INSTRUCTION MANUAL OF

RELIABILITY & MAINTAINABILITY

FOR TRANSFORMER PRODUCTS
INCLUDING POWER & AUTO
TRANSFORMERS, REACTORS AND
SPECIAL TRANSFORMERS.

TBEA SHENYANG TRANSFORMERS GROUP CO. LTD.

TABLE OF CONTENTS
1.0 INTRODUCTION
1.1 The core value
1.2 The Mission
1.3 The Purpose
1.4 Management Structure
1.5 ISO Certificates and other approvals .

3
4
4
4
4
5

2.0 SCOPE ...

2.1 Procurement and purchasing
2.2 Design and Development .
2.3 Manufacturing Process
2.4 Inspection and Testing .
2.5 Coating and Painting Systems .
2.6 Transportation of products
2.7 Acceptance and Storage of products .
2.8 Assembly and Installation .
2.9 Operation and Maintenance ..

5
5
6
6-14
14-17
18-20
20
20-22
22-26
26-27

3.0 TRANSFORMER MAINTENANCE RECORD . 27-29

4.0 EXPORT REFERENCE LIST . 29
5.0 CUSTOEMRS ACKNOWLEDGEMENT LETTERS 29
6.0 APPENDICES
1. Appendix 1: ISO certification and other approvals .
2. Appendix 2: Procurement and Purchasing ..
3. Appendix 3: Design and Development of Products
4. Appendix 4: Painting Systems of TBEA Shenyang
5. Appendix 5: Product Transportation System ..
6. Appendix 6: Export Reference List
7. Appendix 7: Customers Acknowledgement Letters .

30-31
32-38
39-41
42-43
44-49
50-61
62-65

2.1 INTRODUCTION
TBEA Shenyang Transformers Group Co. Ltd (hereafter TBEA Shenyang) is a subsidiary
company parent company TBEA Co. Ltd. TBEA Shenyang has been designing and
manufacturing power and auto transformers ranging from 10MVA/10kV (or below) to
1200MVA/1000kV for over 70 years. TBEA Shenyang also specializes in manufacturing
shunt and controllable reactors, CTs and other special transformers.
TBEA Shenyang owns the largest R&D center for TBEA Group of Companies in Chinas
northeast city called Shenyang, which is also the largest research center and the engine room
for Chinas power industry development. It has 2700 employees on the ground including 330
engineers to design and manufacture reliable and customer orientated transformer products
that suits customers requirement.

Fig.1. TBEA Shenyang R&D Center with land area of 720,000m2

The annual production capacity of TBEA Shenyang stands 80 000MVA with the annual sales
of 0.68 Billion US Dollars that contributes more than half of TBEA Co. Ltd total annual sales
of 2 Billion US Dollar.

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1.1 THE CORE VALUE

The core value of TBEA is Always Reliable. With this core value as a flat form, TBEA
Shenyang has been growing from strength to strength to provide reliable and satisfactory
services to customers in countries like Canada, United States, India, Pakistan and Philippines
to name a few. To live up to the core value that TBEA stands on, the employees have been
reminded often of Always Reliable and the entire workmanship is working vigorously to
manufacture transformer products are considered reliable, high quality and of competitive
prices.
TBEA Shenyang makes sure that its core value Always Reliable to be the objective to be
targeted on every transformer product it manufactures. To achieve the reliability of
transformers, TBEA Shenyang seriously considers various programs it utilizes in the process
of manufacturing transformer products and apply Always Reliable motto in the programs
ranging from procurement and purchasing of accessories, welding, painting, testing,
transportation, commissioning, operation and maintainability.
1.2 THE MISSION
The mission of TBEA Shenyang is to provide reliable and satisfying services to its clients by
meeting their requirements to establish a lasting business relationship with them.
1.3 THE PURPOSE
The purpose of TBEA Shenyang is to serve governments, their people and businesses
throughout the countries of the world through technology innovation and committing
enormous effort to provide quality and affordable products that will be operated in power
turn-key and EPC projects to improve peoples life, economically efficient and effective, and
environmental friendly.
2.1 MANAGEMENT STRUCTURE
To achieve and accomplish the core values, mission and purpose it stands for, TBEA Shenyang
Transformer Group Co. Ltd has a well organized and structured management. Figure 2
summarizes the management and organization of the Company.

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Fig.2: Management Structure of TBEA Shenyang Transformers Group Co. Ltd

1.5 ISO CERTIFICATES AND OTHER APPROVALS
TBEA Shenyang has been in the power industry for more than 70 years of vast experience.
Appendix 1 shows several ISO certification and other approvals from the well known
inspection and testing team around the globe.

2.0 SCOPE OF WORK

This specification generally applies to all transformer products manufactured by TBEA
Shenyang. This includes power equipment in operation, production and at design stage. The
scope of major work and engineering programs it considers being important to apply
Always Reliable value from the start to the commissioning, operation and maintainability.
2.1 PROCUREMENT AND PURCHASING
Procurement and Purchasing of accessories from sub-suppliers are done accordingly in
orderly manner. Sub-suppliers of accessories are screened carefully and make sure they have
qualification and ISO approvals. All of our sub-suppliers are to go through a process of
TBEA products sub-supplier qualification process. Qualified suppliers like Micafil, MR,
Qualitrol, EMB, Shell and Nynas are some of the accessory suppliers on our suppliers list.
Please see Appendix 2 for further information on Procurement and Purchasing. Chart 1 of
Appendix 2 illustrates the process involve for purchasing assessment for suppliers
qualification. Also of appendix 2, the table 1 illustrates the methods in a table form used for
approval of suppliers including evaluation, suggestions and comments.

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2.2 DESIGN AND DEVELOPMENT

Design and Development is the integral part of the operation of TBEA Shenyang. This comes
under Design Department and it basically focuses on research, development and designing of
transformer products. As soon as a client submits his/her transformer technical and design
requirements, the team from International Department Project Management analyses and
prepare documents for approval from superiors for book keeping. After the approval, the
technical specifications are passed on the Design Department. The design engineers carefully
study the clients technical specifications. The engineers then put a lot of effort to do research
and proceed with designing of the transformer following the technical specified with the
required Standards. Some of the standards applied in designing according to technical
specification are IEC, IEEE, AS, ANSI, NEMA among others.
The design is done within the time limit the client sets. The design process goes through
stages of being designed by the engineer, checked by senior engineer and then approved chief
engineer. Should there be clarification needed, our technical consultants and experts are
asked to give input to the design. During the design, the design engineers also take into
consideration the technical specification of suitable transformer accessories. These are then
put forward to the purchasing department to for technical clarification and purchasing process
as outlined in Appendix 2. In the process of designing, the design engineers with the project
management team from the international department also liaise with relevant departments for
R&D and secure relevant information. The appendix 3 gives further information on design
and development procedures.
2.3 MANUFACTURING PROCESS
Manufacturing process involves a lot of effort from not only Manufacturing department but also
required departments like design, purchasing, quality control and technical center. After the
contract agreement is signed between TBEA Shenyang and the client, the production schedule is
sighted upon by both parties. TBEA Shenyang can work vigorously to finish manufacture the
product on time according to the schedule.
The manufacturing department makes sure that it is following strictly the right design patterns,
standards, materials and all available information from relevant departments are being executed
during the manufacturing period. The scopes of work to be done are ranging from determination
of core winding (steel plates and copper) including shape, size and vertical and horizontal
windings. The insulation and assembling of active parts are also important matter to take into
serious consideration. The following pictures summarizes the details of manufacturing process
involve.
2.3.1. Automatic Step-lap stacking

Features:
CNC Cut-to-length Line (German made) with automatic step-lap stacking

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z Step-lap stacking
z high dimensional accuracy
z automatic step-lap stacking
z Precise size insuring close fitting joints
Advantages:
z Better distribution of the magnetic field at the joints of core
z No load loss can be reduced by up to 6% which compared with alternative lap core
z Reduced the noise level up to 5dB

2.3.2. Hydraulic Core Stacking and Erection

Features:
z Straight Core Lamination, Hydraulic core erection to prevent
fitting joints from displacement
z Core lamination station to ensure effective levels of core degree
of stacking
z Core rose steadily
Advantage:
z Ensuring the quality of core manufacturing

2.3.3. Gap Core of Reactor Step-lap Paramagnetic Core Disc Cutting

r Automatic cutting machine

Three-dimensional map of Reactor

Paramagnetic Core Disc

for gapped core of reactor

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Features:
z Automatic step-lap stacking of silicon steel
z The direction of silicon for core disc is as same as the main magnetic flux
z Steel Sheet slot can be completely cut in required bevel at once
Advantages:
z Improve effectively the magnetic line edge of core disc
z Low electromagnetic noise and low overheating
z Improve the mechanical strength of core disc
z Low core loss

2.3.4. Vacuum-Pressure Resin Impregnated Oven for Core Disc

Core Disc

Vacuum-pressure resin impregnated

oven for gapped core

Functions and Features:

z It pumps vacuum from the tank with glue in order to remove air bubbles.
z Vacuum-pressure resin impregnated inside the tank.
Advantages:
z Ensure mechanical strength of core disc firm
z Low noise and low vibration
z Passed the 5g core disc vibration test of resonance frequencies successfully

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2.3.5. Pad Processing

Strip Milling Machine

Processed Pad

Features:
z For processing pads, the punching technique has been replaced by milling technique.
z It is easy to cut the cardboards with the milling technique, smoothen the edges and make
the edges into round corner automatically.
z The surface of the pad is smooth without burr and has no sharp edges.
z Thick pads are more easily to be produced by milling technique.
Advantages:
z Improve electrical field distribution and minimize partial discharge

2.3.6. Winding Strip

Strip Milling Machine (Italian Made)

Processed Strips (3 80 mm thickness)

2.3.7. Winding Coils with Pre-set Tension

Horizontal winding machine

with pre-set tension

Vertical winding machine with

pre-set tension

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Feature:
z Winding coil with pre-set tension devices offering horizontal pre-set tension and axial
pre-set tension
Advantage:
z Improve short circuit withstanding.

