verify the transformer ratio;
1) Comparison method
Ts : Standard transformer
Tr : Transformer under test
2) Voltmeter method
- In case of a delta – delta connection
PRIMARY SECONDARY
- In the case of a star – delta connection
PRIMARY SECONDARY
- In the case of a deltas – star connection
PRIMARY SECONDARY
- 64 -
‫ٻ‬
7.4 Insulation power test

The insulation power factor test is another test that can be made to monitor the dryness of
transformer insulation. Power factor is defined as the ratio of the power dissipated divided
by the input volt-ampere times 100. For power transformer, this is usually less than 1%. The
measurements of power factor are made with a capacitance bridge and the connections are
the same as for the insulation resistance test. Since power factor readings vary with
temperature, all values are corrected to 20ఁ for comparison. Table 7-2 gives the table of
correction values. The power factor value measured at ambient temperature is divided by
the correction factor corresponding to the ambient temperature. Power factor measurements
should be made only on transformer filled with liquid.
௴Table 7-2௵Temperature corrections for insulation power factor test

Temperature correction factors for power
factors
Temp. Deg. C Correction factor – K
10 (50ሥ) 0.80
15 (59ሥ) 0.90
20 (68ሥ) 1.00
25 (77ሥ) 1.12
30 (86ሥ) 1.25
35 (95ሥ) 1.40
40 (104ሥ) 1.55
45 (113ሥ) 1.75
50 (122ሥ) 1.95
55 (131ሥ) 2.18
60 (140ሥ) 2.42
65 (149ሥ) 2.70
70 (158ሥ) 3.70
7.5 Applied potential test

This test is to be conducted to determine that the impressed voltage and impressing time
are in compliance with the permissible standard. Also the winding and bushing CT that are
not to be impressed should be short-circuit and earthed.
7.6 Resistance measurement

Winding resistance measurements can be made to determine if any changes have occurred
in the current carrying path. The winding resistance measurements should be made with a
- 65 -
‫ٻ‬
Wheatstone bridge, Kelvin bridge or similar bridge capable of measuring fractional ohms
accurately. Since resistance varies as a function of temperature, resistance readings are
normalized to one temperature which is equal to the normal winding rise of the transformer
plus 20ఁ. For a 55ఁ rise transformer, the standard temperature would be 75ఁ ; and
likewise for a 65ఁ rise transformer, it would be 85ఁ. The formulas for converting
resistance readings to a standard temperature are as follows:
234.5 75
75୅: R75 Ra u
234.5 Ta
234.5 85
85୅: R85 Ra u
234.5 Ta
R 75 or R 85 = Corrected resistance
Ra = Measured resistance at ambient temperature
Ta = Ambient temperature in ఁ
Winding resistance measurements reported by most manufactures are reported for three
phase units as if all three windings are connected in series. For wye connected values,
measurements should be made between each line bushing and the neutral bushing and then
the three readings summed. For delta windings, the measurements should be made
between each pair of bushings, then summed and multiplied by three-halves to get the
comparison value. In either case, the three separate readings should be saved for future
comparisons.
7.7 Oil test

1) Instruction for taking oil samples
1. Oil sampling valve

2. Hose and connector
3. Sampling bottle
4. Vessel
௴FIG 7-3௵Taking an oil sample with a sampling bottle and vessel

2) To give the general condition of the oil, following tests are needed. The oil condition
can be judged in accordance with table 6-8 and Test report of oil.
- Acid number
- Dielectric breakdown (Refer to Table 6-8)
- Power factor
- 66 -
‫ٻ‬
- Moisture content (Refer to Table 6-8)
In field test, dielectric breakdown voltage is only available by oil-test set
7.8 Test of Bushing Current Transformer

1) Polarity check
2) Resistance Measurement
3) Megger test (If possible)
7.9 Test of alarm devices and control units

1) Actuate each accessory such as the temperature relay, buchholz relay, etc. or
short-circuit the terminal of such an accessory and check its performance from terminals
in terminal box and alarm panel.
2) Check that control units and accessories are cleaned.
3) Check that heat & power circuit are correctly connected..
7.10 Leakage test of transformer

