Pawels Trans A

Manual Installation, Operation and
Part A Maintenance Instructions
Pauwels Power Transformers
PAUWELS TRAFO http://www.pauwels.com/

Antwerpsesteenweg 167 Tel: ++ 32 / (0) 15 / 283 333
B-2800 Mechelen Fax: ++ 32 / (0) 15 / 283 300
Installation, Operation and Maintenance Instructions 4001158/ dmyra. – Mechelen, (7/10/2009 10:21)
Installation, Operation and Maintenance Instructions
Serial Number: 4001158
Transformer: 95 MVA
Year of manufacture: 2009
Manufacturer: PTB
Manufacturer serial number: 4001158
Customer: SEC WOA
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Serial number: 4001158
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General Index
1 General information ...................................................................................................................15

1.1 General information ...........................................................................................................17
1.1.1..IOM-manual structure ..............................................................................................17
1.1.2..Safety instructions and notes ..................................................................................17
1.1.3..Use of most important drawings ..............................................................................17
1.1.4..General figures used in the text...............................................................................18
1.1.5..Use of checklists and forms.....................................................................................18
1.1.6..Special instructions..................................................................................................18
1.1.7..For more information ...............................................................................................18
1.2 Safety practice for transformers and related electrical equipment ....................................19
1.2.1..Basic safety practice................................................................................................19
1.2.2..Transformer specific safety practice........................................................................19
1.2.3..Voltage hazards and temporary grounding (earthing) systems for transformers ....20
1.3 Material Safety Data Sheets(MSDS) .................................................................................22
1.4 Warranty period and conditions .........................................................................................22
1.4.1..Actions to be taken at installation and commissioning ............................................23
1.4.2..Actions to be taken in case of severe abnormal conditions ....................................23
1.5 Insurance ...........................................................................................................................23
1.5.1..Transfer of risks .......................................................................................................23
1.5.2..Transportation damage............................................................................................23
1.5.3..Informing Pauwels ...................................................................................................24
1.6 Tables ................................................................................................................................24
1.6.1..Correction factors for megger and power factor tests .............................................24
1.6.2..Torque values for bolt-nut connection .....................................................................24
1.6.3..Torque values for SEFCOR connectors ..................................................................25
1.7 Conversion tables ..............................................................................................................26
2 General transformer description ..............................................................................................33
2.1 General electrical and mechanical data.............................................................................35
2.1.1..Nameplate: ..............................................................................................................35
2.1.2..General Arrangement Drawing................................................................................35
2.1.3..Schematic Control and Schematic Motor drive unit ................................................35
2.1.4..Test Reports ............................................................................................................35
2.1.5..Overload capability ..................................................................................................35
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2.2 Information on mechanical transformer parts.................................................................... 35

2.3 Tank design ....................................................................................................................... 36
2.3.1 . General tank design ................................................................................................ 36
2.3.2 . Tank handling.......................................................................................................... 36
2.3.3 . Protective measures in tank design ........................................................................ 36
2.3.4 . Tank accessories .................................................................................................... 36
2.4 Non-membrane conservator design .................................................................................. 37
2.5 Transformer grounding (earthing) and equipotential bonding........................................... 37
2.5.1 . Introduction ............................................................................................................. 37
2.5.2 . Parts to be grounded (earthed)............................................................................... 37
2.6 Transformer Painting......................................................................................................... 39
2.6.1 . Painting system....................................................................................................... 39
3 Packing, Transport, Receiving, Storage.................................................................................. 41
3.1 Packing.............................................................................................................................. 43
3.1.1 . General.................................................................................................................... 43
3.1.2 . Transformer body.................................................................................................... 43
3.1.3 . Condenser bushings ............................................................................................... 43
3.1.4 . Hygroscopic electrical parts .................................................................................... 43
3.1.5 . Radiators ................................................................................................................. 43
3.1.6 . Conservator, pipes and cable boxes....................................................................... 44
3.1.7 . Control cabinets ...................................................................................................... 44
3.2 Transport and handling ..................................................................................................... 44
3.2.1 . General transport and handling notes..................................................................... 44
3.2.2 . Handling instructions during loading and unloading ............................................... 45
3.2.3 . Blocking and securing ............................................................................................. 46
3.2.4 . Shipping documents................................................................................................ 46
3.3 Receiving........................................................................................................................... 46
3.3.1 . Inspection of damage.............................................................................................. 46
3.3.2 . Transformer inspection procedure .......................................................................... 47
3.4 Impact recorder ShockLog RD298 .................................................................................... 49
3.5 Performing internal inspections ......................................................................................... 49
3.5.1 . Reasons to perform an internal inspection ............................................................. 49
3.5.2 . Planning the inspection ........................................................................................... 50
3.5.3 . Procedure of an internal inspection ........................................................................ 50
3.6 Dew point measurement ................................................................................................... 50
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3.7 Storage...............................................................................................................................51
3.7.1..Storage of the transformer.......................................................................................52
3.7.2..Storage of accessories ............................................................................................52
3.7.3..End of storage .........................................................................................................54
4 Assembling and installation .....................................................................................................55
4.1 Locating a transformer .......................................................................................................57
4.1.1..Preparation to move a transformer..........................................................................57
4.1.2..Positioning a transformer on its final destination.....................................................58
4.2 General installation topics..................................................................................................60
4.2.1..Planning of the installation.......................................................................................60
4.2.2..Recommended assembling and energization sequence.........................................60
4.2.3..Collecting and preparing the required equipment ...................................................61
4.3 Installation of the transformer body ...................................................................................62
4.3.1..Grounding the tank ..................................................................................................62
4.3.2..Preparation of the transformer before assembling accessories..............................62
4.4 Installation of accessories..................................................................................................62
4.4.1..Unpacking accessories............................................................................................63
4.4.2..Preparing accessories .............................................................................................63
4.4.3..Equipment safety during installation........................................................................63
4.4.4..General assembling instructions for accessories ....................................................63
4.5 Installation of Conservator and Pipes ................................................................................66
4.6 Installation of radiators.......................................................................................................68
4.6.1..Mounting instructions...............................................................................................68
4.6.2..Different types of gaskets used ...............................................................................69
4.6.3..Filling radiators for (partially) oil-filled transformers.................................................69
4.6.4..Draining oil from a radiator ......................................................................................69
4.6.5..Disassembling a radiator from a filled transformer..................................................70
4.7 Installation of CTs ..............................................................................................................71
4.7.1..Current transformers for bottom–connected bushings (phase / neutral)................71
4.7.2..Current transformers for draw lead bushings (phase / neutral)..............................71
4.8 Wiring on the transformer ..................................................................................................71
4.8.1..Mounting instructions...............................................................................................72
4.9 Oil quality requirements .....................................................................................................72
4.9.1..New transformer oil..................................................................................................72
4.9.2..Oil treatment (degassing, streamlining)...................................................................73
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4.9.3 . New treated transformer oil in new equipment ....................................................... 73

4.9.4 . Transformer oil for transformers in service ............................................................. 73
4.10 .. Pulling vacuum .................................................................................................................. 73
4.10.1Before pulling vacuum............................................................................................. 74
4.10.2Establishing connections......................................................................................... 74
4.10.3Pulling vacuum........................................................................................................ 75
4.10.4Troubleshooting ...................................................................................................... 75
4.11 .. Oil filling standard.............................................................................................................. 75
4.11.1Oil filling................................................................................................................... 75
4.11.2Filling procedure in the event of process interruption ............................................. 77
4.12 .. Topping up oil after initial vacuum filling ........................................................................... 77
4.13 .. Air venting.......................................................................................................................... 78
4.14 .. Pre-operational tests ......................................................................................................... 78
4.14.1Mechanical tests and checks .................................................................................. 79
4.14.2Oil sampling and testing.......................................................................................... 79
4.14.3Electrical tests ......................................................................................................... 79
4.15 .. Pre-operational tests and checks of accessories.............................................................. 79
4.16 .. Oil sampling and testing .................................................................................................... 81
4.16.1Sampling ................................................................................................................. 81
4.16.2Required oil quality tests ......................................................................................... 81
4.16.3Oil quality requirement ............................................................................................ 81
4.17 .. Megger test (Required) ..................................................................................................... 81
4.17.1Winding insulation megger test............................................................................... 81
4.17.2Core grounding megger test ................................................................................... 82
4.17.3Accessories insulation megger test ........................................................................ 83
4.18 .. Voltage ratio test (Required) ............................................................................................. 83
4.18.1Ratio meter method................................................................................................. 83
4.18.2Voltage ratio test for turns ratio............................................................................... 83
4.19 .. Vector group test (Optional) .............................................................................................. 83
4.20 .. Insulation power factor test or TAN δ (Special)................................................................. 84
4.21 .. Bushing power factor test (Special test)............................................................................ 85
4.22 .. Winding resistance test (Special test) ............................................................................... 85
4.23 .. Continuity impedance check (Special test) ....................................................................... 86
4.24 .. Removal of surface moisture............................................................................................. 87
4.24.1Removal of surface moisture by vacuum................................................................ 87
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4.24.2Removal of surface moisture by dry air recycling....................................................87

5 Commissioning ..........................................................................................................................89
5.1 Repeating pre-operational tests.........................................................................................91
5.1.1..Energization follows within 4 weeks after installation and testing ...........................91
5.1.2..Energization follows 4 weeks to 6 months after installation and testing .................91
5.1.3..Energization follows later than 6 months after installation and testing....................91
5.2 Operational system tests ...................................................................................................91
5.2.1..Alarm circuits and contacts......................................................................................91
5.2.2..Trip circuits and contacts .........................................................................................92
5.2.3..Remote control ........................................................................................................92
5.2.4..Temperature settings...............................................................................................92
5.2.5..Verification of overpressure relief devices...............................................................92
5.2.6..Voltage relation check .............................................................................................92
5.3 Energization .......................................................................................................................92
5.3.1..Minimum oil stabilising period after final oil filling....................................................93
5.3.2..First energizing at no load conditions. .....................................................................93
5.3.3..Loading the transformer...........................................................................................94
6 Maintenance................................................................................................................................95
6.1 Transformer maintenance..................................................................................................97
6.1.1..Safety during maintenance......................................................................................97
6.1.2..General maintenance guidelines .............................................................................97
6.1.3..External cleaning .....................................................................................................97
6.2 Periodic Inspection of transformers in service ...................................................................98
6.2.1..Oil levels and silica gel ............................................................................................98
6.2.2..Oil quality .................................................................................................................98
6.2.3..Venting.....................................................................................................................98
6.2.4..External circuits and control equipment...................................................................98
6.2.5..(On) Load tap changer – (O)LTC ............................................................................98
6.2.6..De-energized tap changer – DTC............................................................................98
6.2.7..Cooling system ........................................................................................................99
6.2.8..Fans .........................................................................................................................99
6.2.9..Temperature ............................................................................................................99
6.2.10Inspection of tank, cover, gaskets and valves ...................................................... 100
6.2.11Periodic electrical testing ...................................................................................... 100
6.3 Periodic inspection of transformers in storage................................................................ 100
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6.4 Maintenance inspection chart.......................................................................................... 101

