Trafo Manual ABB

PART 5
DISMANTLING AND TRANSPORT
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor
be used for any unauthorized purpose. ABB LIMITED, MANEJA , VADODARA, GUJARAT, INDIA Page - 28 -
5 DISMANTLING AND TRANSPORT
5.1 RESPONSIBILITIES AFTER TRANSFORMER TEST AND PREPARATION FOR SHIPMENT -
GENERAL OVERVIEW +FIGURE F5.1+APPENDIX A5.1
5.2 METHODS OF TRANSPORTATION
5.3 TRANSPORT MODES
5.3.1 TRANSPORT WITH NITROGEN GAS FILLING + DRAWING 1ZYN 4601-204
5.3.2 INSTRUCTIONS FOR FILLING DRY PURE NITROGEN GAS (AT WORKS)
5.4 HANDLING DURING LOADING AND ON SITE
5.4.1 LIFTING TRANSFORMERS
5.4.2 SUSPENDING TRANSFORMERS + FIGURE: F 5.2
5.4.3 MOVING TRANSFORMERS
5.4.4 TRANSPORT OF ACCESSORIES
5.4.5 TRANSPORTATION EQUIPMENT AND TOOLS
5.5 SHIPPING ARRANGEMENTS
5.5.1 GENERAL
5.5.2 SHIPPING BRACES
5.5.3 BUSHINGS
5.5.4 CURRENT TRANSFORMERS
5.5.5 SHUT OFF DEVICES
5.5.6 TIGHTNESS SURVEILLANCE
5.6 PACKING LIST AND TRANSPORT MONITORING
5.6.1 GENERAL
5.6.2 PACKING LIST
5.6.3 ASSEMBLY PACKAGES
5.6.4 TRANSPORT MONITORING
INDEX
Section Description
5.1.1 Scope
5.1.2 Shipping Information
5.1.2.1Packing List
5.1.2.2Shipping braces and covers
5.1.3.0Transportation
5.1.3.1General
5.1.3.2Impact Recorder (If Applicable)
5.1.3.3Other Data
5.1.4.0Successful Shipment Verification
5.1.4.1General
5.1.4.2Impact Recorder
5.1.4.3Other Checks
5.1.4.3.1External Inspection
5.1.4.3.2Internal Inspection
5.1.5.0Arrival at Customer’s Mounting Pad
5.1.5.1General
5.1.5.2Storage on Site
5.1.6.0Re-Assembly Instructions
5.1.6.1Oil Handling and Filling
5.1.7.0Commissioning Tests
5.0 DISMANTLING AND TRANSPORT [REF: 1ZBA 4601-200]
5.1 RESPONSIBILITIES AFTER TRANSFORMER TEST AND PREPARATION FOR SHIPMENT -

GENERAL OVERVIEW.
5.1.1 SCOPE
Provide a specification outlining the actions to be taken and the documentation to be delivered to
meet the Customer’s needs after a transformer has been tested and subsequently prepared for
shipment.
Guidelines will be offered, and where applicable example documents provided, to allow the Power
Transformer Plants to meet Customer expectations in the transportation, verification of successful
shipment, installation, commissioning, operation and life cycle management of their equipment.
This specification will detail in general terms the information and services a Customer requires to
complete the relationship after the transformer has been successfully tendered, designed,
manufactured, tested and prepared for shipment.
5.1.2 SHIPPING INFORMATION
5.1.2.1 PACKING LIST
Who Uses a Packing List?

Manufacturer - to catalogue parts removed for shipment and to confirm the removed, required
parts have been packaged for delivery.
Transport Company - to identify packages to be picked up and delivered, to assess shipping cost.
Customer - to confirm that the required parts have been received, to aid in re-assembly.
What should be on a Packing List?
Identification of all parts, dimensions and weights of major components and accessory boxes.
Shipped components can be grouped into major and accessory parts.
Major parts would include the stripped down transformer, conservator, bushings, surge arresters,
coolers and drums of top up oil. These parts may be packaged (boxed or on skids) to allow for
convenient transport.
Accessories would include all parts removed for shipment from the transformer and the major
components such as all required hardware, gauges, devices, valves, spare components, etc.
These parts are packed in boxes. The packing list must include the weights and dimensions of
the major components and packed boxes to allow the Transport Company to cost the move and
for the specification of cranes at the Customer’s site.
There must be a correlation between the parts shipped, and the completed transformer, to
facilitate re-assembly of the equipment.
A determination should be made if there is a need to differentiate between the packing list for a
truck shipment versus a rail shipment or other transport mode. Export packing will require a
different packing list (and packing instructions) than a packing list for domestic transport. See
SECTION 5.6 [REF: 1ZBA 4601-201] for additional Packing List guidelines.
5.1.2.2 SHIPPING BRACES AND COVERS
Shipping covers and sometimes special braces are required to prepare the transformer for
shipment. These braces and covers must be removed after arrival at Customer’s site during the
re-assembly process. The covers and braces are identified in the shipping documentation and
are painted a contrasting colour, such as yellow, for easy identification.
5.1.3 TRANSPORTATION
5.1.3.1GENERAL
Transportation from the factory to the Customer’s site, nearest rail siding or nearest port is often
arranged by the manufacturer. If the transformer is not delivered directly to a mounting pad at the
Customer’s site, crane handling and/or heavy equipment moving capability as well as additional
transport will be required.
Once at the mounting pad, a large capacity crane and/or heavy equipment moving capability for
the main unit, and small crane capability for the transformer accessories will be required.
The manufacturer must be prepared to make arrangements with reputable, reliable transport,
crane and heavy equipment moving companies on behalf of the Customer for the complete
voyage from factory to Customer’s mounting pad.
The Customer or Customer’s agent may wish to establish some or all of the transportation and off
loading arrangements, but the manufacturer must be in a position to assist when required.
For critical shipments by rail, sometimes a rider is required. The rider accompanies the
transformer (generally riding in the train’s caboose) and can monitor the condition of the journey
as well as report to the manufacturer and Customer on trip progress.
5.1.3.2IMPACT RECORDER (If applicable)
The use of a three dimension impact recorder (also known as a bump recorder or accelerometer)
to monitor the quality of the trip and to chronicle potential excessive shocks to the transformer, is
in many cases a Customer specified requirement.
The impact recorder should be mounted on the transformer cover (rather than the rail car) to
provide a representative record of the impact shocks that the transformer will receive on its
journey. Also, if the transformer is moved from one mode of transportation to another, the impact
recorder can travel the entire journey from the factory to the Customer’s mounting pad.
Core form transformers are to be shipped upright, with the transformer mounted on the rail car or
truck such that the long axis is in the same direction as the direction of travel.
Plan view of a Transformer placed on a Rail Car or Truck
<<<<Direction of Travel>>>>
Transformer Rail Car or T rack
Figure 5.1
The impact recorder must be mounted on the transformer to ensure: the Longitudinal
Acceleration direction lines up with the direction of travel the Lateral Acceleration direction
lines up with the direction a right angles to the direction of travel the Vertical Acceleration
will detect the up and down movement.
Care must be taken to properly set-up and mark the start-up of the impact recorder at the factory.
This same care is critical when marking the impact recorder tape at change of transportation
mode and/or at final removal at the Customer’s pad. In the event of the transformer being
exposed to excessive mechanical shock, a properly set-up and monitored impact recorder can
help pinpoint the time, place, level and direction of the potentially damaging forces.
5.1.3.3 OTHER DATA
Prior to shipping the transformer, tests for future comparison at change of transportation mode
and/or at final unloading at the Customer’s pad should be made. These tests and checks must
include the following:
core ground insulation resistance (megger)
water content (ppm) and dielectric strength (kV) of the oil shipped in unit, if applicable
pressure gauge reading, if applicable
temperature gauge reading, if applicable
o
dew point reading (- C), if applicable
This information must be included with the shipping documentation to allow easy access and
reference for comparison.
5.1.4.0SUCCESSFUL SHIPMENT VERIFICATION
5.1.4.1GENERAL
After leaving the factory, whenever the transformer and components are transferred from one
mode of transportation (rail car, truck, ship, etc.) to another or when they reach the final
destination, checks must be made to confirm that shipping damage has not been sustained.
These checks must be made before the equipment is moved from the transport mode. Since
transformers are shipped partially disassembled, electrical testing to confirm fitness cannot be
performed at this stage. Care must be taken to properly and completely perform the limited
amount of inspection that can be done at this time.
In the event of apparent or suspected damage, claims must be made against the transport
carrier, and ABB and Customer are to be notified immediately.
5.1.4.2IMPACT RECORDER (If Applicable)
Separate instructions are be given in APPENDIX A5.1 AT THE END OF THIS PART, to be used
when impact recorder is provided, on removing the impact recorder at final destination.
Acceptable impact levels for the Longitudinal, Lateral and Vertical Acceleration will be defined by
the individual Factories.
If the transformer and components are being inspected at an interim point, at a change of
transportation mode, the impact recorder tape should be marked with a line and the date, time
and signature of an inspector indicted on the tape below this line. The impact recorder should not
be removed from the transformer and the tape examined until the transformer has reached it’s
final destination.
5.1.4.3OTHER CHECKS
If Shipping weight and dimension limits allow, smaller transformers are shipped with all or most of
the oil required in the main tank. Some of these smaller units may also be shipped with dry
nitrogen or air in the gas space on top of the oil, this gas will be at a positive pressure when the
transformer leaves the factory.
To reduce shipping weight, larger units are totally drained of oil and then filled with dry gas
(nitrogen or air) to maintain winding and insulation dryness during transit. Of the gas filled units,
some will be filled in the factory and then be equipped with temporary gas cylinders for adding gas
to the tank during transit as needed. Other gas filled units will leave the factory with an initial
filling only and no supplementary cylinders added. In all cases, the gas filled units will leave the
factory with a positive pressure of dry gas.
For transformers shipped in oil, check for oil leaks at valves, flanges, bushings and welded
seams. If evidence of oil leaks are observed, take an oil sample for moisture content and
dielectric strength analysis. The laboratory results can be compared to the results obtained at the
factory prior to shipment.
For transformers shipped in oil with a gas layer on top of the oil, perform oil leak checks and draw
oil from suspect units. In addition, theses transformers will be equipped with a vacuum/pressure
gauge to monitor the gas layer pressure. This gauge must be checked and value of
pressure/vacuum noted along with the oil temperature as read from the top oil temperature gauge.
Although the transformer leaves the factory with the gas at a positive pressure (2 - 3 psi), the
pressure reading may be negative if transformer is exposed to colder temperatures or conversely
read a higher pressure if the ambient temperature is higher. The worst case condition is a
reading of zero pressure which may be indicating a leak. If the gauge reads zero, take and oil
sample for moisture and dielectric strength analysis. (a dew point measurement of this gas is
meaningless)
For transformers shipped dry gas filled, the monitoring of the vacuum/pressure gauge and the
temperature gauge is critical and is often checked at various stages of the journey.
A leak will compromise the winding and insulation integrity. The pressure and temperature gauge
values must be recorded and compared to the readings obtained in the factory prior to shipment.
The transformers are shipped with a positive pressure but a negative (vacuum) reading may occur
if the ambient temperature is substantially lower than recorded in the factory. The worst case
condition is a reading of zero pressure which may be indicating a leak. In conditions of zero
pressure or a pressure/temperature relationship that conflicts with the factory results, a dew point
measurement must be taken. The dew point measurement will establish the moisture content of
the gas which can be compared to the measurement made in the factory prior to shipment., PART
6 [REF: 1ZBA 4601-203 and 1ZBA 4601-204] for further information on monitoring dry gas filled
units during shipment.
The following is a general listing of tests and checks that should be performed on shipped
transformers. Not all checks are required for all shipping variations.
5.1.4.3.1 EXTERNAL INSPECTION
Any external evidence of damage or evidence indicating the possibility of hidden damage must be
reported to the carrier’s representative and to an ABB representative before off-loading the
transformer. Take pictures of external damage. The receiver must assume all responsibility for off-
loading damaged transformers. The external inspection prior to off-loading the transformer should
include the following.
Measure the core insulation resistance to ground. The minimum acceptable value is 500 k ohms
o
when measured at 1000 V DC, corrected to 20 C.
Are all tie rods undamaged and nuts tight, all cables tight.
Is all blocking tight and in good condition.
Is there any evidence of load shifting in transit.
Does the impact recorder tape indicate any impacts beyond the acceptance zones on the tape.
Are there indications of external damage such as broken glass on gauges, broken welds on
flanges.
Is the paint finish damaged.
Are all fittings, which were shipped attached, still in place and undamaged (see the outline
drawings).
Is there any evidence of oil leakage around valves, fittings, flanges and tank seams.
Is the pressure in the gas filled transformer tank acceptable according to PART 06. [REF: 1ZBA
4601-203 or 1ZBA 4601-204].
Inspect bushings which are assembled to the tank, or are in crates or boxes for signs of breakage,
are they chipped or otherwise damaged.
Is oil level in bushings normal.
Check the Packing List to confirm delivery of all major components and accessory boxes.
Do crates or boxes show evidence of damage or moisture entrance.
Check the temporary shipping silica gel breather, moisture ingress will be indicated by the
normally blue coloured silica gel desiccant turning pink.
Check that detached radiators, coolers and pumps have openings closed of with blind flanges and
plugs.
If there is no evidence of shipping damage, proceed to off-load the transformer. If shipping

damage is found, contact the nearest ABB Power Transformers representative for further
instructions prior to off-loading the transformer.
Written notations of apparent loss and damage must be made on the carrier’s delivery receipt.
Concealed damage must be reported immediately to the delivering carrier with a request for an
inspection.
See Product Information for specific Receiving Inspection - PART 7 OF THIS MANUAL:
REFERENCES:
1ZBA 4601-207 Transformer Designed with Oil Conservator, Shipped Dry-Gas Filled, Partially
Disassembled
5.1.4.3.2 INTERNAL INSPECTION
During the inspection process, if internal damage is indicated or requires confirmation, an internal
inspection may be required. This internal inspection should only be carried out by factory
personnel or a recognized service organization under factory personnel guidance.
Entry into oil filled or temporary gas filled transformer tank requires training and experience and
must not be attempted by non factory-approved personnel. Special procedures must be followed
for safety and equipment integrity reasons.
5.1.5.0 ARRIVAL AT CUSTOMER’S MOUNTING PAD
5.1.5.1 GENERAL
Upon arrival at the Customer’s site, the transformer and accessories must be inspected to confirm
that shipping damage has not been sustained. Refer to Section 5.1.4.above. At this point some
Customer’s will require as a standard procedure, an inspection, refer to Section5.1.4.3.1.and
5.1.4.3.2 After confirmation of successful shipment, the transformer and components can be
unloaded.
Depending on the main unit weight and the site conditions, a crane may be used to off-load the
transformer or it may be jacked and rolled into place onto the Customer’s mounting pad. PART 8:
[REF 1ZBA 4601-202], for guidelines about Unloading and Moving a Transformer.
5.1.5.2STORAGE ON SITE
There may be occasions when the transformer and components arrive on site before the
Customer is able to begin re-assembly. This time delay can be weeks or several months.
The delivered equipment must be maintained and monitored to ensure that the as built and as
transported conditions are preserved to ensure successful and safe installation when re-assembly
can be completed. PART 8:[REF: 1ZBA 4601-211], Storage on Site Before Assembly.
5.1.6.0 RE-ASSEMBLY INSTRUCTIONS
Although it is not practical to provide an all encompassing procedure for the re-assembly of the
often complex and individual transformer configurations, PART 11 [REF:1ZBA 4601-212],
Transformer Assembly Instructions, provides a general overview. See also PART 10 [REF:1ZBA
4601-218], Oil Conservators Without Air Cell and PART 10:[1ZBA 4601-219], Oil Conservators
With Air Cell, for further assembly instructions.
5.1.6.1OIL HANDLING AND FILLING
See PART 10:[1ZBA 4601-213], Receiving and Handling Transformer Oil on Site - Quality
Control for an overview of oil requirements. For filling transformers and components with oil see
PART 10 REF: [1ZBA 4601-214, Final Oil Filling on Site - Atmospheric Pressure and PART 10:
[REF: 1ZBA 4601-215], Vacuum Oil Filling on Site.
5.1.7.0 COMMISSION TESTS
After the transformer has been fully assembled and filled with oil, commissioning tests must be
performed to confirm fitness prior to energization. See PART 12 [REF: 1ZBA 4601-216],
Acceptance Testing and Energization for a general overview of test to be performed and utilize
PART 13 [REF:1ZBA 4601-217], Field Test Record to report the test data findings.
APPENDIX :A5. 1 Impact Recorder Receive and Return Instructions.
Before unloading the transformer or reactor, the recorder chart must be inspected by a qualified
technician. The unit must not be off-loaded unless the chart reading is within the safe limits, (see
sketch below), and there is no visible signs of damage. No liability will be accepted by ABB
unless this instruction is followed. Exceptions to these instructions must be authorized by the
shipper (ABB).
Safe Limits
Vertical Lateral Acceleration Longitudinal
Acceleration Acceleration
To be defined by
individual Factories.
Will vary from Country to
Country.
-5g C/L +5g -5g C/L +5g -10g C/L +10g
The recorder has been set to operate for a range relative to the center line (C/L) of ± 5g vertical
acceleration, ± 5g lateral acceleration, and ± 10g longitudinal acceleration. For the vertical and
lateral portion of the chart each graduation represents 1g. For the longitudinal portion of the
chart, each graduation represents 2g.
To determine the tape speed, refer to the recorder nameplate, then refer to the tape speed
marking on the side of the tape to determine the daily running record.
Removing Recorder From Transformer
Open the recorder cover and turn off the electrical switch.
Record the finish of the tape movement by drawing a line across the tape. Record the time, the
date, and sign the tape below the line.
Inspect the tape for indications of rough handling.
Inspect the car for signs of damage and record findings on the end of the impact recorder tape.
If there is any indication of potential shipping damage, either through signs of damage on the car
or by impact recorder readings outside of the acceptable limits, then contact the shipper (ABB) for
instructions (ABB Factory phone #)
Return the Impact Recorder to: ABB Power Transformer Division, MANEJA, VADODARA Mark on
the PARCEL “Delicate Instrument, Handle with Care”.
5.2 METHODS OF TRANSPORTATION
The selection of the most suitable method of transportation for the transformer is dependent on
size, weight, customer‘s wishes, and on local conditions.
The following points should always be observed during transport:
5.2.1 A maximum inclination of 30 degrees
A maximum acceleration which equals a shunting impact of approximately (7 miles/ 11.25

