0-WD711-EE610-00002 - Operation and Maintenance Manuals For Aux. TR - Rev A

TOTAL 34 PAGE
Operation and maintenance manuals (Including Cover)

(FOR UNIT AUX TR.)
● PROJECT NAME : KALLPA 830MW COMBINED CYCLE CONVERSION Purpose

PROJECT
□ For Review
● PROJECT CODE : A90015EA ■ For Approval
● DOCUMENT No. : 0-WD711-EE610-00002 □ For Construction
● TITLE : Operation and maintenance manuals(Aux. TR)

□ For Bid
(FOR UNIT AUX TR.)
● OWNER : KALLPA GENERACIÓN S.A. □ For ( )
A 2011.05.20 H.W.JO S.W.Park B.S.MUN For Approval S.H.Kim J.S.Kim
Rev. PREP REVIEW APPR REVIEW APPR

DATE DESCRIPTION
No. HYOSUNG CORPORATION POSCO E&C
Owner:
KALLPA GENERACIÓN
S.A.
Contractor: Subcontractor
Document No 0-WD711-EE610-00002
Operation and maintenance manuals
(FOR UNIT AUX TR.) Rev.No A
Page 2 / 34
REVISION STATUS
Rev. No CONTENTS
A Submit the original document for UNIT AUX TR.
HYOSUNG CORPORATION
KALLPA GENERACION S.A Operation and maintenance manuals(Aux. TR)
Operation and maintenance manuals

For
Aux. Transformer
Item Description Q’ty

3P 60Hz 9580/12740/16000KVA
HJPVBD0040 1 Sets
18000-4160V Dyn1 (ONAN/ONAF1/ONAF2)
● Specification No. : HYW-850484
● KALLPA 830MW COMBINED CYCLE CONVERSION PROJECT
Head Office : 450 Gongduk-Dong, Mapo-Ku, Seoul, Korea 121-020/Tel.+82-2-707-6187/Fax.+82-2-707-6116
Changwon Plant : 454-2 Nae-Dong, Changwon, Korea 641-712/Tel.+82-55-268-9347/Fax.+82-55-268-9366
1 Printed in KOREA 2011

● Safety Notations
Kinds of Mark Meaning of Mark
Danger indicates an immanently dangerous
situation which, if not avoided, results in death
or serious injury to personnel. This signal
word is limited to the most extreme situation
Warning indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury
Caution indicates a potentially hazardous

situation which, if not to avoided, may result in
equipment or installation damage. It may also
be used to alert against unsafe practices.
Electrical Hazard warning

Section 1. Installation and Assembly of Power Transformer
1. Foreword
2. Receiving Transformer and Accessories
3. Inspect Materials on Car
4. Impact Recorder
5. Insulation Dryness
6. Check Your Oil
7. Recommended Tests for Possible Transit Damage
8. Moving and Handling
9. Installing Equipment
10. If You can’t install immediately
11. Storage of Transformer
12. Working inside of Transformer and Maintaining Installation Dryness
13. Assembly
14. Vacuum Equipment and Procedures
15. General Conditions during Oil Processing and Filling
16. Final Vacuum Filling
THE SAFETY NOTATIONS ARE HEADED BY ONE OF TWO HAZARD INTENSITY LEVELS WHICH ARE
DEFINED AS FOLLOWS :
1. DANGER -- Immediate hazard which will result in severe personal injury, death or
property damage.
2. WARING -- Hazard or unsafe practice which could result in severe personal injury,
death or property damage.
3. CAUTION -- hazard or unsafe practice which could result in minor personal injury, or
property damage.

1. Foreword
Every man who works on the receiving, installation and storage of a power transformer should be
constantly aware of what he should not do to protect the quality and reliability of the transformer.
Because of the turnover among personnel responsible for receiving, installation, and storage in the
last few years there is a real need for an educational program which emphasizes all he precautionary
measures necessary.
The ideas offered are intended to help receiving, installation, and storage personnel protect the high
quality and reliability HICO builds into all its transformer. This will also protect the quality and reliability
reputation of the installers, enabling them to energize an extremely valuable transformer with
minimum problems and maximum results.
The first step in a good field installation is to sit down with the customer, contractor, and the work
foreman. Explain, before starting installation, how the transformer should be handled according to the
instruction leaflet furnished with the unit, the necessary equipment and its availability. The customer
or contractor should, or must, make up a list of material and equipment, such as the following items ;
Equipment, tools, dry nitrogen, vacuum pump, oil filter press, pipe or hoses for vacuum and oil,
vacuum gauge, proper pressure, 1000volt Megger, ratio test set, oil test set, clean dry rags, humidity
indicator, oil storage tanks, and anything else that applies to that particular transformer should be on
hand before starting installation.
2. Receiving Transformer and Accessories
It is very important that personnel responsible for receiving transformers know the type of unit being
received and conditions of shipment from HICO. A thorough external inspection and check of the unit
(as well as the transformer accessories on the carrier equipment) should be made before accepting it.
The manufacturer may have a warranty against defective workmanship, design, etc., however, this
does not relieve the receiver or customer of his responsibility if he accepts damaged transformers or
accessories from the carrier. Transformers are shipped under varying conditions by electrical
manufacturers. Shipping conditions vary also, due to customer requirements on manufacture, weight
and size of unit, the ability of the carrier to deliver, as well as the receiver to handle the unit at the job
site.
Persons making inspection of transformers as delivered by carrier should be customer's engineer,

supplier's engineer or service engineer, and the storekeeper or contractor.
If visual inspection reveals external damage, shifting of load on car, oil leaks, loss of gas pressure on
transformer tank, etc., the customer should contact the delivering carrier claim agent at once and
have him make an inspection of the equipment with you, and then the customer should file the proper
claim or claims against the delivering carrier.

3. Inspect Materials on Car
Check the shipping bill of material against the material received. Make sure that everything
(transformer parts, tools, and facilities) needed for proper installation is on hand and in good condition
before you remove the unit from the car or open it. Claim should be turned in against the carrier if
visual damage or shifting of load is evident. Check the details as well. Look for the following during
receiving inspection ;
• Has transformer shifted from original loading position endwise or sideways
• Have anchoring rods or spring loaded Dyna-Comp been bent, loosened, or broken ?.
4. Impact Recorder
4.1 Definition
An impact recorder is an instrument used to record the time and severity of transportation shocks
or impacts which may occur to our commodities during transit.
4.2 Examination
The Download Report of impact recorder presents the important information. The report presents
the Time Slots graph, an Event Summary graph, and the most severe event as well as
configuration information. The report time can be adjusted to focus on an area of the mission.
This Report must be examined before unloading, preferably with a carrier representative. After the
report has been examined and signed, it should be immediately replaced in the recorder and
returned to the HICO location from the transformer was sent.
4.3 The customer will be notified where shipments are delivered with impact recorder.
The customer is required to accept full responsibility for unloading roughly handled or damaged
equipment.
The recorder is part of the shipment. If it is missing or damaged, the seal broken, for has been
disturbed in any way, a specific carrier's inspection report must be issued by the carrier, to relieve
the customer of responsibility for the recorder.
a. Examine the recorder in the presence of the carrier's agent. Both the carrier and customer
personnel sign and date the tape where impacts are recorded in zone B or above.
b. Where possible damage is indicated, the customer should notify HICO representative (if one is
not present at that time) for advice before unloading and also if zone B or above is recorded.
c. Promptly return the signed tape and impact recorder immediately.
4.4 Judgement
The impacts recorded are classified into three zones and we can assume how big shocks are
applied to the transformer according to the following rules.
a. Zone-A
The G-range of this zone is under 3G, including 3G.
The condition of the transportation/shipping in this zone is good. So, we assume that there are
no damages in the transformer caused by the shocks.