6.4.1 . Frequency indications ........................................................................................... 101
6.4.2 . Maintenance activity to perform ............................................................................ 101
6.5 Troubleshooting............................................................................................................... 104
6.5.1 . Electrical malfunction ............................................................................................ 104
6.5.2 . Mechanical malfunction or malfunction of accessories......................................... 105
6.6 Oil quality......................................................................................................................... 106
6.7 Oil sampling..................................................................................................................... 106
6.7.1 . Taking samples for general oil testing purposes .................................................. 106
6.7.2 . Taking samples for DGA tests .............................................................................. 107
6.8 Dielectrical strength......................................................................................................... 107
6.9 Moisture content .............................................................................................................. 108
6.10 .. Particles in oil .................................................................................................................. 108
6.11 .. Dissolved Gas Analysis on transformer oils from the main tank of a transformer .......... 109
6.12 .. Frequency of analysis ..................................................................................................... 109
6.13 .. Evaluation........................................................................................................................ 109
6.13.1Actions................................................................................................................... 111
6.14 .. Replacement of defective parts....................................................................................... 112
6.14.1Ordering replacement or spare parts .................................................................... 112
7 Forms, checklists .................................................................................................................... 113
Receiving inspection report ....................................................................................................... 115
Energization Report ................................................................................................................... 117
Parts ordering form (1) ................................................................................................................ 119
Site commissioning report ......................................................................................................... 121
8 Special instructions................................................................................................................. 137
8.1 Special instructions ......................................................................................................... 139
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Index of tables
Table 1 Minimum recommended (temporary) grounding cable size for copper cable .................. 22
Table 2 Temperature correction factors for megger (K1) and power factor or tan δ tests (K2)........ 24
Table 3 Max. spanner values for bolt – nut connections ............................................................... 24
Table 4 Recommended torque values for SEFCOR connectors................................................... 25
Table 5 International System of units (SI) (Metric practice)........................................................... 26
Table 6 Multiplication factors ......................................................................................................... 26
Table 7 United States System ....................................................................................................... 27
Table 8 SI conversion factors ........................................................................................................ 29
Table 9 Conversion table for pressure and stress ......................................................................... 30
Table 10 Dew point measurement ................................................................................................... 51
Table 11 Minimum number of rods required per set under the transformer .................................... 59
Table 12 Required vacuum pump capacities................................................................................... 61
Table 13 Oil treatment...................................................................................................................... 73
Table 14 Required vacuum for flashing surface moisture ............................................................... 87
Table 15 Vacuum hold times for flashing surface moisture ............................................................. 87
Table 16 Maintenance inspection chart ......................................................................................... 103
Table 17 Electrical malfunction troubleshooting chart ................................................................... 104
Table 18 Mechanical malfunction troubleshooting chart................................................................ 105
Table 19 Water in oil ...................................................................................................................... 108
Table 20 Particles in oil .................................................................................................................. 108
Table 21 Limits for normal values for Pauwels Transformers........................................................ 109
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Table of figures
Figure 1 Example of SEFCOR connector ....................................................................................... 25

Figure 2 Parts to be grounded (earthed)......................................................................................... 38
Figure 3 Outside oil drum storage (method 1) ................................................................................ 53
Figure 4 Outside oil drum storage (method 2) ................................................................................ 53
Figure 5 Sequence of tightening bolt – nut connections (1 -> 2 -> 3 -> 4 -> …)............................. 64
Figure 6 Different types of gaskets ................................................................................................. 65
Figure 7 Gasket joint ....................................................................................................................... 66
Figure 8 Conservator and pipes assembly...................................................................................... 67
Figure 9 Example of radiator No. 92 ............................................................................................... 68
Figure 10 Drain plug No. 95 .............................................................................................................. 70
Figure 11 Vent plug No. 94 ............................................................................................................... 70
Figure 12 Throttle valve No. 93 open................................................................................................ 70
Figure 13 Throttle valve No. 93 closed ............................................................................................. 71
Figure 14 Equalizing pipe connections ............................................................................................. 74
Figure 15 Transformer filling (without conservator) .......................................................................... 76
Figure 16 Transformer filling with conservator .................................................................................. 77
Figure 17 Core grounding assembly ................................................................................................. 83
Figure 18 Vector group test............................................................................................................... 84
Figure 19 Bushing testtap ................................................................................................................. 85
Figure 20 Capacitive bushing representation ................................................................................... 85
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1 General information
15
16
1.1 General information 1.1.2 Safety instructions and notes

This transformer Installation, Operation and All personnel involved in installation,
Maintenance manual (IOM-manual) is your guide to commissioning, operation, maintenance or repair of
installing and energizing the Pauwels the equipment must:
transformer(s). This IOM-manual contains important
information for the safe and reliable use of the • be suitably qualified and
transformer(s). • strictly observe these IOM Instructions
Please read this IOM-manual completely before

starting installation and commissioning. Improper operation or misuse can lead to:
• a reduction in the efficiency of the equipment
• damage to the equipment and property of the
NOTE user
Pauwels cannot be held responsible for any • serious or fatal injury
damage due to improper handling, installation,
use or maintenance of the equipment. If you Safety instructions in this manual are presented in
have any doubts about how to proceed, we three different forms to emphasize important
advise you to contact your Pauwels contact information.
person or the nearest Pauwels representative
directly.
Should you feel unconfident about installing
and/or energizing the transformer completely on DANGER
your own, feel free to contact us. We will be at This kind of information indicates particular
your service to provide more information on danger to life and health. Disregarding such a
complete installation and commissioning warning can lead to serious or fatal injury.
programs or on supervising programs.
CAUTION
This kind of information indicates particular
1.1.1 IOM-manual structure danger to the equipment or other property of
the user. Serious or fatal injury cannot be
This IOM-manual has a logical structure following excluded.
the sequence of activities from transportation over
commissioning to maintenance. A main index listing
the available chapters is included in the beginning NOTE
of the manual. Notes provide important information on a
certain subject.
The IOM-manual consists of 3 parts:
• Part A: Installation, Operation and
Maintenance Instructions
• Part B: Documentation of Transformer
Accessories 1.1.3 Use of most important drawings
• Part C: Transformer Drawings
The text will often refer to specific drawings [part C].
In the Manufacturing Data Record Book (MDRB) – In many cases part numbers will be given. These
a separate binder – the test reports of the numbers refer to the General Arrangement Drawing
transformer and its accessories are included. and the Materials List, e.g.: Drain Plug No. 95.
The most important drawings are the following:
17
The General Arrangement Drawing: shows a side, 1.1.6 Special instructions

top and front view of the transformer. The
dimensions and weight of the fully assembled In case the transformer installation, operation or
transformer are given, as well as the weight of the maintenance requires special instructions, these
oil. All important components are identified by "item instructions are included in section [8]. The special
numbers" which relate to the Materials List. instructions are specifically written for the
The Materials List: can be printed on the General transformer.
Arrangement Drawing or on a separate document.
The Materials List gives the type and brand of most NOTE
accessories. Always consult the special instructions section
[8] to verify if special procedures have to be
Schematic Drawings (of Control & Protection followed during installation, operation or
Circuits and Motor Drive Unit): give information on maintenance.
the connection between the different protective
devices mounted on the transformer.
Name Plate (or Rating Plate): gives the main
electrical characteristics.
1.1.7 For more information
1.1.7.1 Your Pauwels contact person
1.1.4 General figures used in the text During production, transportation and installation
you have continuously been in contact with the
The text contains figures that sometimes indicate Pauwels Project Manager. He is the one who is
specific types of equipment and/or specific responsible for the complete execution of the order
dimensions. These figures are provided to explain until the end of the warranty period. In case of any
general principles and situations. Neither the type questions or problems, contact this person and he
nor the dimensions of these figures necessarily will help you as soon as possible. Normally, you will
apply to the purchased transformer. Only type and have his coordinates at hand.
dimensions on the drawings [part C] apply to the
purchased transformer.
PAUWELS INTERNATIONAL N.V.
This IOM-manual includes a list of figures after the
Antwerpsesteenweg 167
general index.
2800 MECHELEN
BELGIUM
Tel: ++ 32 / (0) 15 / 283 333 (8 am – 5 pm)

1.1.5 Use of checklists and forms Fax: ++ 32 / (0) 15 / 283 300
The text refers to several checklists and forms that

can be found in section [7]. Some of them have to
be completed and forwarded to your Pauwels 1.1.7.2 Pauwels Transformer Service
contact person as soon as possible.
Pauwels Transformer Service (PTS) is the Pauwels
For your convenience, we would advise you to service department. They can handle all operation
make additional copies of these checklists in order related topics such as:
to keep a complete IOM-manual for future use. The
most important checklist is the “Site commissioning • installation and commissioning
report”. This report must be completed and returned • site testing and inspection
before energization of the transformer. • maintenance and repair works
• ordering of repair, spare or additional parts
• supervision on above activities
18
Ensure that all electrical circuits to be worked on

have been traced and de-energized. Ensure that all
During the complete warranty period PTS receives
safety grounds have been correctly applied to
its instructions from the Pauwels Project Manager
protect personnel against the accidental application
for all warranty related topics. However, in very
of power to these circuits (refer to chapter 2 for
urgent cases you can always contact PTS for
more information on temporary grounding.) Do NOT
advice.
assume that someone else has turned off the
For problems or questions after the warranty period power, check for yourself.
has expired or for additional parts or materials (not
Use the padlock and key interlock system where
included in the scope of the order) you can contact
available to protect yourself and others.
PTS directly.
Do not work under equipment that is raised and
insecurely blocked. Do not walk under equipment
PAUWELS TRANSFORMER SERVICE that is suspended from a crane.
Rue Vital Françoisse 220
Do not walk holding a ladder or any other long
6000 CHARLEROI
object near a transformer or overhead lines under
BELGIUM
voltage.
Tel: ++32 / (0) 71 / 47 25 25 Before lifting any object by any means, ensure that
Fax: ++32 / (0) 71 / 47 01 89 its weight can be handled correctly. Use the
appropriate lifting or handling tools.
Do not work on or adjust moving equipment. Do not
work on or adjust mechanical equipment unless its
1.2 Safety practice for transformers motive source has been deactivated.
and related electrical equipment
1.2.1 Basic safety practice