km per hour the permissible speed for heavy loads)
2
5.2.2 A maximum surface load on cover of 1000 kg/m
These figures must not be exceeded.
Suitable measures must be taken to prevent the transformer from sliding during transport.
For example: Placing the transformer on soft wooden boards or beams, and anchoring it with
chains and/or wire ropes in both longitudinal and transverse axes.
The anchoring equipment should be appropriated to the size and weight of the transformer. The
positions of lifters, hauling can be used as anchoring points
5.3 TRANSPORT MODES
Depending on its size and weight, the transformer is transported either with oil filling (lowered oil
level) or with dry gas filling for these transformers. In the factory, all transformers are carefully
dried, filled with degassed and dried oil, and subjected to a series of several tests before delivery.
The instructions given in this section are intended to prevent damage occurring during transport,
and to illuminate the reasoning behind the measures to be carried out when the transformer
arrives on site, which are described in the following sections.
5.3.1 TRANSPORT WITH NITROGEN GAS FILLING
Transformers which, with an oil filling would exceed the permissible or economical
maximum transport weight, are transported without oil filling. In order to prevent moisture
penetrating the transformer tank, it is filled with nitrogen gas while the oil is being drained
off, and when the gas filling is completed, the tank is connected to one or more dry gas
cylinders, which are secured to the tank, and are fitted with reducing valve and a positive
pressure valve to provide a constant positive pressure inside the transformer tank (Please
refer drawing No. 1ZYN 4601-204).
The valves are adjusted to give a positive pressure of approx. 0.035 bar. The dry gas cylinders
have, e.g., a content of 50 litres at a pressure of approx. 200 bar.
To protect the active part against moisture the transformer is filled with dry nitrogen at a positive
pressure of 0.175 kg/sq cm( 2.5 psi) at ABB works before despatch.
THE INTERNAL PRESSURE AT THE TIME OF SHIPMENT IS INDICATED ON DOCUMENTS
PROVIDED WITH THE TANK.
All openings resulting from the removal of fittings for shipment are sealed with suitable gasketted
blanking plates during transport. Transformer despatched according to this method may normally
be stored upto 3 months after arrival at site or else where.
The high pressure of 120 to 140 kg/sqcm is reduced to low pressure of 0.175 kg/sqcm using
regulator, regulator is fixed at factory. One gauge is provided to indicate the cylinder gas pressure
where as other gauge is provided to indicate tank pressure.
When the tank pressure falls below 0.15 kg/sqcm due to leakage / fall of ambient temperature,
the gas from cylinders must be fed manually, to build up required pressure in the tank.
The gas consumption during transport and possible storage is difficult to estimate as it depends
on ambient temperature variation, possible leakages as well as on the duration of transport and
storage
When the pressure in the first cylinder falls below 10 kg/sqcm this should be considered as empty
and immediately its valve should be closed and another cylinder filled properly with gas, should be
connected, if required..Dry nitrogen gas to IS: 1747 with 50 ppm moisture and 1% oxygen by
volume should be used. Nitrogen should be continuously maintained at a positive pressure during
storage of transformer.
INSTRUCTIONS FOR FILLING DRY PURE NITROGEN GAS CYLINDER (AT WORKS)
Lower the oil level to the minimum necessary to dismantle the items such as bushing and turrets-
which must be removed for shipping. Pull 500 mm mercury vacuum after blanking of all openings.
Continue to supply nitrogen until it maintains a steady pressure of 0.17 +0.02 kg/sq.cm above
atmosphere.
Pressure of nitrogen gas shall be maintained at 0.17 +0.02 kg/sq cm at reference temperature.
Pressure should be monitored by taking three readings within 24 hours to ensure that there is no
leakage of gas.
Shut off the gas supply valve and fit dry nitrogen cylinder through nitrogen regulatory valve. The
gas should have moisture content of max. 250 ppm (weight) and contain max. 0.3% (volume) of
foreign admixtures.
The transformer tank filled with dry gas must on no account be opened during transport, nor must
the gas cylinder be removed, if it cannot be reconnected within 48 hours. If the transformer tank
has an obvious leak, or if the gas cylinder shows a significant pressure drop during transport,
make sure that the leak is sealed, and inform ABB
5.4 HANDLING DURING LOADING, AND ON SITE
Caution! Transformers must only be transported in an upright position.
5.4.1 LIFTING TRANSFORMERS
Hydraulic hoists may only be used at the jacking pads provided (see outline drawing). Lifting must
be carried out simultaneously and uniformly for at least two adjoining jacking pads.
Note: Pipe flanges and valves must never be used as lifting or support points.
5.4.2 SUSPENDING TRANSFORMERS
Every transformer is fitted with lifting bolts for suspension purpose (see outline drawing). When
suspending transformers on crane hooks, observe the following points:
The transformer must be suspended from

points shown in the outline drawing.
The ropes must never form smaller angle
than 60 degrees to the horizontal. Thus,
dimension „L“ must be equal to or larger
than dimension „M“ (As shown in Fig. 5.2).
FIGURE 5.2: ROPE LENGTH FOR TRANSFORMER SUSPENSION
5.4.3 MOVING TRANSFORMERS
Transformers are moved or relocated on moving devices or on skids.

When skids are used, armoured rollers can be placed under the transformer, or sliding surfaces
(with the aid of lubricants) can be used.
Note: The presence of paint or dirt on the sliding surfaces or on the skids will increase the frictional
resistance and lead to a sharp increase in the tractive forces required.
5.4.4 TRANSPORT OF ACCESSORIES
For components which must be removed for transport see outline drawing.
Accessory components which are transported without packing must only be lifted by the suspen-
sion lugs provided.
Accessory crates, especially those containing porcelain parts, must not be dropped and must be
protected against slipping.
5.4.5 TRANSPORTATION EQUIPMENT AND TOOLS
For transporting, sliding, moving or relocating a transformer, the following tools and equipment will
be needed:
hydraulic jack, hardwood planks
hardwood beams, softwood beams
electric cable winch or grippers
guide pulleys
wire ropes, shackles
transport rails, tie bars
connecting links.
5.5 SHIPPING ARRANGEMENTS
5.5.1 GENERAL
Large Power Transformers are normally shipped on special low bed trailor. General rules
for unloading transformers from their vehicles are given in PART 8.
Also, always check the Packing List, which includes a transport outline drawing for the
transformer, with shipping dimensions, weights, etc. indicated. Accessories will be
despatched separately by road, oil drums by road. Major quantity of oil by tankers (road
transport) when supply is in the scope of ABB or as agreed in contract..
Important Notes:
a) After dismantling the sub-assemblies like Bushing assembly, conservator assembly,

radiator assembly, header assembly, A-frame assembly, roller assembly etc, all the
hardware and gaskets pertaining to that sub-assembly shall be packed and put in the same
crate as that of the sub-assembly.
b) Each crate has to be marked legibly with the names of the contents packed and suitable
signs shall be marked for opening the boxes.
5.5.2 SHIPPING BRACES
For protection, all openings resulting from shipping disassembly must be closed, oil-tight
and gas-tight, with caps or blind flanges during transport. Temporary shipping covers,
braces and similar hardwares must be replaced or removed before the transformer is energized.
5.5.3 BUSHINGS
In cases where bottom-connected bushings have been disassembled for shipping, the
bushing leads are supported by temporary shipping braces, which are an integral part of
the blind flange cover. For bushings with draw-through bushing leads, the lead is looped
and fastened to the support structure above the core and coils, or fastened to the bushing
flange cover. The bushing leads, lead structure and coils can be severely damaged if you
attempt to remove the covers without first disconnecting the shipping supports.
5.5.4 CURRENT TRANSFORMERS
Current transformers must be short-circuited and earthed (grounded) for Shipping.
5.5.5 SHUT-OFF DEVICES
Shut-off devices shall be in transport position, and throttle valves shall be closed for
shipping.
5.5.6 TIGHTNESS SURVEILLANCE
Extreme care has been taken to prevent moisture entering the transformer. It is important
to regularly check tank pressure during shipping and storage times to verify that no
indication of leaks appears. For gas-filled compartments, the instructions are given in
PART 6
5.6 PACKING LIST AND TRANSPORT MANUAL
5.6.1 GENERAL
In order to meet shipping clearances and to avoid transport damage, some accessories-bushings
for instance- are often disassembled from the tank during shipment and packed separately.
Detailed information on this is given in this instruction. The Packing List also describes, how the
dismantled parts of a large transformer are packaged and marked.
The shipment consists of „the Heavy Parcel“-that is, the sealed transformer tank, containing the
core and coils – and the dismantled parts in crates and boxes.
5.6.2 PACKING LIST
The Packing List is a drawing-numbered document. A full set is contained in a separate box
together with other technical documentation. Each crate or box has the separate sheets of its
own contents packed.
The table carries the identification of the items by name, quantity, and article number or
equivalent.
In order to meet shipping clearances and to avoid shipping damage, some accessories-
bushings for instance- are often disassembled from the tank during shipment and packed
separately. Detailed information on this is given in the Packing List enclosed with
despatch documents.
5.6.3. ASSEMBLY PACKAGES
The parts are organized in Assembly Packages. An Assembly Package consists of all parts
which are needed for a certain group or operation during the assembly, which shall be completed
in a sequence without interruption. „Bushings“ and „Oil preservation systems are examples of
Assembly Packages. Everything belonging to a certain Assembly Package is packed together in
a group of crates and boxes. Those parcels are identified on the Packing List as belonging to that
Package.
The advantage with this system is that only a few pieces have to be opened at a time. Remaining
crates and boxes are to be left closed until they are needed. This keeps the parts under
protection and in good order.
The numbering of the Assembly Packages shows the recommended order of progress which
our Field Service organization has found practical. Of course it is possible to proceed in a different
order, depending on conditions on the site.
At the end of the list of Assembly Packages you find references to the set of fresh gaskets to be
used during assembly, touch-up paint, and a box with documents.
5.6.4. TRANSPORT MONITORING
The monitoring instructions deal with lifting and bracing of the Heavy Parcel, and various items of
checking and visual inspection. Two of these monitoring duties are the following:
The tank is filled with dry nitrogen to a slight over-pressure this has to be monitored en route.
- The final checkpoint is, when the shipment is received on site.
The numbering of the Assembly Packages shows the recommended order of progress
which our Field Service organization has found practical. Of course it is possible to proceed
in a different order, depending on conditions on the site.
At the end of the list of Assembly Packages you find references to the set of fresh gaskets to be
used during assembly, touch-up paint, and a box with documents.
PART 6
MONITORING OF DRY-GAS FILLING OF
TRANSFORMERS DURING SHIPMENT
AND STORAGE
INDEX
6.0 MONITORING OF DRY-GAS FILLING OF TRANSFORMERS DURING SHIPMENT AND

STORAGE
6.1 PRESSURE GAUGE AND FILLING COCK
6.2 PRESSURE LIMITS + FIGURE F 6.1
6.3 MONITORING UNDER STORAGE
6.4 INSPECTION AND REPORTING
6.5 LONG-TIME STORAGE. CHANGE OF GAS CYLINDERS
6.0 MONITORING OF DRY-GAS FILLING OF TRANSFORMERS DURING SHIPMENT AND
STORAGE
This transformer is shipped without oil and with accessories and fittings removed. The tank has
been filled with dry gas to a slight over-pressure in the factory. It is important that the transformer
remains perfectly sealed during shipment and storage. The gas- over pressure shall be monitored
at regular intervals. [REF: 1ZBA 4601-203, 1ZBA4601-204]
6.1 PRESSURE GAUGE AND FILLING COCK
A pressure gauge and filling cock unit are fitted on the side of the tank.
The pressure gauge has a range range 0 -210 kg/sq cm on nitrogen cylinder side and 0 to 2.5
kg/sqcm towards transformer tank side
6.2 PRESSURE LIMITS
The gas pressure in the tank when the transformer leaves the factory is 20 kPa (0.2 atm 3psi) at
a temperature of about 20°C (65-70°F). This pressure will change with the ambient temperature
as shown in the figure F6.1. Even at -25°C there shall be a small positive over pressure and in a
warm climate the pressure still is about 30 kPa.(0.306 kgf/sqcm)
30
20
Over pressure kPa
10
0
-20 -10 0 10 20 30
Centigrades
FIGURE F 6.1
EXAMPLE: CORRECT PRESSURE AT DIFFERENT AMBIENT TEMPERATURES

If, after an inspection, the pressure is completely lost, there must be a serious leak somewhere. It
is possible that there may even have been under-pressure at some time (due to a sudden
temperature drop), and moisture may have entered the tank. Complete loss of gas-filling
pressure must be reported immediately for further action.
I f the pressure read on the gauge is not completely lost, but has fallen below 5 kPa (0.05 atm,
about 1 psi), then the tank shall be filled up with dry gas to the original reading of about 20 kPa.
The guaranteed dryness of the filling gas shall be such that the dew-point is below -40°C (= -
40°F). Before filling, the plastic hose used shall be blown clean with gas from the bottle.
6.3 MONITORING UNDER STORAGE
When the transformer is under storage for a considerable time, the filling pressure shall be
checked and recorded once a month.
Note:
Nitrogen gas is sometimes used instead of dry air. When this is the case, a well visible sign with
that information is affixed to the tank. The content of this Assembly Instruction is valid even for
that case.
This transformer is shipped without oil and with accessories and fittings removed. The tank has
been filled with dry gas to a slight over-pressure in the factory. It is important that the transformer
remains perfectly sealed during shipment and storage.
6.4 INSPECTION AND REPORTING
The pressure control unit shall be inspected at the prescribed check points during shipment. It
shall be checked that
- The pressure in the tank stays above the minimum limit
- There is still considerable pressure in the storage bottle
If the over-pressure in the tank is completely lost, and the cylinder is empty, then there is a
serious leak. It is possible that there may even have been under-pressure at some time (due to
a sudden temperature drop), and moisture may have entered the tank. Complete loss of gas-
filling pressure must be immediately reported for further action.
6.5 LONG-TIME STORAGE. CHANGE OF GAS CYLINDERS.
When the transformer is in transit or stored at the site for a considerable time, the tank pressure
shall be checked and recorded once a month.
The pressure in the storage gas cylinder may decrease with time. If it reaches 1 MPa (10
atmospheric pressure) it should be substituted against a new bottle.
The bottle gas shall have a guaranteed dryness corresponding to a dew-point not above
-40°C (= -40°F). This may be checked from the sampling cock if a dew-point meter is available.
The procedure is as follows:
- Close first the shut-off valve towards the tank
- Then shut the main valve on the bottle
- Disconnect between bottle and reduction valve and install the new bottle
Check that the reduction pressure is correct by bleeding the sampling cock and closing again
- Open valve towards the tank
PART 7
RECEIVING INSPECTION
AND
ARRIVAL ON SITE
7.0 RECEIVING INSPECTION AND ARRIVAL ON SITE
7.1 RECEIVING INSPECTION
[1ZBA4601- 207]
7.2 ARRIVAL AT SITE, UNPACKING AND CHECKING OF THE CONSIGNMENT
7.2.1 ARRIVAL ON SITE
7.2.2 UNPACKING AND CHECKING OF THE CONSIGNMENT
7.2.2.1REMOVING THE PACKING MATERIAL
7.2.2.2INTERNAL INSPECTION
7.2.3 TIGHTNESS
7.3 CHECK LIST AND LOG SHEET
7.3.1 CHECK LIST – CHECKING THE CONSIGNMENT ON ARRIVAL
7.3.2 LOG SHEETS TO BE USED FOR CHECKING TRANSFORMER ON RECEIPT
7.4 SITE ACTIVITY CHART
7.1 RECEIVING INSPECTION
[1ZBA4601-207]
COPIES OF ABB SPECIFICATIONS ARE ENCLOSED
[REFERENCES]:
1ZBA 4601-207 Transformer Designed with Oil Conservator, Shipped Dry-Gas Filled,
Partially Disassembled
7.2 ARRIVAL AT SITE, UNPACKING AND CHECKING OF THE CONSIGNMENT
7.2.1 ARRIVAL ON SITE

Immediately after arrival on site, the transformer and the accessories should be examined for
completeness and visible damage. In the event of damage during transport, a report should be
prepared in the presence of a representative from the last forwarding agent, and ABB must be
informed.
Note Use the packing list enclosed with the consignment to check contents for
completeness.
Any pressure loss in transformer tanks filled with nitrogen gas must be included in the acceptance
report.
In the case of attached nitrogen gas cylinders, an excess pressure of 0.05 bar should be
maintained as minimum.
7.2.2 UNPACKING AND CHECKING OF THE CONSIGNMENT
7.2.2.1REMOVING THE PACKING MATERIAL
Use suitable tools to remove the transformer packing. Packing material of accessories should be
stored as it might be used later in case of return shipment for repairs or overhaul. Accessories
must be kept in their transport containers until final assembly in order to avoid moisture
absorption.
Insulating transformer oil must be stored in accordance with the latest regulations until final oil
filling. See as well PART 10. ”OIL“.
7.2.2.2INTERNAL INSPECTION
An internal inspection is necessary if transport damage is suspected. Flanged covers of bushing

assembly openings and inspection covers must be removed. Core and winding supports, active
part supports and cleats and leads must be checked for damage.
Page Left Blank
Danger! Before removing the tank cover or any other cover, make sure that there is no
overpressure inside the tank.
Note Before any work is carried out inside the tank, always consult ABB.
If the inspection takes longer than 8 hours, dry air should continuously be blown into the tank
after it has been opened, in order to limit the penetration of moist air. Tools and other objects
which are taken into the tank should be fastened to the tank by cords. Make sure that all objects
are removed after the assembly work.
Danger! If any tools or other objects are left out inside the tank, they can cause short-
circuits and failure of transformer.
7.2.3 TIGHTNESS
Oil-filled transformers should be checked for oil traces indicating a leak.