b. Zone-B
The G-range of this zone is between 3G and 6G , including 6G.
The condition of the transportation/shipping in this zone is no good. So, we assume that the
transformer had some harmful damages caused by the shocks. In this case, the transformer
have to be checked the followings.
- Internal visual inspection

- External visual inspection
- Electrical test
• Exciting current
• Phase relationship and polarity test
• Ratio test
• Insulation resistance test
• BCT test
• Function test for all protective devices
• Dielectric test
• Impulse test
But dielectric and impulse tests are not available because of test equipment at site. Because of
this, even though the results of visual inspections are acceptable, the transformer must be
checked carefully for several months after energizing.

5. Insulation Dryness
Drying operations in the factory reduce the moisture content of the paper insulation to a very low level.
This dry condition should be maintained. If there are reasons to question the dryness, the amount of
moisture can be estimated by a dew point measurement for units shipped in dry gas, or by
measurement of insulation resistance or of insulation power factor for units shipped in oil.
The dew point can be measured using an apparatus such as SHAW moisture meter or Alnor
Dewpointer. In making dew point measurements, at least 24 hours should elapse after the
transformer has been sealed and filled with dry gas following vacuum or draining of oil, so that the
gas can come to equilibrium with the surfaces of the insulation. Measurements of dew point made at
intervals several hours apart may be helpful in determining when equilibrium is reached. An estimate
must be made of the average temperature of the transformer insulation. This will require some
judgement, depending upon the weather conditions and exposure of the transformer to wind and
direct sun.
The dry air in the transformer should be at a slight positive gauge pressure, preferably not higher than
2 psi gauge when the dew point is measured.
To determine if dryness is acceptable refer to CURVE 1. Enter the curve horizontally from the left at
the estimated insulation temperature. At the dew point line, move vertically to the dew point scale. For
satisfactory dryness, the measured dew point temperature must be lower than the Temperature
determined from CURVE 1. If the transformer is oil filled, insulation resistance and power factor
measurements should be made and compared with measurements made at the factory.
Factory measurements of insulation resistance and power factor are obtained with the unit oil filled.
Therefore, direct comparison of these quantities when measured with gas instead of oil in the unit is
not possible.
If there are indications of moisture in the insulation the factory should be contacted immediately for
confirmation of the analysis of the measurements, and for recommendations for the drying procedure
to be followed.
• Does visual inspection show external damage to transformer case, cover, drain valve,
cooler valves or any other external accessories mounted on the transformer during
shipment?
• Does the transformer have oil leaks?
• The detail equipment, separately loaded shipped for assembly with transformer at
location, must be carefully inspected for damage or mishandling during transit.
Proper storage is also very important.

6. Check Your Oil
All oil, whether in drums, tank car, or in customer's storage, must be checked and tested for dielectric
strength, power factor and water content. Limits are given hereinafter.
TRANSFORMER OIL SHOULD ALWAYS BE HANDLED AS A

FLAMMABLE LIQUID. IT SHOULD ALSO BE REMEMBERED THIS CLOSED TRANSFORMER
TANK MAY UNDER SOME CONDITIONS ACCUMULATE EXPLOSIVE GASES, AND THAT OIL-
HANDLING PROCEDURES MAY GENERATE STATIC ELECTRICITY. SAFETY PRECAUTIONS
SHOULD INCLUDE PURGING ALL GAS SPACE WITH NITROGEN BEFORE OIL FILLING OR
FILTERING AND GROUNDING THE TRANSFORMER, ITS BUSHINGS, AND ALL OIL-
HANDLING EQUIPMENT.
Samples of oil should be drawn from the lowest point of each container in which oil is received. These
samples must be tested and inspected. Do not use oil from any container unless the sample meets all
of the following requirements :
• Visually Detectable Water – None

• Dielectric Strength - 30kV Minimum with a 2.54 mm gap (IEC60296)
• Power Factor - 0.1% Maximum
• Water Content - 50 ppm Maximum
The temperature of the oil when it is added to the transformer during vacuum filling must be 50℉
(10℃) or higher. If the transformer is to be opened after adding oil, the oil temperature must be at
least 50℉ (10℃) higher than the dew point of the outside air.
Oil should be pumped into the top of the transformer through oil conditioning equipment which will
provide clean oil with a maximum water content of 50 ppm. It is necessary in cold weather, to have
heaters in the oil line so that the temperature of the oil going into the transformer can be as high as
possible (but not to exceed 167℉ (75℃)). The pumps, valves and piping should be arranged so that
the oil is at a slight positive gauge pressure until it reaches a throttling valve just before the oil enters
the transformer.
The throttling valve and all connections between it and transformer should be checked carefully for
leaks, in order to prevent air and moisture from being drawn into the oil as it enters the transformer.
To ensure that all moisture, sludge, carbon and other foreign materials are removed before oil is
pumped into the transformer, oil lines should be thoroughly cleaned and flushed. At the same time,
the filter press should be checked to ensure that clean, dry filter papers have been installed. Pump,
as well as oil lines are cleaned by circulating oil through them with filter press. Check oil sample in
test cup before connecting oil line to top filter press valve.
The use of a filter press is mandatory, and one must be used for filling for adding oil to all
transformers. Place the filter press as close to the transformer as practical, thus reducing change of

contamination of the oil after filtering. Make sure the oil line has sealed joints.
Oil temperature must be above 50℉ (10℃) before it enters the transformer during vacuum filling.
(Oil heaters may be necessary).
If oil samples from the shipping containers test below 30kV with a 2.54 mm gap (per IEC60296),
continue passing oil through filter press until it meet the prescribed dielectric strength (min. 30kV)
before starting to fill transformer with oil through the top filter press valve. This is a must.
Oil heaters may be required for initial oil filling from Fall through the Winter months.
Heater and degassing equipment is recommended during oil filling.
7. Recommended Tests for Possible Transit Damage
1.1 Check pressure on unit with pressure-vacuum gauge. If zero reading, purge with dry air and
check for leaks. Note that pressure varies with temperature, and this factor should be considered.
1.2 Check percent moisture content in transformer. It should never exceed dew point in Curve 1.
MAKE CERTAIN THAT ALL SHIPPING GAS IS REPLACED BY DRY