The pressure of 0.3kg/᎚ which is preferable delivered by nitrogen gas / dry air would be
applied above oil level to the conservator or tank for more than 12 hours continuously, and
visually inspect to see if there are any oil leaks.
* Supply pressure up to 85% of operation pressure of pressure relief device.
7.11 Operational test of other equipment

1) Cooling fan and motor.(If provided)
2) Motor drive unit and manual drive unit of Tap changer. (If provided)
7.12 Valve check

Check that all valves are set at the right position.
7.13 Visual inspection

A visual inspection is a very elemental procedure. Check to following items.
1) Deteriorating gaskets 2) Oil leaks
3) Any damaged accessories 4) Chipped bushing skirt
5) Oil level of oil level indicator and silicagel breather. (If provided)
6) Damaged paint, etc
- 67 -
‫ٻ‬
8. ENERGIZATION OF TRANSFORMER
The transformer should be energized after rest time according to Table 6-7 (12-72hours in
accordance with voltage class). Whenever voltage is applied to the transformer, one stage
of forced cooling is operated and bringing the voltage up slowly if feasible. Hold at rated
voltage and no load for at least 24 hours. Check operation of auxiliary equipment during this
time. Observe transformer carefully, particularly critical temperature areas. Note excessive
audible noise and vibration. The transformer is now ready for service. However, observe
carefully for the first few hours after load is applied. After four or five days service it is
advisable to test dissolved gas of oil drained from sampling valve. If “Cold switching-on” of
transformer at negative temperature (less than -25ఁ) is required, load is applied step by
step with delay at each step at least 24 hours.
9. FACTORY REPAIRE PROCEDURE (CONTACT POINT)

Advice and assistance in dealing with any problems in the operation of our transformers is
readily available from HYUNDAI HEAVY INDUSTRIES CO., Limited, ULSAN KOREA.
Please note that when making any Enquirer concerning our transformers, or their associated
equipment, it is essential to quote the appropriate serial numbers. The serial number
positively identifies the equipment in question and the relevant technical data can them be
quickly and easily referred to by our engineers. The factory address is as follows.
- 68 -
‫ٻ‬
10. SUMMARY OF THE STORAGE METHOD OF THE LARGE POWER TRANSFORMER
1. Remmonded storage time after delivery

Recommended Check point & Maintenance
Sealed condition
Configuration storage time during storage Remark
before shipment
at field Check point Period
The tank is fully N2 gas 1)Gas pressure Weekly

Less than 6 Months
drained and filled
Active Pressure gauge &
with N2 Gas (or Dry parts regulator * gas pressure should be always kept
air) under pressure (Core/coil)
under positive pressure.
of 2 psi(at 25ଇ) Gas cylinder
The tank filled with

oil to cover the 1)Gas pressure Weekly
N2 gas 6 Months~ 12Months
core/coil assembly
2)Oil leakage Weekly
and the space of oil
Active
is filled with N2 Gas parts
(or Dry air) under (Core/coil)
3)Oil test At end of
pressure Oil - Water ppm storage
of 2 psi(at 25ଇ) - Breakdown(KV)
2. Long term storage more than 12 months
The oil preservation

Conservator 1)Oil level Monthly
More than 2)Oil leakage Weekly
system(Conservator)
3)Oil test Annually
should be Oil 1Year - Water ppm
assembled and filled - Breakdown(KV)
Active
with oil up to proper parts
- Acidity
level (Core/coil) Breather
* All accessories should be kept indoor to prevent from a contamination, corrosion, condensation, water penetration and etc.
* The surface of the tank and all exteriors should be kept from rust and corrosion.
- 69 -
‫ٻ‬
3. Procedure for movement and installation