If the transformer is filled with nitrogen gas filled, check the pressure in the tank and in the gas
cylinder. If transformer tank and gas cylinder show a positive pressure, the transformer
insulation is dry.
7.3 CHECK LIST AND LOG SHEET

[PLEASE ALSO FOLLOW INSTRUCTIONS UNDER DO‘S AND DON‘TS MENTIONED
EARLIER IN PART 1.9]
7.3.1 CHECK LIST – CHECKING THE CONSIGNMENT ON ARRIVAL

Serial number …...…………..
Type of transport:
Without oil O
Nitrogen gas positive pressure
a) in the tank
…..……bar, present O
Not present O
b) in the gas cylinder
….…….bar, present O
not present O
Silica gel in breather
not present O
is blue form O
is pink/white O
Support of core-and-coil assembly
In order O
not in order O
not checked O
Leads
in order O
not in order O
not checked O
Core-and-coil assembly
is dry O
is not dry O
drying is required O
Core earthing
in order O
not in order O
not checked O
Shock recorder not provided

provided, no excess strain detectable O
provided, excess strain detectable O
Damages
a) at the tank
not present O
present and reported to ABB O
b) at the accessories
not present O
present and reported to ABB O
c) at the painting
not present O
slightly damaged O
severely damaged O
damages reported to ABB O
Accessories
properly provided O
not completely provided and reported to ABB O
Insulating oil
properly provided O
not properly provided O
_________ _______________________________
Signature of customer / ABB assembly engineer /Representative
Date Date
7.3.2 LOG SHEETS TO BE USED FOR CHECKING TRANSFORMER ON RECEIPT
ITEM CASE TYPE OF CHECK OBSERVATION SIGNATURE

NO. & DATE
7.4 SITE ACTIVITY CHART
RECEIPT AT
SITE
MEASURING OF ERECTION
NITROGEN PRESSURE
CHECK OIL LEVEL AS
APPLICABLE
OIL FLUSHING OF
ERECTION COOLERS / COOLER
ASSEMBLY
EVACUATION AND
OIL FILLING OIL FILLING
OIL BDV AND OIL BDV AND

WATER CONTENT WATER CONTENT
OIL FILLING UNDER OIL FILTRATION

VACUUM AND TOPPING UP COOLER BANK
AIR RELEASING STANDING TIME COMMISSIONING
PART 8
UNLOADING, MOVING, STORING
THE TRANSFORMER
AND
PRECOMMISSIONING CHECKS
8.0 UNLOADING, MOVING, STORING THE TRANSFORMER AND PRE- COMMISSIONING
CHECKS
8.1 INSPECTIONS BEFORE UNLOADING
8.2 EXTERNAL INSPECTION
8.3 UNLOADING AND MOVING THE TRANSFORMER+

[REF:1ZBA4601-202]
8.4 STORAGE OF TRANSFORMER
8.4.1 STORING OF COMPONENTS AND ACCESSORIES BEFORE COMPLETE ASSEMBLING
8.4.1.1 STORING INDOORS IN A DRY ROOM
8.4.1.2STORING OUT DOORS
8.4.1.3INSTALLATION
8.4.2 STORAGE ON SITE BEFORE ASSEMBLY + PRODUCT INFORMATION

1ZBA 4601-211
8.5 PRE-COMMISSIONING CHECKS
FIGURES
F 8.1 EXAMPLE TRANSFORMER SHIPMENT SHOWING TIE-RODS BLOCKINGS.
F8.2 BLOCKING
F 8.3 TYPICAL JACKING PAD
F 8.4 TYPICAL EXAMPLE TRANSFORMER RAISED. CRIBBING PLACED UNDER

TRANSFORMER
F 85 TYPICAL EXAMPLE: TRANSFORMER RAISED. CRIBBING AND ROLLING PLACED UNDER

TRANSFORMER
8.0 UNLOADING AND MOVING THE TRANSFORMER INSPECTIONS BEFORE UNLOADING
Before unloading a transformer from any kind of vessel or vehicle, an inspection of the
transported goods shall be made in order to reveal all kinds of shipping losses or damage.
Shipping papers, packing list with transport outline drawings, instruction leaflets and other
pertinent documents furnished with the transformer must be available for use during the
inspection.
The inspection shall include attendance to the over pressure in pressurized, gas-filled volumes.
External inspections of the goods in transport shall be carried out as below.
EXTERNAL INSPECTION
Any external evidence of damage or evidence indicating the possibility of hidden damage must be
reported to the transporter’s representative and to an ABB representative before unloading the
transformer. Take pictures of external damage. The receiver must assume all responsibility for
unloading damaged transformers. The external inspection prior to unloading the transformer
should include all of the following.
Are all tie rods connected to vehicle, undamaged and nuts tight?
Is all blocking tight and in good condition?

Is there any evidence of load shifting in transit?
Does the impact recorder (when provided) tape indicate any impacts beyond the acceptance zone
on the tape?
Are there indications of external damage such as broken glass on gauges, broken welds on
flanges?
Is the paint finish damaged?
Are all fittings, which were shipped attached, still in place and undamaged (see the outline
drawings)?
Is there any evidence of oil leakage (if units are shipped in oil)?
Is the pressure in the gas-filled tank acceptable?
Porcelains, which are assembled to the tank, or which are inspected because their crates or boxes
show obvious signs of rough handling, shall be scrutinized. Are they chipped or otherwise
damaged?
Is oil level in bushings normal?
Is the Driving Mechanism of OLTC and shaft are aligned properly? Is there any visible
damage?
8.2 EXTERNAL INSPECTION continued
Are all parcels of the shipment in agreement with the shipping documents as to character and
numbers?
Do crates or boxes show any evidence of damage or moisture entrance?
If there is no evidence of shipping damage, proceed to unload the transformer. If shipping

damage is found, contact the nearest ABB representative for further instructions prior to unloading
the transformer. If any damaged parts are noticed lodge claim with under-writing and report to
ABB
Written notations of apparent loss and damage must be made on the carrier’s delivery receipt.
Concealed damage must be reported immediately to the delivering carrier with a request for an
inspection. Following details should be included in report of damages case number with
description of damaged component number of components damaged or list whether damaged
components can be repaired at site.
8.3 UNLOADING AND MOVING THE TRANSFORMER
PRODUCT INFORMATION 1ZBA 4601-202 ENCLOSED
8.4 STORAGE OF TRANSFORMER
8.4.1 STORING OF COMPONENTS AND ACCESSORIES BEFORE COMPLETE ASSEMBLING
Independent of the duration of the storing time, the directions below apply for dismounted
components and accessories, as well as for material to be used in connection with the
assembling work.
8.4.1.1 STORING INDOORS IN A DRY ROOM
In such a room, the following articles should be stored Insulating material such as paper,
pressboard, bakelite, wood, cotton tape etc. Insulated details as paper insulated conductors,
pressboard insulated shielding bodies etc. Chemicals as solvents, glues, varnishes, hardness etc.
Breathers and drying agents Terminal boxes, connection boxes, control cabinets Turrets with built
in current transformers. Radiators Gas relays, oil-level indicators, thermometers, pressure valves
etc. Pipes to oil conservator, pipes to radiators, pipes to turrets etc. Bushings Marshalling box,
OLTC motor drive, fans, pumps, instruments and fittings Control cabinets (Heating elements
provided shall be connected to supply)
8.4.1.2 STORING OUT DOORS
The components mentioned below may be stored outdoors. They should be placed above ground
and covered with tarpaulin etc. Oil conservator with blanking plates for all openings
Radiators and coolers with blanking plates for all openings Structures, A frames, pipe
supports, oil conservator supports, radiators, control cabinets etc.
8.4.1.3INSTALLATION
Before starting with the assembly the transformer must be transported to its foundation.
For this purpose use the pulling lugs and jacking pads provided (see outline drawing). Before
moving the transformer, take care to observe the instructions in the respective section of this
manual.
The foundation should be designed to allow the transformer to stand level. The assembly
location must have the ventilation space necessary for proper functioning of the cooling system.
The transformers should always be separated from one another and from all walls and partitions
to permit free circulation of air. Please also refer IS:10028 [CODE OF PRACTICE FOR
INSTALLATION AND MAINTENANCE OF TRANSFORMERS]
After the transformer has been moved to its final position, fit the fixing devices, if any. Mounting
of wheels under transformer is to be done as per roller arrangement drawing.
Valves which may affect the loading gauge or which may be subjected to damages should be
dismounted before delivery. Remount the valves – the positionings appearing from GENERAL
ASSEMBLY DRAWING. The gaskets surfaces shall be cleaned well and new gaskets fitted.
Check that all valves are closed.
When exchanging a damaged bushing or other component on the cover of a fully oil filled
transformer, we should proceed according to the following:
Close the valve in the pipe between the transformer and the oil conservator. Pump oil from the
transformer tank into the oil conservator so that the oil quantity which need to be drained off to
lower the oil enough below the transformer cover is pushed to the conservator. As the oil is being
transferred from tank to conservator, fill up the tank with dry nitrogen via suitable valve on the
cover or in turrets.
Exchange the faulty bushing and then transfer the oil from conservator to tank by opening the
valve in the pipe between conservator and main tank. De-air the bushings and turrets.
STORAGE ON SITE BEFORE ASSEMBLY

PRODUCT INFORMATION 1ZBA 4601-211 ENCLOSED
8.5 PRE-COMMISSIONING CHECKS
The following are salient points to be checked before commissioning

Check all the gasketed joints to ensure that there is no leakage of transformer oil at any point.
Check any breakages of porcelain. Bushings with cracks or any other defects should be immediately
replaced. Oil level in condenser type bushings should be upto the level mark on oil gauge on side of top
cap. Check the tightness of top cap for condensor bushing.
Release trapped air through air release plugs and valves fitted for the purpose on various fittings like
headers, radiators, and oil communicating bushings, buchholz petcock etc.
Check alarm and trip contacts of buchholz relay, WTIs, dial type thermometer, magnetic oil level gauge,
oil flow indicator, pressure relief device etc.
Ensure that conservator is filled upto the filling level mark on prismatic oil level gauge side and
corresponding to the pointer reading on MOLG side. Special attention to be paid for conservator with flxi
separator.
Make sure that neutral bushings are effectively earthed.

Tank and cooler bank should be earthed at two pints
Check the direction of rotation of fan blades to ensure right blast towards radiators.
Check the direction of rotation of pumps.
Ensure that silica gel in the breather is active and colour is blue and oil in the breather cup is present.
Check that the thermometer pockets on tank cover, header etc. are filled with oil.
CTs secondary terminals must be shorted and earthed if not in use.
Check that the proper terminals in the marshalling box are connected to WTI CT terminals
Check for tightness of all external electrical connections
Check for the arcing horn gap on bushings if provided.
Clear off extraneous materials like tools, earthing rods, pieces of clothes, waste etc
Lock the rollers for accidental movement on rails.
PART 9
TRANSFORMER ASSEMBLY INSTRUCTIONS,
SUGGESTED ERECTION EQUIPMENT / TOOLS
9.0 TRANSFORMER ASSEMBLY INSTRUCTIONS, ERECTION EQUIPMENT / TOOLS
CONTENT
9.1 SCOPE [REFERENCE 1ZBA 4601-212]
9.2 SAFETY NOTATIONS
9.3 GENERAL
9.4 PREPARATION
9.5 EXTERNAL ASSEMBLY
9.5.1 RADIATORS, COOLERS AND PUMPS
9.5.2 NEW GASKETS
9.5.3 MOUNTING THE NITROGEN BLANKET OIL PRESERVATION SYSTEM
9.5.4 LOAD TAP-CHANGERS
9.6. INTERNAL ASSEMBLY
9.6.1.1GENERAL PRECAUTIONS
9.6.1.2ASSEMBLY INSTRUCTIONS FOR BUSHINGS
CONDENSER BUSHINGS FOR 245 kV AND 145 kV CLASS
LOW VOLTAGE BUSHINGS
CHECKING BEFORE MOUNTING THE BUSHINGS
CHECKING THE SECONDARY LEADS OF CTS
9.6.2 BUSHING INSTALLATION
9.6.3 BUSHING CURRENT TRANSFORMERS
9.7 CLOSING THE TRANSFORMER AND FINAL DEWPOINT MEASUREMENTS
9.8 ELECTRICAL TESTS
9.9 ERECTION EQUIPMENTS/ TOOLS
9.0 TRANSFORMER ASSEMBLY INSTRUCTIONS
9.1 SCOPE [REFERENCE PRODUCT INFORMATION 1ZBA 4601-212]
These instructions are intended to help in the installation of transformers to maintain their quality
and reliability.
The recommendations are not a complete manual for all the operations during the field assembly
of a large transformer. It is assumed that competent and responsible supervision and
workpersonnel are available for the job - that good order, cleanliness and personal safety
precautions are observed - in accordance with common sense and local regulation.
The following text highlights a few particular procedures and precautions that are specific for the
ABB Transformer make, or are of critical importance for a good result.
9.2 SAFETY NOTATIONS
Safety notations are intended to alert personnel of possible personal injury, death, or property
damage. They have been inserted in the instruction text prior to the step in which the condition is
cited.
The safety notations are headed by one of three hazard intensity levels
1) Danger
2) Warning
3) Caution
PLEASE ALSO REFER TO “PART 1”, SAFETY INSTRUCTIONS FOR DETAILS.
9.3 GENERAL PRECAUTIONS
The transformer should not be opened during periods of inclement weather or when
condensation is forming on the internal surfaces of the transformer. Never
enter a transformer with dirty or wet clothing. Clean cloth overshoes
or nitrile rubber overshoes should be worn.
All tools, equipment and material entering the transformer shall be listed and checked to verify
all material has been removed from the transformer.
Tools must have working surfaces hardened so that they will not peel or chip during normal use;
also, working surfaces must not be coated in any way such as painting or plating. Tools that are
polished metal or have black oxide body finish are preferred.
To prevent accidental disassembly during normal use, all tools with movable parts must use
double side flush-riveted joints and or all fasteners or moving parts must be retained by staking or
deforming the last thread by welding or coating.
Tools such as hammers and screwdrivers must have one piece heads. Molded-on plastic or
fiberglass handles are preferred; if the handle is wood, it must be retained by a wood or plastic
wedge.
Nameplates or tags attached to tools should be removed. If a nameplate is necessary for tool
identification, the plate must be non-metallic and be secured with non-conducting tape.
While the transformer is open, do not permit anyone access to the transformer until they have
emptied all pockets, checked for loose objects, and removed watches, rings, and other objects.
Dry air must be used to ventilate the inside of the tank when it is opened for internal fitting. The air
must have a dew point less than -40°C and sufficient airflow for the number of operators in the
tank must be maintained.
Do never use nitrogen or other gases than air for ventilation.
Nitrile gaskets should be changed during the assembly operations. New gaskets are provided
with transformer detail parts
The mechanical relief devices shall be installed prior to beginning the assembly operations to
prevent excessive pressure build-up on the tank.
The transformer tank shall be grounded prior to beginning any assembling operations.
9.4 PREPARATION
The transformer shall be moved into position on the substation pad and the base should be
leveled. Install shims under the base for leveling if necessary.
The transformer base shall be supported on the foundation pad or piers as appropriate.
The transformer foundation should be prepared so that the transformer shall have adequate air
circulation necessary to cool the transformer.
9.5 EXTERNAL ASSEMBLY
The items removed and shipped separately are listed on the General Assembly, or packing list.
The items generally removed and shipped separately are the bushings, cooling equipment, forced
oil pumps (if the transformer has an OFAF rating), arresters and arreseter mounting brackets and
the sudden pressure relay. The number of accessory items removed will vary depending on the
physical size of the transformer.
All air or gas fittings and all oil fitting joints that are preassembled at the factory must be
checked for leaks and resealed.
9.5.1 RADIATORS, COOLERS AND PUMPS
Radiators, coolers, the associated oil pumps and piping shipped as detail items that are
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.
The radiators or coolers 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. The detailed
illustrations for mounting and piping arrangements are shown on the General assembly drawing.
Use new gasket material when installing the radiators, coolers, or pumps.
9.5.2 NEW GASKETS
USE NEW GASKET MATERIAL, SUPPLIED ALONG WITH TRANSFORMER WHEN

INSTALLING THE RADIATORS, COOLERS OR PUMPS
9.5.3 MOUNTING THE NITROGEN BLANKET OIL PRESERVATION SYSTEM
(If Applicable)
If the transformer is equipped with a nitrogen blanket oil preservation system, the nitrogen
system control cabinet generally remains on the transformer for shipment. If it was removed,
install the cabinet and the nitrogen bottle. If the cabinet is already mounted, install the nitrogen
bottle and connect the piping to the control. If the transformer was shipped in oil, the tubing
connection from the cabinet to the gas space is not connected. This prevents oil from entering
the line during shipment. Check the line to be certain it is clear of oil and connect the tubing at
the cabinet. The nitrogen supply valve should remain closed in either case.
9.5.4.1 GENERAL
MR TYPE Tap-Changers are usually shipped mounted on the transformer

WARNING:
DO NOT OPEN ANY COVERS OR FITTINGS UNLESS THE INTERNAL
PRESSURE IS AT ZERO GAUGE. FAILURE TO RELIEVE THE
PRESSURE COULD CAUSE THE PART BEING REMOVED TO BE A
HAZARDOUS FLYING OBJECT. ALWAYS RELIEVE INTERNAL
PRESSURE SLOWLY THROUGH VALVES.
Before placing Tap-Changers in service, read the appropriate Tap-Changer instruction leaflet.
The leaflets are included in PART 4.2. Always follow the inspection and filling instructions given
in the Tap-Changer instruction leaflet.
9.5.4.2TAP-CHANGERS MOUNTED FOR SHIPMENT

No internal assembly operations or taping are required.
Before final oil filling and placing the Tap-Changer in service, check the operation of the Tap-
Changer as noted in the instruction GIVEN BY OLTC supplier.
Fill the Tap-Changer compartment as instructed in the Tap-Changer instruction leaflet.
OLTC should not be operated unless otherwise its divertor compartment is filled with oil.
9.6 INTERNAL ASSEMBLY
9.6.1.1GENERAL PRECAUTIONS
When opening the transformer, take necessary precautions to prevent moisture or dirt from
entering the transformer or moisture condensation in the transformer.
Necessary confined entry procedures should be followed in compliance with company policy or
local regulations.
WARNING:
When transformer has been shipped with nitrogen, the gas should be replaced with dry air
prior to making any entrance into the tank. The oxygen content must be at least 19.5 %
prior to entering the tank.
To remove the nitrogen, it is advisable to pull vacuum to fully remove all nitrogen and Break
vacuum with oil.
CAUTION
Be certain the internal pressure in the transformer is a zero gauge before
opening the manhole cover.
Open the transformer at the manhole cover. It is preferred to have only one manhole open at a
time. It is also recommended that the tank opening be covered with clear plastic or a tarpaulin.
Purge the air/oil hoses with dry air /oil from the supply to remove any moisture and dirt in the
hoses prior to use. Make the connections for the dry air supply in the tank space below the
working level in the tank.
WARNING
DO NOT ENTER THE TRANSFORMER OR BREATHE THE INTERNAL

ATMOSPHERE UNLESS THE OXYGEN CONTENT OF THE GAS INSIDE
THE TRANSFORMER IS AT LEAST 19.5%. OXYGEN CONTENTS LESS
THAN THIS CAN CAUSE DROWSINESS, INJURY OR DEATH.
TRANSFORMERS SHIPPED IN GAS ARE NOT SAFE TO ENTER.
ALWAYS CHECK THE OXYGEN CONTENT.
CAUTION
To prevent contamination of the transformer, only the manhole and the opening for the
item being installed should be opened. Cover all other openings with dry
pressboard or a clean plastic sheet. This will also minimize the flow of dry
air from the unit.
Start the airflow into the transformer. The volume must be sufficient to maintain continuous
airflow outward through the tank openings.
9.6.1.2ASSEMBLY INSTRUCTIONS FOR BUSHINGS
9.6.1.2.1CONDENSOR BUSHINGS FOR 245 k V AND 145 k V CLASS:
These are supplied by M/S SSB INDUSTRIES BANGALORE.