2.3.8. Hydraulic Transposition

z Standard transposition shape

z Transposition does not damage outsourcing
insulation of conductor

Hydraulic transposition

2.3.9 Winding Block Assembly

Procedure:
z All windings and insulation parts are
assembled at required positions
accurately on the platform.
Winding Block Assembly

z Before the assembling of the windings,

each winding is compressed firmly and
after the assembly of the windings, the
overall windings are compressed firmly.
z The assembled windings are desiccated
by kerosene vapor and compressed again
the entire winding firmly.

Advantages:
z To ensure accurate axial winding size and accurate distance between the
windings
z To improve short circuit withstanding

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2.3.10 CNC Plasma Cutting

z Little distortion during cutting
z High dimensional cutting

CNC plasma cutting machine

2.3.11 Plate Bending Forming

1000 tons Hydraulic machine

Cover bending chart

Feature:
z No welding stress
z No potential leak
z Increasing the overall structural quality

2.3.12 Surface Sand-blasted

z The grade of removing rust is Sa 2

z Ensuring paint adhesion firmly
z Improving the corrosion resistance of products

Sand Blast Room

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2.3.13 Special Paint Room

z Three-dimensional walking down structure which

ensures all surface spray in place
z Film uniform and magnificent, well adhered
z Environmental Safety and protection
Large sized paint room

2.3.14 Lead Shield and Cold Welding

z Leads connection adapts to the method of cold

welding and mechanical connections and the active
part tidiness reaches the requirement of high-voltage
and large-capacity.
z The wrapping of leads shield insulation and the
electrode shape can meet the requirement of the high
electric field.

2.3.15 Vapor Phase Drying

Vapor phase drying plant (MICAFIL)

z Dry winding, phase assembly and active part.

z Below 10Pa, the vacuum heating temperature can reach up to 125. Under this
condition, the vapor inside the insulation are dried thoroughly and heated evenly. Further
more, the insulation parts are not easily aging, and insulation contains water level that
can be controlled under 0.3%, 0.2% and 0.1% respectively as per different voltage
ratings.
z Computer automatic controls the whole process.

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z Detecting the water percent of insulation for adjusting the insulation quality by Moisture
Meter.
z Reduce dielectric loss, enhance insulation strength and extend the service life.

2.3.16 Oil Processing and Preservation

Vacuum insulation oil system

- High flow vacuum oil filter

Vacuum and constant temperature oil preserving

system Clean jar for purified oil.

Vacuum oil system is used for oil purification and storage. After the purification process, the
quality standard of oil can reach with: voltage withstanding >70kV, water content <10PPm and
gas content <0.5%. For every 100mL oil, 2m sized grains quantity is filtered less than 1000,
which satisfies the requirement of any transformer products below 1000kV. Vacuum system
prevents purified oil from moisture.

2.3.17 High-Vacuum Oil Filling

Under vacuum condition, the oil is pumped into

the tank intermittently and continuously for
immersing insulation parts, improves the
insulation strength and reduces partial discharge.

High-vacuum oil pumping unit

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2.3.18 Active Part Moisture Proof

z Strictly control the dew point of compressing air
at the outlet.
z During assembling, the tank will be filled by dry
air to prevent moisture on insulation surface of
active part.
Dry air generator

2.3.19 Air Cushion Vehicle

Air cushion

Air cushion vehicle transporting products

The maximum load capacity of air cushion vehicle is 350 tons. The maximum load capacity of
560 tons or 630 tons can be loaded while using two air cushion vehicles in parallel.

2.4 INSPECTION AND TESTTING

The transformer products shall be subjected to the following type, routine, and special tests at
TBEA Shenyang Transformers Group Co. Ltd (hereafter TBEA Shenyang). The test shall be
carried out in the presences of the Purchasers representatives and all expenses will be
included in the quotation. If the test methods are not prescribed in IEC 60076 or other
standards, we agree that those test methods shall be subject to the agreement before the
contract between manufacturer and purchaser.

1000kV ultra high voltage testing hall

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Product under test monitoring and control

room

2.4.1

Radiographic Test

TBEA Shenyang can perform radiographic test on welded joints of the transformer according
to ASME Code Section V, clause 2. We are able perform radio graphic inspection for butt
welds joints including horizontal and vertical joints
2.4.2

Type Test

TBEA Shenyang can able to do Type Tests in the areas outlined below. We may not be able
to do the transportation test at acceleration equal to 2g however our design value is greater
than 3g. The following type tests can be done as per standard specified.
a. Temperature Rise Test IEC 60076-2/1993
b. Gas in oil analysis (chromatographic analysis) (IEC 60076-2/1993, Gas in Oil
Analysis IEC61181/2007
c. Radio Influence Voltage Measurement
d. Checking of the effectiveness of the Control Stray Flux System
e. External Infrared Thermography of the tank.
2.4.3 Routine Test
TBEA Shenyang can able to perform routine test outlined from below. For PD detection
using UHF technique, we sometimes ask the manufacturers of PD monitoring systems and
UHF sensors to carryout the detection and cost of these are included in quotation if and only
if our client wants PD detection analysis. TBEA Shenyang can also be able to do seismic
withstand test standards like America standard IEEE 693/2005.
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.

Core Insulation test

Measurement of winding resistance
Measurement of the voltage ratio and check of the voltage vector relationship
Measurement of short circuit impedance
Measurement of load losses
Induced voltage test with internal partial discharge measurement
Measurement of no load loss and no load current (10 %, 90%110%) of the rated
voltage
Oil leak test,
Test on OLTC (On-load tap-changers)
Dielectric test
Tightness Test
Insulation oil test
SFRA Fingerprint test
Measurement of power taken by fan and oil pump motors

2.4.4 Special Test

TBEA Shenyang can do special tests and some of them are:
a). Measurement of zero-sequence impedance
b). Measurement of no-load losses and exciting current at low voltage
c). Measurement of the harmonic of the no load current

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d). Measurement of sound pressure, intensity and power level

e). Performance test
2.4.5

TBEA Shenyang can able to perform Insulation levels and Dielectric Tests

a). Applied potential test corresponding to insulation level of neutral

b). Lightening Impulse Test
c). Switching Impulse test for line terminals
d). Long Duration AC voltage test with partial discharge measurement
e). Measurement of the dielectric dissipation factor and the capacitance (at rated
frequency).
f). Measurement of insulation resistance and polarization index of all possible
elementary insulating zones of auto transformer
g). TBEA Shenyang can provide transformer capacitance equivalent circuit including the
capacitance value.
2.4.6

Lightening Impulse Test,

TBEA Shenyang can be able to perform Lightening Impulse test:

a).

Rated lightening impulse withstand voltage 1.2/50 /sec.

b). The lightening impulse test, full wave according to IEC 60076-3/2000, clause 13.
c). The test with lightening impulse test chopped on the tail according to IEC 60076-3/2000
clause 14.
d). The reduced full wave test for the crest value of the voltage
2.4.7 Rated switching impulse withstand voltage
2.4.8 Applied Potential test according to IEC 60076-3/2000 clause 11
2.4.9 Long Duration Induced AC voltage test with Partial Discharge measurement
a). The partial discharge measurement on maximum voltage which is according to IEC
publication 60270/2000
2.4.10 Test Plan
The table 1 below shows the schedule for test and measurement that can be done is sequential
order.

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Sequential

Test Type

Order
1

Radiographic Test

Check the effective of Control Stray Flux System

Oil Leak test

Tightness Test

Insulation oil Test

Measurement of winding resistance

Measurement of voltage ratio and check of voltage vector relationship

Measurement of insulation resistance and polarization index for all possible insulating zones of the
auto-transformer

Core Insulation test

10

Long Duration Induced AC voltage test with partial discharge measurement and measurement of
dielectric dissipation factor and the capacitance

11

Measurement of no-load loss and no-load current

12

Lightening Impulse test

13

Switching Impulse test for the HV (400kV) line terminal

14

Performance Test and Applied Potential test corresponding to insulation level of neutral

15

Induced voltage Test with internal partial discharge measurement and Long Duration induced AC
voltage test with partial discharge measurements.

