Issue Revision History Approved Date

B Document re-written Rahul 12.02.14

1 Application

This note explains the welding method (MMAW-Manual Metal Arc Welding) at site for repairing
a leak through the welded joint of power transformer tanks and fittings.

2 Preparatory works before welding:

2.1 De-energize the transformer and check the earthing of tank is proper.

2.2 Check the oil level:

Before starting the work, the oil level in the tank should be checked. The oil level in relation to
the area to be welded should be 100 mm or more above the area to be welded.

2.3 Create a vacuum above the oil level in tank to temporarily stop the leak.
This may be done by closing buchholz relay valve and draining sufficient oil from bottom filter
valve (1ZYN 200820-068) on pumping out to conservator to obtain necessary vacuum inside
the tank. Vacuuming is not essential if the leak is only a sweating one. Welding without oil can
be done if the tank wall thickness is more than 9 mm. In that case steps are to be taken to
repaint inside burnt paint and also to cover from inside to prevent welding sparks entering into
tank.

2.4 If oil level cannot be maintained above the welding point, keep a nitrogen blanket inside the tank
In that condition there is chance for burning of the inside painting.

2.5 Cleaning:
Remove the oil and paint from the surface to be welded. Prepare a suitable point on
transformer tank for clamping the earth lead of the arc welding set.

2.6 Peen the weld

Use the ball end of a ball peen hammer and a blunt or round nose chisel to stop the weld leak
of possible.

2.7 Fire precaution

All steps shall be taken to prevent starting and spread of fire from the welding point. In
flammable materials should be removed from the area. Keep fire-fighting kit nearby.

PREPARED: DATE Responsible department TITLE:

Parth Hingu 05-09-2008 PPTR-Design Procedure for Repairing
APPROVED: DATE Take over department Language
English
P.Ramachandran 05-09-2008 Weld leak at field
Revision ORDER NO. Page
B Standard 1(4)
Document No.

ABB INDIA LIMITED 1ZYN200820-082

 Issue Revision History Approved Date
B Document re-written Rahul 12.02.14

3 Leak Welding

3.1 Welding condition

All purpose, Coated Current

Welding Set Polarity welding rod (Amperes)
(As per AWS code A5.1)
E6012,
DC Straight E6013 3.15 mm 120±10
E7014
E7018 2.5/3.15 mm
AC Same as above 120±10

Use type 308 stainless steel electrode for making repairs on non-magnetic steel (e.g.: High current
LV bushing mounting flange, turret). When DC current is used, straight polarity is preferred,with
the electrode negative.

3.2 Apply a stringer bead-sealing weld in a single quick pass.

This weld should be deposited horizontally or vertically depending upon the nature of work. If
the weld is deposited vertically, deposit the bead from top to down to drive any liquid seepage
ahead of weld. Remove the slag from the deposited metal. Successive beads are deposited
adjacent and over the first sealing weld. Remove the slag from the deposited metal after each
weld.

3.3 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 this sequence to prevent any liquid
seepage interfering with the welding operation.

3.4 Patch Method:

As an alternative, a patch may be welded to the transformer tank to repair a leak. The
recommended method is as below:
First tack-weld a 5-6 mm thick plate over the area where the leak is found. The length and
breadth of the plate are to be decided before welding. Weld the sides of this plate first, then
horizontally across the top of the patch and finally horizontally across the bottom as shown, in
figure.

PREPARED: DATE Responsible department TITLE:

Parth Hingu 05-09-2008 PPTR-Design Procedure for Repairing
APPROVED: DATE Take over department Language
English
P.Ramachandran 05-09-2008 Weld leak at field
Revision ORDER NO. Page
B Standard 2(4)
Document No.

ABB INDIA LIMITED 1ZYN200820-082

 Issue Revision History Approved Date
B Document re-written Rahul 12.02.14

1 2

This welding sequence is recommended to prevent any liquid interfering with or contaminating the
weld.

3.5 Precautions during welding:

The quality of the weld metal is affected by the oil present on the surface of the weld area. This
should be removed with dry cloth after each weld.

4 To repair a weld leak in a radiator the arc welding is recommended:

1. Remove the radiator from the transformer tank.

2. Find the exact position of the leak by cleaning with wire brush and sandex

3. If the leak is around the flange (i.e. Mig welded areas), weld the leak with 3.15 mm electrode
(E-6012 orE-7018) with current setting 110-125 Amps.

4. If the leak is along the edges of the fin (i.e. TIG and Seam welded area ), use slightly reducing
oxy-acetylene welding flame under neutral flame to remove oil traces and to pre heat damaged
area. After 5 minutes carry out GTAW (Gas tungsten arc welding) with DC power source.
Set the current approx. 80/100 A and fuse the edges slowly. Check visually for total fusion.

5. Clean the repaired area and check with a suitable leak detector after filling with air or oil

6. If there is no leak, apply touch up paint.

5 Inspection of weld:

Clean the repaired area and check the weld with chalk powder if the transformer is filed with oil and
with soap water in case of nitrogen filling. Liquid dye penetration test may be done to ensure
soundness of welding.

PREPARED: DATE Responsible department TITLE:

Parth Hingu 05-09-2008 PPTR-Design Procedure for Repairing
APPROVED: DATE Take over department Language
English
P.Ramachandran 05-09-2008 Weld leak at field
Revision ORDER NO. Page
B Standard 3(4)
Document No.

ABB INDIA LIMITED 1ZYN200820-082

 Issue Revision History Approved Date
B Document re-written Rahul 12.02.14

6 Finishing

After checking for the leak, clean the area completely and apply touch up paint (Primer+ Finish
Paint)

Do not energize the transformer without oil circulation with vacuum chamber in the filter machine
(Min 48 hrs.) plus settling time (more than 3-8 days).

PREPARED: DATE Responsible department TITLE:

Parth Hingu 05-09-2008 PPTR-Design Procedure for Repairing
APPROVED: DATE Take over department Language
English
P.Ramachandran 05-09-2008 Weld leak at field
Revision ORDER NO. Page
B Standard 4(4)
Document No.

ABB INDIA LIMITED 1ZYN200820-082