Every employee must have a safety program and
1.2.2 Transformer specific safety
he has to know how to use it in the event of an practice
accident.
Do not walk on a transformer or its parts unless the
Ensure that safety equipment and tools are always unit has been de-energized.
close at hand.
Do not walk on a transformer under vacuum. Never
Keep suitable fire extinguishing equipment and perform any electrical tests on a transformer under
qualified personnel available. Make sure that the vacuum. Do not apply vacuum when it is raining or
equipment used is suitable for fire involving oil filled when the transformer is unsupervised.
electrical installations.. Make sure that it is correctly
charged and that you know how to use it. When pressure tests are being performed or when
vacuum is being applied, the pressure must be
Always be alert to emergencies. If an accident equalized between the main tank and the (On)
should occur, quickly utilize the safety equipment, Load Tap Changer compartment if these
emergency tools and equipment at hand. Before compartments are separated by terminal panels
you begin a project, ensure that at least two people which might not be able to withstand pressure
know first aid procedures and that they have the differences mechanically. Find out which parts will
proper first aid kits at hand. not be able to withstand a complete vacuum.
Ensure that all protective equipment required for Before removing any cover plate or transformer
the job is available to all workers and ensure that it fitting, ensure that the overpressure inside the
is used correctly. This equipment may include hard- transformer is zero and that the oil level is lower
hats, breathing apparatus, eye protection, gloves, than the opening in question.
foot protection, …
19
In the event of a sudden change in the weather circuits or devices, or overriding of the functions of
bringing penetrating rain or snow, provisions must these circuits or devices could allow minor
be made for closing the tank quickly and problems to develop into a major problems. This
pressurizing it with nitrogen in order to preserve the may result in a total loss of the transformer,
insulation. damage to other equipment and injury of personnel.
To allow anyone entering a transformer the air has A pressure relief device incorporates heavy spring
to support life with a sufficient oxygen level (19.5 in compression, DO NOT DISMANTLE such a
%). device, unless suitable safeguards have been
implemented, otherwise personnel injury may
Extreme precautions are to be taken to protect the
occur.
insulation of the transformer from any damage and
to prevent the ingress of foreign objects and Recommended commissioning checks must be
moisture during the checking and erection of the performed before the first energization of the
transformer. transformer.
Whilst the transformer is open, no one may be
allowed on top of it, unless this person has emptied
his/her pockets, has checked himself/herself for the
presence of objects such as watch, rings etc. and 1.2.3 Voltage hazards and temporary
has removed them. These precautions must be grounding (earthing) systems for
taken to prevent objects from falling into the
transformer. transformers
Anyone going inside a transformer must wear clean 1.2.3.1 Voltage hazards
clothes and clean synthetic-rubber boots.
Never stand directly on any part of the insulation. The turns ratio between the windings of any power
transformer makes them capable of transforming
Clean rags, sheets of paper, etc. are to be used what are normally considered harmless voltages
under the working surfaces in the transformer to into dangerous and even lethal levels.
prevent objects from falling into the windings.
Electrical welders, continuity checking instruments
All tools must be listed. For “safety first” reasons and insulation testing apparatus are examples of
they must be attached to the wrists or belt, so that sources of so-called harmless voltages. Even if
they cannot fall into the windings. these are direct current (DC) devices, they are
Smoking is not allowed on the transformer, nor is it capable of producing voltages high enough to be
allowed in the vicinity of an oil-processing plant. hazardous to human life, when the circuits they are
connected to are made or interrupted.
Lamps used for lighting the inside of the
transformer must be the shielded type with a Other situations which may present hazardous
maximum voltage of 36 V. Debris from a broken conditions include the high voltage produced by
lamp bulb may not be able to drop out. open circuited current transformers (including these
which are used for Winding-Temperature-
• If in spite of all preventive measures something Indicators, WTIs) which have current flowing in the
does fall into the transformer tank and cannot primary circuits and the electrical charge which may
be retrieved, do not proceed with the by retained by condenser style bushings after the
energization and do not perform any electrical transformer has been disconnected from the
tests that may cause damage to the external circuits. The open circuit voltage that is
transformer. Immediately contact Pauwels developed depends on the design of the CT, but is
instead. nearly always dangerously high. NEVER
disconnect a CT secondary while the primary circuit
is energized. CTs must be connected to a suitable
Correct operation of all protective circuits and
load or must be shorted by a link that is suitable for
protective devices for the transformer should be
carrying the rated secondary current.
checked on a regular basis. Neglection of these
20
Delta-connected windings that are not connected to It is important to ground ALL terminals of the
any external circuit may also retain a charge after transformer (not just HV circuit) to protect against
the transformer has been de-energized for a period back-feed from the low voltage or tertiary voltage
of time. circuits.
Only screw type grounding clamps may be used.
Clip-on clamps are not acceptable. Clamps must
DANGER always be securely tightened. Clamps and cable
For personnel and equipment safety reasons: size are to be selected in accordance with the short
ground the transformer tank as soon as circuit capability of the power system at the
possible, ground all bushings whenever transformer terminals and for the maximum
possible and connect CT secondary circuits to duration of time that the fault current will flow before
a suitable load or short-circuit them. the protection system de-energizes the circuit. If the
actual fault capacities are not known, National
Standards provide recommended levels that can be
used.
1.2.3.2 Preventive measures Grounding cables are to be securely lashed to

structural members or other fixed objects to prevent
When personnel is working on de-energized violent whipping of the cable due to electromagnetic
transformers, winding terminals should be suitably forces developed by the flow of the fault current
short-circuited and grounded according to the (violent whipping may loosen or disconnect the
correct safety practice in order to avoid injury or ground clamps). For similar reasons, no slack or
even death (see section below). loops in the grounding cables may be allowed.
Unused current transformers must always have If multiple grounding cables are used in parallel,
their secondary windings short-circuited with they must be twisted or lashed together to prevent
suitably sized wire to avoid high open circuit mechanical reaction between the cables during the
voltages. flow of fault current. The grounding clamps must be
installed touching each other to prevent them from
pulling together and from possible loosening during
a) Recommendations concerning temporary a fault.
grounding (earthing) systems Groundings are to be applied from each of the
transformer terminals to the station grounding bus.
Temporary groundings, used while personnel are Phase-to-phase jumpering after one phase has
working on de-energized transformers, must always been grounded is permissible. This short circuit
be applied in accordance with the approved safety limits the amount of fault current which circulates
and operation practices issued by the employer. In through the grounding cable back to the phases.
addition, they must be in accordance with the Jumpering is usually not suitable in HV switchyards
instructions for the specific grounding equipment due to the large inter-phase clearances.
used.
Temporary grounding is required for a number of b) Minimum grounding (earthing) cable sizes
reasons:
• Induced voltage from adjacent energized lines. The following minimum grounding cable sizes are
• Fault current feed-over from adjacent lines. recommended, in association with suitably sized
• Lightning strikes anywhere on the circuit. screw type grounding clamps:
• Switching equipment malfunction or human
error.
• Accident initiated contact with adjacent lines.
21
Min. cable size per • Accidental Release Measures

Max
Max fault phase • Handling and Storage
duration of
current • Exposure Controls/Persona Protection
fault current AWG mm2
• Physical and Chemical Properties
<22 kAmps 25 cycles 1x2/0 ~1x70 • Stability and Reactivity
22-34 kAmps 25 cycles 1x4/0 ~1x110 • Toxicological Information
34-60 kAmps 25 cycles 2x4/0 ~2x110 • Ecological Information
Table 1 Minimum recommended • Disposal Considerations
(temporary) grounding cable size • Transport Information
for copper cable • Regulatory Information
• Other Information
c) Establishing the grounding (earthing) system

NOTE
The information provided in the Material Safety
Data Sheets is correct to the best of our
DANGER knowledge at the date of its publication. The
Ensure that at least one person is present who information given is designed as a guidance for
is trained in the correct application of temporary safe handling, use, processing, storage,
grounding systems. transportation, disposal, and release and is not
to be considered as a warranty or quality
specification. The information relates only to
In order to physically attach temporary groundings the specific material in combination with any
in a correct manner, first ensure that the circuits are other materials or in any other process, unless
intentionally de-energized. Use an approved specified in the MSDS or in this IOM-manual.
voltage detector to assure yourself that the circuit is
dead. Next, clean oxides and contaminants from
the conductor to be grounded, whether it is cable or
busbar. When attaching the screw type ground
1.4 Warranty period and conditions
(earth) clamp, use the torque recommended in your
safety procedures or by the clamp manufacturer.
Although the equipment is under warranty for a
certain period, it is advisable to do whatever is
necessary to minimize the impact of abnormal
conditions.
1.3 Material Safety Data Sheets(MSDS) • Minor problems may cause serious defects in
certain cases.
Material Safety Data Sheets for the potentially • Never energize a transformer that is not fit for
hazardous materials and products are included in use.
the documentation [part B]. The information in the
• Always follow the instructions in this IOM-
MSDS refers only to new materials and products as
manual.
manufactured, before their use in/on a transformer
• In case of doubt, contact Pauwels
or electrical product.
The content of Material Safety Data Sheets may
The applicable warranty period and conditions are
include:
indicated in the contractual terms and conditions.
• Identification of the Substance/Preparation and
the Company/Undertaking
• Composition/Information of Ingredients
• Hazards identification
• First aid Measures
• Fire-fighting Measures
22
1.4.1 Actions to be taken at installation 1.5 Insurance