16

Measurement of no-load loss and no-load current again

17

Measurement of the harmonics of the no-load current

18

Measurement of Short Circuit Impedance

19

Measurement of Load Losses

20

Measurement of Zero-Sequence Impedance

21

Temperature Rise Test

22

Gas in oil analysis

23

Check the External Infrared Thermography of the tank

24

Test on On-Load Tap-Changers

25

Measurement of Sound Pressure/ intensity and power levels

26

Measurement of the radio influence voltage

27

Measurement of power taken by fan and oil pump motors

28

SFRA Fingerprint Test

29

Measurement of No Load Loss and exciting current at low voltage

30

All other Tests and Measurements shall be done as necessary and according to the requirements
and standards

Table 1: Schedule for Tests and Measurements

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2.5 COATING AND PAINTING SYSTEMS OF TBEA SHENYANG

Specification for Coating Requirements of Load Transformers. See Appendix 4 for detail
information of the coating and painting system of TBEA Shenyang.
TBEA Shenyang can able to provide the coating system to supply protection against any
atmospheric corrosion however we can not specify how long it can last without need for
maintenance. From our experience, the painting can last for about 4 to 5 years but paint
maintenance can be done when realized that the products need paint maintenance.
TBEA Shenyang can design anti-corrosion coating as per clients requirement according to
the transformer installation site environment. Paints shall be applied in the shop in the frame
of SSPC PA1 and cannot apply field painting. Internal surfaces shall be painted as TBEA
Shenyang applies in some of its products.
TBEA Shenyang makes sure that all external and internal paints of any transformer product
are to be compatible with the transformer oil we supply. TBEA Shenyang has been in the
transformer industry for more than 70 years of experience with proven record to make sure
painting does not affect or deviate the quality of the transformer oil.
The cover painting for the transformer will be thicker and it can include anti skid solution.
Since we have so much experience for coating systems, we are able to do anti skid coating
system on the cover.
The outer top-layer shade shall be by RAL 7038 and internal shade is fair.
TBEA Shenyang will make sure the final product will be good looking, homogeneous, free
from leaks and the product will have a good adhesion to the transformer matrix.
For maintenance for the damages from shipment, it is recommended that the paint can be
taken to the site to repair the damaged part.
2.5.1 Coating Procedure Description
This may include surface preparation and treatment for problematic areas.
2.5.1.1 Preparation before coating
Before the coating of metal surface, it must be thoroughly degreased, remove oxidizing and
other contaminating materials attached on the surface, so that the coating can adhere to stick
cohere reliably on the metal surface.

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(a). Removing Oil

Should there be any greasy dirt discovered on the surface before the treatment of steel and
iron along with the painting of the product, we should proceed with oil removing process
immediately by dipping the cleaning rags in the toluene then wipe off thoroughly the greasy
dirt on the surface with the rags.
.
(b). Sand (Dirt) Blasting
(i). The transformer tank with all the accessories are kept in a closed door area and start
blasting the sand/dirt off.
(ii). After the blasting of steel and iron surfaces of the transformer and accessories, the steel
and iron are grayish white color that reaches the level Sa2.5.
(iii). Within 8 hours after the blasting of accessories, the coating process is applied to both
top and below of the surface.
(c). Pre-treatment of steel products
(i). Any product that uses steel should undergo the pretreatment process.
(ii). Pre treatment is applied to the welded parts of the tank that includes the welded joints.
The non homogeneous surfaces of welded joint parts, the greasy parts, and welded dregs are
thoroughly eliminated, thus revealing the true colors of steel and iron.
(d). Treatment of Acidic Phosphorization Cleaning
(i). Small and medium accessories along with long and large components are treated by the
use of acid cleaning Phosphorization process for treatment.
(ii). The coating process is applied to top and bottom surfaces within 48 hours of acidic
treatment on all the accessories (Besides the treatment of spare parts).
(e). The edge of tank and accessories - edge, joints and corners polishing process
(i). The top and bottom sections of the tank along with any elevated enclosure and any
similar surfaces are placed on gas cutting surface process to shear any plane that has exposed
edges and corners. This edging process must be done before the coating. The bevel edge
requirement is R3.
(ii). The top and bottom sections of tank are treated with any material that has not been
treated. After the treatment of the bottom material, there must be an abrade stain removal
processing. After the abrade processing surface condition, the colors of steel and iron
become real grayish white that can reach the Sa2.5 level.

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2.5.1.2 Brush Painting

(a). For painting, firstly dip the paint brush in the paint then carry on with brush painting. It
must guarantee the paint film evenly and required thickness.
(b). On every product edge, bend angle, flange and the back of the flange border with other
edge spots on the surface are to be brush painted before the spray painting is applied to all the
surfaces including top, bottom, edges, joints and corners. The required width of the brush
painting is 150mm from edges and corner lines within the scope of the whole surface for
brush painting. The brush paint is not only applied to the flat surfaces but also edges, corner
lines and narrow spot of the scope.
(c). For Anti Corrosion Requirement of paint, the brush painting is applied to the whole
flange surface by using a method called brush coating. This creates the coating corrugation.
(d). After the brush and spray paintings of edges and corners, it is a must that all the sections
are painted thoroughly as line upon line. The spray and brush painting thickness control is
approximately about 40m. This can protect the edges and corners from rust.
2.6 TRANSPORTATION OF PRODUCTS

TBEA Shenyang has well organized and arranged equipment that can able to lift, move, load,
unload and transport transformer products. It makes sure that the products are handled with care
when lifting and loading. After the loading, the products are loaded on carriers according to their
sizes and transported to the port to be exported to the clients destination. Appendix 5 covers the
Transportation System in detail from one point to another for delivery.

2.7 ACCEPTANCE AND STORAGE OF PRODUCTS

2.7.1 Acceptance and inspection
When a transformer product arrives at the designated site, immediate inspection and
acceptance are required. Acceptance items are as follows:
(i). Check the position of the main body on transport vehicle and record impact (if any) on
the body. Should a visible displacement or impact is found, record the specified area,
picture shall be taken and contact the concerned transportation company at once. If
necessary, internal inspection shall be carried out by concerned people.

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(ii). Check rating plate, drawing of rating plate and some other documents, see whether the
products are in accordance with the contract.
(iii). Check if there is any document absent according to a documentation called List of
Transformer Documents.
(iv). Check if all accessories are at arrival site according to Packing List and inspect damages,
if so record and report accordingly.
2.7.2

Storage

(i). For transformer transported with nitrogen

a). First check the nitrogen pressure. It shall be positive pressure at normal temperature. If the
pressure is zero, the product is probably moistened. Further
inspection shall be made.
b). Test oil residual at the bottom of the tank. If the value of U is according to specific value
given in product instruction manual (generally is about U35 to 40 KV), water content
(generally 25 to 30 mg/L) and the nitrogen pressure is positive, the transformer can be stored
with nitrogen for 3 months. Otherwise, the transformer shall be stored with oil and not with
nitrogen.
c). Nitrogen pressure shall be kept at 10-30kPa (refer to product manual for exact value)
during storage with nitrogen. If lower than 10kPa, its necessary to add nitrogen with purity
more than 99.99%, and with dew point lower than -40 C.
d). Checking of nitrogen pressure is done every week. If nitrogen pressure decreases rapidly
(even lower than 10kPa), there is leakage. Find out leakage point and take necessary actions
to fix it.

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c). If transformer is to be stored for more than 3 months or residual oil doesnt conform to
requirement of sub clause (b), the transformer shall be filled with oil for storage. In this case
conservator shall be mounted. Open blind flanges on tank cover, fill oil from valve at the
bottom of the tank to let nitrogen escape. Fill in oil to the required level. The oil filling
requirement is as follows:
U50KV, (generally, please refer to the product manual), water content to 20 mg/ L, (refer
to manual), tg<0.5% (at 90).
d). Make sure to remove air above oil in conservator, drain off residual oil at tank bottom
before oil filling. Pay attention to ventilation if nitrogen drain is done indoor.

(ii). For transformer transported with oil

a). When oil sample shows U30 kV, water content30 mg/L (please refer to the manual),
the transformer is probably moistened. Further inspection is needed. Replace the oil with
requirement according to sub clause (c) and store the transformer with oil.
c). If oil sample shows U50KV, water content25mg/L, tg 0.5% (at 90), and
transformer will be installed within 2 months, please refer to product manual. The
transformer can be stored without conservator.
d). If the transformer will not be installed within 2 months and in the case of sub clause (a),
the transformer shall be mounted with conservator and stored with oil. Fill oil with the
requirement. After oil filling, get rid of air above oil according to the instruction of
conservator.
e). Check oil level often in case the oil level is lower. If so, add qualified oil.

2.8 ASSEMBLY AND INSTALLATION

Assemble and install the components according to the product manual. Take extra precaution
when assembling the components. The entire process is summarized in the process shown in
Fig. 3.

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2.8.1 Check before operation

(i). Check if all the components are mounted according to their instructions. For example,
whether thermometer socket is filled with oil, whether earthing terminals on mounting
flanges of bushings and check whether dehydrating breather and the absorbent are in good
condition.
(ii). Check whether all the butterfly valves are in open condition
(iii). Check the indication and rotation of tap-changer to see if phase contacts are in step and
if oil compartment is filled with oil.
(iv). Check whether the terminals of bushing CT are connected well. The transformer is not
permitted to operate with secondary open-circuited.
(v). Check whether main body and earthing bushing of core are earthed.
(vi). Check if oil in conservator and in bushing is in required level.
(vii). Check the wiring of all kinds of protective, control and measuring devices. Check their
signal and actuation. Check fan-motor and controlling system of cooler (radiator).Check
rotation, oil flow direction of oil pump.
(viii). Check whether oil, water (in case of water cooler ) pipes of cooler are correctly
connected. Check whether they are blocked or whether there is leakage somewhere.
(ix). Check ratios at all tap-positions (pay attention to indicating position of driving units).
(x). Measure DC resistance at each tap position and compare them with the factory routine
test.
(xi). Check polarity of transformer, polarity and current ratio of bushing CT (polarity of CT
can be checked before mounting).