AIR BEFORE ENTERING TO MAKE A VISUAL INTERNAL INSPECTION.
7.3 Check de-energized tap changer alignments and contacts with nameplate. Check for shifting of
core and coils, and check for breakage, loose or lost bolts, nuts, etc.
1.4 Make ratio test on all windings and taps. All windings and taps should check within 1/2 of one
percent. Tank should be open to the atmosphere during tests with dry air flowing through the
transformer.
1.5 Check winding continuity and resistance if unit is off ratio.
1.6 After filling with oil make Megger test on insulation resistance. HV to XV and GR, XV to HV and
GR, and HV and XV to GR. Coils should be under oil for comparison with shop measurements.
7.7 If core yoke shows signs of shifting, disconnect core ground bushing and end frame ground
bushing from tank cover and test end frames to core with 1000 volt Megger. This might happen
when unit has been subjected to severe shocks in transit by carrier.
(Minimum acceptable valves are 50 mega-ohms.)

1. ENTER CURVE AT INSULATION TEMPERATURE ℃ LEFT OR ℉ RIGHT.
2. MOVE TO DEW POINT LINE.

3. READ THE MAXIMUM ACCEPTABLE DEW POINT, ℉ ON BOTTOM OR ℃ ON TOP
4. USE THIS CURVE FOR PRESSURE BETWEEN 0 AND 5 PSI.
Curve 1. Dew point limit

8. Moving and Handling
NEVER ATTEMPT TO MOVE A FULLY ASSEMBLED TRANSFORMER.

MOVING A FULLY ASSEMBLED TRANSFORMER MAY CAUSE DAMAGE TO THE EXTERNAL
APPURTENANCES OR INTERNAL STRUCTURES.
CONTACT OUR LOCAL REPRESENTATIVE FOR SPECIAL INSTRUCTIONS PRIOR TO
MOVING ANY TRANSFORMER.
TRANSFORMERS MUST BE MOVED IN THE UPRIGHT POSITION UNLESS THE UNIT WAS
ESIGNED FOR HORIZONTAL SHIPMENT. THE OUTLINE DRAWING AND THE EXTERNAL
ASSEMBLY DRAWINGS SHOW THE POINTS FOR LIFTING, JACKING OR PULLING THE
TRANSFORMER. NEVER ATTEMPT TO LIFT OR MOVE A TRANSFORMER FROM ANY PART
OTHER THAN THE FITTINGS PROVIDED FOR THAT PURPOSE.
8.1 Setting the transformer on the foundation

Note the transformer base diagram on the outline drawing and be certain the foundation pad and
piers support the transformer in the designated areas. In some instances a separate base diagram
is supplied and it will be included in the instruction book.
8.2 Cooling air requirements

The transformer must be positioned so that adequate air circulation is provided to cool the
transformer.
9. Installing Equipment
9.1 Equipment for transformer installation
• Oil purifier with hose (>6000ℓ/h)

• Vacuum pump with horse (>3000ℓ/min)
• Vacuum gauge (Up to 0.01 torr)
• ARC welder
• Compressor
• Hydraulic crane
• Main lifter
• Vacuum chamber
• Hydraulic compressor
9.2 Equipment for transformer site test
• Oil Tester (>60kV/2.5mm)

• Megger (1000V, 2000MΩ)
• Megger (500V, 1000MΩ)
• Multi Tester (Voltage/ohm/current)
• Hook Meter

• Oxygen Meter
• Hygrometer
• Dew Point Meter
• Temperature Meter
• Power Factor Meter (10kV)
• Buzzer (DC)
• Dry Air
• N2 Gas
9.3 Tool list
• Spanner (10, 11, 13, 14, 17, 19, 22, 24, 27, 30, 32, 36, 42, 46)
• Ratchet Wrench (13, 17, 19, 22, 24, 27, 30)
• Box spanner (17, 19, 22, 24)
• Pipe wrench (Large, Medium, Small)
• Adjustable wrench (6, 8, 10, 12, 15 inches)
• Hygrometer
• Glue for O-ring
9.4 Special tools
• Vacuum Hose with 1 inch adjustable flange

• Vacuum sensor with recorder
• Dry Air Hose with 2 inches flange
• 2 inches adjustable flange for oil filling & filtering
10. If You Can’t Install Immediately
When a transformer arrives at its destination but PERMANENT connection location is not yet ready,
it may be necessary to store it temporarily. When this happens, such factors as length of storage
time, location and method of storing must be carefully on considered.
Each of the following conditions require a different method of storage, so each will be discussed
separately in the following sections.
• Temporary storage of transformers in dry gas - 3 months maximum
• Storage in oil (completely assembled)
• Storage in oil (not completely assembled)
11. Temporary Storage of Transformer in Dry Gas 6 Months Maximum
11.1 Temporary storage of transformers in dry gas (6 months maximum)

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 gas pressure up to six months from date of
shipment.

If the transformer is to be stored in dry gas, do not remove dehydrating material. Be careful to
prevent the loss of nitrogen pressure, or air entering the transformer during the percent oxygen
test and pressure check(5% oxygen maximum).
Transformer stored in gas for a period up to six months will require positive assurance that the
gas pressure is continuously maintained. The easiest method of accomplishing this is using inert
equipment.
The inert dry gas equipment should be installed as soon as the transformer is on a solid level
foundation in the storage area. This should be done within a few days, not exceeding one week,
after delivery of transformer.
See CHECKING TRANSFORMER AT TIME OF ARRIVAL if the transformer received is not

equipped for inert dry gas. Temporary pipe connections can be made between inert dry gas
equipment, the top filter pressure valve, or vacuum connection on tank cover.
After installing the inert dry gas equipment and a full cylinder of dry nitrogen, pressure test
transformer for four hours at 4.2 PSI (0.3 kg/cm2) pressure by increasing nitrogen pressure and
checking tank for leaks with soap suds. After pressure test, reduce pressure to 1.4 PSI (0.1
kg/cm2).
A positive dry gas pressure must be maintained at all times.
Reading of transformer gas pressure and cylinder pressure should be recorded every day for the
first two weeks. These reading 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, the pressure readings may be reduced to once every seven
days.
An accurate log is important as it may be the determining factor in any decisions that may have to
be made on further drying of the windings.
Transformers should not be stored more than three months in this sealed condition.
To place unit in service, the same procedures should be applied as though the transformer had
just been received. Follow recommendations under "Checking Transformer at Time of Arrival."
When vacuum filling with oil extend the vacuum cycle, prior oil filling, by an additional four hours.
Check List :
a. Place transformer on a solid, level foundation.
b. Install and connect inert dry gas equipment.
c. Fill with dry gas to a pressure of 1.4 PSI (0.1 kg/cm2). A positive dry gas pressure must be
maintained at all times. Make 4.2 PSI (0.3 kg/cm2) pressure test on tank.
d. Keep daily record of gas pressure for 2 weeks.
e. Then keep a weekly record of pressure for entire storage period.
f. If the gas pressure remains constant in the nitrogen bottle, and there is a positive pressure in
the transformer, it can be assumed that the tank is gas-tight.