and commissioning
1.5.1 Transfer of risks
The warranty becomes operational on the condition
that following steps have been taken: The transfer of risks is closely related to the
delivery terms and conditions stipulated in the
1. Before energization: a complete (fax)copy of
contract or order. We refer to the contractual terms
the “Site commissioning report” has been sent
and conditions for more information about which
to your Pauwels contact person. Make sure
delivery term applies. For more information on
that all tests and inspections have been
delivery terms (FOB, CIF, DDU, …) and their
satisfactory before energization. Especially all
implications, we refer to the international literature
securing and protective accessories have to be
about this topic.
checked. When not all parameters are
according to the requirements, do not
energize. We will evaluate the report and
advise you how to proceed.
2. After energization: a complete (fax)copy of the 1.5.2 Transportation damage
“Energization report” has been received by
Pauwels latest one week after energization.
NOTE
Only upon receiving these 2 reports the contractual Under no conditions should a damaged
warranty conditions, concerning operational shipment or any part of that shipment be
defects, will be applied. unloaded until the damage claim has been
resolved with the carrier(s).
During operation it is recommended to record all
events (readings, inspections, tests, network
conditions, …) in a transformer log book. This log
book should be available at the time of an NOTE
intervention. In case of any doubt, file a hidden damage
claim. This allows for later filing of additional
claims if hidden damage is detected during
installation or commissioning.
1.4.2 Actions to be taken in case of
severe abnormal conditions Upon receiving a transformer and/or its accessories
with visual external or potential (hidden) internal
First of all, take all necessary preventive measures damage:
to minimize the risks of damage. If the transformer
has not yet been switched off by own securing 1. Check for visible damage before unloading
systems, make it manually! A quick response often 2. Check the impact recorder for high readings
prevents things from getting worse. Once personnel 3. When assessing the damages sustained by
are safe and equipment conditions are stabilized, packing and/or contents: describe your
contact your Pauwels contact person and provide findings in the transport document intended for
as much information on the event as possible. the carrier and be sure to keep a copy. If need
Never start neither any corrective measures nor re- be, write down a joint statement together with
energizing without the approval of Pauwels. the driver.
4. You may subsequently unload.
Further procedure or assessment of damages after

receipt:
23
a) If you received an insurance certificate and/or TºC 5 10 15 20 25 30

in case land carriage was preceded by MARIN K1 0.36 0.50 0.70 1.00 1.40 2.00
TRANSPORT K2 1.03 1.02 1.00 1.00 1.00 1.00
1. follow the instructions on the flip side of the
insurance certificate conscientiously
2. never sign any clean receipts but formulate TºC 35 40 45 50 55 60
your reserve in these documents. K1 2.80 4.00 5.60 7.85 11.20 16.00
3. always inform our ”insurance” department K2 1.01 1.02 1.065 1.10 1.17 1.27
b) If you did not receive an insurance certificate
and in case land carriage was not preceded by TºC 65 70 75 80
MARIN TRANSPORT
K1 22.00 32.00 45.00 62.00
1. hold the carrier immediately liable by
K2 1.46 1.56 1.75 2.00
registered letter
2. inform our transport and insurance Table 2 Temperature correction factors for
departments immediately megger (K1) and power factor or tan δ
3. always do what is necessary to limit the tests (K2).
present damages and prevent subsequent
damages.
c) In case of transport by rail: have the competent
authorities make a report at the arrival station. Megger test: Resistance at 20 0C = Resistance at
mean oil temperature * K1
Power factor (or tan δ) test: Power factor at 20 0C
= Power factor at mean oil temperature / K2
1.5.3 Informing Pauwels
Inform your Pauwels contact person as soon as
possible. We assume all goods have arrived in
good condition if one week after customs 1.6.2 Torque values for bolt-nut
clearance, we have not received any damage connection
report or statement from the customer. Section [7]
contains a “Receiving inspection report” for this
purpose. Complete this report and send it to your
Maximum Without gasket (b) With
Pauwels contact person.
Torque gasket
values in (c)
Nm (a)
Bolt diameter Steel Stainless All bolt
1.6 Tables (8.8) steel (70) types
bolts bolts
1.6.1 Correction factors for megger M 6 (x 1) 9 6 <6
M 8 (x 1.25) 22 16 <8
and power factor tests
M 10 (x 1.5) 45 32 8 - 16
M 12 (x 1.75) 77 56 16 - 24
Multiply the measured insulation resistance by the
approximate correction factor, given by the table M 16 (x 2.0) 193 135 32 - 64
below, to bring the measured value back to a 200C M 20 (x 2.5) 369 273
reference temperature. M 24 (x 3.0) 639 471
M 30 (x 3.5) 1260 897
M 36 (x 4.0) 2340 1632
Table 3 Max. spanner values for bolt – nut
connections
24
Hardware
Remarks: Aluminium
Silicon Bronze Galv. Steel
This table applies to bolt – nut connections that are Stainless Steel
not greased (μ = 0.14 steel and 0.20 for stainless Bolt
steel): Dia in-lb ft-lb N-m in-lb ft-lb N-m
• the given values are in Nm and they are values (J) 2
at 80% of elasticity limit of the material. 5/16” 180 15 20.3 120 10 13.6
• values in lbs-ft can be found by multiplying the 3/8” 240 20 27.1 180 15 20.3
Nm values by 0.737 1/2” 480 40 54.2 300 25 33.9
• the simple method of “1/4 turns past tight” to
tighten bolts, can be used if an appropriate 5/8” 660 55 74.6 480 40 54.2
torque spanner tool is not available. This 3/4” 840 70 94.9 720 60 81.3
however is not recommended.
Table 4 Recommended torque values for
SEFCOR connectors.
Also considered as joints without gasket are (see
also section [4]):
• Gasket systems with gasket grooves or gasket Remarks
stops
• Connectors are not necessarily part of
• High density fiber gaskets
PAUWELS scope of supply.
• Recommended torque values do not
For impregnated cork and nitrile rubber the gasket necessarily apply for other connector brands.
material is the limiting factor. The general rule of 10 Please consult specific documentation.
2 2
N/mm maximum pressure and 2N/mm minimum
1
applies .
Torque values for other bolt – nut material
combinations can be found in the specific literature.
1.6.3 Torque values for SEFCOR

connectors
Figure 1 Example of SEFCOR connector
1
This pressure range can be obtained by reducing
2
the gasket thickness to 2/3th of its original value. See figure “Example of SEFCOR connector“
25
1.7 Conversion tables
Quantity Unit of Symbol Formula

Base units
Length Meter m
Mass Kilogram kg
Time Second s
Electric current Ampere A
Thermodynamic temperature Kelvin K
Amount of substance Mole mol
Luminous intensity Candela cd
Supplementary units
Plane angle Radian rad
Solid angle Steradian sr
Derived units (with special names)
Force Newton N Kg m/s2
Pressure. Stress Pascal Pa N/m2
Energy. Work. Quantity of heat Joule J Nm
Power Watt W J/s
Derived units (without special names)
Area Square meter m2
Volume Cubic meter m3
Velocity Meter per second m/s
Acceleration Meter per second m/s2
Specific volume Cubic meter per kilogram m3/kg
Density Kilogram per cubic meter kg/m3
Table 5 International System of units (SI) (Metric practice)
Multiplication factor Prefix Symbol

SI Prefixes
1 000 000 000 000 000 000 = 1018 Exa E
1 000 000 000 000 000 = 1015 Peta P
1 000 000 000 000 = 1012 Tera T
1 000 000 000 = 109 Giga G
1 000 000 = 106 Mega M
1 000 = 103 Kilo k
100 = 102 Hecto h
10 = 101 Deca da
0.1 = 10-1 Deci d
0.01 = 10-2 Centi c
0.001 = 10-3 Milli m
0.000 001 = 10-6 Micro µ
0.000 000 001 = 10-9 Nano n
0.000 000 000 001 = 10-12 Pico p
0.000 000 000 000 001 = 10-15 Femto f
0.000 000 000 000 000 001 = 10-18 Atto a
Table 6 Multiplication factors
26
Linear measure
Inches Feet Yards Rods Furlongs Miles
1.0 .08333 .02778 .0050505 .00012626 .00001578
12.0 1.0 .33333 .0606061 .00151515 .00018939
36.0 3.0 1.0 .1818182 .00454545 .00056818
198.0 16.5 5.5 1.0 .025 .003125
7920.0 660.0 220.0 40.0 1.0 .125
63360.0 5280.0 1760.0 320.0 8.0 1.0
Square and land measure
Sq.
Sq. feet Sq. yards Sq. rods Acres Sq. miles
inches
1.0 .006944 .000772
144.0 1.0 .111111
1296.0 9.0 1.0 .03306 .000207
39204.0 272.25 30.25 1.0 .00625 .0000098
43560.0 4840.0 160.0 1.0 .0015625
3097600.0 102400.0 640.0 1.0
Avoirdupois weights
Grains Drams Ounces Pounds Tons
1.0 .03657 .002286 .000143 .0000000714
27.34375 1.0 .0625 .003906 .00000196
437.5 16.0 1.0 .0625 .00003125
7000.0 256.0 16.0 1.0 .0005
14000000.0 512000.0 32000.0 2000.0 1.0
Dry measure
Pints Quarts Pecks Cubic feet Bushels
1.0 .5 .0625 .01945 .01563
2.0 1.0 .125 .03891 .03125
16.0 8.0 1.0 .31112 .25
51.42627 25.71314 3.21414 1.0 .80354
64.0 32.0 4.0 1.2445 1.0
Liquid measure
Gills Pints Quarts U.S. Gallons Cubic feet
1.0 .25 .125 .03125 .00418
4.0 1.0 .5 .125 .01671
8.0 2.0 1.0 .250 .03342
32.0 8.0 4.0 1.0 .1337
7.48052 1.0
Table 7 United States System
27
Quantity Multiply by to obtain
Ounce-force 0.278 014 Newton N