-23-

(xii). Test oil according to the requirement (please refer to product manual).
Process of Acceptance to Operation of Product

LIFTING AND TRANSPORTATION

NOT MOIST IN TRANSPROTATION

TRANSPORTED WITH NITROGEN

FILL OIL ESCAPE NITROGEN

STORAGE WITH NITROGEN

ACCEPTANCE

MOIST IN TRANSPORTATION

STORE TRANSFORMER WITH OIL

MAIN BODY DRYING TREATED

INSPECTION BEFORE ASSEMBLY

INNER INSPECTIONAND INSTALL BUSHING

FILL OIL ESCAPE NITROGEN

FINAL ASSEMBLY

VACUUM PUMPING

INSTALL CONTROL CIRCUIT

OIL FILLING UNDER VACUUM

OILNESS U50Kv, WATER CONTENT15ppM, GAS CONTENT15%, tg0.5%

FILL OIL AND PLACE FOR 48HOURS

RELEASE VACUUM

OILNESS DONT ACHIEVE STANDARD OR MOISTENEDHOT OIL CIRCULATION

TIGHTNESS TEST FOR TRANSFORMER

PATCH PAINT ON
SURFACE

TEST AND INSPECTION BEFORE OPERATION

DISMANTLE SUPPORT FOR INSTALLATION ETC.

Fig. 3 The process of acceptance and operation of products

-24-

OPERATION

2.8.2 Test Before Operation

(i). No-load test
Before test, connect the signal contact of Bucholz relay to the trip circuit of transformer.
Over current protection shall react instantaneously. The source side of transformer is
provided with the protecting device. Connect source to that side of Transformer in order to
cut off the source in abnormal condition. Then raise the voltage slowly to the rated voltage.
Remain it for 30 minutes. Measure on-load loss and on-load current and compare them with
factory routine test.

(ii). No-load impulse test

First, reset the over current protection of Buchholz relay. When the protecting breaker is
switched on, phase timing difference is less than 0.01s. Impulse voltage is the rated system
voltage and is applied on HV side. The switching time of the breaker is not more than 5
times, During the impulse, voltage (including the first time impulse) once reaches the peak
value and the test is regarded as passed. If no peak value appears during the 5 impulse tests,
the impulse test is passed too. Neutral point shall be earthed for neutral point earthing
transformer.
(iii). If top oil temperature rise does not exceed 50k when the transformer is operated under
rated voltage for 6 hours at no-load, its not necessary to start coolers.

-25-

(iv). On-load tap-changer test shall be done according to its instruction. Cooling system and
control circuit shall be tested.
(v). Do the other routine tests according to requirements.
(vi). After the test, connect the signal contacts of Buchholz relay to the alarm circuit and the
trip contacts to the trip circuit. Set the value of over current protection.
(vii). After the tests, make chromatogram analysis of oil, compare the values with those got
before the tests.

2.9 OPERATION AND MAINTENANCE

2.9.1 First, start cooling system (for OFWF system, start oil pump first and then water pump).
If the coolers operate well (operate for more than 1 hour), put transformer into operation.
2.8.2 If a part of coolers operate, the burden can be calculated according to the following
formula:

Sn =

np p 0
S H , KVA
pk

Where:
Snburden carried by n coolers, KVA
Pthe heat burden of each cooler under the full burden operation of transformer, KW
P=(P0+Pk)/(N1)KW
Nthe number of the mounted coolers
P0no-load loss under the rated voltage and rated frequency, KW
Pkload loss at appropriate tap at full load, KW
SHrated capacity of transformer, KVA
nthe number of the operated coolers (nN1)
2.9.3 During operation, inspect the core by the core earthing bushing. Connect the meter
before cutting off the earthing bushing. Pay attention to the high voltage caused by
instantaneous open circuit. The earthing bushing shall be reliably earthed again after
measurement.

-26-

2.9.4 Oil adding during operation

Extended from gas sampling device of conservator are two pipes, one is oil adding pipe with
butterfly valve at end, the other is oil draining valve. Add oil from oil filling pipe, meanwhile
open gas release plug on butterfly valve. Close plug and open butterfly valve (exhaust gas
from pipe) after oil overflow from plug, and then add oil till normal level, close butterfly
valve and cover plate.
2.9.5 If oil can be seen from the inspection window on gas sampling device, its necessary to
open the valve on gas exhausting pipe to release gas. Close the valve when oil level rises
above inspection window.
2.9.6 In the first operating month of transformer, take oil sample for test and chromatogram
analysis every week.
2.9.7 During operation, transformer oil shall conform to the following requirements at least:
U40KV,

water content25mg/L,

tg4% (at 90.) Please refer to the product manual.

2.9.8 Maintenance and periodical inspection of components are stated in their instructions.
2.9.9 For OFAF transformer, when the fan of coolers stop, oil pump is still running,
transformer can continue to operate as long as top oil temperature doesnt exceed 53K.
2.9.10 For OFWF transformer, if ambient temperature for cooling system is lower than 0,
cold-proof measures shall be taken. When water-cooled coolers are stopped, water inside the
cooler shall be drained off.

3.0 TRANSFORMER MAINTENANCE RECORD

TBEA Shenyang has been and continues to provide liable service even after sales through our
After Sales Service department. We continue to communicate with our clients on the status of
our products to make sure they are in good operational conditions.
Should there be any failure; the necessary measures are taken immediately to rectify the
failure. TBEA Shenyang is not only reliable in designing, manufacturing and other areas of
concern but also reliable in providing after sale service to the satisfactorily of our valuable
clients. TBEA Shenyang longs to maintain a good and reputable relationship with its clients
even to act swiftly to meet the requirements and urgent needs of its clients. Table 2 and Table
3 show the major test and field failures respectively which have been recorded and rectified
to the satisfactorily.

-27-

3.1 Test Failure Rate (69kV and above transformers)

Year

2004

2005

2006

2007

2008

2009

Total

Total
Units
Tested

150

195

204

247

259

201

1256

Major
Test
Failure

Test
failure
rate (%)

0.0

0.5

1.5

0.4

0.4

0.6

Industry 2.0
Standard
Failure
Rate (%)

2.0

2.0

2.0

2.0

2.0

2.0

Table 2: The major test failure of transformer products from 2004 to 2009.
According to Table 2, the major test failure means any test failure that requires to un-tank the
C&C assembly for repairing. HVDC and Shunt Reactor units are not included on the list.
3.1.1 Major highlights as per table 2.
(i). The products of TBEA Shenyang were in operation performing outstanding performance
(ii). More than 1000 units were tested over the last 6 years with only 8 major failure tests.
(iii). Yearly and total rates are much lower than industry standard failure rate (2%)
(iv). Root causes of failures;
(a). Five failures were related to manufacturing processes
(b). Two due to defective materials
(c). One related to design practices
3.2 Field Failure Rate (69 kV and above Transformers)
3.2.1 Major highlights as per table 3.
(i). The products of TBEA Shenyang were in operation performing outstanding performance
(ii). More than 1200 units were installed over the last 10 years with only 2 major failure.

-28-

(iii). Root causes of failures;

(a). One failure was related to defective material (conductor)
(b). Another failure was due to defective accessories (bushing)
Year

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

Total

Units
installed
each
year

83

92

97

78

85

120

135

162

187

221

118

1378

Units
with
major
failure
during
service

Table 3: The major field failure of transformer products from 1999 to 2009.
(iv). Solution of each failures;
(a). Product was sent back to the factory and replaced the defective material
(b). The product was sent back to the factory and replaced the bushing
(v). Current Status of these products.
(a). They have been installed back on time and are currently operating smoothly.

4.0 EXPORT REFERENCE LIST

TBEA Shenyang has been manufacturing transformer products for over 70 years. With its
corporate vision to expands and provide reliable services at the global stage, TBEA Shenyang
has been working with various clients of the around the world. We have our office for North
American market is located in Pasadena, US. We also have offices in Philippines, Pakistan,
India, and South Africa to name a few. Please refer to Appendix 6 to see export references of
TBEA Shenyang since 1987 to North America, Gulf Region and General Reference.

5.0 CUSTOMERS ACKNOWLEDGEMENT LETTERS

During the years of its production, TBEA Shenyang has been working with its clients with
respect and understanding. Many of these have valued the liable service provided by TBEA
Shenyang. Appendix 7 shows acknowledgment letters from various customers to express
their honest view about the products.