Note that temperature changes will change pressure readings.
WHERE THE UNIT IS NOT STORED COMPLETELY FILLED WITH

OIL, SPECIAL ATTENTION SHOULD BE GIVEN TO GAS LEAKS. ONE SMALL LEAK CAN
LOSE A DANGEROUS AMOUNT OF GAS.
WHEN THE GAS PRESSURE FALLS DUE TO A LEAK, THE TRANSFORMER WILL
BREATHE IN MOIST AIR.
MOISTURE REDUCES DIELECTRIC STRENGTH OF THE INSULATION AND OIL.
11.2 Storage in oil (completely assembled)

If the transformer must be stored for more than three months, we recommend complete assembly
and vacuum filling with oil as noted in the appropriate installation leaflet. 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 for this to apply.
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 HICO.
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.
Also make insulation resistance and power factor tests and compare with factory test values. If all
test results are satisfactory, the transformer may be energized.
If the transformer is equipped with pumps, operate one half of the pumps for 30 minutes and then
operate the other half for 30 minutes. Repeat this operation every three months during the
storage period.
11.3 Storage in oil (not completely assembled)

If the transformer cannot be completely assembled and storage beyond 3 months is anticipated,
the transformer should be vacuum filled with oil and an oil preservation system installed.
Transformers with sectionalized tanks must have the permanent top section installed.
Transformers that use COPS(Conservator Oil Preservation System) oil preservation system must
have the liquid level checked daily for the first two weeks. After two weeks, the liquid level must
be checked once a week. An accurate log of the level and date of reading must be maintained
and be available upon request.
If the transformer uses the inert dry gas oil preservation system or the oil preservation system is
COPS and is not going to be installed before storage, a positive internal pressure must be
maintained.
For transformers with COPS system not mounted, temporary pipe connections can be made and
HICO can obtain, upon request, the necessary inert dry gas equipment.
Vacuum fill the transformer until the oil level is 12 inches from the cover. Break the vacuum with
dry nitrogen.

After installing the inert dry gas equipment, pressure test the transformer for four hours at 6 PSI
gauge pressure. Then check the tank for leaks.
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.
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 the
transformer using the procedures in the installation leaflet.
12. Transformer Installation Procedures
FAILURE TO SUPPORT THE TRANSFORMER BASE PROPERLY MAY

RESULT IN DAMAGE TO THE TRANSFORMER TANK AND ADJACENT APPARATUS IN THE
SUBSTATION.
Move the transformer into position on the substation pad and make certain the base is level. Install
shims under the base for leveling if necessary. The pressure relief device must be installed on the
transformer during the assembly and oil filling procedures.
The recommended procedure for assembly and oil filling transformers is to introduce dry air into the
transformer and perform the internal assembly operations.
12.1 Opening the transformer

When you open a transformer, take precautions to prevent moisture or dirt entering the
transformer or moisture condensing in the transformer. Always observe these precautions:
DO NOT ENTER ANY TRANSFORMER UNTIL THE GAS IN THE

TANK IS REPLACED BY DRY AIR. OXYGEN CONTENT INSIDE TRANSFORMER MUST BE
MIN 19.5% & MAX 30% BEFORE ENTERING THE INSIDE FOR INSPECTION AND INTERNAL
FITTING.
DRY AIR SHIPMENT DOES NOT IMPLY THAT THE OXYGEN CONTENT TEST MAY BE
SAFELY OMITTED. THE OXYGEN CONTENT MUST ALWAYS BE CHECKED. OXYGEN
CONTENT MIN 19.5% & MAX 30% MAY CAUSE DROWSINESS AND/OR INJURY AND
DEATH.
12.2 Purging gas from the transformer tank

Measure the oxygen content of the gas in the transformer. If the oxygen content is less than 19.5%, the transformer
must be purged and filled with air of the recommended oxygen content. The purge may be accomplished by
evacuating the transformer to a pressure of 5 Torr or less and filling with dry air.
12.3 Breaking vacuum

Never break vacuum with atmospheric air, always use dry air or dry nitrogen.
12.4 Weather
Do not open the transformer or leave it open during rapidly changing weather conditions, unless
the opening is completely protected from weather.
12.5 Clothing
Never enter a transformer with dirty or wet clothing. Clean cloth shoe covers or nitrile rubber
overshoes must be worn.
12.6 Ventilation of tank

Dry air must be used to ventilate the inside of the tank when it is opened for internal fitting or for
inspection. These restrictions must also be followed :
a. The dry air must have a dew point not higher than -58℉(-50℃).
b. Purge all air hoses with dry air to remove all moisture and dirt prior to use.
c. Use a pressure regulator to reduce the pressure of the incoming air.
d. Dry air should be blown into the transformer below the working level to maintain flow of air
out through the cover opening. Air hoses may be taken into the transformer if they are
clean, dry and made from an oil-proof material.
d. The dry air flow rate should be adjusted to maintain continuous airflow outward through the
tank openings. To conserve dry air and prevent the entrance of dirt and moisture, place a
light cover of plywood, hardboard, or plastic over the manhole opening. The work should be
performed in a sequence such that when accessories such as bushings are being installed,
only one opening other than the manhole will be open at any time.
12.7 Maximum internal relative humidity

Never work inside the transformer if moisture is forming on the internal surfaces.
NEVER OPEN THE TRANSFORMER, IF HUMIDITY IS ABOVE 85%.
12.8 Temporary closing of the transformer
a. Remove all the tools and working material from the transformer.
b. Continue to purge the transformer tank with dry air for 30 minutes after all the material has
been removed.
c. Seal the tank and pressurize it with dry air to 3 PSI.

d. If the next work period and re-opening of the transformer will not occur within three days, we
recommend after sealing the tank, that you pull vacuum on the transformer to an absolute
pressure of 2 torr or less and hold this level for 4 hours. Break the vacuum with dry air and
pressurize the tank to 3 PSI.
13. Assembly
Dry air must be used ventilate the inside of the tank when it is opened for internal fitting.
13.1 External assembly

The items removed and shipped separately are listed on the packing list. The items generally
removed and shipped separately are the bushings, cooling equipment, mounting brackets, etc.