Please refer to the installation and maintenance manual of supplier for details.
Bushing mounting is very important and delicate operation. Hence should be done very
carefully. Help from ABB representative / bushing manufacturer may be taken for this operation
9.6.1.2.2 LOW VOLTAGE BUSHINGS
Bushings provided with draw lead design should be assembled by taking care of items like oil
seal, gasket between porcelain and top stem, jumper/lead connection from transformer winding.
Bushing provided with stem type design should be assembled by opening the inspection cover.
9.6.1.2.3CHECKING BEFORE MOUNTING THE BUSHING:
Check that detachable turrets, pockets/bushing mounting plates etc. Are properly mounted as per
the general assembly drawing. Leads and other hardware items for connections are available and
bushing CTs are properly assembled inside the turrets. Check that secondary leads from CTs are
connected to respective terminal boards.
9.6.1.2.4 CHECK THAT SECONDARY LEADS OF CTS
Mounted on core coil assembly or on tank are mounted to terminal boards on tank/cover/pockets
as shown in general assembly drawing.
9.6.2 BUSHING INSTALLATION
On large transformers, the bushings will be removed for shipment to meet shipping clearances
and to avoid shipping damage to the bushings. The bushing leads may be supported by
temporary shipping braces which are an integral part of the blind flange. The flange will be
indicated with a warning note if this method is used. The bushing leads must be
disconnected from these temporary braces before the blind flange covers or shipping
covers are removed.
An alternate method of supporting the bushing leads is to tie the coiled lead to the highest point
on the transformer superstructure.
CAUTION
Failure to disconnect the leads from the temporary shipping braces before the blind
flanges or shipping covers are lifted can cause damage to the leads, bridge
structure and associated coils, and may necessitate return of the
transformer to the factory for repair and retesting.
The bushings removed for shipment should remain in the shipping crates until they are required
for the transformer assembly provided that the shipping crates maintains a 7 Degree angle of
inclination. Note the requirements in the bushing instruction leaflet for temporary storage.
Clean the bushing thoroughly before installing it in the transformer. It is recommended to
perform a power factor and capacitance test of the bushings as noted in the bushing instruction
leaflet prior to installation in the transformer.
Install the bushings in the transformer. When a draw-through-lead or draw-rod design is used,
this will be noted on the outline drawing. The procedure for installing the bushing and
connecting the leads is described in the bushing instruction leaflet. Ground the external bushing
terminals after they are installed and connected.
9.6.3 BUSHING CURRENT TRANSFORMERS
Check the current transformer ratios, lead continuity, and polarity at the terminal points in the
control cabinet.
WARNING
AN ENERGIZED CURRENT TRANSFORMER IS DANGEROUS IF THE
SECONDARY IS AN OPEN CIRCUIT. DEATH OR SERIOUS INJURY
CAN RESULT FROM CONTACT WITH THE TERMINALS.
THE SHORT CIRCUITING DEVICES MUST BE CONNECTED TO THE APPROPRIATE
TERMINALS IN THE CONTROL CABINET IF THERE IS NO LOAD CONNECTED TO THE
TRANSFORMER.
9.7 CLOSING THE TRANSFORMER AND FINAL DEWPOINT MEASUREMENTS
After the assembly has been completed, remove all the tools and working material from the
transformer, seal the transformer and pressurize with dry air or nitrogen to 20 kPa;
[3 PSI (0.2 bar)].
If the exposure time has been excessive or there are others factors that suggest the transformer
may have been exposed to excessive moisture contamination, then it is advised that transformer
be evacuated to 2 Torr (.266 Pascal) or less and held for 4 hours. The vacuum shall then be
broken with dry air or nitrogen until the pressure reaches 20 kPa 3 PSI (.2 bar)
The transformer shall remain under pressure for at least 12 hours until equilibrium is reached,
and then measure the dewpoint. If the surface moisture is less than 0.8%, based upon the
dewpoint of the gas and the insulation temperature, proceed with the final vacuum filling
procedures. If the dewpoint is unacceptable, the transformer insulation must be dried.
When taking dewpoint measurements, it is advisable to take the measurement in the early
morning hours prior to sunrise. When this is done, the insulation temperature can be taken to
closely match the gas temperature. When taking the dewpoint during periods of extreme ambient
temperature variation or during the afternoon hours, the insulation temperature should be
measured directly after the dewpoint is taken.
9.8 ELECTRICAL TESTS
If the following electrical tests have not been made as part of the receiving inspection, make the
following tests before beginning any oil filling procedures.
CAUTION
If the transformer tank is not filled with oil, the test voltage on the windings must be
limited to low voltage preferably 415 volts on HV side.
Measure the power factor and capacitance of the bushings before installing the bushings
in the transformers. Refer to the appropriate bushing instruction leaflet for the proper
procedures. (Optional Test)
2. Measure the core resistance to ground.

The minimum acceptable value is 500 k Ohm when measured at 1000 volts.
3. Measure the core clamp resistance to ground.

The minimum acceptable value is 500 kOhm when measured at 1000 volts.
4. Measure the ratio of all bushing current transformers and verify proper polarity.
5. Check the turns ratio of the transformer (TTR) at all tap positions.
The measured turns ratio should be + 0.5 % of the nameplate voltage ratio.
FOR OIL FILLING PLEASE REFER TO OTHER PARTS 10 AND 11
9.9 SUGGESTED ERECTION EQUIPMENTS/ TOOLS
ONE OR TWO NOS. MOBILE CRANES HAVING A FREE VERTICAL LIFT SUITABLE FOR
LIFTING HV BUSHINGS AND LIFTING CAPACITY OF 3 TONNES EACH. STEEL/ MANILA /
NYLON ROPES AND “D “ SCHACKLES FOR LIFTING 3 TONNES WEIGHT FILTER MACHINE
OF CAPACITY MINIMUM 6000 LITRES PER HOUR IN EXCELLENT WORKING CONDITION. IT
MUST BE CAPABLE OF HEATING TRANSFORMER OIL UP TO 80 DEG. C (HEATING
SHOULD BE INDIRECT) AND MUST BE EQUIPPED WITH INBUILT HIGH VACUUM
DEGASSING CHAMBER FILTER ELEMENTS. THE FOLLOWING ACCESSORIES SHOULD
ALSO BE PROVIDED NON-COLLAPSABLE HOSEPIPES OF ADEQUATE LENGTH AND SIZE
PROVIDED WITH NIPPLES / ADAPTORS.
- TWO NOS. FLANGES EACH OF SIZES 25, 50 AND 80 MM PIPE SUITABLY THREADED FOR
CONNECTING THE HOSE PIPES AND PROVIDED WITH HOLES FOR FASTENING ON MAIN
UNIT VALVES
-THE INCOMING ELECTRICITY SUPPLY CAPACITY MUST BE ADEQUATE TO OPERATE

THE MACHINE WITH ALL ITS HEATERS “ON”.
VACUUM PUMP OF CAPACITY 1500-2500 LPM WITH BOOSTER OF 600- 900 cub–m/hour
–3
AND CAPABLE OF ULTIMATE VACUUM OF I X 10 [TEN TO POWER MINUS THREE] MILLI
BAR], ALONG WITH FOLLOWING ACCESSORIES
-NON-COLLAPSIBLE HOSES WITH SUITABLE FLANGES FOR CONNECTING TO MAIN TANK
-CONDENSER FOR CONDENSATION OF MOISTURE
–3
-SUITABLE GAUGE FOR MEASURING UPTO 10 PRESSURE MILLI BAR TO CONFIRM
EFFICIENCY OF VACUUM PUMP
WHENEVER REQUIRED STORAGE TANK FOR TRANSFORMER OIL OF ADEQUATE

CAPACITY PROVIDED WITH 50 MM BOTTOM DRAIN – CUM FILTER VALVE AND ANOTHER
50 MM TOP VALVE. THE TANK SHOULD HAVE AN AIRTIGHT INSPECTION COVER AT THE
TOP AND MUST BE PROVIDED WITH A BREATHER AND OIL LEVEL SIGHT WINDOWS.
TANK SHOULD BE PAINTED WITH OIL RESISTANT PAINT FROM INSIDE AND MUST BE
CLEANED THOROUGHLY BEFORE STORING THE OIL. CAPACITY OF STORAGE TANK
SHOULD BE EQUAL TO THE TOTAL OIL QUANTITY OF COMPLETE UNIT.
ADEQUATE NUMBER OF ALUMINIUM TRAYS FOR SALVAGING TRANSFORMER OIL

LEAKAGES
9.9.7 TWO SETS OF FIXED ENDED SPANNERS METRIC SIZES 4 TO 36
9.9.8 TWO COMPLETE SETS OF RING ENDED SPANNERS METRIC SIZES 4 TO 36
9.9.9 ONE COMPLETE SET OF ALLEN KEYS SET OF SCREWDRIVERS, CENTERING TUMMIES,
FLAT ENDED TUMMIES, PIPE WRENCHES, PLIERS, HAMMERS, ADDERS, HOLE PUNCHES,
OTHER TOOLS NORMALLY REQUIRED FOR SUCH WORK. SIX MM THICK 3 PLY NYLON
ROPES OF 15 METRES LONG
9.9.11 HOLDITE, ARALDITE, AND QUICK SETTING M-SEAL
9.9.12 OIL TEST SET IN GOOD WORKING CONDITION HAVING 2.5MM GAUGES FOR ADJUSTING
THE SPHERE GAP
9.9.13 FIVE kV MEGGAR PREFERABLY MOTOR DRIVEN AND CAPABLE OF READING UP TO
50000 MEGA OHMS HAND DRIVEN 500 VOLT MEGGAR CAPABLE OF READING UPTO
ATLEAST 50 MEGA OHMS TWO NOS. MULTI METERS PREFERABLY DIGITAL TYPE
HAVING FOLLOWING RANGES AC VOLTAGE: 0 – 2.5, 0- 25, 0- 100, 0- 250, 0- 1000
AC CURRENT: 0- 100 milli AMPS, 0- 1 A, 0- 10 A
9.9.16 SINGLE/ 3 PHASE SUPPLY WITH DP SWITCHES
9.9.17 2.5 MM SINGLE CORE COPPER LEADS (APPROXIMATELY 50 METERS) THREE LITERS OF
CARBON TETRA CHLORIDE
9.9.19 MUSLIN CLOTH AND WASTE CLOTH IN SUFFICIENT QUANTITY AS REQUIRED AT SITE.
9.9.20 HOT AIR BLOWER FOR DRYING PORCELAIN BUSHINGS
9.9.21 VACUUM HOSEPIPES FOR OIL CONNECTIONS SHOULD BE OF OIL RESISTANT

MATERIAL. NATURAL RUBBER SHOULD NOT BE USED. THEY SHOULD WITHSTAND FULL
VACUUM. NECESSARY ADAPTERS FOR CONNECTING TO FILTER MACHINE OUTLET,
FILTER MACHINE, INLET, FILTER VALVES ON MAIN UNIT, BUCHHOLZ RELAY PIPE, OIL
FILLING PIPE ON CONSERVATOR, ETC.
9.9.22 INSTRUMENTS FOR CHECKING HUMIDITY.
ADEQUATE LENGTH OF 10 MM INNER DIA. PVC PIPE SUITABLE FOR VACUUM WITH
SUITABLE ADAPTORS FOR CONNECTING THIS PIPE TO STANDARD 25 MM OR 50 MM
FLANGED VALVES.
9.9.23 PULLING WINCHES / PULLING EYES

9.9.24 STEEL ROPES
9.9.25 STEEL PLATES
9.9.26 RAILS 90 LBS/YARD GREASE
9.9.27 WOODEN SLEEPERS
9.9.28 HYDRAULIC/ MECHANICAL SCREW JACKS WITH LOCKING ARRANGEMENT, CAPACITY OF
EACH SHOULD BE MINIMUM 50 % OF THE TOTAL WEIGHT OF MAIN UNIT WITH OIL.
POWER PACK SYSTEM TO OPERATE ALL THE JACKS SIMULTANEOUSLY
9.9.29 MEASURING TAPES MINIMUM 25 METRES LONG
9.9.30 LEVEL TUBE/ LEVEL BOTTLE (PLASTIC)

9.9.31 STAINLESS STEEL/ SUITABLE GLASS BOTTLES FOR OIL SAMPLES
9.9.32 NITROGEN CYLINDER WITH REGULATOR AND PRESSURE GAUGES
9.9.33 WELDING MACHINE
9.9.34 GAS CYLINDERS WITH NOZZLES, TORCH FOR GAS CUTTING OXY ACETYLENE
9.9.35 PRESSURE/ VACUUM EQUALISATION PIPES AND VALVES
9.9.36 ADAPTERS 80 TO 25 MM THREE NOS. EACH 80 TO 50 MM THREE NOS. EACH 50 TO 25
MM THREE NOS. EACH
9.9.37 VALVES: 25 MM FLANGED TYPE WITH POSITION INDICATORS AND LOCKING DEVICES 50
MM FLANGED TYPE WITH POSITION INDICATORS AND LOCKING DEVICES
9.9.38 ADAPTERS SUITABLE FOR VALVE AND PRESSURE GAUGE BUSHING LIFTING
EQUIPMENTS AS SPECIFIED IN THE INSTRUCTIONS ON BUSHINGS VACUUM GAUGE
RANGE 0 – 50 MILLI BAR WITH LEAST COUNT OF ONE MILLI BAR TUBE: 5 INNER DIA
TRANSPARENT TUBE TO USE AS OIL GAUGE SHALL BE CAPABLE OF WITHSTANDING
FULL VACUUM.
9.9.39 TINTED GLASS BOTTLES WITH GROUND GLASS STOPPER ALUMINIUM CANS WITH
SCREW-ON CAPS (PREFERABLE FOR LONG TRANSPORTATION DISTANCES) UNTINTED
GLASS BOTTLES, WRAPPED IN NON-TRANSPARENT FOILS FOR PROTECTION AGAINST
LIGHT.
PART 10
OIL
SPECIFICATION
TESTING
PURIFICATION
RECEIVING AND HANDLING
FILLING ON SITE AND
VACUUM OIL FILLING
ON SITE
10 OIL
10.1 GENERAL
10.2 SPECIFICATION FOR INSULATING OIL + TABLE T 10.1 DIELECTRIC STRENGTH
+TABLE T 10.2: SPECIFICATION FOR INSULATING OIL
10.3 TESTING OF THE OIL + TABLE T 10.3
10.4 INTERPRETATION OF TESTS ON OIL + TABLE T 10.4
10.5 OIL SAMPLING +FIG F10.1
10.6 LABORATORY TESTING
10.7 DIELECTRIC STRENGTH + TABLE T10.5, T10.6, T10.7
10.8 OIL PURIFICATION + FIG F10.2
10.9 STORAGE
10.10 LABELLING, HANDLING, SAFETY AND DESTRUCTION OF INSULATING OIL
10.11 OIL FILLING
10.11.1 OIL FILLING RECEIVING AND HANDLING OF TRANSFORMER OIL ON

SITE [PRODUCT INFORMATION 1ZBA 4601-213]
10.11.2 FINAL OIL FILLING ON SITE - ATMOSPHERIC PRESSURE [PRODUCT
INFORMATION 1ZBA 4601-214]
10.11.3 OIL CONSERVATORS WITHOUT AIR CELL [PRODUCT INFORMATION
1ZBA 4601-218]]
10.12 VACUUM OIL FILLING ON SITE [PRODUCT INFORMA TION 1ZBA 4601-215]
10.1 GENERAL
Specification and test methods for unused mineral insulating oils, with and without additives, are within the
scope of IS 335 "New insulating oils- specifications”
The properties of our unhibitited oil after aging are excellent. However if inhibition is required, only Di-
Tertiary-Butyl-Paracresol (DBPC) may be used in amounts up to 0.3% by weight.
If the insulation oil is supplied separately in tanks without additional precautions, the moisture
content exceeds 10 ppm in most cases. According to pretreatment and the duration of transport
the insulating oil may contain dissolved gas (air).
Before the oil is pumped into the tank the responsible assembly leader has to decide whether a
treatment (drying, degassing) of the insulating oil is necessary .