-29-

APPENDICES
Appendix 1: ISO Certification and other approvals

ISO 9001:2008 FM Certificate

ISO 14001:2004 Certificate

-30-

Appendix ? Customers Certificates

Laboratory Accreditation Certificate

ISO 9001:2008 Technical Inspection Certificate

-31-

Appendix 2: Procurement and Purchasing

1. Aim and Scope
This procedure applies to the purchase control of raw materials and parts required by transformers and reactors as well as the appraisal of the supplier.
2. Standard cited
GB/T 190002000

Quality Management Systemfoundations and terms

GB/T 190012000

Quality Management Systemrequirements

3 Responsibilities
The Purchasing Department is in charge of applying for investigating supplier. The Management Information Department is responsible for organizing
assessment. The Management Information Department, Quality Control Department, Technological Center, Process Department and the Purchasing
Department will participate in the assessment of the supplier. The Technological Center and Process Department are responsible for proposing
standard and requirements for process. The Quality Control Department is in charge of inspection.
4. Assessment of the supplier
4.1 Input
4.1.1 Prerequisites for qualified suppliers
a). Products of the supplier must have a Production License (within the term of validity) and observe the present national standard and inspection
standard during the production and inspection.
b). Supplier must have the capability of examining and testing its products. Examination and test records as well as qualified report should be offered.
If some particular items can not be examined or tested, the examination and test must be done in a test unit with certain qualifications. The relevant
qualified report should be offered.

-32-

c). Suppliers products must meet our companys requirements for design, process, test and other relevant conditions.
d). Suppliers products must pass the test of our company with a year of trial use.
e). Its production capability, production conditions, equipment and production process must meet the requirements for production.
4.1.2 Material Grading
The Purchasing Department classifies the suppliers products into three grades, A, B and C in accordance with the Importance Grading of the Quality
Features of Main Common Materials for Transformers (Q/TT J31.02.2-2005) of TBEA Shenyang Transformer Group Co., Ltd.
4.2 Assessment of the supplier
4.2.1 Evaluation of new suppliers raw materials and parts of A and B grades
According to the prerequisites for designated manufacturers proposed by the Purchasing Department, the Head of the Management Information
Department develops the inspection plan, method of investigation and form of evaluation, reports it to the chief engineer and puts them into practice
after obtaining approval. Specific steps are listed as below:
a). If it is necessary to make an inspection of the suppliers factory, the Management Information Department should organize the technology
supervisor of the Technological Center, Process Department, Quality Control Department and the Purchasing Department to make an on-site
inspection.
b). In accordance with their respective duties and powers, personnel participating in on-site inspection define the focus of the investigation. Heads of
every department participating in the assessment of suppliers must make strict examination and evaluation of suppliers products. They must make
item-by-item inspection according to each departments requirements for products, carefully complete the record of inspection on the supplier and
submit it to the supervisor of the Management Information Department after signing their names;
c). Supervisors of the Management Information Department shall organize relevant personnel to complete the Trial Form of Inspection on the Parts
and Raw Materials of Transformers according to the on-site inspection record. After signed by the inspectors, it will be submitted to the chief engineer
of the company for approval. He/she will decide whether to purchase the products for trial use. If approved, the Management Information Department

-33-

will inform the Purchasing Department to buy the products for trial use.
d). Within one year of the trial use being approved, the Management Information Department shall organize the departments concerned to re-assess the
suppliers products with reliable operation and no indicators influencing the performance of transformers according to the feedback of incoming
inspection, transformer assembly and test, on-site installation and operation quality. Complete the Approval Form of Qualified transformer parts and
raw materials Supplier after they are proved to be qualified. After being signed by the inspectors, it will be submitted to the chief engineer or GM for
approval. The supplier will become a qualified one if approved.
e). If it is impractical to organize personnel to make an on-site inspection of the supplier. The Purchasing Department shall collect relevant information,
such as international quality certification, test certificate from domestic technology supervision institutions, quality feedback of the same industry,
appraisal from similar product users and spot check by the Quality Control Department to make an assessment. The Management Information
Department shall organize the departments concerned to complete the Inspection and Trial Use Form of Transformer Parts and Raw Materials. After
being signed by the participants in the assessment, it will be reported to the chief engineer or GM who will decide whether to buy its products for trial
use. Upon approval, the Management Information Department shall inform the Purchasing Department in writing to purchase its products. The
supplier will be defined as qualified following the regulations in d).
f). If the purchase has to be made from other than the qualified supplier due to the requirement of the user or for some special reason, the purchaser
will write a report to explain it(this report is valid once and can not be used another time) and obtain the approval of the head of the department, vice
general manager and project manager.
4.2.2 The purchaser must write a report on the assessment of raw materials and parts of Grade C by new suppliers that influence the quality of the
transformer, explain the reasons and obtain the approval of the head of the department and of the company.
5 Purchase process control
5.1 Develop the purchase plan
According to the earlier purchase list, production statement, production technology preparation plan and production plan as well as the raw materials
and parts needed, the purchaser will develop the purchase plan and submit it to the planner and head of the department and the supervisor of the
company for approval.

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5.2 Contract signing

The purchaser will sign a contract or an agreement with the qualified supplier according to the purchase plan. After that, the contract must obtain the
approval of the planner, head of the department, supervisor of the company and project manager by signing their names and affixing it with the seal of
the company in quadruplicate. The contract will be kept by the supplier and the company.
5.3 Product verification
After the raw materials and parts enter the factory, the purchaser will complete the Material Acceptance List, make six copies and submit them to the
Logistics Center the next day. At the same time, necessary quality certificates of the items sent for verification will be given to the warehouse keeper
who will inform the Quality Control Department to check the materials according to the practice and dispose them according to the result of the check:
a). If Qualified, the materials will be stored in the warehouse following the Warehouse Management Procedure.
b). If Substandard, the materials will be returned or be viewed as inconsistent with the certificate (substitute) following the Substandard Product
Control Procedure. The keeper can also apply for concession.
5.4 Reimbursement
The purchaser goes to the Finance Department with the list of materials received signed by the examiner to reimburse the payment for goods. The
Finance Department will check if it is the product offered by the Qualified Supplier List. If it is, the payment will be reimbursed; otherwise, it will be
reimbursed only if relevant purchase approval formalities are available.
5.5 Emergency clearance
Follow the Emergency Clearance ProcessQG/SB35.952004.

-35-

6 Process of re-assessing the supplier

6.1 The purchaser shall note down the quality status of the purchased goods each month, including the name, specification, model and quantity of the
goods as well as the causes of substandard materials and the result of disposal.
6.2 The Quality Control Department will do as the following according to the result of verification and the feedback from users about the quality:
a) As for raw materials and parts that have serious problems and have incurred very bad impact on the user, the Quality Control Department shall
report to the Management Information Department. The Purchasing Department shall contact the supplier to handle the issue. Also, compensation
will be made for the loss following the Quality Reward-punishment Management Methods. The Quality Control Department will give a written
notice to stop the supply according to the severity of the problem with the quality or inform the supplier in writing to rectify and reform within a
set time. The Management Information Department will organize relevant personnel to go to the suppliers place to make another assessment
(following Article 4 of this procedure). If it meets the requirements, we will continue the business with the supplier. Otherwise, it will be
disqualified.
b) As for raw materials and parts with relatively minor problems, the purchaser will go through the formalities of concession or returning the goods
and offer specific corrective measures.
6.3 If the quality of the products provided by qualified supplier decreases, the Purchasing Department shall give a written notice to the supplier and
ask it to make rectification and reform or the Management Information Department shall organize relevant departments to re-assess its products
(following Article 4 of this procedure). If the supplied products have a very unstable quality or cant reach the required quality level after internal
rectification and reform, the Quality Control Department shall give a written notice to the supplier and require it to make rectification and reform
within a set time, and suspend or cancel its qualification as a qualified supplier. In addition, the Quality Control Department shall inform the
Purchasing Department and other departments concerned in writing.
6.4 The Purchasing Department shall keep a file of the selected qualified supplier, including:
--Product testing report, appraisal documentation, supplier trial use approval formalities and inspection report;
--Sample of suppliers products and its qualifications (quality system certifications and sales performance, etc.)
--Supplier's quality performance and feedback.

-36-

6.5 The Purchasing Department shall evaluate periodically the quality performance of the supplier and make decisions on future evaluation and
disposal according to its qualifications. If the supplier has many problems with quality or the problem is very serious, we shall re-assess its products
(following Article 4 of this procedure).
6.6 The Management Information Department, Purchasing Department and Quality Control Department shall make periodic spot checks and
evaluation of the supplier (1-2 years).
7. Supplier Assessing Process Chart

Chart 1: (i). Purchase Control Procedure QG / TB35.38.36 2001

-37-

(ii). Form of Investigation on Trial Use of the Transformer Parts and Raw Materials, Form of investigation on the suppliers capability of ensuring quality,
Approval Form of Suppliers of Parts and Raw Materials of Transformers which is shown in table 1 of this appendix. .
Approval Form of Qualified Suppliers of Parts and Raw Materials of Transformers

Serial No.:

Date:
1. State of Trial Use

Supplier
Goods supplied
Result of incoming testing
State of in-house trial use
State of installation and trial use

2. State of Production and Ex-factory Inspection

Productivity
Testing equipment
Result of periodic apparatus and instruments testing
Testing standard and relevant systems
Testing record
Result of sample testing

3. State of Raw Materials, Measuring instruments and after sale service

Result of raw materials and parts testing
Result of measurement testing
State of after sale service

4. Technical Documents
Process documents and national standard

Product instructions
Ex-factory testing record
Product quality inspection report

5. Suggestions on rectification and reform & assessment conclusion

Quality Control Department

Technical Center

Process
Depart

Approved:

Management Info. System

Date

Table 1: Approval Form for Qualified Suppliers

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Purchasing Dept

Appendix 3: Design and Development of Products

Designing process is the integral part of the entire process. TBEA Shenyang invests much effort and time to meet the technical requirements of customers
during the designing process. Chart 2 shows the design & development process.
Customers Technical
Specification & Requirement
No

Consideration & approval by

International Department
Project Management

Further information
and/or clarification
Key:

Yes
No

Design and Development

Ask for
clarification

Regular review & consultation

Relationship

Planning, R&D, Analyze Technical

Specification Satisfactory
Yes

Review, approval
and comments by
senior/chief
engineers and
consultants

Design and Development Process

(application of technical
specification & required
standards) and Design approval
Approve

Liaise and agreement with

Purchasing department and
other relevant departments

Clarification

International Department
Project Management

Chart 2: Design and Development Process

Customers
comments, design
and technical review
Quotation Process and
Contract Agreement
Processes

Yes

Is customer
satisfied?