Pound-force 4.448 222 Newton N
Force
Newton 3.596 942 Ounce-force oz.f
Newton 0.224 809 Pound-force lbf
Pound-force-inch 0.112 985 Newton-meter N-m
Pound-force-foot 1.355 818 Newton-meter N-m
Torque
Newton-meter 8.850 748 Pound-force-inch lbf-in
Newton-meter 0.737 562 Pound-force-foot lbf-ft
Pound-force per square
6.894 757 Kilopascal kPa
inch
Foot of water (39.2F) 2.988 98 Kilopascal kPa
Inch of mercury (32F) 3.386 38 Kilopascal kPa
Pressure.Stress
Pound-force per
Kilopascal 0.145 038 lbf/in2
square inch (psi)
Kilopascal 0.334 562 Foot of water (39.2F)
Kilopascal 0.295 301 Inch of mercury (32F) in Hg
Foot-pound-force 1.355 818 Joule J
British thermal unit 1.055 056x103 Joule J
Calorie 4.186 800 Joule J
Energy. Work. Kilowatt hour 3.600 000x106 Joule J
Heat Joule 0.737 562 Foot-pound-force ft-lbf
Joule 0.947 817x10-3 British thermal unit Btu
Joule 0.238 846 Calorie cal
Joule 0.277 778x10-6 Kilowatt hour kW-h
Foot-pound-force/second 1.355 818 Watt W
British thermal unit per
0.293 071 Watt W
hour
Horsepower (550ft.lbf/s) 0.745 700 Kilowatt kW
Power Foot-pound-
Watt 0.737 562 ft-lbf/s
force/second
British thermal unit
Watt 3.412 141 Btu/h
per hour
Horsepower
Kilowatt 1.341 022 hp
(550ft.lbf/s)
Degree 17.453 29x10-3 Radian rad
Angle
Radian 57.295 788 Degree
Temperature Degree Fahrenheit tºC=( tºF-32)/1.8 Degree Celsius °C
Degree Celsius tºF=1.8x tºC+32 Degree Fahrenheit °F
Length Inch 25.400 Millimeter mm
Foot 0.304 800 Meter m
Yard 0.914 400 Meter m
28
Quantity Multiply by to obtain
Mile (U.S.Statute) 1.609 347 Kilometer km

Millimeter 39.370079x10-3 Inch in
Meter 3.280 840 Foot ft
Meter 1.093673 Yard yd
Kilometer 0.621 370 Mile (U.S.Statute) mi
Area Square inch 0.645160x103 Square millimeter mm2
Square foot 0.092 903 Square meter m2
Square yard 0.836 127 Square meter m2
Square mile (U.S.Statute) 2.589 998 Square kilometer km2
Acre 4.046 873x103 Square meter m2
Acre 0.404 687 Hectare ha
Square millimeter 1.550 003x10-3 Square inch in2
Square meter 10.763 910 Square foot ft2
Square meter 1.195 990 Square yard yd2
Square mile
Square kilometer 0.386 101 mi2
(U.S.Statute)
Square meter 0.247 104x10-3 Acre
Hectare 2.471 044 Acre
Volume Cubic inch 16.387 06x103 Cubic millimeter mm3
Cubic foot 28.316 85x10-3 Cubic meter m3
Cubic yard 0.764 555 Cubic meter m3
Gallon (U.S. liquid) 3.785 412 Liter l
Quart (U.S. liquid) 0.946 353 Liter l
Cubic millimeter 61.023 759x10-6 Cubic inch in3
Cubic meter 35.314 662 Cubic foot ft3
Cubic meter 1.307 951 Cubic yard yd3
Liter 0.264 172 Gallon (U.S. liquid) gal
Liter 1.056 688 Quart (U.S. liquid) qt
Mass Ounce (avoirdupois) 28.349 52 Gram g
Pound (avoirdupois) 0.453 592 Kilogram kg
Short ton 0.907 185x103 Kilogram kg
Gram 35.273 966x10-3 Ounce (avoirdupois) oz(avdp)
Kilogram 2.204 622 Pound (avoirdupois) lb (avdp)
Kilogram 1.102 311x10-3 Short ton
Table 8 SI conversion factors
29
mm of
2 mm of
unity bar mbar Pa KPa MPa kgf/cm mercury psi
water
(torr)
1 bar 1 1000 100.000 100 0.1 1.01972 750.062 10197.16 14.5038
-3
1 mbar 0.001 1 100 0.1 0.0001 1.01972x10 0.7501 10.1972 0.0145
-5
1 Pa 0.00001 0.01 1 0.001 0.000001 1.01972x10 0.0075 0.10197 0.000145
1 kPa 0.01 10 1000 1 0.001 0.010197 7.5006 101.972 0.145
1Mpa 10 10.000 1.000.000 1000 1 10.1972 7500.62 101972 145.038
1 kgf/cm2 0.981 980.7 98066.5 98.0665 0.09807 1 735.56 10.000 14.2233
1mm of
-3
mercury 0.00133 1.333 133.3 0.13332 0.1333x10 0.001539 1 13.5951 0.01934
(1 Torr)
1 mm of -6
0.000098 0.098 9.807 0.009807 9.807x10 0.0001 0.07356 1 0.00142
water
-3
1 psi 0.06895 68.95 6895.06 6.895 6.895x10 0.07031 52.717 703.012 1
Table 9 Conversion table for pressure and stress
30
31
2 General transformer description
33
34
2.1 General electrical and mechanical Oil in: main tank, radiators, conservator (at 200C)
data • Total liquid
• Total mass
The supplied power transformer has been designed • Shipping mass of heaviest part
according to specific ratings and characteristics as
listed on the drawings [part C]. The factory
inspection results are provided in the Manufacturing
Data Record Book (MDRB).
2.1.3 Schematic Control and
Schematic Motor drive unit
The schematic drawings provide all information
2.1.1 Nameplate: concerning control and protection circuits and the
corresponding settings.
General electrical data and network conditions,
e.g.:
• Standard
• Transformer type 2.1.4 Test Reports
• Vector group
• Rated power (MVA) All values measured during factory testing (as
• Voltages requested in the order) are listed on the test reports
• Frequency which are included in the MDRB.
• Number of phases .. • Excitation current
• Tap positions • Load and no load losses
• … • Percent impedance voltage
• Zero-impedance voltage
Working conditions • Sound level
• …
• maximum altitude above sea level
• maximum temperature rise of winding and top
oil temperature
2.1.5 Overload capability
Other information
• Dielectric insulation levels The transformer is designed to permit loading in
accordance with the applicable standards. If tested
• Connections for operation
during factory testing, the test results are available
• Short-circuit conditions
in the MDRB.
2.1.2 General Arrangement Drawing

2.2 Information on mechanical
General mechanical data transformer parts
• Dimensions: length, width, height of the
completely assembled transformer Some mechanical parts and other topics require
extra information. This is why the text below
• Untanking height
provides a short description of some of the major
• Mass core and windings
transformer parts. In addition, you will find
• Tank and fittings
information about the standard painting system
used for the transformer
35
DANGER
Before jacking, lifting or moving a transformer,
always consult the General Arrangement
2.3 Tank design Drawing to make sure that the right devices are
used.
2.3.1 General tank design Do not attempt to jack, lift or move a
transformer at any time while it is under a
The tank is a welded steel construction that is vacuum. This applies even if a partial vacuum is
designed to operate over a range of top oil present.
temperatures as per specified standard or customer
specifications. Furthermore, the tank-cover-
conservator combination can sustain the specified
pressure and vacuum levels as per specifications.
2.3.3 Protective measures in tank
For more specific details on the tank design, we
refer to the General Arrangement Drawing. design
The transformer tank, conservator and radiators are Although the tank is designed to withstand certain
most likely designed for full vacuum, but to be sure pressures, a pressure relief device (if requested)
always check the transformer nameplate. protects it against splitting under high internal
pressures caused by exceptional working
conditions. The tank may be supplied with an
optional switch. A gas detector type Buchholz relay
CAUTION
with alarm and trip contacts is a commonly used
Never apply full vacuum unless the nameplate
accessory for this purpose.
states that the tank / conservator has been
designed for full vacuum.
CAUTION
Do not close a valve that may isolate a full oil-
filled tank, because this can produce a very
2.3.2 Tank handling high internal over- or underpressure due to the
thermal expansion of the oil. This can damage
The tank / cover has certain handling possibilities the transformer or parts of it. Besides this,
which are indicated on the General Arrangement humidity or water can penetrate and damage
Drawing. These might be: the insulation system.
• jacking bosses
• lifting lugs
• moving facilities (wheels) DANGER
• Anchor lugs are provided to anchor the Fault gases generated during operation are
transformer. combustible, keep away from fire if gases
release.
2.3.4 Tank accessories

The tank is provided with all necessary accessories
according to customer specifications and in
accordance with the applicable standard. For more
information on specific accessories, please see
documentation.
36
2.4 Non-membrane conservator 2.5 Transformer grounding (earthing)

design and equipotential bonding
A non-membrane conservator has been used in 2.5.1 Introduction
order to take into account the rise and fall of the oil
level due to changes in transformer loading and For safety of both personnel and equipment all
ambient temperature. The main tank is connected metal parts and accessories of the transformer
to the conservator through a pipe equipped with a should be connected to ground potential.
valve. The air space in the conservator is directly in
contact with the oil and it is connected to the
atmosphere through a dehydrating breather.
This system requires a small amount of
2.5.2 Parts to be grounded (earthed)
maintenance; ensure that the silica gel is replaced
when needed. The period of time between two
Parts that are not welded to the tank or cover are
replacements depends on a number of factors such
connected with tank or cover by means of metal-
as relative humidity and rate of change of loading
strip in the factory. These connections have to be
and ambient temperatures. This cannot be
remade during installations.
predicted in advance, periodic inspection is
necessary. Remarks:
To allow sufficient space for oil expansion, the • Connections made by bolts are not considered
internal capacity of the conservator is defined by as connected to ground potential.
the specified load and ambient temperatures listed • Remove paint or rust before (re-)making
in the standard and/or specifications. Furthermore, grounding (earthing) connections.
the conservator is provided with adequate access
for cleaning, a shut-off valve to the main tank, and
filling / draining devices. Client grounding (earthing) connections are always
found in accessible positions near the bottom of the
For most load tap changer transformers the tank (a minimum of 2 groundings/earthings
conservator contains a separate section for the diagonally located). For the exact location we refer
(O)LTC (completely separate, no liquid or gas to the General Arrangement Drawing [part C]:
intermixing). Some (O)LTC designs may have a
small, separate conservator. These will be clearly
indicated on the General Arrangement Drawing
[part C]
37
Figure 2 Parts to be grounded (earthed)
1. Drycol breather
2. Conservator and parts
3. Tap changer
4. Bushing
5. Cable box
6. Current transformer
7. Lightning arrester
8. Current transformer
9. Marshalling kiosk
Motor drive unit
Drycol breather
10. Oil-air cooler
11. Radiator
12 Fan
13. Oil-water cooler
14. Pump
15. Equipotential bonding 25
2
mm (M6)
16. Grounding (earthing)
connection 70 mm2 (M12)
17. Ground connection client
(flat 30x10 / stainless
steel)
38
coat (PUR). The minimum total thickness of the EP

layer(s) is 100 μm, the total thickness of the
The grounding (earthing) connections on the
transformer are made of flexible copper strips of 70 complete system (EP + PUR) is minimum 160 μm.
mm2 with M12*20 bolts and washers. The painting system resists satisfactorily a salt
The equipotential bonding is made of flexible spray test in accordance with ASTM-B117
copper strips of 25 mm2 with M6 bolts and washers. specifications, for more than 1000 hours.
The connection is made by means of stainless steel

bolts and washers.
2.6.1.3 Qualities of the paint
a) Primer paint (EP)