10.2 SPECIFICATION FOR INSULATING OIL
The insulating oil must meet the values given in Tables T10.1 and T10.2 below, before being filled
into the tank.
TABLE T 10.1: DIELECTRIC STRENGTH
Breakdown voltage
Operating voltage New transformers prior to the first Transformers

energization having been in
service
(kV) IEC 156 IEC 156
kV / 2.5 mm kV / 2.5 mm
> 170 ≥ 50 ≥ 50
70 – 170 ≥ 50 ≥ 40
< 70 ≥ 50 ≥ 30
MATERIAL SPECIFICATION FOR TRANSFORMER OIL
This material specification describes the requirements on unused, uninhibited, Insulating mineral
oil of standard quality and grade. It essentially corresponds to IS 335. The oil may be used in
transformers and in reactors.
10.2.1. HEALTH ASPECTS
The oil may be harmful. See directions for labelling, handling, safety and destruction below in 10.10
10.2.2. GENERAL REQUIREMENTS
The oil shall consist of severely solvent refined and/or severely hydrotreated mineral oils. It shall
be clear and free from sediment and suspended matter.
The oil shall be PCB (Polychlorinated Biphenyl) -free. The detection limit of the measuring method,
used to verify this fact, must be below 2 ppm.
The oil shall not contain any synthetic anti-oxidant.
10.2.3. REQUIREMENTS ON OIL PROPERTIES
The uninhibited mineral insulating oil complying with this specification shall meet the
requirements given in Table T10.2 below.
The test methods used to verify the requirements on the various parameters are according to IS
Specifications.
TABLE T 10. 2 [REF: 1ZYN-117001-2] SHOWING SPECIFICATION FOR TRANSFORMER OIL
SR. CHARACTERISTIC REQUIREMENT METHOD OF REMARKS

NO. TESTS
i) Appearance The Oil shall be clear A representative __
and transparent and sample of the oil
free from suspended shall be examined
matter of sediments in a 100 mm thick
o
layer at 27 C
o 3
ii) Density at 29.5 C, Max. 0.89 g /cm IS 1448 (P:16) See Note 1
iii) Kinematic Viscosity, IS 1448 (P:25) --
Max., at
o
a) 27 C 27 cSt
o
iv) Interfacial tension at 27 C, 0.04 N/m IS 6104 --
Min
o
v) Flash point, Pensky-Marten 150 C IS 1448 (P:21) --
(closed) Min.
o
vi) Pour point, Max. -10 C IS 1448 (P:10) --
vii) Neutralisation value
a) Total acidity, Max. 0.02 mg KOH/g IS 1448 (P:2) Alcoholic
potassium
b) Inorganic acidity / alkalinity Nil IS 1448 (P:2) hydroxide
solution of
0.02 N should
be used in
place
of 0.1N
indicated
in test method
viii) Corrosive Sulphur Non-Corrosive Annex B OF IS 335 --
ix) Electric strength IS 6792

(breakdown voltage) with
2.5 mm gap.
a) New unfiltered oil, Min 30 kV (rms.) --
b) After filtration, Min. 70 kV (rms.) See Note 2
SR OIL REQUIREMENT METHOD OF REMARKS
NO CHARACTERISTIC TESTS TABLE T 10.2
CONTINUED
x) Dielectric dissipation factor 0.002 IS 6262 See Note 2
(tan δ) at 90 C, Max.
o
xi) Specific resistance IS 6103

(resistivity)
--
o 12
a) At 90 C, Min 35 X 10 ohm-cm
o 12
b) At 27 C, Min 1 500 X 10 ohm-cm --
xii) Oxidation stability Annex C OF IS 335 --
a) Neutralisation value after 0.2 mg KOH/g --

oxidation, Max.
b) Total sludge, after 0.06 percent by --
oxidation, Max. weight
xiii) Ageing characteristics after -- IS 12177 --

accelerated ageing (open method A
beaker method with copper
catalyst)
a) Specific resistance IS 6103 --
(resistivity)
o 12
1) at 27 C, Min 2.5 X 10 ohm-cm --
o 12
2) at 90 C, Min 0.2 X 10 ohm-cm --
b) Dielectric dissipation factor 0.20 IS 6262 --
(Tan δ) at 90 C, Max.
o
c) Total acidity, Max. 0.05 mg KOH/g IS 1448 (P:2) --

d) Total sludge, Max. 0.03% by weight Annex A of IS --
12177
xiv) Presence of oxidation The oil shall not IS 13631 Value of
inhibitor contain anti-oxidant 0.5%(Max.) shall
additives. be treated as
absence of
oxidation
inhibitors.
xv) Water content, Max. 30 ppm in bul IS 13567 7ppm after
40 ppm in drum treatment at
ABB.
xvi) SK Value 4-8% Annex D OF IS 335 --
xvii) PONA Analysis

a) Paraffins 48 - 52 % -- --
b) Oliffins Nil -- --
c) Nepthen 38 - 42 % -- --
d) Aromatic 8 - 10 % -- --
NOTES:
o
1 Density of the oil may be measured at ambient temperature and converted at 29.5 C using the
following equation:
29.5 ρ = ρt [1+ X (t-29.5)]
Where
o
t = ambient temperature (in C),
ρt = density measured at temperature t, and
-5
X = correction factor (equal to 65 X 10 approximately)
2 As a consequence of the tendency for water absorption to occur due to breathing on storage even
when drums are sealed the oil shall be filtered to remove moisture and particulate contaminants
present in the original sample before the test as follows:
o
A sufficient quantity of oil is heated to 90 + 2 C, then filtered hot under vacuum corresponding to
an absolute pressure of about 2.5 kPa through a sintered glass filter of porosity grade 4’.
A portion of the filtrate is cooled in a desiccator and used immediately to measure electric
o
strength, if required, and specific resistance at 27 C. The remaining hot filtrate is immediately
o o
used for measuring dielectric dissipation factor at 90 C and specific resistance at 90 .C
3 For both phenol and amine types of indicators, qualitative method as per Annex D of IS 335 shall
be adopted. In case of ambiguity (marginal cases) in finding the intensity of colour, a quantitative
method as given in Annex D of IS 335 shall be adopted. Value of 0.5 (Max.) shall be treated as
absence of DBPC(DI-TERTIARY–BUTYL–PARA–CRESOL)- Phenolic type inhibitor.
4 If pour point depressant is included in the oil this shall be done by agreement between purchaser
and supplier. In this case the generic nature of the depressant shall be made known to the
purchaser.
However no pour point depressant that clogs the filters are allowed. To prove this the method of
treatment of oil listed in IEC 296 is used.
5. Following tests shall be conducted at ABB/destination site on sample drawn from the
tanker/drum(s) before accepting the delivery of oil.
TEST Acceptance norms.

a) Density As per SL. no. ii) above
b) BDV As per SL. no. ix (a) above
c) S.K.Value As per SL no. xvi)
6 PLEASE REFER TO TEST CERTIFICATE OF OIL FOR ACTUAL VALUES.
10.3 TESTING OF THE OIL
10.3.1 RECOMMENDED TESTS

The following tests are recommended:
(A) Dielectric dissipation factor
(B) Neutralization value
(C) Interfacial tension
(D) Electric strength
(E) Water content
(F) Sludge content
Dissolved gas analysis
TABLE T 10.3: TIME INTERVALS FOR OIL CHECKINGS
YEARS AFTER
INITIAL OPERATING VOLTAGE (kV)
OPERATION
≤ 73 73 - 170 > 170
0(initial operation) TEST (A) TO (F) TEST (A) TO (F) TEST (A) TO (G)
1 (G)
2
3 (G) (G)
4
5 TEST (A) TO (F) TEST (A) TO (F) TEST (A) TO (G)
6 (G)
afterwards in 5 year intervals in 3 year intervals(G) in 2 year intervals(G)
in 5 year intervals :all in 5 year intervals:
tests (A) TO (F) all tests (A) TO (F)
10.4 INTERPRETATION OF TESTS ON OIL INTERPRETATION CRITERIA: TABLE T 10.4
Criteria Operation Test Permissible Measures to be

voltage method limiting value taken if values are
not permissible
Breakdown voltage > 170 kV > 50 kV Filtering
70 - 170 kV IEC 156 > 40 kV Drying
< 70 kV > 30 kV (Purification)
Water content > 170 kV ISO R 760 < 20 mg / l Drying
< 170 kV < 30 mg/l (Purification)
Dielectric all voltages IEC 247 < 0,2 (20 %) Exchange of the oil
dissipation factor IEC 250 at 90 °C
Neutralization value all voltages IEC 296 < 0,5 mg Exchange of the oil
KOH/g oil
Interfacial tension IEC 296 > 15 mN/m Exchange of the oil
10.5 OIL SAMPLING
Samples of oil must only be taken at the provided extraction points (drain valves / oil sampling valves as
shown in the outline drawing).
Oil sampling can be done from top, middle and lower part of tank. Suitable pipe work is provided
inside transformer tank for sampling from the parts and the three sampling valves are provided at
easily accessible heights.
Before taking an oil sample clean the drain valve and slowly drain off at least 5 liters of oil. This oil is not
suitable for sampling as it may lead to wrong evaluation of the condition of the complete oil filling. Take
test samples only after the above mentioned amount of oil has been drained.
Use clean and dry sample containers only. Be sure to remove all residue of cleaning fluids. Before filling
the sample container, rinse it with the oil to be sampled. Protect the oil sample from light. The following
sampling containers are recommended:
- Tinted glass bottles with ground glass stopper
- Aluminium cans with screw-on caps (preferable for long transportation distances)
- Untinted glass bottles, wrapped in non-transparent foils for protection against light
Take at least 1 litre of oil for testing. Samples to be tested for water-, gas- or air content must be
taken in special containers as shown in Fig.1 to prevent leakage or penetration of gases and
water.
Fig. F10.1 EXAMPLE OIL SAMPLING FOR TESTING OF GASES AND WATER
1 OIL DRAIN VALVE Oil

drain valve
2 ADAPTER FLANGE
3 SYNTHETIC RUBBER HOSE
Synthetic rubber hose
4 HOSE CLIP Hose clip
5 GLASS BOTTLE Glass bottle
10.6 LABORATORY TESTING
For a comprehensive determination of the serviceability of the insulation oil, full chemical and
physical analysis is required. Such analyses are usually performed in specially equipped
laboratories only. Testing of the dielectric strength is described below in 10.7
10.7 DIELECTRIC STRENGTH
10.7.1 IEC-METHOD
The IEC test gap consists of two 12.5 mm (=0.5 inch) spheres, or VDE semispheres, spaced 2.5 mm (0.1
inch) apart. The test cup is filled slowly to avoid the formation of air bubbles. The oil should have a
temperature of 15-25°C (59-78°F). Testing is started right after completion of the filling. The test voltage of
2 kV/s is raised six times consecutively, each time until breakdown occurs.
After each breakdown the oil in the gap is stirred with a clean, dry glass rod of 2 mm (0.080 inch)
diameter. The average value of the six results is considered to be the dielectric strength of the oil
which must comply with the values of table one. If any one of the six breakdown voltages lies
more than 15% below the specified value the test must be repeated with a new sample:
The dielectric strength of the oil can be improved by filtering and drying.
10.7.2 ASTM D-1816 METHOD
This method is compatible with the IEC method; it also employs spherically capped electrodes
spaced at 0.080 or 0.040 inch. Six breakdowns are performed and the average value of the last five
is the valid value. (That of the first breakdown is disregarded).
10.7.3 ASTM D-877 METHOD
This method specifies 1-inch-diameter circular disc square-edged electrodes spaced at 0.1inch. One
breakdown on each of five samples is made. This method is not recommended for oil tests by ABB
because it has, during repeated tests, been established as non-responsive to contamination and even to
water in oil.
10.7.4 GAS ANALYSIS ON TRANSFORMER OIL
Incipient faults in oil filled transformer are usually the result of electrical or thermal excess stress
of either transformer oil or insulating materials. It is known that such excessive stresses produce
a mixture of gases characteristic of which give an indication of the type of faults and materials
associated with the faults. It is recommended that analysis of dissolved gases in transformer oil
by gas chromatographic equipment is made at the time of commissioning and then at an interval
of maximum six months
10.7.5 ANALYSIS METHOD
10.7.5.1 SAMPLING OF OIL FROM TRANSFORMERS
Oil in transformers can be sampled through drain or sampling valve near bottom of tank. Special care
shall be taken not to introduce air, foreign matter or dirty oil into sampling container. For this
purpose, first 0.5 to 1.0 litre of oil from the transformer shall be over-flown through the oil container.
Shape of the sampling container and sampling method shall be in accordance with standard procedures
and IS: 9497
Sampled oil shall not be exposed to air before analysis.
10.7.5.2 GAS ANALYSIS : TABLE T 10.5
Gases to be analysed and criteria for the gases found in transformer oil are tabulated below.
1 Gases to be analysed normally O2, N2 , H2,CO, CO2, CH4
2 Gases to estimate abnormality H2, CH4, C2H2,C2H4,C2H6
3 Gases to estimate deterioration CO, CO2, CH4
10.7.5.3 GAS CONTENT IN OIL BY FAULTS
TABLE T 10.6
SL TYPE OF FAULTS DECOMPOSIBLE GASES IN TRANSFORMER

NO OIL
1 OVER HEAT OF OIL CH4, C2H4,H2, (C2H6,C2H2,C3H6,C3H8)
2 ARCING IN OIL H2, C2H2, (CH4,C2H4)
3 OVER HEAT OF SOLID CO, CO2, ( H2, C2H4)

INSULATING MATERIAL
4 OVER HEAT OF SOLID CH4, C2H4, CO, CO2,H2
INSULATING MATERIALS
5 ARCING OF OIL AND H2, C2H2,CO, ( C2 H4)
PAPER COMBINATION
GASES IN ( ) SHOWS CONTENTS WHICH APPEAR RARELY
10.7.5.4 PERMISSIBLE CONCENTRATIONS OF DISSOLVED GASES IN THE OIL OF

A HEALTHY TRANSFORMER (IN PPM)
TABLE T 10.7
GAS LESS THAN 4 YEARS 4 –10 YEARS IN MORE THAN

IN SERVICE SERVICE 10 YEARS IN
SERVICE
HYDROGEN H 2 110- 150 200- 300 200- 300
METHANE CH4 50- 70 100- 150 200- 300
ETHANE C2H6 30- 50 100- 150 800 -1000
ETHYLENE C2H4 100- 150 150- 200 200- 400
ACTYLENE C2H2 20- 30 30- 50 100- 150
CARBON MONOXIDE 200- 300 400 -500 600- 700
CARBON DIOXIDE 3000- 3500 4000-5000 9000- 12000
NOTE: 1
PLEASE REFER IS:10593 FOR DISSOLVED GAS ANALYSIS, FAULT IDENTIFICATION AND
REMEDIAL ACTION. AND ALSO REFER IS 3638, IEEE STANDARD C57.104-1991, IEC 599,
NOTE 2:
TRANSFORMER OVER HEATING CAN LEAD TO CELLULOSE DECOMPOSITION AND PRODUCTION

OF CO AND CO2. THESE TWO GASES ARE ALSO PRODUCED DURING THERMAL
DECOMPOSITION OF OIL. THERFORE ANALYSIS OF GAS MEASUREMENT OF CO AND CO2
CANNOT BE USE D AS UNAMBIGUOUS INDICATION OF PAPER DEGRADATION. IN ADDITION TO
CO AND CO2, THE AGEING PROCESS OF THE PAPER PRODUCES SEVERAL OIL SOLUBLE
BYPRODUCTS, MOST NOTABLY THE FURANIC COMPOUNDS (FFA). THE MONITORING OF
FURANIC COMPOUNDS BY ANNUAL SAMPLING OF OIL AND USING HIGH PERFORMANCE
LIQUID CHROMOTOGRAPHY (HPLC) IS RECOMMENDED AS A PREVENTIVE MEASURE.
10.8 OIL PURIFICATION
Oil purification comprises drying, de-gassing and filtering. Drying removes free and dissolved
water, de-gassing removes dissolved gasses and filtering removes all floating solids above a size
to be defined.
Oil purification is done under vacuum. Therefore, only purification plants must be used which employ
vacuum processing. Vacuum oil purification plants remove all water from the oil through evaporation
under vacuum, while degassing the oil at the same time.
Fig. F 10.2 shows the usual circulation method employed for field oil purification. To prevent the
oil from re-absorbing moisture while in the tanks, vacuum-proof tanks should be used and a
vacuum maintained above the oil surface. Thereby the oil is also prevented from being saturated
with air. If no vacuum-proof tank is available, mount a silica gel breather on each tank to minimize
moisture ingress. The oil purification is finished when the dielectric strength of the oil meets the
specified value.
Sufficient tanks must be available to hold the total oil volume. However, even then purified and
non-purified oil is mixed constantly during the purification process. In addition, it is possible that
pockets of untreated oil might remain in a tank. In any case, oil circulation is rather time
consuming.
The "Alternating Tank Method" avoids this disadvantage, but it requires two tanks, each large
enough to hold the total oil volume. The tanks should be vacuum proof, or equipped with silica gel
breathers. The oil is processed from one tank into the other via the oil purification plant which
considerably reduces the processing period.
FIG. F10. 2 FLOW DIAGRAM FOR TRANSFORMER OIL PROCESSING
1 Oil tank (preferably vacuum tight) 2 Oil purification plant

3 Connection to vacuum pump or silica gel breather
10.9 STORAGE
Insulating oil must be stored in clean containers designated for oil storage; Mixing with other type
of oil such as used oil, cable oil, lubricating oil, fuel oil and contamination with solids must be
strictly avoided. Even small quantities of contaminants can considerably impair the insulating
properties of the oil. Containers used for oil storage should be individually and carefully examined
for cleanliness and tightness. The containers must be protected against penetration of moisture
during storage.
If cleaning of containers must be done on site, the following procedure must be employed:
1) Rinse the container thoroughly with lead-free gasoline or kerosene until the solvent shows no
discoloration after using
2) Drain the container completely and dry it
3) Immediately after drying, seal the container to avoid moisture condensation.
Oil in drums should be stored in a closed room. In order to avoid environmental pollution special
care should be taken to prevent leaking of the drums.
10.10 LABELLING, HANDLING, SAFETY AND DESTRUCTION OF INSULATING OIL
10.10.1 GENERAL
This document offers general recommendations on safe handling practices for mineral-based oils
and precautions to avoid adverse health effects. The legal requirements and local rules for
different countries must be followed for each specific case of handling mineral based oils. It is
emphasized that the supplier must forward specific advice on individual products.
The specific product information is recommended to include:

- Transportation classification
- Information on composition
- Biological, properties
- Labelling
- Health hazard
- Fire and explosion hazard
- Preventive measures
- Personal protective equipment
- First aid
- Emergency action in case of fire
Spillage and decontamination
10.10.2 LABELLING
The labelling has to be done in accordance to the rules and guidelines issued by the various central and
state government bodies from time to time.
10.10.3 SAFE HANDLING
Most insulating oils have a low level of toxicity but the range of exposures can be very wide. To
prevent adverse effects, the extent of possible exposure in any situation needs to be assessed
and appropriate precautions established to control that exposure is at an acceptable level
In all cases it is desirable to minimize exposure.
The main contact areas from exposure to oils are the skin and eyes. Some processes also create oil
mist which is fine enough to enter the upper and lower respiratory tract and cause contamination of
body surface.
10.10.4 PREVENTIVE MEASURES
The main preventive measures can be summarized as follows:

- Avoid inhalation of any mist, fumes or vapour generated during use.
- Avoid contact with the skin.
- Avoid contact with the eyes.
10.10.5 PERSONAL PROTECTIVE EQUIPMENT
The personal hygiene is of big importance.

Therefore:
- Wash hands carefully before eating and drinking.
Ms -i - Change heavily contaminated clothing.
10.10.6 FIRST AID,
First Aid due to inhalation is unlikely to be needed under normal use

For skin contact, the first aid is to wash " with soap and water”.
For eye contact, wash out eyes thoroughly with water.
Better consult a doctor if there is risk of swallowing
10.10.7 SPILLAGE AND DECONTAMINATION
Take up spills with dry chemical absorbent. The spill should be disposed by normal disposal
methods based on state and local codes.
10.10.8 DESTRUCTION
Insulating mineral oil can be destructed by burning or can be reused for other purposes than as
insulating oil. Before choosing the way of destruction the oil has to be classified regarding the
degree of contamination
10.10.9 USED OIL CAN BE SEPARATED IN FOUR GROUPS:
1. Non contaminated and also free of water.