Design and Technical Review

Questions and Answers
No
-39-

1. Design and development planning

To meet quality characteristics, statutory and regulatory requirements, contract requirements and to avoid errors at the design and development stages,
our company controls the processes of design and development strictly.
The Technical or Design Center organizes the design and development planning, reviewing, verification and validation for the design and development
stages to ensure effective communication and clear assignment of responsibility.
2. Design and development inputs
The design and development department determines the inputs relating to products and maintains records. These inputs include functional and
performance requirements of contracts, statutory and regulatory requirements, information derived from previous similar designs and other requirements
essential for design and development. These inputs are reviewed for adequacy.
3 Design and Development Output
The outputs of design and development are in a form suitable for verification against the design and development input and are approved prior to final
drawings. Design and development outputs shall provide appropriate information for purchasing, production and service provision; contain all reference
product acceptance criteria, and specify the characteristics of the product that are essential for its safe and proper use.
4 Design and development review
Systematic reviews of design and development shall be performed to evaluate the ability of the results of design and development to meet requirements,
and to identify any problems and propose necessary actions. Records of the results of the reviews and any necessary actions shall be maintained.
Manufacturing Engineering Department approves the drawings or changes drawings and chooses the optimal product construction to produce high
quality products with economical and reasonable manufacturing methods. Records of the results of the approvals and any necessary actions are
maintained.

-40-

5 Design and development verification

Verification is performed by Technical Center in accordance with planned arrangements to ensure that design and development outputs must meet the
design and development input requirements, the input of design stage includes contract, technical agreement and related standards etc. Records of the
results of the reviews and any necessary actions are maintained.
Manufacturing Engineering Department performs the verification to ensure reasonableness and applicability of manufacturing methods, parameters,
manufacturing procedures, materials and equipment, and to ensure the product quality stability, low cost, etc. in a small batch or repetitious production.
Records of the results of the reviews and any necessary actions shall be maintained.
6 Design and development validation
Validation is performed by Technical Center in accordance with arranged plan to ensure that the resulting product is capable of meeting the
requirements for the specified application or intended use. When required the Service Center asks for a "product performance survey" from the
customer. The relevant departments provide verification information. Quality Assurance Department provides the final test reports of the products.
Technical Center conducts the verification for new products. It maintains the records of the validation and verification of design and development.
7 Control of design and development changes
Design and development changes are identified and records maintained by Technical Center, the changes are reviewed, verified and validated, as
appropriate, and approved before implementation. Technical Centre and Manufacturing Engineering Department perform the control of design and
development changes and maintain records of the results of the reviews of changes and any necessary actions.

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Appendix 4: Painting System of TBEA Shenyang

TBEA Shenyang has a lot of experience with the following painting systems.
A. Epoxy zinc-rich primer + Epoxy micaceous iron oxide primer + Polyurethane
1. The inner surface painting requirement:
- Epoxy Primer (white) once
- The thickness of the Paint Film is about 40-50m
2. The requirement of the outer surface painting
- First painting: Epoxy zinc-rich primer twice. The thickness of the Paint Film is about 40-50m.
- Second Painting: Epoxy micaceous iron oxide primer twice. The thickness of the paint film is about 100-120m
- Third Painting: Acrylic polyurethane enamel twice. The paint thickness is about 50m
The total thickness of the outer surface paint film is not less than 250m
3. The brush and spray painting of tank cover for Anti skid
The routine process of fully painting the top surface of the tank. Brush painting the top cover of the tank for Anti skid. The thickness of the paint film on
tank cover is greater than 350m.
B. Epoxy primer + epoxy paints + Polyurethane series
1. The inner surface painting requirement
- Thick epoxy primer (white) once
- The thickness of the Paint Film is about 40-50m
2. The requirement of the outer surface painting
a) First painting: Thick Epoxy primer (white) twice. The thickness of the Paint Film is about 60-80m.

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b) Second Painting: Epoxy micaceous iron oxide primer once. The thickness of the paint film is about 40m
c) Third Painting: Thick epoxy intermediate coating twice. The paint thickness is about 160 -200m.
d) Acrylic polyurethane enamel twice. The paint thickness is about 50m
The total thickness of the outer surface paint film is not less than 350m

3. The brush and spray painting of tank cover for Anti skid
The routine process of fully painting the top surface of the tank. Brush painting the top cover of the tank for Anti skid. The thickness of the paint film on
tank cover is greater than 450m.

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Appendix 5: Product Transportation System

The transportation system of TBEA Shenyang to lift, load and transport transformer products at various points.

Starting Point:

TBEA Shenyang Transformer Group Co.,Ltd. No. 32 Kaifa Avenue Tiexi District Shenyang 110144 China.

Destination: Customers approved port

Transportation MethodIntermodal
1. TBEA Shenyang Transformers Factory Port of China (Dalian or Tianjin, here we choose Dalian Port for illustration) : By Truck
2. Port of China Customer Designated Port: By sea
3. Customer Designated Port Transformer

installation site : By Truck, Jack and Roll

4. TBEA Shenyang Transformer Factory Dalian, China : By Truck

Routine: From Factory to Port
Distance: 356 Km, Freeway, Bridge, Road available for truck, no obstacle.

5. Options for available trucks

5.1. Heavy Transaction Engine
a. WILLEME TG300

-44-

9270

TypeTG300
Drive Model: 8x 8 Transactions, Hustle

3350
2350

3500

Made in: France

Rated Power: 600 horse

1625

b. Yiweike EZ250
Type EZ250
Rated Power525Horse

c. MAN FE600A
Rated Power600Horse

-45-

3740

1625

5.2. Heavy Smooth Trailer

Nicolas Heavy Rigger
Made byNicolas, France
Type: NICOLAS STG17.15
Single Axial3 Ton
Max. Loading Weight per Axial29 Ton
Axial Distance1.6M
Width: 3.63M
Trailer Height: 1.080.27M

6. Transportation Arrangement - The following procedures are followed

6.1 Truck Preparation and Coordination
Check details of the truck after Notification of Loading the Goods.
Check Truck as per Operation and Maintenance Manual
Function Test of Trailer on Brake, Transaction for : Emergency &Positive Brake
Trailers Hydraulic Device Leakage Checking
Tyre Pressure Checking
Commissioning of Truck

-46-

 Hydraulic 300MP Min.

Hydraulic Meter Margin: 20% Max.

6.2 Loading of Transformer

Before Loading:

Physical Inspection, Measurement checking will be performed and record measurement and signed by each party.

Smoothing Trailer Parked on the dedicated place.

Remark will be taken on the loading position, gasket for increasing the friction.
Gravity Checking
13mm Steel Rope, 5 Tons Steel Ring Rope20mm Screw Device for safety banding the transformer during transportation.
Timely inspection for impact recorder and Automatic Nitrogen Filling Device.

6.3 Road Arrangement

Constant Communication Walkie-talkie, Mobile phone, Navigator,
SpeedBend Pass 2Km/h Bridge Pass: 5Km/hMax: 15Km/h
Bridge PassConstant SpeedShift, Brake, Acceleration Not Allowed.
Cross Roads and Other High Obstacle: Min Speed, Person Inspection
Unsmooth Road Pass: Radial and Axial Smoothing Adjustment, Trailer Smooth, 3g Max.

-47-

 Rest During NightMain Hydraulic to Min, Shut Down All Hydraulic Handle
Check Safe of Goods for Each Parking

6.4 Number of required days: Truck Available = 3 Days, Loading = 1 Day, Road Transportation = 3 Days

7. Port of China - Customer approved destination port: By sea

a) Stowage and Calculation (by loading instrument)
Calibration of initial stability height at ships departure
After correction of free water Gmo=1.69m
Rolling period T=13.9 seconds
Conforming to navigation requirements

b) Dunning of Heavy Lift

To be decided in accordance with the strength surface of bottom of heavy lift. Taking the TURBINE PACKAGE of 165MT as an example, Skid
Cargo given: Dunnaging materials: Log: 10*10*200cm, Dunnaging surface: (4 supporting beams) 49m2
Dunnaging method (See sketch)

-48-

Transformer Load below Deck

Transformer Safety Position at Sea

2x300MT MF Crane of Heavy Vessel

-49-

Appendix 6: Export Reference List

1. The export reference for North America
Voltage (kV)
Countr
y

USA

USA

Name
of
Client

Client Contact
Name
and Ph #

LADW
P
LADW
P

USA

LADW
P

USA

LADW
P

USA

LADW
P

USA

SDG&
E
Hydro

Canada

USA

NEE
PAWA
AES
Corp.