2.6 Transformer Painting
Two components, polyamine adduct cured epoxy
The transformer painting is always in accordance paint. Contains zinc phosphate and mio.
with the specifications of the customer.
Composition:
Remark:
Solvents: Xylen, …
Preparation and painting of metal parts
(conservator, pipes, radiators, ...) are equivalent to Solids (62%):
preparation and painting for the main transformer - resin: epoxy
(unless otherwise specified). - pigments: zinc phosphate, colour pigments
- micaceous iron oxide
- additives
2.6.1 Painting system Adhesion after polymerization: cross cut test in

accordance with ISO 2409, class 0
2.6.1.1 Preparation
b) Enamel (PUR)
In accordance with ISO 8501-1 : 1988 or SIS
55055900.
A two components acrylic polyurethane coating with
Sandblasting to class Sa 2 1/2 i.e. derusting to a micaceous iron oxid.
clean metal surface. Previous painting, rust and mill
scale are completely eliminated and a surface with Composition:
very good adherence properties is obtained. Solvents: aromatic hydro carbons
Depending on the specified painting system Zinc Solids (54%):
spraying or Hot-dip-galvanising may also be applied - resin: acrylic
to the outside structures only. - color pigments
- micaceous iron oxid
- additives
2.6.1.2 Painting system Adhesion after polymerization on primer paint:

cross cut test in accordance with ISO 2409, class: 0
The different coats of paint are applied by spraying. Aspect: matt, gloss meter GARDNER 60°: 35%
(unless otherwise specified)
The painting system and color is indicated on the
General Arrangement drawing. The two component Color: see General Arrangement drawing
painting system consists of one or more anti
corrosive primer paint layers (EP) and a finishing
39
Corrosion resistance: salt spray test following

ASTM-B117: 5 % NaCl. After 1000 hours at a
thickness of 100 µm rust extension max. 0.5 mm.
2.6.1.4 All inner transformer surfaces
Preparation: identical to outside structures

System: a two component epoxyprimer, 30 µm,
white
Qualities of the paint:
- contains zincphosphate and is oil resistant
- after submerging in oil and in combination
with high temperatures (120 °C) there
might be only a slight discolorisation
40
3 Packing, Transport, Receiving, Storage
41
42
3.1 Packing c) For details of dismounted parts for transport,

see the General Arrangement Drawing and
3.1.1 General Materials List [part C].
The packing type, dimensions, weights and degree

of protection depend on:
3.1.2.1 Seperately deliverd oil
• Allowed dimensions and/or weight for handling
and transport Separately delivered oil is usually packed in sealed
• Means of transportation (railway, road, (metal)-drums of 200 liters. The drums are
seatransport, …) collected on standard pallets (4 drums per pallet).
• Legal obligations concerning transportation For bigger quantities also special oil-tanks or
• Limitations given by roads, railways, … containers can be used.
• Limitations due to local handling equipment
• Customer specifications
Each package is marked and contains a packing-

3.1.3 Condenser bushings
list. These packing lists will be a usefull tool during
installation on site so make sure that they stay with
Condensor bushings are packed in the original
the packages.
wooden box or crate. Each condenser bushing in
an hermetic sealed plastic bag which contains a
small quantity of silica gel (for humidity control).
3.1.2 Transformer body

The transformer body is not packed (unless
3.1.4 Hygroscopic electrical parts
otherwise specified), sensitive parts (especially on
the top) are protected by wooden barriers or metal
Parts which are under oil or oil-filled under working
caps. Shock recorders are provided if specified.
condition, and which must be dismantled for
(See further in this section)
transport, are packed under oil or filled with oil. The
All openings of the transformer tank, radiators, necessary gas-space for the thermal expansion of
cover, oil-filled cable boxes, turrets of the bushings the oil during transport is provided.
or conservator, etc.., have been sealed by blind
If packing under oil or oil-filling is not possible, the
flanges. All dismounted parts have been packed
parts will be pre-impregnated with oil, then packed
separately (see below).
in hermetic sealed plastic bags whith a quantity of
silica gel (for humidity control). The sealed bags are
packed in wooden boxes.
Remarks:
a) Transformers which are partially filled with oil
or which are empty of oil during transportation,
are equipped with an inert gas pressure
system. This to prevent humidity entering the 3.1.5 Radiators
transformer body
b) Smaller transformers can be transported Radiators are packed on pallets as a standard.
completely assembled and completely filled Crates or boxes are provided if specified.
with oil. In these cases there is no need for an
inert gas pressure system. Another advantage
is that the installation time is seriously
reduced.
43
3.1.6 Conservator, pipes and cable DANGER

boxes Take all necessary safety measures during
handling and transportation to prevent personal
These parts are packed on pallets and protected harm.
with a plastic cover.Crates or boxes are provided if Especially pay attention during the lifting or
specified. jacking of a transformer: Never work under a
non-secured lifted or jacked transformer.
Never attempt to move a transformer by
pushing against the tank itself or any of the
accessories.
3.1.7 Control cabinets Do not weld other attachments to the tank, nor
loop cables around the tank or any of the
Control cabinets are provided with bags of an accessories.
adequate quantity of silica gel for a storage of some
weeks to prevent condensation water damage. The
corners of the cabinets are protected by special
Always handle a transformer as gently as possible.
profiles.
Heavy shocks or impacts can damage the
Control cabinets are packed on pallets and transformer internally without any external sign of
protected with a plastic cover. Crates or boxes are damage. That is why the prescribed receiving
provided if specified. inspection must be followed without any deviation.
[see further in this section]
3.2 Transport and handling CAUTION

Should the transformer tank be dropped,
In many cases, a transformer has to travel long contact Pauwels immediately. Even dropping a
distances before reaching its final destination. tank 25 mm (1 inch) may cause internal damage
During this journey many handling operations are or damage the tank.
needed for loading, transportation, unloading and
transfer to other carrier types.
Please note that the means of transportation are
It is obvious that during this critical period in the important parameters during the design of a
lifetime of the transformer all necessary precautions transformer. This information is used to calculate
have to be taken to assure safe arrival in optimal the maximum allowed impacts in all directions.
conditions. During railway transportation especially the impacts
may be higher. As a result, the design has been
made accordingly.
3.2.1 General transport and handling

notes CAUTION
Railway transport is only allowed if this method
First of all, it is very important to have experienced was specified in the purchase order and if the
people on board who can handle a power design has been made accordingly.
transformer. Problems often arise when people are
not familiar with handling transformers. Personal
harm and damage to the transformer are to be If specified, impact recorders are provided to record
prevented at all costs. the impacts that occurred during transportation.
44
3.2.2 Handling instructions during Never attempt to lift the transformer unless the
loading and unloading transformer cover is securely fastened to the tank.
Ignoring this advice may result in deformation of the
tank and damage to the core and windings.
3.2.2.1 Lifting a transformer by crane
Pauwels transformers are designed with lifting lugs
Usually, the transformer body will be lifted by crane No. 105 that can lift an assembled and fully filled
during loading and unloading. The smaller transformer.
packages can be lifted by crane or forklift.
Lifting points are clearly marked by the red painted
surfaces. In case of any doubt, consult the General
Arrangement Drawing (or other drawings 3.2.2.2 Jacking a transformer
concerning transportation) before lifting.
Also jacking can be a helpful method during loading
or unloading, although handling by crane is
preferred. Jacking, however, becomes more useful
DANGER
for final positioning of the transformer on its
Only use lifting points to lift the complete
foundation as described in section [4]
transformer or assembly. Always use all lifting
points together. Consult the General Pauwels transformers are always equipped with
Arrangement Drawing for the location of these jacking steps No. 102. These jacking steps are
lifting points. designed in such a way that each step can support
half the weight of the transformer (in addition to the
required mechanical design safety factors). This is
Only an experienced crew should be allowed to done to ensure the safety of the transformer when
move and position a transformer by crane. Ensure unbalanced movements are made.
that the capacity of the lifting equipment is suited to
the load being lifted, including the angle from the
vertical that the crane boom must provide.
DANGER
Do not attempt to move a transformer by crane if • Do not jack the transformer from any other
there is inadequate space in any direction. The point than the jacking steps provided.
crane boom must be able to be swung, raised or • Never jack the transformer when it is under
lowered safely. Take great care concerning other vacuum.
electrical equipment that may be energized, • Always use all jacking points together. In
including overhead lines. exceptional cases jacks can be used two by
two at one side of the transformer. In this
Take care to use spreader bars between the
case, pay attention to the angle of the
cables, or use a lifting beam appropriate in order to
transformer.
keep the lifting cable roughly vertical. THE
• Do not support the transformer for an
LOADED CABLES SHOULD NEVER ANGLE
extended period of time using the jacks only.
MORE THAN 15 DEGREES FROM THE
• Add sufficient support blocking under the
VERTICAL.
tank base (if a flat base) or under the skids (if
An empty tank or a tank partially stripped of a skid base) as soon as possible.
subassemblies may slope slightly when lifted by • Never work under the transformer when it is
lifting lugs. Should the tank begin to tilt significantly, raised solely on jacks.
immediately put the transformer down and
investigate before continuing.
1. For maximum safety and stability, the jacks
Attach guide ropes to the skidding eyes at the base
must be placed under the jacking steps as
of the tank to guide the tank into position. Do not
centrally as possible. A steel or wooden block
allow the transformer to swing freely from the
must always be placed under the jack that
crane. Do not lift the load higher than necessary.
must be sitting flat and level on the ground.
45
2. The ground must be capable of supporting the 3.2.4 Shipping documents

weight of the transformer with the area of the
ground contact used (defined by the size of the The contents, routing, destination and the
pads under the jacks and the gross weight of conditions of the carrier's agreement are carefully
the transformer). documented for each shipment. Invoices of
3. The full plunger surface of the jack has to be shipment, bills of loading, etc.., are transmitted to
located completely under the jacking step. the carrier's agent. A copy of the packing list
4. Jack the transformer evenly in order to accompanies the shipment.
distribute the stress evenly.
5. While lowering the transformer, ensure that it
is lowered gently and evenly. Release
pressure SLOWLY to avoid dropping the CAUTION
transformer. In case of an abnormality during shipment,
follow the instructions of the Insurance
guidelines available in section [1].
3.2.3 Blocking and securing