2. Contaminated oil and free of water.
3. Oil containing water.
4. Spilled oil
10.10.10 NON CONTAMINATED OIL
Non, contaminated oil is free of particles free of water and free of PCB (Polychlorinated
Biphenyles). Prior to destruction the oil has to be tested for PCB. The non-contaminated water
free oil is destructed by burning.
10.10.11 CONTAMINATED OIL FREE FROM WATER
Contaminated oil free from water is an oil with particles and/or containing PCB. It shall be filled in drums,
approximately 209 litres of size, and sent to the local authority for disposal.
10.10.12 OIL BLENDED WITH WATER
Oil blended with water should be sucked up and collected in a tank and delivered to the local
authorities. There the water is separated from the blend and the oil can thereafter be used for
asphalt production.
10.10.13 SPILLED OIL
Oil spills is taken up with a dry chemical absorbent. It should be assembled and put on a platform
and passed on to a container made of concrete. After the sedimentation of the absorbent the oil
can be used for asphalt Production.
10.11 OIL FILLING
10.11.1 OIL FILLING: RECEIVING AND HANDLING OF TRANSFORMER OIL ON

SITE PRODUCT INFORMATION 1ZBA 4601-213 ENCLOSED [THREE
PAGES]
10.11.2 FINAL FILLING ON SITE –ATMOSPHERIC PRESSURE PRODUCT

INFORMATION 1ZBA-4601-214 ENCLOSED, 3 PAGES
10.11.3 OIL CONSERVATORS WITHOUT AIR CELL [PRODUCT INFORMATION 1ZBA 4601-218] 2
PAGES
10.12.0 VACUUM OIL FILLING ON SITE
PRODUCT INFORMATION 1ZBA 4601-215 ENCLOSED [13 PAGES].
PART 11
ERECTION AND ASSEMBLY
11 ERECTION AND ASSEMBLY
11.1 GENERAL
11.2 MOUNTING OF ACCESSORIES
11.3 BOLTING/ SCREWING CONNECTIONS
11.4 PAINT
11.5 CONSERVATOR AND BRACKETS
11.6 COOLING EQUIPMENT
11.7 BUSHINGS
11.8 PIPES AND FITTINGS
11.9 OTHER ACCESSORIES
11.10 ELECTRICAL CONNECTIONS
11.11 OIL FILLING
TABLES
T 11.1 A MAXIMUM RECOMMENDED TORQUE

T 11.1 B MAXIMUM RECOMMENDED TORQUE
T 11.1 C TORQUE FOR GAKETETTED JOINTS
FIGURE
F11.1 ARRANGEMENTS FOR OIL FILLING – SCHEMATIC PICTURE
11 ERECTION AND ASSEMBLY
11.1 GENERAL
Commissioning of a transformer should, as a rule, be carried out by the manufacturer's experts.

Should this not be possible or the user decides to have the commissioning carried out by his own
personnel, the following instructions should prove as useful guidelines.
However, the assembly of transformers must only be carried out by well-trained staff who is familiar with
the relevant safety regulations. Also refer parts EARLIER DESCRIBED regarding arrival on site,
unpacking and checking of the consignment, installation, checklist for the consignment on arrival.
11.2 MOUNTING OF ACCESSORIES
The transformer should be assembled when the weather is dry. In order to minimize the
penetration of humidity and dust into the inside of the tank during assembly, all openings must be
re-closed as soon as possible.
Caution! Blank flanges must only be removed from tank and accessories if this is
necessary for the assembly and immediately before starting with the mounting procedure
Separately supplied parts must be checked for cleanliness, humidity and damages before the
assembly. The inside of conservator, radiator, pipes, etc. must be clean and dry. The inner
coating must not be damaged. If parts are soiled, they must be cleaned thoroughly. Only those
kind of cleaning agents are to be used, which do not leave any residues. Humidity can be removed
by flushing with hot air or with hot transformer oil.
Accessories like cooling fans, pumps, OLTC and components for supervision and control, oil level
indicator, flow indicators, gauges, buchholz relay, PRV, thermometers etc. are assembled according to
leaflet/ description valid for the components. After assembling locking strip/card /pin shall be removed for
correct functioning of Oil Flow Indicator.
11.3 BOLTING/SCREWING CONNECTIONS
All oil tight and / or vacuum tight screwing connections must be made with special care. Only the gaskets
supplied by ABB or gaskets of the same quality must be used.
Sealing surfaces must be checked for damages of any kind. They must also be free of rust, paint, oil and
grease.
Caution Roughness on surfaces resulting from transport handling must be evened.

Contaminations must be removed.
After the gasket and the connection parts have been fitted, the screws must only be turned a little,
one by one (about 1-2 turns). This shall be repeated until all screws around the gasket are
tightened. This procedure guarantees, that the pressure on the gasket is applied evenly.
When remounting blanking plates, connection flanges etc., the gasketting surface shall be cleaned well
and new gaskets fitted.
Assemble the control cables according to the drawing of wiring system and connect the cable ends to
terminal blocks in instruments, terminal boxes, junction boxes and control cabinets according to valid
connection diagram.
11.3.1 SPECIFICATION OF TORQUES FOR BOLTS AND NUTS
11.3.2 GENERAL
The maximum recommended torque can be calculated on the basis of the material properties and 70% of
the proof stress can be considered as limit value for tightening torque. The general classification can be
made as follows. For all inspection covers, pin screws are used.
11.3.3 BOLTS AND NUTS

Bolts and Nuts should conform to property class of 4.6 of IS 1367 having UTS of 4200 kg/sq mm
and yield stress of 2400 kg/sqcm.
EXAMPLE FOR PIPE CONNECTIONS: [HIGHLIGHTED BOLD IN TABLE 11.1A]

TABLE T 11.1 A MAXIMUM RECOMMENDED TORQUE N-m
BOLT SIZE UNPLATED: TORQUE N-m ZN PLATED GALVANISED
M 10 20 25
M 12 36 40
M 16 90 110
M 20 175 210
M 24 300 360
M 30 600 720
M 36 1050 1260
11.3.4 Bolts and nuts should conform to property class of 8.8 of IS 1367 having UTS of 7000 kg/sqcm
and yield stress of 4200 kg/sqcm
EXAMPLE: FOR TANK- COVER CURB

TABLE T 11.1 B: MAXIMUM RECOMMENDED TORQUE N-m
BOLT SIZE UNPLATED: TORQUE N-m ZN PLATED

GALVANISED
M 10 35 40
M 12 60 70
M 16 145 170
M 20 280 340
M 24 490 590
M 30 970 1160
M 36 1700 2040
11.3.5 Recommended torque for bolts/studs only for GASKETED JOINTS. Based on maximum
pitch generally used for that class of bolt, for example: radiator valves, valves.
TABLE T 11.1 C: TORQUE FOR GAKETETTED JOINTS
BOLT SIZE TORQUE N-m

M 10 20
M 12 30
M 16 50
M 20 70
M 24 100
11.4 PAINT
Damaged paint coatings must be repaired. Only the paint supplied by ABB or equivalent must be
used for this purpose. The damaged spot on the inside or outside must be smoothened to provide
an even transition to the undamaged paint. The surface must then cleaned from dust, grease and
other contaminations by using a chemical-cleaning agent. Commercial paint removers are suitable
as chemical cleaning agents.
The procedure described in the following is to be repeated at least three times, in order to obtain a
protective, multiple-layer coat of paint:
- The paint shall be applied in a thin and even layer.

- The paint must dry out completely (on the average over a period of approx.8
hours).
- Afterwards the repainted area must be smoothened carefully and all dust shall be
removed.
When the third coating has dried out completely, the repaired component can be assembled.
11.5 CONSERVATOR AND BRACKETS
The conservator must be assembled ready for operating before mounting the bushings and / or
other components which must be filled with oil. This guarantees that oil filling of the transformer
can be started immediately and without further delay after the assembly has been completed.
Conservator and brackets must be mounted to the transformer as shown in the outline drawing. The
distance in height between transformer tank and conservator as indicated on the outline drawing must be
strictly observed.
The conservator is mounted on separate A- frame assembly as shown in the general assembly
drawing.
The conservator is in two compartments: one for the main transformer separated by other
compartment for OLTC connection.
Flxi separator bag is mounted inside main conservator compartment. Magnetic oil level gauge with
its float is suitable for FLXI separator mounting.
Before the conservator is assembled it shall be checked that belonging equipment, example oil
level indicator- functions satisfactorily. The breather is connected to the oil conservator and it is very
important that joints and couplings in the pipe between breather and conservator are airtight.
11.6 COOLING EQUIPMENT
Valves which are not dismantled like shut off valves for radiators, coolers and possible headers
are provided with blanking plates during transport. Check that valves are closed and remove
blanking plates before assembling the coolers
11.6.1 SEPARATELY STANDING RADIATOR ASSEMBLY
The radiator battery is supplied separately. The radiators are mounted to the frame along with oil
pumps, oil flow indicators ,non- return device and suitable valves. Openings at the radiator frame,
at the transformer and at the radiators are closed by blind flanges. They must be removed before
the assembly.
Caution: Desiccant bags inside the radiators, if provided, must be taken out.
The gasket between radiator flange and butterfly valve must be centered. The radiator battery
including all accessories (piping, valves and extension joints etc.) is erected and assembled as
shown in the outline drawing.
Fans must be mounted to the attachments provided for this purpose on radiators as shown in the
general assembly.
11.7 BUSHINGS
The bushings are mounted as described earlier. Please refer supplier‘s catalogue.
11.8 PIPES AND FITTINGS
The assembly is done as shown in the outline drawing and the piping scheme. The venting pipes
between the transformer tank and the Buchholz relay and between the tap changer, Buchholz relay
and the protective relay rise by about 3 –7 degrees to ensure an unhindered excape of any gas
from the transformer.
Caution
The sealing surfaces of pipes and fittings must not be subjected to any kind of mechanical stress.
There is sufficient space/clearance between pipes and live parts. These spaces/ clearances must be
strictly observed.
Breather pipe, conservator pipes, equalizing pipes, cooler pipes etc. should all be assembled
properly as per the general assembly drawing. The pipes shall preferably placed 3 to 7 degrees
upward from the transformer. Internal surfaces of pipes should have been treated with oil resistant
paint and external surfaces as per the specification required.
11.9 OTHER ACCESSORIES
All other accessories disassembled for transport and not mentioned above must be mounted now. The
assembly position is shown in the outline drawing.
11.10 ELECTRICAL CONNECTIONS

All electrical connections for current transformers, supervisory equipment etc. shall be made as
indicated in the Circuit Diagram of Transformer supervision. For the fans, attention must be paid
to the direction of rotation.
Caution Cables shall not be layed over sharp edges
After the cables have been connected the compression glands at control cabinet and devices must be
tightened and protected against the penetration of dust and humidity by means of a permanently elastic
sealing substance.
In the case of steel-armored cables, the armoring is to be earthed on one side (usually inside the
control cabinet).
The tank must be connected with the functional grounding of the system at two diagonally
opposite points. The location of the earthing pads is shown in the outline drawing.
All metal parts are to be connected to the earthing pads by means of flexible conductors.
11.11 OIL FILLING
PLEASE REFER PART 10

FIG. F11.1 ARRANGEMENTS FOR OIL FILLING – SCHEMATIC PICTURE
1 –Transformer 11 –connection full vacuum Gauge

2 –oil treatments plant connection f. vac. Gauge
3 –vacuum hose 12 –oil inlet slide valve oil inlet slide valve
4 –oil hose 13 –inlet pump inlet pump
5 –oil filling connection 14 –filter
6 –gate valve for oil treatment plant 15 –heating heating
7 –air vent valve 16 –degassing chamber degassing chamber
8 –manometer 17 –discharge pump discharge pump
9 –lower shut-off gate valve 18 –oil outlet gate valve oil outlet slide valve
10 –vac. Flange with 19 –vacuum pump vacuum pump
sight glass 20 –gas ballast valve gas ballast valve
21 –vacuum valve vacuum valve
22 –vacuum gauge vacuum gauge
PART 12
ACCEPTANCE TEST AND
ENERGIZATION
12.0 ACCEPTANCE TESTING AND ENERGIZATION
12.1 PRODUCT INFORMATION 1ZBA 4601-216 [11 PAGES]
12.2 STANDING TIMES + TABLE T 12.1
12.3 CHECKING
12.3.1 GENERAL
12.3.2 ELECTRICAL TESTS,
12.3.2.1 PROTECTIVE DEVICES
12.3.2.2 WINDING RESISTANCE
12.3.2.3 MEGGER TEST
12.3.2.4 OIL SAMPLES
12.4 RECOMMENDATIONS FOR ENERGISING
12.5 SOAKING TIME VS. MAX. OPERATING VOLTAGE OF TRANSFORMERS
12.6 RECOMMENDED REQUIREMENTS OF INSTRUMENTS USED FOR PRE-COMMISSIONING

TESTS + T 12.2
12.7 OVER LOAD PROTECTION FOR ENERGISING UNLOADED TRANSFORMER + T12.3
12.0 ACCEPTANCE TEST AND ENERGIZATION
12.1 PRODUCT INFORMATION 1ZBA 4601-216

[ 11 PAGES]
12.2 STANDING TIMES
Since it is almost impossible to remove all gas inclusions from the insulation during evacuation and,
on the other hand, small quantities of residual gas can cause internal discharges, it is necessary that
the residual gas in the insulation is dissolved in the insulating oil. This is a slow process which is
accelerated with rising temperature of the oil penetrating into the insulation. However, residual
gases can only be dissolved in oil, if the oil itself is highly de-gassed.
The following soaking periods are valid for oil temperatures of appr. 20 °C starting from the time when all
insulating material is covered by oil until putting into service.
TABLE T 12.1: SOAKING TIME VS. MAX. OPERATING VOLTAGE OF TRANSFORMERS
Highest operating voltage (k V) Standing time(days)

≤ 72,5 1
> 72,5 - 123 3
> 123 - 170 3
> 170 - 245 5

> 245 - 420 7
> 420 7
12.3 CHECKING
12.3.1 GENERAL
Before the transformer is put into service, various checkings must be performed.
12.3.2 ELECTRICAL TESTS
We recommend to perform the following checks before energizing the transformer.
12.3.2.1PROTECTIVE DEVICES
A functional test has to be performed on all protective devices of the transformer.
12.3.2.2WINDING RESISTANCE
Winding resistances depend on the temperatures. The measured data should be converted to the
same reference (say 75 deg. C) operating temperature and compared to the data mentioned in the
transformer test certificate.
12.3.2.3 MEGGER TEST
Check the insulation resistance beween the windings as well as each winding to ground with a 5 kV
Megger-Tester. Insulation resistance of core to ground and secondary wiring to ground are to be
tested with a Megger-Tester of 1 kV only.
12.3.2.4 OIL SAMPLES
Sample has to be taken and the dielectric strength must be tested. If the results of test do not
comply to the requirements, the oil must be dried and de-gassed by circulating through an oil
purifying plant.
12.4 RECOMMENDATIONS FOR ENERGISING
When energising an unloaded transformer, overvoltages occur on the energised as well on the not-
loaded side. Inner flashovers can occur even when an unloaded transformer is energized. On the
energised side, overvoltages occur as a consequence of reflections. On the no-loaded side capacitive
and inductive voltages can interfere with voltages which are caused by vibrations of the windings.
The following recommendations should be observed while energizing an unloaded transformer in
order to exclude possible dangers:
1 A transformer should always be connected to the main power supply on the HV

side. If the HV-winding is provided with an on-load tap-changer, the latter
should be adjusted to the tap position with the maximum number of
windings ( TAP 1).
2. When energizing 3-phase-transformers, the synchronism of the circuit-breakers

has proved to be important with respect to formation of switching surges.
Measurements have shown that the smaller the time delay between the
third pole and the second one, the smaller the over voltage level.
Therefore, an examination of the synchronism of the circuit breakers
should be made during the first commissioning of transformers with a
voltage rating 245 kV and above.. If necessary adjustment of the
synchronism must be performed.
3. Lightning arresters are the best protection against switching surges for all terminals
which are not grounded. To prevent capacity transmitted voltage peaks,
the low voltage terminals of generator transformers and the tertiary
terminals of system transformers should be connected to capacitors
installed between terminal and ground. Protection with capacitors is not
necessary if the capacity to the ground of the connected busbars or cables
is approximately 0.05 µF/phase.
4. Before energizing an unloaded transformer ensure that all short-circuit connections

are removed from the secondary terminals. If there is a short-circuit, it must
be eliminated before energising the transformer.
The following TABLE T 12.3 gives recommendations for over voltage protection for energising
unloaded transformers with regard to the voltage ratio.
12.5 TABLE T 12.2

RECOMMENDED REQUIREMENTS OF INSTRUMENTS USED FOR PRE-COMMISSIONING
TESTS
SL TEST MEASURING INSTRUMENT REQUIRED LEAST

NO. INSTRUMENT RANGE ACCURACY COUNT
1 Ratio, polarity and Voltmeter 0-500 V +/- 2 % 5V
phase relationship
-6
2 Resistance Bridge 0 – 100 ohms +/- 2 % 1x10
ohms
3 Insulation Meggar 0-50,000 +/- 5 % 5 Mohms

resistance M –ohms at the
lowest
scale
4 Excitation current Ammeter 0-200 m A +/- 0.5 % 1mA
5 Oil BDV BDV meter 2.5 mm 0-100 k V +/-2% kV
gauge 2.5 mm +/- 0.1mm GO-
NO-GO
6 Moisture in oil Moisture meter 0-100 ppm 1 ppm 1 ppm
12.6 TABLE T 12.3

OVER LOAD PROTECTION FOR ENERGISING UNLOADED TRANSFORMER
Voltage ratio of the Putting in Lightning Protection Examination of

transformer circuit on arrestors on all capacitors on the
HV/LV or HV/LV/TV the HV-side not earthed ter- the LV-or synchronism of
minals> 30kV TV-side the circuit
Kv breakers in case
of a 3-phase
transformer
110/30 X
110/6,3...30 X X
110/6,3...30/10 X X
110...245/15...27 X X X
245/110...132/10 X X X X
345...525/15...27 X X X X
345...525/110...245/10...20 X X X X
750/15...27 X X X X
750/245...525/30 X X X X
X = is recommended
PART 13
FIELD TEST RECORD

AND
FIELD QUALITY PLAN
FIELD TEST RECORD GENERAL CONTENT [REF:1ZBA 4601-217]
13.1 RATIO TEST
13.2 CHECK OF VECTOR GROUP INSULATION TEST CHECK OF POTENTIAL CONNECTION

BETWEEN TANK AND TURRET
13.5 POLARITY CHECK OF CURRENT TRANSFORMERS
13.6. CHECK OF WINDING TEMPERATURE CIRCUITS
13.7. OIL TEST
13.8. OPERATIONAL TEST OF SUPERVISORY EQUIPMENT
13.9. OPERATIONAL TEST OF OTHER EQUIPMENT
13.10 FIELD QUALITY PLAN
13.0 FIELD TEST RECORD : GENERAL CONTENT
[ REFERENCE: PRODUCT INFORMATION 1ZBA 4601-217]
Order No
Transformer type Serial No
Tap-changer type Serial No
Motor-drive Serial No
Mechanism type
CONTENT
NOTE: MARK X for the respective test, which are carried out under Yes.
Yes No
13.1. Ratio test _________________________
13.1.1 Windings _________________________
13.2. Check of vector group _________________________
13.3. Insulation test _________________________
13.3.1 Windings _________________________
13.3.2 Current Transformers _________________________

13.3.3 ................................................................................Control-circuit cabling and auxiliary power cabling _____
13.3.4 Core _________________________
13.4 Check of potential connection between tank and turret _______________________
13.5. Polarity check of Current Transformers _________________________
13.6. Check of winding temperature circuits _________________________
13.7. Oil test _________________________
13.8. Operational test of supervisory equipment _________________________
13.9. Operational Test of other equipment _________________________
13.9.1 Coolers _________________________
13.9.2 On-load tap-changer with motor drive mechanism _________________________
Customer represented at test _________________________
13.1 RATIO TEST
13.1.1 WINDINGS
Tap Magnetizing No measured on ___kV side Calculate measured on Calcula

changer on __-kV side load d voltage ___kV side ted
Position current voltage
Volt Volt Volt Volt v-w Volt Volt Volt Volt Volt
u-v u-w u-v-w u-v u-w v-w u-v-w
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Voltage between phase – 0 checked?