Year
Delivery
Sign
or
Contrac
operatio
t
n

Qt
y

Capacit
y
(MVA)

No. of
windin
g

Freq
.
(Hz)

Primar
y

Secondar
y

Tertiar
y

Cooling

Operatio
n Status

Mr .Bina
Vatanpour
( 213 )3672212

900

three

60

235

225

buried

OA/FA/FA

Fine

2003

2004

Mr. Bina
Vatanpour
( 213 )3672212

533

three

60

525

230

13.8

FOA

Fine

2005

2006

13.8

OA/FA/FA

Fine

2005

2006-200
7

ONAN

Fine

2007

2008

OA/FA/FA

Fine

2007

2008/200
9

ONAN/ONAF/ONA
F

Fine

2009

2010

Mr. Bina
Vatanpour
( 213 )3672212
Mr. Bina
Vatanpour
( 213 )367221
Mr. Bina
Vatanpour
( 213 )3672212

133

three

60

525/3

230/3

16

three

60

34.4

5040V

160

three

60

287.5

138

Mr. Carlos Cuevas

(626) 7959955

224

three

60

230

69

Mr. Ross Lowry

(204) 4743834

95

three

60

230

132.8

66

ONAN/ONAF/ONA
F

Fine

2009

2010

632MV
A

50

500

15

15

OFAF

Fine

2009

2010

13.8

three
Mr.Vijai
(703) 522 1315

-50-

Voltage (kV)
Countr
y

Name
of
Client
AES

USA

Corp.

Client Contact
Name
and Ph #

Qt
y

Capacit
y
(MVA)

No. of
windin
g

Freq
.
(Hz)

Primar
y

Secondar
y

Mr.Vijai
(703) 522 1315

377MV
A

three

50

500

20

Mr.Vijai
(703) 522 1315

300MV
A

three

50

220

132

Tertiar
y

Year
Delivery
Sign
or
Contrac
operatio
t
n

Cooling

Operatio
n Status

ODAF

Fine

2009

2010

OFAF

Fine

2009

2010

AES
USA

Corp.

13.2

2. The export reference list for Gulf Region

No

Time

Country

Product
Specification

Quantity

Clients Name and

(Set)

Contact person

Operation Status

1992

Turkey

63MVA, 141/11kV

Fine

1994

Syria

125MVA, 242/13.8kV

Fine

1998

Iran

63MVA, 230/6.9kV

63

Fine

Nov. 1998

United Arab
Emirates
(UAE)

1001000kVA,
11/0.433kV

615

Fine

1999

Iraq

95kVA, 132/10.5kV

Fine

1999

Iraq

8MVA, 135/6.6kV

Fine

Oct. 1999

UAE

90MVA, 220/132kV

Fine

-51-

No

Time

Country

Product
Specification

Quantity

Clients Name and

(Set)

Contact person

Operation Status

2000

Syria

20MVA, 66/20kV

Fine

2000

Egypt

125MVA, 220/66kV

Fine

10

May 2000

UAE

11/0.433kV, 500kVA

20

Fine

11/0.433kV, 100KVA

200

Fine

11

April 2001

UAE
11/0.433kV, 250KVA

100

Fine

12

2001

Iran

125MVA 230/10.5kV

Fine

13

2001

Iran

125kVA, 132/10.5kV

Fine

14

February,
2002

UAE

11-6/0.415kV,
1500kVA

50

Fine

2002

Iran

50MVA
154/132/20kV

Fine

2002

Iran

50MVA 154/10.5kV

Fine

2003

Iran

160MVA
230/154/20kV

Fine

Sep, 2003

UAE

100KVA11/0.433KV

250

Fine

Sep, 2004

Turkey

160MVA
400/36/13.8kV

Fine

Nov, 2004

UAE

250KVA11/0.433KV

100

Fine

500KVA11/0.433KV

200

Fine

15

16

17

-52-

No

Time

Country

Product
Specification

Quantity

Clients Name and

(Set)

Contact person

1500KVA11/0.433KV

100

Fine

Operation Status

18

Oct, 2005

Iran

75MVA 66/10.5kV

Fine

80

Fine

Oct, 2005

United Arab
Emirates

2000KVA11/0.433KV

19

100KVA11/0.433KV

249

Fine

100KVA11/0.433KV

200

Fine

5750KVA33/0.415KV

Fine

20

Jan, 2005

United Arab
Emirates

21

Dec, 2005

UAE
2000KVA33/0.415KV
160MVA 400/13.8kV

22

23

24

April, 2008

Dec, 2008

April, 2009

Turkey

Turkey

Turkey

Fine
1

160MVA
400/36/13.8kV

Fine
Fine

240MVA 400/20kV

Fine

80MVA 33/20kV

Fine

40MVA 20/6.3kV

Fine

25MVA 20/6.3kV

Fine

240MVA 400/20kV

Fine

80MVA 33/20kV

Fine

40MVA 20/6.3kV

Fine

25MVA 20/6.3kV

Fine

-53-

No

Time

Product
Specification

Country

Quantity

Clients Name and

(Set)

Contact person

Operation Status
United International Trading Co; Ltd.

25

Feb., 2009

Saudi
Arabia

SFZ-133000/115

26

June, 2009

Iraq

SF-75000/132

Fine

27

30-Sep-09

Turkey

720MVA 400/20kV

Fine

28

30-Apr-10

Turkey

720MVA 400/20kV

Fine

29

August, 2010

Iraq

SFF-31500/20

Manufacturing

30

August, 2010

Iraq

SFFZ-50000/110

Manufacturing

CrissyRubrico P.O.Box75599AlKhobar31952|
KSAT+96638812227 F+96638812225
www.uitc.com.sa crissy@uitc.com.sa

Fine

3. General Export Reference List from 1987-2008

The transformers & reactor exported by TBEA Shenyang Transformer Group Co., Ltd (Former: SHENYANG TRANSFORMER CO., LTD.) from
1987 are as follows:
Capacity
(MVA)

Country

Qty

No. of
winding

Freq.
(Hz)

Voltage (kV)