During transportation, make sure that the 3.3 Receiving
transformer body is blocked and secured in all
directions. This should be done to prevent the
The process of receiving a transformer begins
transformer body from shifting.
when the rail car, the trailer or the vessel is
a) TRUCK TRANSPORT: The transformer body presented for unloading. If possible, ensure that the
has to be chained into position or secured into final site or the unloading point is inspected, so that
position by any other means. the rail car or trailer can be positioned to make the
b) RAILWAY TRANSPORT: The transformer unloading as easy and as straightforward as
body is usually secured by tension rods or possible.
chains, welded or bolted onto the car body.
It is recommended that the inspection be performed
“DO NOT HUMP” signs should be placed on
in the presence of the representative of the carrier.
each end of the rail car loaded with
transformers. Remarks:
c) TRANSPORT BY SHIP: The transformer body
In case of different loading, unloading or transfer
is usually blocked by timber sections bolted
stages during transportation, the below guidelines
onto wood decked vessels or by steel blocking,
have to be followed in each stage. This should be
welded onto metal decked vessels.
done to make sure that possible damage is
detected as early as possible.
CAUTION
If blocking or other securing equipment is
loose, bent or missing on arrival, the possibility 3.3.1 Inspection of damage
for shipping damage exists. See section
RECEIVING below for inspection and reporting The process of receiving must include a careful and
procedures. thorough inspection of the transformer and
accessories before unloading is permitted or
begins. This inspection aims to uncover any
damage that may have occurred during shipment.
The inspection process must include a thorough
inspection of the exterior of the transformer, the
bracing, the packing of parts and components that
46
are shipped detached from the main unit, as well as equipment necessary for the complete inspection
the inspection of the impact recorder (if supplied). should be gathered before the inspection process
begins. The list of equipment should include:
It is recommended that the external inspection
takes place as soon as possible. If damage is • All necessary safety equipment, such as
found, an immediate internal inspection of the hardhats, gloves, etc..
transformer - on the rail car or on the trailer - is • Flashlight
recommended. • Tools (to open manholes, etc.)
Pauwels has a warranty providing protection • Suitable grounds for grounding the
against defective design and manufacturing, but transformer, bushings and tank
does not accept responsibility for damage that • Notebook and a camera with flash for
occurs while the transformer is in transit. Damage recording purposes
that occurs during shipment may be the • Thermometer for measuring the ambient
responsibility of the carrier. The carrier is relieved of temperature
responsibility once the shipment has been accepted • Megger. (nominal voltage of 500 – 5000 V DC)
at the destination. This is why careful inspection is • Dielectric oil-test equipment
required before you accept the shipment.
Remarks: In case of internal inspection:
A “Receiving inspection report” is included in • Clean plastic boots (if there will be personnel
section [7]. Complete this report and return it to entry)
your Pauwels contact person within one week after • String or cord for securing tools, flashlight etc..
the arrival inspection. • Clean rags or other clean wiping material
In case of any damage, a claim procedure has to • Material, covering manholes or handholes to
be started immediately. Follow the instructions in keep out moisture laden ambient during
the insurance guidelines available in section [1] inspection
• Dry air installation for injecting dry air to chase
away the inert gas (nitrogen)
3.3.2 Transformer inspection CAUTION

procedure All tools or equipment that will be used over an
open manhole or handhole or that will be taken
The different steps are the following: inside the transformer, have to be secured by a
cord or string to a point outside the tank so that
1. Preparing for the inspection. they can be pulled out if dropped. Also be aware
2. Inspection of the external portion of the of the specific weight of the oil, swimming is not
transformer and attachments. possible.
3. Inspection of the accessories and all other
components shipped with the main unit.
4. Receiving tests
3.3.2.2 The external inspection

Internal inspection has to be avoided, except when
there might be internal damage.
a) Preliminary inspection
A preliminary inspection of the shipment must
include looking for signs of damage to the blocking,
guy rods or cables, signs of impact on covers,
3.3.2.1 Preparing for the inspection control boxes, major paint scrapes etc.. Note these
observations on the form "Receiving inspection
The inspection should take place with a report" in section [7]. Do not attempt to repair any
representative of the carrier present. All the damage to the transformer main body or to any of
47
the components.After the preliminary inspection may result in broken blocking, pulling out of the
please proceed with the next steps in the receiving bolts or crushing and splintering of the blocks.
procedure. Tie down rods or cables may stretch and
become loose under high impacts. Check that
they are straight and tight all around.
b) Inspection of the impact recorder and inert gas • If the transformer was shipped oil-filled,
pressure system carefully look for signs of leakage on welded
If specified, an impact recorder (No. 145) has been joints, bolted and welded flanges and covers.
installed. This will be indicated on the General Inspect all valves (drain valves, sampling
Arrangement Drawing valves, radiator valves) for damage or leaks.
Check whether the oil level is providing the
See further for more information.
right reading.
Inspect the nitrogen or dry air pressure system (if • All control cabinets (main control cabinet, LTC
applicable). If required, an inert gas pressure motor drive etc..) should be tightly sealed and
system has been installed. This will be indicated on closed. Inspect for damage by water ingress
the General Arrangement Drawing. and for signs of tampering.
See further for more information. • Check that the de-energized tap changer
mechanically moves correctly (if applicable).
Electrical checks will be performed later during
the commissioning process.
c) Detailed external inspection
Pauwels has taken all necessary precautions to • Inspect radiators for dents, scrapped paint,
limit damage during shipping. However, even the damaged or missing fans (if applicable).
most elaborate steps cannot totally eliminate the • Check all bushings for cracked or damaged
possibility of damage during transit. The largest porcelain. Check for oil around gasketted
component, and the one most seriously affected by joints. Check the oil level on oil-filled bushings
potential damage, is the main tank and the core (the bushing must be vertical or nearly vertical
and winding assembly it contains. That is why the to check this).
external inspection should begin there. Report all • Check arresters (if any) for cracked or
observations on the form "Receiving inspection damaged porcelain.
report". If damage is found, photograph the areas of • Check the conservator tank (if applicable) for
concern to substantiate any claims. Do not remove dents or scrapes or other signs of damage.
or open any part of the shipment until the carrier's • Check the shipment against the bill of loading
representatives have made their inspection. and report any shortages.
• Examine the tank for signs of oil leakage, paint

scrapes, dents or other signs of damage.
• Examine timber bracing, steel blocking, 3.3.2.3 Inspection of accessories
boltdown rods and cables for signs of shifting
of the load. Locate the packing list, so that all accessories can
be checked off as they are inspected. Check for
INSPECTION HINTS damage to each crate or package. Open and
inspect the contents of each package while
• Depressed steel rail cars will usually have referring to the packing list. If any packing or items
steel blocking welded to the car, sitting tightly are missing, immediately notify the carrier's
against the base of the transformer. Shifting of representative and Pauwels.
the load can result in dents in the transformer
at the location of the blocks and/or of the steel
blocking itself. Also look for scratched paint.
• Flat rail cars and trailers will usually have
wooden blocking sitting tightly against the base
or skid base of the transformer, bolted to the
bed of the car or trailer. Movement of the load
48
CAUTION
Hygroscopic materials are protected by packing 3.3.2.5 Internal inspections
in hermetically sealed plastic bags, including
silica gel as indicator for unacceptable moisture If internal damage is suspected it is recommended
penetration. After inspection, store these to perform an internal inspection of the unit. (See
materials according to the instructions on the further in this section.)
package (close bags and store in dry room), or
mount them immediately.
3.4 Impact recorder ShockLog RD298

3.3.2.4 Standard receiving tests The electronic impact recorder, ShockLog RD298,
is a 3-dimensional, registration type. Before
a) Core grounding megger test transport, this device will be mounted on the cover
The core grounding megger test is to be performed of the transformator.After arrival on site, please
whenever possible. We refer to section [4] for note the correct date and time during removal of
detailed information. On a completely assembled this device and send the registrated data for
and oil-filled unit one can also perform the winding analysis to:
insulation megger test. Please note however that
the unit has to be oil filled for safe measurement.
PAUWELS TRAFO BELGIUM N.V.
Division: Quality Control VT
b) Dew point measurement Antwerpsesteenweg 167
A dew point measurement is required upon arrival B-2800 MECHELEN
of inert gas filled units when tank pressure is below BELGIUM
0.05 bar. This test gives a good indication of the
amount of moisture the insulation is containing.
More detailed information is given further in this
IOM-manual .
c) Additional receiving tests if damage or water 3.5 Performing internal inspections

ingress is suspected
Some additional tests have to be performed if 3.5.1 Reasons to perform an internal
internal damage or water contamination of the inspection
insulation system is suspected. Strictly follow the
guidelines described in the testing sections. A full internal inspection is only necessary when
• Insulation power factor test. Section [4] gives there are good reasons to do this. These reasons
complete information on this test. can be:
• Ratio and resistance tests. Section [4] gives • signs of severe damage on the outside of the
complete information on this tests. transformer which indicate that there may also
be internal damage
In addition, oil tests can be performed to detect • that the impact recorder indicates that there
moisture contamination. For taking oil samples and were excessive forces on the load during
for oil testing, please refer to section [6]. The oil shipment [see earlier in this section]
tests that are most important in receiving • that the megger test shows far too low
applications are: readings which cannot be explained by the
water content of the oil. In this case, it is
• Dielectric strength appropriate to first test the oil before
• Water content considering a full internal inspection that
• Power factor requires draining of the oil.
49
handholes or covers in the tank cover. In this case,