The number of accessory items removed will vary depending on the physical size of the
transformer.
All air or gas fittings and all oil fittings that are pre-assembled at the factory must be checked for
leaks.
13.2 Radiators with fans

Radiators with fans and piping shipped as accessory items that are to be assembled at the final
location must be thoroughly inspected prior to installation to be certain that no water or foreign
material is in the oil space.
Avoid opening the equipment when it is at a temperature lower than the ambient air in order to
prevent condensation. If there is any evidence of moisture contamination, the equipment must be
thoroughly dried by flushing with hot oil. The radiators should be installed on the transformer the
same day they are opened. Do not permit the cooling apparatus to stand exposed after opening
for inspection or flushing.
Vacuum procedures may be started on the main tank prior to completion of the installation of the
cooling equipment. When all of the cooling is installed, a minimum of 4 hours of additional
vacuum processing is required on these components prior to beginning oil filling.
DO NOT ATTEMPT TO OPERATE THE PUMP VALVES WHEN THE

PUMPS ARE IN OPERATION. ALWAYS SHUT OFF THE PUMP MOTOR BEFORE OPENING
OR CLOSING ANY VALVES. FAILURE TO FOLLOW THESE PRECAUTIONS MAY CAUSE
EQUIPMENT DAMAGE AND PERSONAL INJURY.
13.3 Internal assembly (If it be needed)

The following procedure should be followed to maintain a flow of dry air during assembly.
a. Prepare the connections for the dry air supply to the tank space below the core and coils.
b. Purge the air hoses with dry air from the supply to remove any moisture and dirt in the
hoses prior to use.
c. Connect air hose to transformer.
d. Be certain the internal pressure in the transformer is at zero gauge before opening the
manhole cover.
e. Open the manhole cover of transformer.
f. Start the air flow into the transformer. The volume must be sufficient to maintain continuous
air flow outward through the tank openings.
Be certain the internal pressure in the transformer

is at zero gauge before opening the manhole cover.
DO NOT ENTER TRANSFORMER OR BREATHE THE INTERNAL

ATMOSPHERE UNLESS THE OXYGEN CONTENT OF THE AS INSIDE THE
TRANSFORMER IS MIN 19.5% & MAX 30%. OXYGEN CONTENTS LESS THAN THIS CAN
CAUSE DROWSINESS, INJURY OR DEATH. TRANSFORMER SHIPPED IN GAS ARE NOT

SAFE TO ENTER. ALWAYS CHECK THE OXYGEN CONTENT.
TO PREVENT DAMAGE TO THE TRANSFORMER INTERNAL

STRUCTURES IT MAY BE NECESSARY TO INSTALL CLEAN TEMPORARY STRUCTURES
ABOVE THE CORE AND COILS TO SUPPORT WORKERS INSIDE THE TRANSFORMER.
13.4 Bushing installation

The bushings will be removed for shipment to meet shipping clearances and to avoid shipping
damage to the bushings. A method of supporting the bushing leads is to tie the coiled lead to the
highest point on the transformer super-structure.
The bushings removed for shipment should remain in the shipping crates until they are required
for the transformer assembly. Clean the bushing thoroughly before installing it in the transformer.
The bushings have accessories (bottom terminal, top terminal) and the accessories must be
assembled before transformer assembly.
13.5 Bushing current transformer
AN ENERGIZED CURRENT TRANSFORMER IS DANGEROUS IF

THE SECONDARY IS AN OPEN CIRCUIT. DEATH OR ERIOUS INJURY CAN RESULT
FROM CONTACT WITH THE TERMINALS. THE SHORT CIRCUITING DEVICES MUST BE
ONNECTED TO THE APPROPRIATE TERMINALS IN THE CONTROL CABINET IF THERE
IS NO LOAD CONNECTED TO THE CURRENT TRANSFORMERS.
13.6 Recommended assembly sequence

Assemble unit in the following order (refer to “Section 6. Bolt & nut tightening” for torques).
a. Install Radiators with fans

b. Install Radiator bottom supporters
c. Install Arrester supporters
d. Install HV, LV Arrester supporters
e. Install Bushings
f. Install air chamber
g. Install breather & other accessories
h. Install Arrester earthing cable
13.7 Closing the transformer and final dew point measurements

Remove all the tools and working materials from the transformer. Seal the unit and evacuate to 2
Torr or less, hold for 4 hours, and fill with dry air to 3 PSI. Allow the transformer to sit under
pressure for at least 12 hours, until equilibrium has been reached, and then measure the dew
point. If the dew point is in the acceptable range on curve 1, proceed with final vacuum filling
procedures.

If the measured dew point is not in the acceptable range on curve 1, additional processing is
required to remove moisture. The process requires raising the temperature of the core and coils
while the transformer is under vacuum (refer to section 14.1).
14. Vacuum equipment and procedure
14.1 Core and coil temperature

The primary purpose of vacuum drying is to remove moisture and absorbed gas. To remove
moisture with vacuum only, the temperature of the core and coils must be above 50℉ (10℃).
The following procedure may be used to elevate the temperature of the core and coils just prior to
vacuum procedures required in paragraph 16.
a. Drain all oil from transformer

b. Pull the vacuum specified in Table II. Hold at this vacuum or less for 30 Minutes.
c. Spray hot oil in through the cover of the transformer. Maintain a vacuum of 10 Torr or less
on the transformer during the oil spraying operation in order to prevent oxidation of the oil
and to aid in the removal of gas from the insulation. Pump the oil from the bottom of the
transformer through filters or degassing/dehumidifying equipment, and through a heat
exchanger, and back to the cover of the transformer.
Use the minimum amount of oil necessary to establish circulation. Degassing/dehumidifying

equipment is the preferred method for this process.
The oil temperature entering the top should be between 122℉ (50℃) and 167℉ (75℃). Continue
the hot oil circulation under vacuum until the temperature of the core and coils is 50℉ (10℃) or
higher. The temperature of the core and coils will be elevated to equilibrium conditions when the
output oil temperature becomes constant. At this point, the temperature of the core and coils can
be assumed to be near the temperature of the output oil.
The heating rate can be increased by closing the bottom valves to the coolers or radiators and by
using simple blanketing on the outside of the tank.
14.2 Vacuum pumps

To attain the vacuum levels specified and to maintain these levels during oil filling, a good
vacuum pump with adequate capacity is required.
Normally a pump with 150 CFM capacity is adequate. The pumps must be capable of attaining a
blank off pressure of 0.2 Torr or less.
14.3 Vacuum connections

Connections from the pump to the transformer tank must be as short as possible and a diameter
of three inches. There should be no low spots in the vacuum line in which oil or water can collect.
The vacuum system must be capable of attaining a blank off pressure of 0.3 Torr or less.
The vacuum piping must be arranged so that oil will not splash or spray from the oil pumping into
the vacuum line. Most systems provide an oil trap in the vacuum line to protect the pump from the
insulating oil. The efficiency of most pumps is dependent upon the conditions of the pump oil. If

the pump oil becomes cloudy from moisture or thins out because of insulating oil contamination it
should be changed
14.4 Pressure measurement