Year

Remarks

OFAF

1987

Delivery or
operation
1987

15.75

OFAF

1988

1988

110

27.5

ONAN

1988

1988

50

110

27.5

ONAN

1988

1989

two

50

220

6.9

OFAF

1988

1989

two

50

130

6.6

ONAF

1988

1989

China *

three

50

Primary
Tertiary
242

250

Pakistan

two

50

220

40

China *

two

50

25

China *

two

25

Pakistan

25

Pakistan

180

Cooling

Secondary
121

Sign Contract
11

25

Pakistan

two

50

15.75

6.6

ONAN

1988

1989

250

Pakistan

two

50

220

15.75

OFAF

1989

1989

167

China *

three

50

550

220

OFAF

1989

1990

52.7

China *

two

50

220

22

OFAF

1989

1990

25

Pakistan

two

50

15.75

6.6

ONAN

1989

1991

160

Pakistan

three

50

220

132

OFAF

1990

1991

60

Thailand

two

50

112

24

ONAN/ONAF

1990

1991

60

Thailand

two

50

112

24

ONAN/ONAF

1990

1991

40

Thailand

two

50

67

12-24

ONAN/ONAF

1990

1991

160

Pakistan

three

50

220

132

OFAF

1991

1992

150

Bengal

two

50

242

15.75

OFAF

1991

1992

150

Bengal

three

50

230

135

OFAF

1991

1992

150

Vietnam

two

50

20

11

OFAF

1991

1991

63

Turkey

two

50

141

11

OFAF

1991

1992

62.5

Indonesia

two

50

150

20

OFAF

1991

1992

60

Thailand

two

50

112

24

ONAN/ONAF

1991

1992

60

Thailand

two

50

67

12-24

ONAN/ONAF

1991

1992

60

Thailand

two

50

67

12-24

ONAN/ONAF

1991

1993

50

Thailand

two

50

112

22

ONAN/ONAF

1991

1992

44

Indonesia

two

50

20

11

OFAF

1991

1993

37.5

Philippines

two

60

115

13.8-13.8

ONAN/ONAF

1991

1992

10.7

Pakistan

three

50

132

11.5

ONAF

1991

1991

10

Indonesia

two

50

20

3.45

ONAF

1991

1992

10

Indonesia

two

50

11

3.45

ONAF

1991

1993

13

Pakistan

two

50

132

11.5

ONAN/ONAF

1992

1994

34.5

11

11

34

3.45

250

Pakistan

two

50

235

15.75

ONAF

1992

1993

160

Pakistan

three

50

220

132

ONAN/ONAF

1992

1993

90

Malaysia

two

50

132

33

ONAN/ONAF

1992

1993

60

Thailand

two

50

67

12-24

ONAN/ONAF

1992

1993

45

Malaysia

two

50

132

33

ONAN/ONAF

1992

1994

30

Malaysia

10

two

50

132

11

ONAN/ONAF

1992

1994

30

Malaysia

10

three

50

132

11

ONAN/ONAF

1992

1994

26

Pakistan

22

two

50

132

11.5

ONAN/ONAF

1992

1995

25

Pakistan

two

50

15.75

6.9

ONAN

1992

1993

25

Pakistan

two

50

230

69

ONAN/ONAF

1992

1993

15

Malaysia

two

50

132

11

ONAN/ONAF

1992

1994

15

Malaysia

three

50

132

11

ONAN/ONAF

1992

1994

7.5

Malaysia

two

50

132

11

ONAN/ONAF

1992

1993

380

Pakistan

two

50

235

20

ODAF

1993

1995

300

China

two

50

550

15.75

OWAF

1993

1995

125

Syria

two

50

242

13.8

OWAF

1993

1994

90

Malaysia

two

50

132

33

ONAN/ONAF

1993

1997

60

Malaysia

three

50

132

22

ONAN/ONAF

1993

1995

45

Malaysia

two

50

132

33

ONAN/ONAF

1993

1995

40

Pakistan

two

50

20

6.6-6.6

ONAN/ONAF

1993

1995

30

Malaysia

three

50

132

11

ONAN/ONAF

1993

1995

12.5

Pakistan

two

50

132

6.3

ONAN/ONAF

1993

1993~1994

Viet Nam

two

50

13.8

3.3

ONAN

1993

1993

150

Bangladosh

two

50

242

15.75

ODAF

1994

1995

63

Malaysia

two

50

132

10.5

ONAN/ONAF

1994

1995

11

10

10

10

10

25

Bangladesh

two

50

20

6.3-6.3

ONAN/ONAF

1994

1995

15

Antigua

two

50

69

11

ONAN

1994

1995

10

Malaysia

three

50

132

6.3

ONAN

1994

1994

10

Malaysia

two

50

10.5

6.3

ONAN

1994

1994

41.7

Bangladesh

two

50

132

34.5

ONAN/ONAF

1995

1996

Viet Nam

two

50

13.8

3.3

ONAN

1993

1993

150

Bangladosh

two

50

242

15.75

ODAF

1994

1995

63

Malaysia

two

50

132

10.5

ONAN/ONAF

1994

1995

25

Bangladesh

two

50

20

6.3-6.3

ONAN/ONAF

1994

1995

15

Antigua

two

50

69

11

ONAN

1994

1995

10

Malaysia

three

50

132

6.3

ONAN

1994

1994

10

Malaysia

two

50

10.5

6.3

ONAN

1994

1994

41.7

Bangladesh

two

50

132

34.5

ONAN/ONAF

1995

1996

40

Vietnam

two

50

110

1.5

ONAN/ONAF

1995

1995~1996

50

Philippines

two

60

115

34.5

OFAF

1995

1995

50

Thailand

10

two

50

115

23.1

ONAN/ONAF

1995

1995~1996

25

Philippines

two

60

34.5

3.45

ONAN/ONAF

1995

1996

4.3

China*

two

50

66

6.3

ONAN

1995

1995

China*

two

50

66

6.3

ONAN

1995

1996

300

Pakistan

two

50

230

15

ODAF

1996

1997

190

Pakistan

two

50

230

11.5

ODAF

1996

1998

160

Pakistan

three

50

220

132

ONAN/ONAF

1996

1998

25

Pakistan

two

50

11.5

6.3

ONAN/ONAF

1996

1997

50 kVA

Indonesia

6252

two

50

20

0.4

ONAN

1996

1997

11

63

Iran

two

50

230

6.9-6.9

ONAN/ONAF

1997

1998

40

Iran

two

50

20

6.9-6.9

ONAN/ONAF

1997

1998

15

Malaysia

20

two

50

132

11

ONAN/ONAF

1997

1999

5.2

Vietnam

two

50

15

0.38

ONAN

1997

1998

125

Iran

two

50

400

10.5

ONAN/ONAF

1997

2001

125

Iran

two

50

230

10.5

ONAN/ONAF

1997

2001

125

Iran

two

50

132

10.5

ONAN/ONAF

1997

2001

100

Philippines

three

60

138

69

OA/FA/FA

1997

1999

10

Burma

two

50

66

11

ONAN

1997

1998

60

Malaysia

three

50

132

22

ONAN/ONAF

1997

1999

90

Malaysia

50

two

50

132

33

ONAN/ONAF

1997

2000

26

Pakistan

18

two

50

132

11.5

ONAN/ONAF

1998

2001

40

Pakistan

two

50

132

12

ONAN/ONAF

1999

1999

20

Syria

two

50

66

20

ONAF

1999

2000

125

Egypt

three

50

220

66

ONAN/ONAF

1999

2000

95

Iraq

two

50

132

10.5

ONAN/ONAF

1999

1999

Iraq

two

50

135

6.6

ONAN

1999

1999

26

Pakistan

two

50

132

11.5

ONAN/ONAF

1999

2000

400

Yugoslavia

three

50

400

231

OFAF

2000

2001

40

China

two

50

116

10.5

ONAN/ONAF

2000

2001

25

China

two

50

116

10.5

ONAN/ONAF

2000

2001

120

China

three

50

550/ 3

242/ 3

OFAF

2000

2001

720

China

two

50

550

20

ODAF

2000

2001

840

China

two

50

550

20

2000

2004

250

China

three

50

550/ 3

242/ 3

2001

2003

13.8

11

11

10.5

35

36

ODAF

160

Iran

three

50

230

154

20

ONAN/ONAF

2001

2003

50

Iran

three

50

154

132

20

ONAN/ONAF

2001

2002

250

China

two

50

550/ 3

22

FOA

2001

2003

160

Pakistan

three

50

220

132

ONAN/ONAF

2002

2003

71

Pakistan

two

50

550/ 3

13.2

ODWF

2002

2003~2004

100

China

two

50

242

10.5

OFWF

2002

2003

282

China

two

50

525/ 3

199/ 3

ODAF

2002

2004

160

Pakistan

three

50

220

132

ONAN/ONAF

2002

100

China

two

50

242

13.8

OFWF

2003

2004

900

America

three

60

235

225

OA/FA/FA

2003

2004

250

China

two

50

500

22

FOA

2004

2005

63

China

split

50

22

6.3-6.3

OA/FA1/FA2

2004

2005

150

Pakistan

three

50

525/3

231/3

ONAN/ONAF1 /ONAF2

2004

2004~2005

370

Indonesia

two

50

150

20

OFAF

2004

2005

533

America

three

60

525

230

FOA

2005

2006

10Mvar

America

one

60

OA

2005

2006

Reactor

11

11

buried

23

13.8

230/3

200

Pakistan

three

50

525/V3

231/V3

23

ONAn/ONAF1 /ONAF2

2005

2006

160

Pakistan

three

50

220

132

11

ONAN/ONAF

2005

2006

40

Congo

two

50

242

10.5

ONAN

2005

2007

133

America

three

60

525/V3

230/V3

13.8

OA/FA/FA

2005

2006-2007

200

Pakistan

three

50

525/3

231/3

23

ONAN/ONAF1 /ONAF2

2006

2007

300

Philippine

three

60

230

115

13.8

ONAN/OFAF/OFAF

2006

2007

167

Tadzhikistan

three

50

525/V3

230/V3

11

ONAN/OFAF

2006

2007

120

Vietnam

two

50

525/V3

20

ODAF

2006

2007-2008

360

Vietnam

two

50

242

20

ODAF

2006

2007-2008

50

Vietnam

three

50

115

6.8

ONAN

2006

2007-2008

50

Vietnam

three

50

20

6.8

ONAN

2006

2007-2008

550/ 3

71

Pakistan

two

50

13.2

2006

2007

120

China

(Smoothing Reactor)

50

2006

Manufacturing

200

Pakistan

three

50

500/ 3

220/ 3

22

ONAN/ONAF1/ONAF2

2007

2008

150

Pakistan

three

50

500/ 3

220/ 3

11

ONAN/ONAF1/ONAF2

2007

2008

250

Pakistan

three

50

220

132

11

ONAN/ONAF1/ONAF2

2007

2008

125

Vietnam

three

50

225

115

23

ONAN/ONAF1/ONAF2

2007

2008

250

Vietnam

three

50

225

115

23

ONAN/ONAF1/ONAF2

2006

2008

16

America

three

60

34.4

5040V

ONAN

2007

2008

125

Vietnam

three

50

215

115

10.5

ONAN/ONAF1/ONAF2

2007

2008

24.65

India

seven

50

11

132

OFWF

2007

2008

-60-

ODWF

N0TE:
1. Abbreviation for cooling system
ONAN.............. Oil-immersed self-cooled

ONWF ............. Oil-immersed forced-water cooled

ONAF ............. Oil-immersed forced-air cooled

OFWF.............. Forced-oil

forced-water cooled
OFAF .............. Forced-oil forced-air cooled
*

ODAF............... Forced directed-oil forced-air cooled

.......... With on-load tap-changer

ii.......... Auto-transformer

* ................With international loan

*

with Siemens technology

-61-

Appendix 7: Customers Acknowledgement Letters

1. Pakistan National Transmission & Dispatch Company

-62-

2. Malaysia State Power

-63-

3. Serbia Power Transmission Company

-64-

4. China Shajiao Electric Power

-65-

Prepared by:

Jeffers Teargun Heptol

International Business Department
TBEA Shenyang Transformer Group Co.Ltd
Add: 32, Kaifa Road, Tiexi Distric, Shenyang 110144
Peoples Republic of China
Email: Tbea_Jeffers@sina.com
Website: www.tbea.com