Yes No
13.2 CHECK FOR VECTOR GROUP
Connect 1U with 2u
Magnetized on kV side
Measured voltage U between
Vv Ww Uv Vw Wv Connection
Connect 1U with 2u
Magnetized on kV side
Measured voltage U between
Vv Ww UV Vw Wv Connection
The vector group corresponds with connection diagram No

Remarks
13.3 INSULATION TEST
13.3.1WINDINGS Megger kV
Note Maximum 5kV megger
Terminal to earth M ohm

Terminal to terminal M ohm
Weather conditions:
13.3.2 CURRENT TRANSFORMERS Megger KV
Note Maximum 1kV MEGGER
Location: Terminal: to earth M-ohm

Weather conditions:
13.3.3 CONTROL-CIRCUIT CABLING AND AUXILIARY POWER CABLING

Megger V
Note Maximum 1kV megger
Cables to earth (min value) M ohm
13.3.4 CORE
Megger___________ V Note Maximum 1kV megger

The Megger must be of an of ABB Transformer approved type
Core - earth ________________M ohm
Yoke beams -earth ________________Mohm
Weather conditions_____________________________________________________________
REMARKS:___________________________________________________________________
____________________________________________________________________________
13.4 CHECK OF POTENTIAL CONNECTION BETWEEN TANK AND TURRET
The potential connection between tank and turret has been checked with buzzer
13.5 POLARITY CHECK OF CURRENT TRANSFORMERS
Check of Current Transformers according to diagram No
Location/terminal Location/terminal Location/terminal

Location/terminal Location/terminal Location/terminal
13.6 CHECK OF WINDING TEMPERATURE CIRCUITS
CURRENT TRANSFORMER FOR
Location Location Location
Measured resistance for:
Current transformer ohm ohm ohm
Instrument ohm ohm ohm
13.7 OIL TEST
The oil level checked in Date

Transformer ___________________
Tap-changer/diverter switch ___________________
Other separate compartments ___________________
The oil system has been de aired ___________________
Oil samples are taken from Breakdown voltage kV

Oil conservator
Transformer/reactor tank Breakdown voltage kV
Cooling group No Breakdown voltage kV
Cooling group No Breakdown voltage KV
Oil test equipment type with electrodes
Electrode distance mm
Oil samples for dissolved gas analysis have been taken
REMARKS
13.8 OPERATIONAL TEST OF SUPERVISORY EQUIPMENT
Alarm circuit tested to Trip circuit tested to

Control Control Control Breaker
circuit room circuit
Cabinet Cabinet
No/OK No/OK No/OK No/OK
Gas detector relay transformer
Gas detector relay tap changer
Oil level indicator tap changer High
Low
Oil level indicator transformer High
Low
Pressure relief valve for transformer
Pressure relay for transformer
Pressure relay for tap changer
Flow indicators for coolers
Cooler group 1 min oil flow
max. oil flow
Cooler group 2 min oil flow
max. oil flow
Manometers for
coolers
Cooler group 1 min oil
pressure
Max. oil
pressure
Cooler group 2 min oil
pressure
max. oil
pressure
No/OK No/OK No/OK No/OK

Thermometer for top oil
Set for alarm Deg
Set for trip Deg
Set for start of
Cooler group 1 Deg
Cooler group 2 Deg
Thermometer for kV winding
Set for alarm Deg
Set for trip Deg
Set for start of
Cooler group 1 Deg
Cooler group 2 Deg
Thermometer for kV winding
Set for alarm Deg
Set for trip Deg
Set for start of

Cooler group 1 Deg
Cooler group 2 Deg
13.9 OPERATIONAL TEST OF OTHER EQUIPMENT
13.9.1 COOLERS
1. Pump rotation direction checked

2. Fans rotation direction checked
3. Over current protection tipped at 2-phase connection:
Fan No After Current setting Pump No After Current setting

(sec.) (A) (sec) (A)
1
2
3
4
5
7
8
9
Alarm obtained for tipped current protection at terminals _______ in the control cabinet.
13.9.2 ON-LOAD T AP-CHANGER WITH MOTOR DRIVE MECHANISM
The position indicators in motor drive mechanism and tap changer

indicate the same position
Shaft coupling lubricated with grease
Gear box filled with lubricant to correct level
Motor drive mechanism checked and test runned
lubricated
end position contacts
local/remote control
interlocking switch manually and with the crank assembled
setting of motor protection
tripping time for blocked motor
pressure relay tested
heating element connected and In operation
13.10 FIELD QUALITY PLAN
SL CHARACTERISTICS/ TYPES OF QUANTUM/ ACCEPTANCE REMARKS

NO ITEMS CHECK FREQUENCY CRITERIA
OF CHECK
1 CHECK ON RECEIPT
1.1 MAIN EQUIPMENT
TEMPORARY STORE
1.1.1 IF THE PERMANENT PHYSICAL AT THE TIME HARD LEVEL --
LOCATION IS NOT OF STORAGE GROUND
READY ,ENSURE THAT
TEMPORARY STORAGE
IS DONE IN A SUITABLE
LOCATION
1.1.2 CHECK THAT THE PHYSICAL
EQUIPMENT IS NEVER AT THE TIME UNPOLLUTED --
STORED IN A OF STORAGE
POLLUTED AREA
1.1.3 CHECK THAT THE
EQUIPMENT IS KEPT NORMAL AIR
ON SLEEPERS/ ROLLER PHYSICAL AT THE TIME DIRECTION --
MOUNTED OF STORAGE SHALL BE
FACILITATING FREE CONSIDERED
FLOW OF AIR
UNDERNEATH.
FOR GAS FILLED
1.1.4 STORAGE , READING OF MAINTAIN GAS USE
PERIODICALLY CHECK PRESSURE DAILY PRESSURE OF PRESSURE
THE GAS PRESSURE GAUGE AND 0.1 TO 0.2 GAUGE
AND ENSURE THE RECORD Kg/Sqcm AND
READING OF RECORD
PRESSURE AND ON LOG
TEMPERATURE AS SHEET
LOGGED
1.1.5 THERMOMETER , FLOW NO PHYSICAL --

INDICATORS ETC. PHYSICAL AT THE TIME DAMAGE
CHECK THAT THESE OF STORAGE
ARE STORED WITHOUT
DAMAGE TO FRAGILE
PARTS.
1.1.6 OIL DRUMS , CHECK
THAT THE DRUMS ARE AT THE SEALS
STORED IN PROTECTD TIME OF INTACT , NO
AREA AND ARE NOT PHYSICAL STORAGE LEAKAGES --
PLACED ON THEIR SIDE 100 %
FACE
1.1.7 OIL LEVEL GAUGE , NO PHYSICAL
BUCHHOLZ RELAY, PHYSICAL AT THE DAMAGE --
SILICA GEL BREATHER TIME OF
ETC. CHECK THAT STORAGE
THESE ARE STORED 100 %
WITHOUT DAMAGE TO
FRAGILE PARTS
SL. CHARACTERISTICS/ TYPES OF QUANTUM ACCEPTANCE REMARKS
NO ITEMS CHECK FREQUENCY OF CRITERIA
CHECK
1.1.8 COOLING SYSTEM, AT THE NO PHYSICAL
CHECK THAT ITEMS TIME OF DAMAGE
CONNECTED AS PUMP PHYSICAL STORAGE 100% --0
MOTOR ARE STORED
INDOOR
1.1.9 CHECK THAT PHYSICAL AT THE
SUPPORTS AND TIME OF NO PHYSICAL
FABRICATED PARTS STORAGE 100% DAMAGE
ARE NOT PLACED
DIRECTLY ON GROUND
BUT KEPT ON WOODEN
BATTONS/PLANKS
1.1.10 BUSHINGS- CHECK AT THE COVERED --
THAT BUSHINGS ARE PHYSICAL TIME OF STORE
STORED IN STORAGE
RESPECTIVE CASES IN
CLOSED PLACE
1.1.11 MARSHALLING BOXES- AT THE
CHECK THAT THE TIME OF
MARSHALLING BOXES PHYSICAL STORAGE COVERED
ARE STORED IN STORE
CLOSED PLACE IN THE
CASES
1.1.12 LOOSE ITEMS-CHECK AT THE NO PHYSICAL
THAT LOOSE ITEMS PHYSICAL TIME OF DAMAGE
ARE STORED IN STORAGE
CLOSED PLACE
1.1.13 COMPLETE AS LISTED AS LISTED INSTRUCTION USE
RECEIPT/STORAGE MANUAL CHECK
CHECK LIST LIST
2.0 ERECTION CHECK PHYSICAL ONCE BEFORE COMPLETE SET
2.1 DOCUMENT CHECK VERIFICATI ERECTION OF ERECTION CHECK
FOR AVAILABILITY OF ON DRAWINGS, LIST
ALL RELEVANT INSTRUCTIONS,
DRAWINGS AND TEST
DOCUMENTS CERTIFICATES
2.2 SITE PREPARATION – VISUAL ONCE BEFORE FOUNDATION USE
CHECK THAT THE ERECTION DRAWING LOGSHEET
TRANSFORMER YARD
IS PROPERLY LEVELED
2.3 CHECK THAT RAILS PHYSICAL ONCE BEFORE FOUNDATION USE LOG
ARE LEVELLED AND ERECTION DRAWING SHEET
EXACT LOCATION OF
ROLLER ASSEMBLY IS
MARKED IN
PERMANENT LOCATION
OF THE TRANSFORMER
WHERE APPLICABLE.
2.4 OIL FILTERATION ONCE BEFORE OPERATION USE LOG
PLANT- CHECK FOR ERECTION MANUAL FOR SHEET
AVAILABILITY OF OIL PHYSICAL FILTERING
FILTERATION PLANT OF MACHINE
ADEQUATE CAPACITY
CHECK
2.5 CHECK FOR FACILITIES OPERATINN USE LOG
FOR OPERATION OF PHYSICAL ONCE BEFORE MANUAL FOR SHEET
FILTER MACHINE SUCH ERECTIONAT THE FILTERING
AS: TIME OF MACHINE
-PROPER POWER STORAGE
SOURCE
-CABLE OF ADEQUATE
CAPACITY AND LENGTH
-HOSE PIPE OF
ADEQUATE CAPACITY
AND SUITABLE ENDS
ERECTION CHECK PHYSICAL ONCE BEFORE RATING AND
2.6 CHECK FOR VERIFICAT ERECTION DIAGRAM ALSO
AVAILABILITY OF ION PLATE AND OIL SPEC.
SUITABLE AND QUANTITY GA.DRAWING
ADEQUATE QUANTITY CHECK
OF OIL
2.7 CHECK THAT ALL PHYSICAL 100% BEFORE PACKING LIST
ITEMS AND ERECTION NO DAMAGE
ACCESSORIES ARE
INSPECTED FOR
DAMAGE
2.8 CHECK THAT THE PRE- PHYSICAL 100% BEFORE FOUNDATION
ERECTION DRAWING,
ERECTION SURVEY HAS
LAYOUT DRG. --
BEEN CARRIED OUT TO IN LINE WITH
ENSURE THAT SPECIFICATION
TRANSFORMER YARD IS S
READY IN ALL RESPECTS
AND TO VERIFY AND
ACHIEVE THE POSITION
OF VARIOUS
EQUIPMENTS TO BE
CONNECTED, LEVEL OF
FLOOR/RAILS, POSITION
OF FOUNDATION BOLTS,
POCKETS AND
CUTOUTS, ALIGNMENT
OF CABLE TRENCHES
ETC.
2.9 CHECK THAT PROPER 100% BEFORE INSTRUCTION --

TOOLS AND TACKLES COMMEN- MANUAL
ARE USED FOR PHYSICA CEMENT OF
TRANSPORTING L ERECTION
VARIOUS ITEMS TO
ERECTION SITE
CHECK
2.10 CHECK THAT PHYSICAL 100% BEFORE NO CRACKS
TRANSFORMER IS VERIFICA ERECTION SHOULD
JACKED UP USING TION APPEAR NEAR
ONLY THE JACKING JACKING LUGS
LUGS PROVIDED FOR
THE PURPOSE AND
THAT NO OTHER
PARTS ARE USED FOR
THIS PURPOSE
2.11 CHECK THAT PHYSICAL 100% BEFORE ROLLER

ROLLERS (WHEREVER ERECTION ASSEMBLY
APPLICABLE) ARE DRAWING AND
GREASED PROPERLY FREE
BEFORE ASSEMBLING MOVEMENT OF
UNDER THE ROLLERS.
TRANSFORMER TANK.
2.12 CHECK THAT ITEMS PHYSICAL 100% BEFORE NONFLURRY

TO BE MOUNTED ARE ERECTION DRY CLOTH
CLEANED WITHOUT --
LEAVING ANY LOOSE
FIBRES WITH DRY
CLOTH.
2.13 CHECK THAT OIL OPERATIO ONCE DURING BDV AND USE
FILLING IS DONE NAL OIL FILLING MOISTURE PPM VACUUM
UNDER VACUUM AS PER OIL GAUGE
STRICTLY AS PER SPEC.
INSTRUCTION
CHECK THAT OPERATIO DURING RELEVANT REFER
2.14 BUCHHOLZ RELAY NAL PROCESS-ING VALVES TO BE INSTRUCTI-
AND CONSERVATOR CLOSED AS -ON
ARE NOT SUBJECTED PER VALVE MANUAL
TO FULL VACUUM DIAGRAM
PLATE
2.15 CHECK THAT THE OPERATIO AFTER AS PER USING
TRANSFORMER HAS NAL COMPLETION OF INSTRUCTIONA OIL
BEEN PROPERLY OIL CIRCULATION L MANUAL. TESTING
DRIED BY TESTING OIL IN TANK SET FOR
SAMPLE FROM TANK BDV AND
AND OLTC DIVERTER PPM KIT
SWITCH FOR -BDV OF FOR
OIL MOISTURE
-MOISTURE
CONTENT
CHECK
2.16 ENSURE THAT THE OIL PHYSICAL 100% BEFORE INSTRUCTION USE LOG
FILLING IN THE ERECTION MANUAL SHEET
CONSERVATOR (AIR-
CELL TYPE)IS DONE
AS PER THE OIL
FILLING INSTRUCTION
GIVEN AT SPECIFIED
RATE AND CHECK THE
WORKING OF
PRESSURE RELIEF
VALVES.
2.17 CHECK FOR ANY PHYSICAL 100% BEFORE NO DAMAGE LOG SHEET
DAMAGE TO CT S AND COMMISSI-ONING
CHECK CLEANINESS
CHECK THAT CT
2.18 SECONDARY LEADS PHYSICAL 100% BEFORE NO DAMAGE USE LOG
ARE ALL IN TACT AND COMMISSIONING SHEET
KEPT SHORTED UNTIL
RESPECTIVE LEADS
ARE CONNECTED
2.19 COMPLETE ERECTION INSTRUCTION USE
CHECK LIST AS LISTED AS LISTED MANUAL CHECK
LIST
2.20 COMPLETE USE

PRECOMMISSIONING AS LISTED AS LISTED INSTRUCTION CHECK
CHECK LIST MANUAL LIST
3. COMMISSIONING
CHECKS USE LOG
3.1 SILICA GEL COLOUR PHYSICAL 100 % BLUE SHEET
3.2 OIL LEVEL IN UPTO THE USE LOG

CONSERVATOR PHYSICAL 100% MARKING ON SHEET
BUSHING , BREATHER GAUGE
HOUSING, OLTC
DIVERTER EACH
CHECK THAT THE
3.3 MARSHALLING BOXES USE LOG
ARE PROVIDED WITH PHYSICAL 100 % PROPER SHEET
GASKET AND BOXES CLOSING
ARE MADE DUST
PROOF
3.4
CHECK THE
CORRECTNESS OF
THE WIRING FOR PHYSICAL 100% WIRING USE
CONNECTION TO OTI DRAWING LOGSHEET
COOLERS, FANS
CORRECTNESS OF
3.5 WTI, OTI, MOG, OPERATIO 100% LOG SHEET
BUCHHOLZ RELAY, NAL
COOLER CONTROL
CONTACTS
3.6 OIL SAMPLE FROM