The pressure in the tank during vacuum operations must be measured through a connection to
the top section to the section of the tank above the oil level. Do not use pressure measurement at
locations other than the tank itself. We recommend measuring the pressure in the tank with a
properly calibrated aneroid gauge or manometer. If mercury gauges are used, a trap must be
provided which will prevent mercury from entering the transformer.
14.5 Vacuum leak test

The entire vacuum system must be free from leaks. Otherwise it may be difficult or impossible to
attain the specified vacuum levels. Also, any leaks will permit moist air water to be drawn into the
transformer.
When the required vacuum level (see table III) is reached, close the valve connecting the
transformer to the vacuum pump. Wait for ten minutes and then begin monitoring the pressure. If
the pressure rises more than the value specified in Table I, the transformer should be checked for
leaks and the leaks sealed before proceeding.
If all the leaks have been repaired and this rate of pressure rise cannot be obtained, this may
indicate that the transformer insulation is wet. Check the dew point.
Table I. Leak Rate

Maximum Allowable Leak Rate
Tank Oil Volume (Gallons)
(Torr Rise in 10 Minutes)
Less than 5000 0.80
5001 – 7500 0.53
7501 – 10000 0.40
10001 – 12500 0.32
12501 – 15000 0.27
15001 – 17500 0.23
17501 - 20000 0.20
20001 - 22500 0.17
15. General conditions during oil processing and filling
15.1 Weather
It is permissible to perform operations during inclement weather if the following conditions are
met:
a. The tank shall have been vacuum tested as noted in these instructions.
b. The transformer top must be covered with tarpaulin or other suitable cover to prevent free
water from collecting on the tank cover.
c. The vacuum level must be monitored closely for any sudden rise in pressure indicating a
leak in the tank.

15.2 Vacuum application

The transformer tanks are designed to withstand full vacuum.
15.3 Vacuum procedure

The evacuation and oil filling operations are intended to be a continuous uninterrupted process.
If the power to the vacuum pump is interrupted, close all the valves and seal the transformer. If
the internal pressure does not exceed 20mmHg by the time the power is restored, open the
valves and continue the vacuum filling. If the internal pressure exceeds 20mmHg, purged
vacuum and the process re-started. Use dry gas to break the vacuum.
15.4 Oil filling

Transformer oil is very sensitive to contamination. Tanks, pumps, pipes, and hoses in which the
oil is shipped or handled must be clean and free from moisture and other contaminants.
THESE TRANSFORMERS WERE PROCESSED AND FILLED WITH

OIL AT THE FACTORY THAT MET THE FEDERAL PCB REGULATIONS IN EFFECT AT THE
TIME. THE PURCHASER SHOULD TAKE THE NECESSARY PRECAUTIONS SO THAT PCB
CONTAMINATION IS NOT INTRODUCED DURING THE FIELD OIL FILLING OR
MAINTENANCE OF THE TRANSFORMER.
Tests must be made of each shipping container (drum, tank, truck or railroad car) of oil. The
dielectric strength, power factor and water content must be determined.
As received electrical strength, measured per ASTM D-877, must be at least 30kV with a 2.54
mm gap. The power factor shall not exceed 0.05% and water content shall not exceed 50 ppm at
68℉ (20℃). The oil must be tested and meet these specifications before it is used for filling a
transformer.
The oil must be pumped into the top of transformer through oil conditioning equipment to remove
any contamination that may have been introduced during transit and storage and to reduce the
moisture content to 50 ppm. The oil must also have dielectric strength of 30kV before filling.
TRANSFORMER OIL MUST ALWAYS BE HANDLED AS A

FLAMMABLE LIQUID. NOTE THAT A CLOSED TRANSFORMER MAY UNDER SOME
CONDITIONS ACCUMULATE EXPLOSIVE GASES, AND THAT OIL-HANDLING
PROCEDURES MAY GENERATE STATIC ELECTRICITY. SAFETY PRECAUTIONS MUST
INCLUDE GROUNDING THE TRANSFORMER, ITS BUSHINGS, AND ALL OIL HANDLING
EQUIPMENT.
The temperature of the oil must be 50℉ (10℃) or higher when it is added to the transformer
during vacuum filling. In cold weather, heaters in the oil line may be required to elevate the
temperature of the oil going into the transformer. The oil temperature should not exceed 167℉
(75℃).
THE HOT OIL FLOW SHOULD BE DIRECTED SO THAT IT DOES

NOT SPLASH ON BUSHING PORCELAIN. FAILURE TO DO THIS MAY BREAK THE
BUSHING PORCELAIN WITH THERMAL SHOCK.

15.5 Electrical tests

If the following tests have not been made as part of the receiving inspections, Make the following
tests before beginning any oil filling procedures.
If the transformer tank is not filled with oil, the test voltage on the windings must be
limited to 1000 volts or less.
a. Measure the power factor and capacitance of the bushings before installing the bushing in
the transformers.
b. If the core ground point is accessible, measure the core resistance to ground.
The minimum acceptable value is 50 mega-ohms when measured at 1000 volts, out of oil.
c. Measure the ratio of all bushing current transformers.
d. Check the turns ratio of the transformer at all tap positions.
16. Final Vacuum Filling

General conditions during oil processing and filling:
A. The tank must be vacuum tested as noted in these instructions (refer to section 14.5).
B. The transformer top must be covered with suitable cover to prevent free water from collecting
on the tank cover.
C. The vacuum level must be monitored closely for any sudden rise in pressure indicating a leak
in the tank. If practical, the transformer should be completely assembled, including the
pressure relief device, and radiators. Vacuum procedures may be started prior to the
completion of the installation of all the cooling equipment. When all the cooling is installed, a
minimum of 4 hours of additional vacuum processing is required on these components prior
to beginning oil filling.
BEFORE APPLYING VACUUM TO A TRANSFORMER, BE CERTAIN

THERE IS SUFFICIENT SLACK IN THE EXTERNAL LINE CONNECTIONS TO THE BUSHING
TO ALLOW FOR BUSHING MOVEMENT CAUSED BY FLEXING OF THE TRANSFORMER
COVER AND/OR WALLS. FAILURE TO RELIEVE THIS STRESS AT THE BUSHING
CONNECTION MAY RESULT IN DAMAGE TO THE BUSHING SEALS AND LOSS OF OIL.
LOSS OF OIL WILL CAUSE AN ELECTRICAL FAILURE.
16.1 Procedures for final vacuum filling
• The transformer should be completely assembled prior to beginning the vacuum processing
and oil filling. All equipment should be grounded.
• Vacuum fill the main unit as follows.
• The core and coil temperature must be 50℉ (10℃) or higher prior to starting this process.

a. Connect vacuum line as shown in Fig 1.

b. Connect oil filtering equipment as shown in Fig 1. to Drain valve V1.
c. Check the conditions of each valves depending on “Valve condition”
d. Pull vacuum on the main unit and hold as specified in Table II.
At that time, Check the leakage as per paragraph 14.5.
e. Open Drain valve V1, start oil filling through oil purifier under vacuum condition.
f. When the pointer of oil level gauge of main tank is reached at level 25℃, stop pulling
vacuum and oil filling.
g. Break vacuum with dry nitrogen gas. Oil level may decrease slightly.
h. Pressurize headspace to 2~3 PSI nitrogen gas.
i. After filling oil and filtering , allow the transformer to set idle for the time specified in
Table II. If the test results of insulating oil comply with following conditions, execute the
other site tests.
- Dielectric breakdown voltage min. 30kV (IEC296)
- Water content max. 50 ppm
- Power factor max. 0.1%
j. If oil test results are not acceptable, oil has to be purified again.
- Refer to oil filtering line as shown in Fig 2.
- And then, maintain vacuum condition for 20∼30 minutes to remove moisture.
- Break vacuum with dry nitrogen gas.
- Pressurize headspace to 2~3 PSI nitrogen gas.