Activities Procedure Inspection & Check points Remark
1. Before movement ሪ Check the transformer condition 1)Oil test
( Water ppm, Breakdown, Acidity)
2. Preparation for movement
1) Oil drain ሪThe tank should be filled with dry air
during oil drain and disassembling.
2) Disassemble ሪ Disassemble the conservator
ሪ All opening holes should be sealed with
the blind plates.
3) Gas filling ሪ Fill with dry air (or N2) up to the pressure of 1)Gas pressure
2 psi (0.21 kg/cm2)
4) Impact recorder ሪ Attach the Impact recorder on its mounting seat. 1)Recording paper, Battery
3. Before assembly Main tank ሪ Measure the dew point of the gas in main tank 1)Dew point
(after movement)
Bushing ሪ Check the bushing 1)Oil level and Insulation power factor
Fan ሪ Check insulation resistance of the fan & pump 1)Insulation resistance
motors
Radiator &
ሪ Check the inside of radiator & conservator visually 1)Visual check & Cleaning in side
Conservator
Others ሪ Check all accessories visually 1)Visual check
4. Assembly ሪ Follow the instruction manual HHIS-WZ-TE-100(08)
5. After assembly ሪ To determine the moisture content of insulation 1)Dew point

(Before start vacuum) and vacuum level and holding time based on
the dew point reading,
Measure dew point of the gas in tank
6. Vacuum, oil filling, circulation ሪ Follow the instruction manual HHIS-WZ-TE-100(08)
and site tests
** HEAD OFFICE **
1) HYUNDAI HEAVY INDUSTRIES CO., LTD
ELECTRO ELECTRIC SYSTEMS
TRANSFORMER PRODUCTION DEPARTMENT
1, CHEONHA-DONG, DONG-KU, ULSAN, KOREA, 682-792
2) HOMEPAGE: www.hyundai-elec.com
3) TEL: 82-52-202-8375, 82-52-202-7772,
4) FAX: 82-52-202-8665
5) E-MAIL: [email protected],[email protected] & [email protected]
** SEOUL OFFICE **
1) HYUNDAI HEAVY INDUSTRIES CO., LTD
ELECTRO ELECTRIC SYSTEMS
HYUNDAI B/D, 140-2, KYE-DONG, JONGNO-GU, SEOUL, KOREA
2) TEL: 82-80-029-5555 (Collect Call)
3) FAX: 82-2-3668-0888
- 70 -
‫ٻ‬
Doc No : TB-G-45-014-001
Vendor Data Book (Transformer) Rev No : 0X
2.9 Spare and Special Tool
Page 15 of 19G G
Plant : Document No. : Rev.
Al Dur IWPP BA-E-37-V001-001 2
Title : (Total 17 pages including cover)
Spare and Special Too List

for
Transformers
2 Mar. 30, 2010 FINAL Yeong-Dae Kim Tae-Ho Kim Jung-Su Lee
1 Nov. 26, 2009 ISSUE FOR CONSTRUCTION Yeong-Dae Kim Jung-Soo Lee Gyou- Chul Lee
0 Apr. 24, 2009 ISSUE FOR CONSTRUCTION Yeong-Dae Kim Jung-Soo Lee Gyou- Chul Lee
A Feb. 24, 2009 ISSUE FOR INFORMATION Yeong-Dae Kim Jung-Soo Lee Gyou- Chul Lee
REV. DATE DESCRIPTION BY CHK APP
Project :
KINGDOM OF BAHRAIN
AL DUR INDEPENDENT WATER & POWER PROJECT
Project Co. :
AL DUR POWER AND WATER COMPANY BSC(C)
EPC Contractor :
Vendor :
Doc No : BA-E-37-V001-001
Spare and_Special Tool List Rev No : 0
1.Spare and Special Tool List

1.1 Spare Part List for Erection and commissiong
1.1.1 3Ph 255/338 MVA, 230/15.75kV, Step-up Transformer(STG)
No. Description Specification Unit Q’ty Remark
1 Silica gel Silica gel kgG 80
2 Touch up paint RAL 7035 G 80
3 NFB 10EA per 1 Transformer Each Type(2ea) G 1

Aux. relay 2EA per 1 Transformer G
4 Each Type(2ea) 1
for fan control panel
1.1.2 3Ph 196/261 MVA, 230/15.75kV, Step-up Transformer(GTG)