TRANSFORMER OPERATIO BEFORE AS PER OIL TEST
BEFORE ENERGISING NAL ENERGISING INSTRUCTION SET FOR
SHOULD BE TESTED MANUAL BDV, PPM
FOR BDV AND KIT FOR
MOISTURE CONTENT MOISTURE
3.7 IR VALUES OPERATIO 100% TEST
NAL CERTIFICATE
USING VALUE FOR
MOTORISE GENERAL
D COMPARISON
2500VOLTS
MEGGAR
3.8 MAGNETISING OPERATIO 100% USE MILLI
CURRENT AT 400 NAL AMMETER
VOLTS FROM HV SIDE
3.9 CHECK THAT FOR OPERATIO 100% INSTRUCTION USE LOG

PURPOSE OF NAL MAUAL SHEET
VARIOUS CONTACTS
PROTECTION AND SHOULD
ALARM ARE CARRIED CLOSE
OUT AS PER
INSTRUCTION MANUAL
AND RECORDED IN
LOG SHEET
3.10 COMPLETE AS LISTED AS LISTED INSTRUCTION USE
COMMISSIONING MANUAL CHECKLIST
CHECKLIST
3.11 TRIAL OPERATION OPERATIO SATISFACTORY USE LOG
FOR 24 HOURS AND NAL 100% OPERATION SHEET
CHECK FOR ANY FOR 24 HOURS
ABNORMAL NOISE /
TEMPERATURE RISE
PART 14
TROUBLE SHOOTING
14 TROUBLE SHOOTING
14.1 MAINTENANCE AND REVISION
14.1.1 GENERAL
14.1.2 CHECK LIST - MAINTENANCE
14.1.3 TROUBLE SHOOTING
14.2 STORAGE
14.2.1 TRANSFORMER DISASSEMBLED TRANSFORMER WITH LOWERED OIL LEVEL

TRANSFORMER WITH DRY-GAS FILLING
14.2.2 TRANSFORMER READY FOR OPERATING
14.2.3 ACCESSORIES
14.2.4CHECKING LIST STORAGE
14 TROUBLE SHOOTING
14.1 MAINTENANCE AND REVISION
14.1.1 GENERAL
ABB transformers are designed to reduce maintenance to a minimum.
In order to ensure trouble-free operation, maintenance works must be

carried out in regular intervals. Checking list "Maintenance" shows the
recommended time intervals for maintenance.
Detailed instructions concerning maintenance works of various accessories

can be found in the catalogues of the respective manufacturers, which are
included in this manual. ( PART 4)
CHECKING LIST – MAINTENANCE
SUBJECT CHECK TIME PERIOD REMARKS
YEAR MONTH
S
Insulating oil Dielectric strength 3
Moisture content 3
Neutralisation value 3
Interfacial surface tension 3
Water content 3
Sludge content 3
Gas analysis 3
Tank 2
Conservator 2
Cooling equipment 2
Piping 2
Bushings 2
Oil tightness Cable sealing ends 2 if applicable
Cable boxes 2 if applicable
Buchholz relay 2
Gate valves 2
Valves 2
Tank 1
Conservator 1
Bushings 1
Oil level Cable sealing ends 1 if applicable
Cable boxes 1 if applicable
Thermometer pockets 1
Tank 6 Release vent screws
Cooling equipment 6 until oil emerges.
Venting devices Intermediate piping 6 Afterwards
Bushings 6 screw plugs tight
Piping 6
Buchholz relay 6 if applicable
cable sealing ends 1
All metal parts 6
Tank 6
Motors 6
Earthing devices Star points 6 if applicable
Surge arresters 6 if applicable
Control cabinet 6
Steel armoured cabling 6
Shut-off devices In position "service" as see plan "Position of
required shut-off devices"
(if provided)
Buchholz relay Direction of oil flow 1
Float Contacts 1
1
gas sampling device 1 if applicable
Functional test 1
14.1.2 CHECKING LIST MAINTENANCE CONTD…
SUBJECT CHECK TIME PERIOD REMARKS
year months
Contact setting 1 Setting see Technical

Dial-type Position of maximum pointer 1 data
Thermometers Functional test 1
Polarity 3
transformers Ratio 3
Short-circuit connection 3
Oil level Contact setting 1
indicators Float 1
Functional test 1
Silicagel 1
Breathers Oil level 1
Venting pipes 1
Insulation resistance 3 With 1000 V Megger
Internal wiring Correct wiring connections 3 Tester,
Corrosion Paint 1 Touch-up
Protection Blank steel parts 1 Grease
Bushings 1
Fittings 1
Cleanliness Indicating devices 1 Remove loose parts,
Tank cover 1 if applicable
Fans
Terminal box Connections 1
On-load tap [as per EASUN-MR See instructions of the
Changer CATALOGUES] manufacturer
Protective relay
for OLTC See instructions of
manufacturer
Thermostat Functional test 1 NOT PROVIDED
Resistance Functional test 1
thermometer
Pressure relief Functional test 1 SEE
device MANUFACTURERS
CATALOGUE
14.1.3 TROUBLE SHOOTING CONTINUED
Protective& FAULT Possible cause Remedial measure Detailed
supervisory description
instruments,
components
Buchholz relay Buchholz Oil loss Maintain the shutdown status.
relay Violent oil surge Carry out tests and measurements
tripping due to inside as described above.
flashover. Vent the transformer and put it
Violent gas back into operation when faults
generation due to cannot be found or faults have
inside failure. been eliminated
Violent vibration
Fault tripping
Protective Tripping EASUN-MR Maintain the shutdown status.
device for due to CATALOGUE Check the tripping mechanism. Operating
OLTC strong oil Remove and check the diverter Instructions
surge switch.Reset the tripping of
mechanism and put the OLTC
transformer into operation
Resistance Oil Transformer Reduce load of the transformer Operating.
thermo meter temperat-- overloaded or Put fans or cooling equipment in instructions
ure too inadequate service of thermo-
high cooling. Clean the cooling equipment meter manu-
Thermostat Incorrect Check the position of butterfly facturer
---------------- ----------- temperature valves
Dial type Winding adjustment Adjust incorrect temperature
thermometer or oil setting. Check the thermometer by
for oil or temp. too comparative measurements
winding temp. high Check the electrical connections
and the tripping mechanism
Check control devices for cooling
equipment
Check current transformers and
thermometers
14.1.3 TROUBLE SHOOTING (CONTINUED)
Protective and FAULT Possible cause Remedial measure Detailed

supervisory description
instruments
Various
components
Oil level Oil level too Not enough oil Check for tightness Operating
indicator low (low Top-up oil instructions
temperature or of
oil loss) manufacturer.
Oil flow monitor No Gate valve Top-up cooling water to the Operating
Oil closed , pipe required level instructions.
flow clogged,, pipe Check the electrical
leaky,oil connections
circulation pump
faulted(no
voltage or
voltage too low,
defective
winding,incorrec
t direction of
rotation, bearing
damage)
Pressure relief Internal Conservator Check the pipes and shut-off
device tank pipe shut-off or devices Operating
pressure clogged. Check the transformer as instructions.
too high Electric described in "Buchholz relay
flashover inside Above.
the tank
14.1.3 TROUBLE SHOOTING( CONTINUED)
Protective & Fault Possible cause Remedial measure

supervisory
instruments,
components
Motor drive for Drive cannot be No voltage supply at motor- Check supply feeders.
OLTC operated electrically protective switch See operating instructions of
Motor protective switch not in OLTC
operating position. Close motor protective switch
Open circuit on one or more Correct it.
motor phases
Drive keeps on Brake contactor stuck Clean or replace
running
Motor protective Emergency stop button is on Repair or replace emergency
switch trips during or stuck. stop button
operation of motor Motor current excessive due Check drive for stiffness with
drive to overload or phase failure crank handle. Request a
factory engineer, if a
mechanical fault in the tap-
changer is suspected
Off-circuit tap Operation not possible Adjusting device defective Repair adjusting device;
changer Gas in Buchholz relay operate multiple the tap
Carbon formation on contacts changer once a year over all
positions (extraction
points).Check the transformer
as described for the Buchholz
relay
Dehydrating The drying crystals High atmospheric humidity, Replace dehydrating agent.
breather turn from blue to pink glass cylinder leaky. Replace glass cylinder or seal
and then to white Moisture in conservator, pipe properly.
from below leaky, glass cylinder seal pipe leaks, check the oil
from the top leaky.Moisture in conservator, for
in general pipe leaky, glass cylinder moisture content.
leaky. Flush the conservator with
Glass cylinder burst, dry air
maintenance interval
14.1.3 TROUBLE SHOOTING (CONTINUED)
Protective and Fault Possible cause Remedial measure
supervisory
instruments
Various
components
Electrical Breakdown voltage too low. Breather inoperable or Put breather into operation.
breakdown voltage Water content too high transformer in service Seal or repair coolers.
of the oil very low. Contact manufacturer; dry
Leaks in water cooling the oil, if necessary
system.
Water pressure reducer
inoperable.
Protective spark Frequent operation Electrical arcing distance Adjust the clearance
gap on bushings no longer correct between the arcing horns
and screw them tight
Terminal lugs on Discoloration of connecting Poor contact making Clear the contact faces.
bushing control parts Tighten the screws
Control cabinet Electrical apparatus does Excessive humidity in Set the cabinet heater to a
not operate control cabinet. higher temperature
properly.Contacts corroded Water or dust inside the Seal the cabinet door, fit a
contaminated.Appa cabinet. dust filter if
-ratus housing bent Excessive high necessary.Protect the
temperature in the cabinet against solar
cabinet irradiation; provide for
better ventilation
Earthing Earthing line interrupted Excessive currents due Clean the contacts, tighten
connection to external flashovers. the screws and check the
Impermissible current electrical distances. Open
loops through multiple up current loops. Only one
earthing. earthing with a sufficient
cross section
14.1.3 TROUBLE SHOOTING( CONTINUED)
Protective and Fault Possible cause Remedial measure

supervisory
instruments
Various comp .
Presssure gauge Oil pressure in HV- Incorrect contact adjustment. Correct the contact adjustment
for HV-bushing bushing too high Bushing overloaded, oil
temperature too high due to Check the reading.
solar irradiation Check the bushing; reduce the
transformer load, increase the
cooling effect
Pressure monitor Oil pressure of the Incorrect contact adjustment Correct the contact adjustment
for HV-bushing HV-bushing too high Bushing overloaded, oil
temperature too high due to Check the pressure monitor and
solar irradiation. reset the auxiliary switch.
Violent vibration on
transformer Check the bushings; reduce the
transformer load; increase the
cooling
Air flow No air flow or Protective screen iced up or Clean protective screen, open the
monitoring reduced air flow clogged. frost flaps
Cooler clogged or very dirty. Clean coolers
Fan motor faulty (winding
defective or overheated,
bearing damage).Incorrect Check the supply leads
direction of rotation
Repair fans
Oil sightpot Traces of oil on the Leakages in the oil circuit or Seal and repair coolers
water surface the water cooling system
PART 15
STORAGE
15. STORAGE
15.1 TRANSFORMER DISASSEMBLED : WITH LOWERED

OIL LEVEL
15.2 TRANSFORMER WITH DRY-GAS FILLING
15.3 TRANSFORMER READY FOR OPERATION
ACCESSORIES
15.5 CHECK LIST FOR STORAGE
15 STORAGE
15.1 TRANSFORMER DISASSEMBLED : WITH LOWERED OIL LEVEL
A transformer with lowered oil level (i.e. the entire insulation of the core and coil assembly has to be
completely covered with oil) must be provided with a dehydrating breather during storage, in order to
avoid the ingress of humid air in the transformer tank.
In case heating elements are installed in the motor drive cabinet, and control cabinet, they must be
connected to a power supply system to prevent the formation of condensation water. The heating
elements shall be checked at regular intervals.
The silica-gel content of the dehydrating breathers is to be checked every 2 weeks. When more than 2/3
of the blue silica-gel filling have turned light, the filling has to be exchanged. However, it can be reused
after having been dried at 120 °C (24 hrs.). At the same time the tank has to be examined for oil traces.
Should any leakage be detected, they have to be sealed immediately. Before commissioning and after a
long storage the oil is to be checked for moisture content. Motor drive cabinet and control cabinet have be
checked for Condensation of water
15.2 TRANSFORMER WITH DRY-GAS FILLING
In case it is not possible to store the transformer completely mounted or with oil filling, the transformer is
to be filled with dry gas in order to prevent the ingress of moisture during storage.
After the transformer has been filled with dry gas/ air, one or several gas cylinder attached to the tank has
to be connected. In order to provide a constant positive pressure in the transformer tank, the gas cylinders
are connected via pressure-reducing and pressure relief valve (see also chapter on transport( PART 5) in
this instruction manual). The valves have been adjusted to maintain a positive pressure in the tank ie
approx. 0.25 bar. The pressure is to be checked every two weeks.
Caution: The pressure must not fall below 0.05 bar.
In case of leakages in the transformer tank have been detected or in the case of high pressure loss in the
gas cylinders, the leakage has to be sealed.
If there are heating elements provided in the motor drive cabinet and control cabinets, they have to be
connected to a power supply system, in order to avoid the formation of condensation water.
The storage with dry-gas filling should be not be longer than 6 months. If the storage exceeds 6 months,
the ABB must be contacted.
15.3 TRANSFORMER READY FOR OPERATION
This type of storage is to be preferred over all other alternatives. After arriving at the place of installation
the transformer should be assembled completely and filled with oil. The heating elements installed in the
motor drive cabinet and control cabinet have to be connected to a power supply system, in order to
prevent the formation of condensation water. The heating elements have to be checked at regular
intervals.
The condition of the silica-gel content in the dehydrating breathers has to be checked every 2 weeks.
Should more than 2/3 of the blue silica-gel filling have turned light, the filling must be exchanged.
However, it can be reused after drying at 120 °C (24 hrs.). At the same time it is necessary to check the oil
level in the conservator, and to examine the tank for oil traces. Should any leakage be detected, they have
to be taken care of immediately. Before commissioning and after long storage the oil is to be checked for
humidity.
15.4 ACCESSORIES
The accessories shall be stored in compliance with the printed-on storage instructions and the hints given
in the brochures for the individual accessory parts. In principle the accessories should be stored in their
respective transport packing in dry rooms. Possibly, dessicant bags have to be enclosed in the crates.
All accessories shall be protected against damages.
15.5 CHECK LIST FOR STORAGE
Time periods
SUBJECT CHECK YEAR MONTH REMARKS
Insulating oil Dielectric strength 1
Moisture content
Oil level Conservator 1
Oil tightness Tank 1
Conservator 1
Piping 1
Buchholz relay 1
Bushings 1
Earthing Tank 6
Fans Test run 3 1 hour
Control Heating 1
cabinet
Oil circulation Trial run 3 1 hour
pumps
Silica gel Silicagel 1
breathers
Cleanness Cooler 1
Bushings 1
Tank 1
Corrosion Final coat 1 Touch up
protection
Bushings During storage or at time 1 Before the
of handling the bushing bushing is
can be placed: assembled on
- either in horizontal the tank, the
position whole surface
- on inclined, but with the should be
head at the highest point dried and
cleaned
Please take care that the thoroughly.
oil level indicator always Observe
directs to the bottom. A standing times
respective label is fixed on
every bushing or shipping
crate.

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PART 5

DISMANTLING AND TRANSPORT

5.1 RESPONSIBILITIES AFTER TRANSFORMER TEST AND PREPARATION FOR SHIPMENT -

5.1.2 SHIPPING INFORMATION

5.1.2.1 PACKING LIST

Who Uses a Packing List?

5.1.2.2 SHIPPING BRACES AND COVERS

5.1.3.2IMPACT RECORDER (If applicable)

Plan view of a Transformer placed on a Rail Car or Truck

5.1.3.3 OTHER DATA

5.1.4.0SUCCESSFUL SHIPMENT VERIFICATION

5.1.4.2IMPACT RECORDER (If Applicable)

Is all blocking tight and in good condition.

Is there any evidence of load shifting in transit.

Is the paint finish damaged.

Is oil level in bushings normal.

Do crates or boxes show evidence of damage or moisture entrance.

If there is no evidence of shipping damage, proceed to off-load the transformer. If shipping

5.1.4.3.2 INTERNAL INSPECTION

5.1.5.0 ARRIVAL AT CUSTOMER’S MOUNTING PAD

5.1.6.0 RE-ASSEMBLY INSTRUCTIONS

5.1.6.1OIL HANDLING AND FILLING

5.1.7.0 COMMISSION TESTS

APPENDIX :A5. 1 Impact Recorder Receive and Return Instructions.

-5g C/L +5g -5g C/L +5g -10g C/L +10g

Removing Recorder From Transformer

5.2 METHODS OF TRANSPORTATION

The following points should always be observed during transport:

5.2.1 A maximum inclination of 30 degrees

A maximum acceleration which equals a shunting impact of approximately (7 miles/ 11.25

5.3 TRANSPORT MODES

5.4 HANDLING DURING LOADING, AND ON SITE

Caution! Transformers must only be transported in an upright position.

5.4.2 SUSPENDING TRANSFORMERS

The transformer must be suspended from

FIGURE 5.2: ROPE LENGTH FOR TRANSFORMER SUSPENSION

5.4.3 MOVING TRANSFORMERS

Transformers are moved or relocated on moving devices or on skids.

5.4.4 TRANSPORT OF ACCESSORIES

5.4.5 TRANSPORTATION EQUIPMENT AND TOOLS

5.5 SHIPPING ARRANGEMENTS

a) After dismantling the sub-assemblies like Bushing assembly, conservator assembly,

5.5.2 SHIPPING BRACES

5.5.4 CURRENT TRANSFORMERS

Current transformers must be short-circuited and earthed (grounded) for Shipping.

5.5.5 SHUT-OFF DEVICES

5.6 PACKING LIST AND TRANSPORT MANUAL

5.6.3. ASSEMBLY PACKAGES

5.6.4. TRANSPORT MONITORING

- The final checkpoint is, when the shipment is received on site.

MONITORING OF DRY-GAS FILLING OF

TRANSFORMERS DURING SHIPMENT

6.0 MONITORING OF DRY-GAS FILLING OF TRANSFORMERS DURING SHIPMENT AND

6.1 PRESSURE GAUGE AND FILLING COCK

6.2 PRESSURE LIMITS + FIGURE F 6.1

6.3 MONITORING UNDER STORAGE

6.4 INSPECTION AND REPORTING

6.5 LONG-TIME STORAGE. CHANGE OF GAS CYLINDERS

6.1 PRESSURE GAUGE AND FILLING COCK

6.2 PRESSURE LIMITS

EXAMPLE: CORRECT PRESSURE AT DIFFERENT AMBIENT TEMPERATURES

6.4 INSPECTION AND REPORTING

6.5 LONG-TIME STORAGE. CHANGE OF GAS CYLINDERS.