Fig 1. Schematic for vacuum and oil filling
Fig 2. Schematic for filtering

Table II : Vacuum Treatment and Oil Filling
VACUUM TREATMENT AND OIL FILLING
COMPLETE ALL ASSEMBLY X

PREPARATION
COMPLETE CORE AND COIL TEMP. TO 10°C X

DRAIN ALL OIL X
CLOSE INERTAIRE SHUT OFF VALVE X

OPEN ALL RADIATOR VALVES X
VACUUM LEVEL PRIOR TO AND FOLLOWING

2 Torr
OIL FILLING
VACUUM
VACUUM LEVEL DURING OIL FILLING 2 Torr
VACUUM HOLD TIME AFTER REACHING

2 Hours
SPECIFIED VACUUM LEVEL, BEFORE OIL FILLING
VACUUM HOLD TIME AFTER REACHING

30 Minutes
SPECIFIED VACUUM LEVEL, AFTER OIL FILLING
OIL TEMPERATURE : MINIMUM °C 10

MAXIMUM °C 75
OIL DIELECTRIC BREAKDOWN VOLTAGE kV. Min 30

(PER ASTM D-877)
WATER CONTENT OF OIL. ppm. MAX 50
FILLING
OIL POWER FACTOR (Percent Maximum) 0.1
RATE OF FILLING
OIL FLOW gpm. MAX. 30
HOUR TO FILL. MIN. 4
OIL HEIGHT AFTER FILLING 25℃ level of Oil Level Gauge
FILTERING 3 Times
STANDING TIME AFTER VACUUM TREATMENT AND OIL

24 Hours
FILLING, BEFORE ENERGIZING
CODES :
X or VALUE = REQUIRED PROCEDURE
R = RECOMMENDED PROCEDURE

Section 2. Repairing Weld Leaks
1. Transformer Tank and Fittings
2. Alternate Method using a Patch
3. Radiator

Instructions for Repairing Tank Leaks

This instruction leaflet is intended to give general instructions concerning recommended practices for
repairing a weld leak in power transformers or their auxiliaries. Variations of these instructions may be
desirable for special repair tasks. But normally the weld leak may be successfully sealed if these
instructions are followed.
1. Transformer Tank and Fittings
Transformer tank and their fittings are fabricated from 6mm to 16mm thick welding quality low carbon
steel, which are joined by manual, semi-automatic and automatic welding, using a manual shielded
arc, submerged arc and inert arc process.
To repair a weld leak in a case seam or around one of the fittings the following is recommended.
1.1 De-energize the transformer. Check the liquid level in relation to the area to be welded. It should
be 100mm or more above the area to be welded. Should the area to be welded be above the
liquid level or if the liquid has been removed from the case, blanket the transformer with dry air.
1.2 If the liquid has not been removed, pull a vacuum of several pounds per square inch above the
liquid to stop the liquid leak. This may be done with a vacuum pump or by sealing all fittings on the
tank and draining sufficient oil to obtain the necessary vacuum.
VACUUM IS NOT ALWAYS REQUIRED, ESPECIALLY WHEN

A SWEATING LEAK IS TO BE REPAIRED AND THE TANK WALL IS RELATIVELY THICK.
1.3 Peen the weld leak closed, if possible, with the ball end of a ball-peen hammer or with a blunt or
round-nosed chisel.
1.4 Grind or scrape the paint from the area to be welded and prepare a suitable point for attaching the
ground lead to the arc welding machine.
1.5 Either a-c or d-c welding current may be used. When d-c current is used, straight polarity is
preferred, that is the electrode is negative. The welding machine is adjusted to supply the desired
welding current. so value between 115 to 125 amperes should be used, depending upon the
welding operator's ability and the individual task at hand.
1.6 Apply a string bead sealing weld over the weld defect in a single, quick pass. This weld should be
deposited horizontal or vertically depending upon circumstances. If the weld is deposited vertically,
it is recommended that it be made downward to drive any liquid seepage ahead of the weld.
Successive beads are deposited adjacent and over the first sealing bead or a single pass may be
weave across it to complete the weld. If the beads are deposited vertically, deposit these beads
from the top down if any liquid seepage is present; otherwise they may be deposited upward if
preferred.
Remove the slag from the deposited weld before depositing each successive weld bead or pass.
Liquid interferes with the welding operation and the quality of the deposited metal.
It should be wiped off with a dry cloth. All welds should be deposited in a sequence as below to

prevent any liquid seepage interfering with the welding operation other than the final sealing at the
lowest point of the weld leak.
1.7 lean the repaired area and check with a suitable leak detector to be sure the leak has been
stopped.
1.8 After testing for leaks, re-clean the area and apply touch-up paint.
Fig 1. Welding sequence for patch
2. Alternate Method using a Patch
A patch may be welded to the transformer case to repair a leak as an alternate to the method above.
The recommended method is as follows.
2.1 De-energize the transformer and pull a vacuum, peen the weld. clean the weld area, check the
liquid level. Select the 1/8" electrodes and adjust the welding machine as above.
2.2 Fit a patch of 4.5mm or 6mm thick steel over the area to be sealed. Tack this patch in place, then
weld it to the transformer case by welding the sides first, vertically downward, then horizontally
across the top of the patch and finally horizontally across the bottom.
This welding sequence is recommended to prevent any liquid interfering with or contaminating the
weld. (See Figure 1.)
2.3 Clean the repaired area and check with a suitable leak detector to be sure the leak has been
stopped.
2.4 After testing for leaks, re-clean the area and apply touch-up paint.
3. Radiators
The HICO radiators consist of different numbers of fin elements welded to each other and to a
formed header. The elements are made from two sheets of 1.2mm thick mild steel continuously
welded along their outer edges and with intermediate seams between the individual lobes.
Field repair of a seam between lobes or replacement of an element is not recommended. The
radiator should be returned to the factory for repair.