4 Each Type(2ea) 1
1.1.3 3Ph 82/47-35//106/62-44 MVA, 15.75/11.5-11.5kV, Unit Auxiliary Transformer


4 Each Type(2ea) 1
1.1.4 3Ph 3 MVA, 11/0.415kV, Station Transformer

Page 2 of 17G G
Doc No : BA-E-37-V001-001
1.1.5 3Ph 3.3 MVA, 11/0.415kV, Station Transformer


1.1.7 3Ph 0.63 MVA, 11/6.9kV, Auxiliary Transformer

Page 3 of 17G G
Doc No : BA-E-37-V001-001
1.2 Spare Part List For Two(2) Years

Oil level gauge for main
1 TJD-0231G04H05 pc 1
conservator
Oil level gauge for oltc pcG
2 TJD-0265G04H01 1
conservator
Silica gel Breather for main pcG
3 T0115(5KG) 1
conservator
Silica gel Breather for oltc pcG
4 T0114(3KG) 1
conservator
5 Buchholz relay EE3-ML pcG 1
AKM34405-15X-12.0 pcG
6 Oil temperature indicator +PT100
1
AKM35406-15X-12.0 pcG
7 Winding temperature indicator +PT100
1
8 Pressure relief device 208-023-01 pcG 1

3PH 50HZ 400V pcG
9 Cooling fan with motor 2
(TJD-2137Q)
10 Complete set of gaskets NBR setG 1

RTKG 245-1050/2000 pcG
12 H.V Bushing 245KV 1050KV BIL 2000A
1
GOH 170-16 pcG
13 L.V Bushing 36KV 170BIL 16KA
1
COT 750-800 pcG
14 H.V Neutral bushing 170KV 750KV BIL 800A
1
Page 4 of 17G G
Doc No : BA-E-37-V001-001

1 TJD-0231G04H05 pc 1
conservator
Oil level gauge for oltc pcG
2 TJD-0265G04H01 1
conservator
3 T0115(5KG) 1
conservator
Silica gel Breather for oltc pcG
4 T0114(3KG) 1
conservator
AKM34405-15X-12.0 pcG
1
AKM35406-15X-12.0 pcG
1

3PH 50HZ 400V pcG
(TJD-2137Q)

RTKG 245-1050/2000 pcG
12 H.V Bushing 245KV 1050KV BIL 2000A
1
GOH 170-16 pcG
13 L.V Bushing 36KV 170BIL 16KA
1
COT 750-800 pcG
14 H.V Neutral bushing 170KV 750KV BIL 800A
1
Page 5 of 17G G
Doc No : BA-E-37-V001-001

1 TJD-0231G04H04 pc 1
conservator
2 T0114(3KG) 1
conservator
AKM34405-15X-12.0 pcG
1
AKM35406-15X-12.0 pcG
1

3PH 50HZ 400V pcG
(TJD-2137Q)

30F/4500 pcG
10 H.V Bushing 36KV 4500A
1
20F/4500 pcG
11 X.V Bushing 24KV 4500A
1
20F/4500 pcG
12 X.V Neutral bushing 24KV 4500A
1
20F/3150 pcG
13 Y.V Bushing 24KV 4500A
1
20F/3150 pcG
14 Y.V Neutral bushing 24KV 4500A
1
Page 6 of 17G G
Doc No : BA-E-37-V001-001

1 TJD-0265G04H01 pc 1
conservator
2 T0130(1KG) 1
conservator
AKM34405-15X-6.0 pcG
1
AKM35406-15X-6.0 pcG
1

25.8KV 400A pcG
9 H.V Bushing (TBA20041S)
1
10F/4500 pcG
10 L.V Bushing 12KV 4500A
1
10F/4500 pcG
11 L.V Neutral bushing 12KV 4500A
1
Page 7 of 17G G
Doc No : BA-E-37-V001-001