To repair weld leaks around the header flange, along the outer edge of the elements or in the weld
where the elements join the header or each other, the following procedure is recommended.
3.1 Close the radiator valves between the radiator and the transformer case. Drain the liquid from the
radiator and remove the radiator from transformer case.
3.2 Grind or scrape the paint from the area to be repaired. Also remove any liquid. dirt or foreign
matter.
3.3 If the weld to be repaired is around the header flange use 3mm diameter electrodes with current
settings between 115 to 125 amperes. Weld horizontally around the flange.
3.4 A slightly reducing oxygen-acetylene welding flame is recommended for repairing a weld along the
edge of an element, a weld joining the elements to each other, or a weld joining the elements to
the header. The recommended procedure for repairing a leak along the edge of an element is
outlined below:
Fig 2. Radiator Section prepared for welding Fig 3. Radiator Section after welding
a. Heat the full length of the seam with the oxy-acetylene torch to drive out all trapped oil.
b. Find the exact location of the leak by means of a suitable leak detector.
c. When the exact location of the leak has been determined, notch the edge of the element as
shown in Figure 2 at points 50 to 75mm on either side of the leak. These notches may be cut
with a hack saw, a file, or a small grinder.
d. Start by filling one of the notches. Next, fill in the second notch. Finally fuse the edges of the
element between the notches moving forward with a slightly weaving motion. Be sure to tie this
weld into both filled notches.
Figure 3 shows the repaired element before touching up the repaired area.
3.5 Clean the repaired area and check with a suitable leak detector to be sure the leak has been
stopped.
3.6 After testing for lea is, re-clean the area and apply touch-up paint.
3.7 Reinstall the radiator.

Section 3. Bolt and Nut Tightening
1. Standard Tightening of Bolt and Nut
2. Tightening Sequence for Bolt and Nut Tightening and Re-tightening

1. Standard Tightening of Bolt and Nut
The standard tightening torque is give as follows.

Dimension(mm)
Standard Standard tightening
Hex-Bolt Hex-Nut Material
Bolt & Nut torque(kg-cm/lb-ft)
A B C A B
M6 11.5 10 6 11.5 10 SM250 50±10 / 3.6±0.7
M8 15 13 8 15 13 SM250 120±20 / 8.7±1.5
M10 19.6 17 10 19.6 17 SM250 240±40 / 17.4±2.9
M12 21.9 19 12 21.9 19 SM250 420±100 / 30.4±7.2
M12 21.9 19 12 21.9 19 Brass 300±60 / 21.7±4.3
M14 25.4 22 14 25.4 22 SM250 670±150 / 48.5±10.9
M16 27.7 24 16 27.7 24 SM250 1050±200 / 75.9±14.5
M18 31.2 27 18 31.2 27 SM250 1450±250 / 104.9±18.1
M20 34.6 30 20 34.6 30 SM250 2050±300 / 148.2±21.7
M24 41.6 36 24 41.6 36 SM250 3550±600 / 256.7±43.4
M30 53.1 46 30 53.1 46 SM250 7050±1200 / 509.8±86.8
M39 69.3 60 39 69.3 60 SM250 16000±2400 / 1157.0±173.6
M42 75 65 42 75 65 SM250 19750±3200 / 1428.1±231.4
M48 86.5 75 48 86.5 75 SM250 29700±5000 / 2147.6±361.6
Fig 1. Hex-bolt
Fig 2. Hex-nut

2. Tightening Sequence for Bolt and Nut and Re-tightening

Tightening sequence of bolt & nut is given as follows
Fig 3. Sequence of bolt & nut tightening

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Operation and maintenance manuals (Including Cover)

● PROJECT NAME : KALLPA 830MW COMBINED CYCLE CONVERSION Purpose

● PROJECT CODE : A90015EA ■ For Approval

● DOCUMENT No. : 0-WD711-EE610-00002 □ For Construction

● TITLE : Operation and maintenance manuals(Aux. TR)

● OWNER : KALLPA GENERACIÓN S.A. □ For ( )

A 2011.05.20 H.W.JO S.W.Park B.S.MUN For Approval S.H.Kim J.S.Kim

Rev. PREP REVIEW APPR REVIEW APPR

A Submit the original document for UNIT AUX TR.

Operation and maintenance manuals

Item Description Q’ty

● Specification No. : HYW-850484

● KALLPA 830MW COMBINED CYCLE CONVERSION PROJECT

Head Office : 450 Gongduk-Dong, Mapo-Ku, Seoul, Korea 121-020/Tel.+82-2-707-6187/Fax.+82-2-707-6116

Changwon Plant : 454-2 Nae-Dong, Changwon, Korea 641-712/Tel.+82-55-268-9347/Fax.+82-55-268-9366

1 Printed in KOREA 2011

Caution indicates a potentially hazardous

2 Printed in KOREA 2011

Section 1. Installation and Assembly of Power Transformer

3 Printed in KOREA 2011

2. Receiving Transformer and Accessories

Persons making inspection of transformers as delivered by carrier should be customer's engineer,

4 Printed in KOREA 2011

3. Inspect Materials on Car

5 Printed in KOREA 2011

- Internal visual inspection

6 Printed in KOREA 2011

• Does the transformer have oil leaks?

7 Printed in KOREA 2011

6. Check Your Oil

TRANSFORMER OIL SHOULD ALWAYS BE HANDLED AS A

• Visually Detectable Water – None

8 Printed in KOREA 2011

7. Recommended Tests for Possible Transit Damage

MAKE CERTAIN THAT ALL SHIPPING GAS IS REPLACED BY DRY

1.5 Check winding continuity and resistance if unit is off ratio.

9 Printed in KOREA 2011

1. ENTER CURVE AT INSULATION TEMPERATURE ℃ LEFT OR ℉ RIGHT.

2. MOVE TO DEW POINT LINE.

4. USE THIS CURVE FOR PRESSURE BETWEEN 0 AND 5 PSI.

Curve 1. Dew point limit

10 Printed in KOREA 2011

8. Moving and Handling

NEVER ATTEMPT TO MOVE A FULLY ASSEMBLED TRANSFORMER.

8.1 Setting the transformer on the foundation

8.2 Cooling air requirements

9.1 Equipment for transformer installation

• Oil purifier with hose (>6000ℓ/h)

9.2 Equipment for transformer site test

• Oil Tester (>60kV/2.5mm)

11 Printed in KOREA 2011

9.3 Tool list

9.4 Special tools

• Vacuum Hose with 1 inch adjustable flange

10. If You Can’t Install Immediately

11. Temporary Storage of Transformer in Dry Gas 6 Months Maximum

11.1 Temporary storage of transformers in dry gas (6 months maximum)

12 Printed in KOREA 2011

See CHECKING TRANSFORMER AT TIME OF ARRIVAL if the transformer received is not

A positive dry gas pressure must be maintained at all times.

13 Printed in KOREA 2011