1 TJD-0265G04H01 pc 1
conservator
2 T0130(1KG) 1
conservator
AKM34405-15X-6.0 pcG
1
AKM35406-15X-6.0 pcG
1

25.8KV 400A pcG
1
20F/6300 pcG
1
20F/6300 pcG
1
Page 8 of 17G G
Doc No : BA-E-37-V001-001

1 TJD-0265G04H01 pc 1
conservator
2 T0130(1KG) 1
conservator
AKM34405-15X-6.0 pcG
1
AKM35406-15X-6.0 pcG
1

25.8KV 400A pcG
1
10F/3150 pcG
1
10F/3150 pcG
1
Page 9 of 17G G
Doc No : BA-E-37-V001-001

1 TJD-0265G04H01 pc 1
conservator
2 T0130(1KG) 1
conservator
AKM34405-15X-6.0 pcG
1
AKM35406-15X-6.0 pcG
1

25.8KV 400A pcG
1
15KV 400A pcG
10 L.V Bushing (TBA10041S)
1
15KV 400A pcG
11 L.V Neutral bushing (TBA10041S)
1
Page 10 of 17G G
Doc No : BA-E-37-V001-001
1.3 Spare Part List For Special Tools

1 Screw Drive set #8 (PLUS & MINUS) set 1
2 Open ended Spanner 10mm ૫ 32mm setG 1
3 Wire Stripper 1mm ૫ 3.2mm eaG 1
4 Socket Wrench 12.7SQ (10mm ૫ 32mm) setG 1
6" (9.5mm ଩ 20mm) eaG 1
5 Adjustable Wrench 10" (16mm ૫ 29mm) eaG 1
12" (19mm ૫ 34mm) eaG 1
#250 ( 6mm ଩ 26mm) eaG 1
6 Pipe Wrench #300 (10mm ଩ 32mm) eaG 1
#600 (38mm ଩ 65mm) eaG 1
7 Tool Box W600[L700×W250×H150] eaG 1

Sling Wire(84mmX7m) & eaG
8 Sling Wire & Shackle 4
SWL:85Ton
TS-10015(100Ton) & eaG
9 Hydraulic Jack 4
Hand Pump:THP-3A
Page 11 of 17G G
Doc No : BA-E-37-V001-001

6" (9.5mm ଩ 20mm) eaG 1
12" (19mm ૫ 34mm) eaG 1
#250 ( 6mm ଩ 26mm) eaG 1
#600 (38mm ଩ 65mm) eaG 1
7 Tool Box W600[L700×W250×H150] eaG 1

SWL:85Ton
TS-10015(100Ton) & eaG
9 Hydraulic Jack 4
Hand Pump:THP-3A
Page 12 of 17G G
Doc No : BA-E-37-V001-001

6" (9.5mm ଩ 20mm) eaG 1
12" (19mm ૫ 34mm) eaG 1
#250 ( 6mm ଩ 26mm) eaG 1
#600 (38mm ଩ 65mm) eaG 1
7 Tool Box W600[L700×W250×H150] eaG 1

SWL:35Ton
TS-5015(50Ton) & eaG
9 Hydraulic Jack 4
Hand Pump:THP-2A
Page 13 of 17G G
Doc No : BA-E-37-V001-001

6" (9.5mm ଩ 20mm) eaG 1
12" (19mm ૫ 34mm) eaG 1
#250 ( 6mm ଩ 26mm) eaG 1
#600 (38mm ଩ 65mm) eaG 1
7 Tool Box W600[L700×W250×H150] eaG 1

SWL:17Ton
9 Hydraulic Jack 4
Hand Pump:THP-2A
Page 14 of 17G G
Doc No : BA-E-37-V001-001

6" (9.5mm ଩ 20mm) eaG 1
12" (19mm ૫ 34mm) eaG 1
#250 ( 6mm ଩ 26mm) eaG 1
#600 (38mm ଩ 65mm) eaG 1
7 Tool Box W600[L700×W250×H150] eaG 1

SWL:17Ton
9 Hydraulic Jack 4
Hand Pump:THP-2A
Page 15 of 17G G
Doc No : BA-E-37-V001-001

6" (9.5mm ଩ 20mm) eaG 1
12" (19mm ૫ 34mm) eaG 1
#250 ( 6mm ଩ 26mm) eaG 1
#600 (38mm ଩ 65mm) eaG 1
7 Tool Box W600[L700×W250×H150] eaG 1

SWL:17Ton
9 Hydraulic Jack 4
Hand Pump:THP-2A
Page 16 of 17G G
Doc No : BA-E-37-V001-001

6" (9.5mm ଩ 20mm) eaG 1
12" (19mm ૫ 34mm) eaG 1
#250 ( 6mm ଩ 26mm) eaG 1
#600 (38mm ଩ 65mm) eaG 1
7 Tool Box W600[L700×W250×H150] eaG 1

Sling Wire(37mmX5m) eaG
SWL:17Ton
9 Hydraulic Jack 4
Hand Pump:THP-2A
Page 17 of 17G G

Power Transformer Erection Manual

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DOC.

SHIPMENT, STORAGE AND ERECTION

z Signal words such as DANGER, WARNING, CAUTION, NOTICE and Safety

Indicates an imminently hazardous situation, which, if not avoided,

Indicates a potentially hazardous situation, which if not avoided,

Indicates a potentially hazardous situation, which, if not avoided, may

Provides helpful information.

QUALIFIED OPERATORS ONLY

z A qualified person must:

2) Be skilled in the installation, construction or operation of the equipment and be aware of

4) Be trained and authorized to perform the service, maintenance or repair of this

6) Be trained in rending first aid.

2. SAFETY REGULATIONS ……………… 7

4. INSPECTION OF THE EQUIPMENT AFTER DELIVERY ……………… 18

5. STORAGE TRANSFORMER PRIOR TO ENERGIZATION ……………… 23

6. TRANSFORMER INSTALLATION ……………… 27

6.8.1 Cautions for vacuuming and oil filling

7. SITE TEST ……………… 61

Hazardous or unsafe working that has possibility of injury, death or property

1) Supports for Climbing

2) Lifting and jacking

4) Transformer Internal Pressure

5) Transformer Internal Atmosphere

8) Care on Transformer Cover

1) Working near Energized Transformer

3. SHIPMENT (and Transportation)

3.1 Main Transformer

3.3 Detail Parts

3.4 Impact Recorder: If requested

1) Unloading at the port

Take care against the following

The normal speed is as follows.

ᇪ : Less than 10ᇈ

(2) By freight car or truck.

3.6 Equipment of dry air or dry nitrogen gas for transportation.

ᐭࣜ Joint connection by connecting valve

௴ FIG 3-2 ௵ Schematic diagram of equipment (typical)

3.6.1 Check of equipment

3.6.2 Operation of equipment

2) Disconnect coupling to transformer ( ᐲ ).

࣯ࣥ Check the remained gas by checking the pressure on 2.1

9) Inside pressure of transformer is changed 0.035௥0.35 Ꭰ/᎚(0.5~5 psi) according to the

3.6.3 Replacement of empty gas bottle (Refer to FIG. 3-2)

1) Remove the cover plate from the case ᐳ.

2) Close the valve ᐵ.

7) Slowly open cylinder valve ᐵ

4. INSPECTION OF THE EQUIPMENT AFTER DELIVERY

4.2 Main tank

4.2.1 External Inspection

4.2.2 Impact recorder (If provided)

4.2.3 The gas pressure and dew point of transformer

3) Dew point of dry air;

௴ FIG. 4-1 ௵ Temperature difference versus pressure difference graph

4.2.4 Internal Inspection

4.4 Checklist of transformer after delivery

3. GAS GAUGE PRESSURE IN CYLINDER

4. IMPACT RECORDER 5. TANK DAMAGED

5. STORAGE TRANSFORMER PRIOR TO ENERGIZATION

5.2 Gas used for filling the tank

5.3 Preparations for Storage

1 Nitrogen gas or Dry air (-50୅ G GP Leak test