a minimal quantity of oil has to be drained.
If it seems that an internal inspection is required,
contact Pauwels immediately to inform us about the For smaller transformers it will be impossible to
situation. We will study the observations and give physically enter the transformer. This means all
you advice on how to proceed with the internal inspections will have to be conducted by removing
inspection or we will send a certified technician to manholes and handholes, one at a time, to prevent
perform the inspection. the ingress of moisture-laden ambient air by cross
breathing.
Please note that an internal inspection exposes the
transformer to risks. If any damage occurs due to Remarks:
improper handling (entering, exposure time) of the
During the inspection look for:
transformer, we cannot be held responsible. So
please be careful and strictly follow the guidelines. • parts of the transformer structure that are
laying on the tank floor or floating in the
residual oil. This includes small pieces of
insulation. Look for loose bolts, washers, nuts,
etc.
3.5.2 Planning the inspection • parts of the transformer and lead structure that
appear broken or bent. Look for loose key
It is a good idea to plan the internal inspection in spacers in the windings, loose clamping and
advance if possible. Ensure that all equipment is in support blocks.
proper working order, that all emergency safety • damage around leads. Winding leads that are
equipment is present and operational and that all disconnected from draw lead bushings for
members of the team know their duties. transit are tied into a loop and secured to the
lead support structure. If these break loose,
the end of the lead can damage other
components in the transformer.
3.5.3 Procedure of an internal • strange murkiness or cloudiness of the oil,
especially if water contamination is suspected.
inspection
Look for liquid water on the tank floor (liquid
water sinks in oil). Look for evidence of
Always read and follow the guidelines in the Danger
condensation.
& Safety section [1]
• Look for signs of corrosion on bare metal
A full internal inspection requires draining all the oil parts.
into dry, clean tanks of suitable capacity, while
filling the transformer tank with dry air and having a
Inform Pauwels and the carrier what was
dew point equal to or less than -510C.
discovered. If damage was found, file a damage
claim, but do not perform any further work until
Pauwels gives approval and guidance.
DANGER
Do not attempt to enter a transformer tank,
unless the internal gas has been tested for
sufficient oxygen content to support life.
Testing should be done with an approved 3.6 Dew point measurement
detector. A minimum of 19.5% of oxygen is
always required. For security reasons, a second How to perform the dew point measurement can
person must be present. only be explained in relation to the equipment that
is used. That is why we refer to the dew point
measurement instrument manual.
A partial internal inspection is possible if the internal Pauwels requires that the moisture level of the
components can be observed through manholes or insulation be less than or equal to 1% for a
50
transformer installed in the field. This is reflected in

the line drawn in the curve in Table 10 (based on
Piper ∗).
An assumption inherent in using the curve to
estimate overall transformer dryness is that the gas
is in equilibrium with the insulation. This means that
the vapor pressures of gas and insulation are
equal. This is true if:
• the solid insulation is reasonably uniformly dry
(e.g. no large amount of water vapor has been
suddenly and recently introduced by an event
such as people breathing and perspiring inside
the tank during internal inspection or internal
assembly.)
• the gas has been in contact with the solid
insulation, in a closed system, for a minimum
of 24 hours but preferably for 48 hours
• the temperature of the gas is about equal to
the temperature of the solid insulation.
Table 10 Dew point measurement
If these three assumptions are approximately met,
then use the curve in Table 10. Draw a horizontal
line from the insulation temperature on the vertical
axis, and read the minimum required dew point
from the horizontal axis.
3.7 Storage
Liquid-filled transformers are meant to always have
their insulation covered by oil. Without oil they will
survive satisfactorily for some period of time, such
as during shipping. However, prolonged storage
without the insulation immersed may cause future
problems, as the insulation will pick up moisture
and contaminant. Apart from this, internal voids
may form in the insulation as the liquid gradually
drains out of the insulation.
When a transformer has to be stored, the
procedures below have to be followed for safe
storage.
Remarks:
• The higher the voltage and the larger the MVA
of a transformer, the more important the
storage conditions. However, it is always better
to store the transformer correctly.
• If a transformer is fully assembled, oil-filled and
pre-tested, the general maintenance
instructions can be followed (refer to section
∗ [6]).
Moisture Equilibrium Between Gas Space and
Fibrous materials in Enclosed Electric Equipment /
John D. Piper . – AIEE, December 1946, volume 65
51
• Store accessories in a safe place. (oil drums,

DANGER
bushings, radiators, conservator, fans, etc..).
For your personal safety and for the safety of
For instructions, see below.
the equipment, always ground all terminals
• Perform the recommended maintenance as
when transformers are in temporary storage.
described in the maintenance chapter (section
[6]) if longer periods of storage are required.
3.7.1 Storage of the transformer

3.7.1.2 Oil-filled transformer with inert gas
If possible, the transformer should be stored in its cushion
correct position on the prepared foundation. This
foundation must be strong enough to support the When the conservator cannot be installed, the
mass of the complete transformer, accessories and transformer can be stored with an inert gas
liquid. It must be level and must support the cushion. The maximum storage period is limited to
transformer base evenly. 6 months. Always do a weekly check of the inert
gas pressure that should be above 0.05 bar.
If the permanent foundation is not available, then
the transformer must be stored on a solid platform • Connect and supply panel heaters to prevent
that is suitably prepared to provide proper support damage by condensation.
for the transformer base. Indoor transformers • Ground all bushings and the tank to prevent
should be stored indoors. damage by unexpected lightning (see section
[1]).
• Store accessories in a safe place. (oil drums,
bushings, radiators, conservator, fans, etc..).
For instructions, see below.
3.7.1.1 Completely assembled or at least with
conservator
If the correct maintenance activities in section [6] 3.7.1.3 Transformers without any oil and
are performed, a completely filled transformer with completely filled with an inert gas
conservator can be stored for unlimited time.
Assemble and fill the transformer completely with Total storage time is limited to 3 months from the
oil as soon as possible, at the latest within 30 days time the transformer has left the factory. The inert
after arrival on site (or maximum 90 days after gas overpressure must be checked weekly.
shipment from the factory). In the intermediate • Connect and supply panel heaters to prevent
storage period the inert gas installation (if damage by condensation.
applicable) should be checked weekly.
• Ground all bushings and the tank to prevent
• Mount the silica gel air breather(s) by means of damage by unexpected lightning (see section
a temporary pipe connection to prevent [1]).
unnecessary under- or overpressure because • Store accessories in a safe place. (oil drums,
of ambient temperature changes. bushings, radiators, conservator, fans, etc..).
• Activate and check all gas bleeders (if For instructions, see below.
applicable).
• Connect and supply panel heaters to prevent
damage by condensation.
• Ground all bushings and the tank to prevent 3.7.2 Storage of accessories
damage by unexpected lightning (see section
[1]). All accessories that are shipped separate from the
transformer must also be stored correctly. All
shipping crates or boxes that are opened for the
52
receiving inspection must be carefully resealed and

stored in a dry clean atmosphere between +50C
and +300C. It is recommended that all accessories,
boxes or crates that are marked FRAGILE also be 3.7.2.2 Bushings
stored indoors in a dry, clean room and above
+50C. All accessories stored outdoors must be Bushings are packed in wooden boxes or crates. All
covered and protected from severe weather. condenser bushings (or other bushings with
hygroscopic parts) are packed separately in a
hermetically sealed plastic bag to keep moisture out
and do contain a bag of desiccant. Prior to storage,
check that the bushing upper end terminal and
3.7.2.1 Storage of oil shipped in drums
wrap is tight and undamaged. Replace the
desiccant if necessary. Ensure that oil-filled
Mineral oil in drums may be stored inside a building
bushings are stored with the top of the cap elevated
that protects them from water accumulation on the
at a minimum of a 200 angle.
cover. In this case, local fire regulations must be
followed for storage of flammable materials. Remark:
Oil drums that are stored outside must be Bushings packed in their original boxes are always
positioned in such way that water cannot elevated at the right angle
accumulate on the top of the drum. (water can be
Bushings thus protected from the environment may
draw into the drum during temperature cycling, thus
be stored outdoors, although if indoor facilities are
contaminating the oil).
available, it is highly recommended that they be
Corroded steel drums may start leaking. This used instead. Regularly verify that the desiccant is
condition must be avoided by ongoing inspection of dry.
the stored drums.
There are two acceptable methods of outside drum
storage, illustrated below in order of preference:
3.7.2.3 Radiators
All radiators and radiator assemblies that are

shipped separately have their openings sealed with
a shipping gasket covered by a temporary attached
cover plate. Ensure that all seals are tight before
storage. Storage conditions must ensure that water
will not collect and stand around sealed openings.
Figure 3 Outside oil drum storage (method 1) Radiators and radiator assemblies should not sit
directly on the ground, but should be on timber
Bungs must be set parallel to the ground so that oil supports above the ground.
covers them both. This restricts cross breathing.
3.7.2.4 Fans
Fans have weatherproof motors and can be stored

outside. However, since their shipping positions are
not necessarily the normal working positions it is
required that they be stored inside in a dry, clean
Figure 4 Outside oil drum storage (method 2) atmosphere and above +5 C.
0
Cover the drum with a plastic sheet, tied in place to

avoid water accumulation on the top.
53
3.7.3 End of storage

3.7.2.5 Pumps, conservator and pipework
Check the transformer and all stored components
It is recommended that they be stored inside in a again just before final assembling and testing in
dry, clean atmosphere and above +50C. accordance with the standard receiving procedures
in section [3].
Pumps and connecting pipework are sealed with a
shipping gasket and a temporary cover plate.
Check all sealed openings prior to storage.
If inside storage is impossible, pumps and pipework
may be stored outdoors up to 30 days after the
arrival date.
For storage periods exceeding 30 days, it is
recommended that bags of fresh, dry silica gel be
attached to the inside of the blanking plate
(attachment to the blanking plate means it is
unlikely the bag will be accidentally left inside
during final assembly).
3.7.2.6 Control cabinets
Control cabinets shipped separately from the

transformer are usually packed in wooden crates or
boxes. Venting openings or breathers may be
closed to prevent water ingress. A bag of sufficient
silica gel is placed inside the control box to pick up
the moisture of the inside air during the normal
shipping time.
Unpack all control cabinets immediately after
arrival.
• Verify that the silica gel is dry and that there is
no corrosion damage.
• Check for loose or broken parts (plug-in relays,
wiring channels etc..).
• Verify that all venting openings are open and
mount breathers.
• Connect heaters to the appropriate power
supply. If heaters cannot be connected to the
supply, check the silica gel weekly and replace
it if necessary.
• Store the cabinet indoors in a dry, clean room
0 0
and between +5 C and +30 C.
54
4 Assembling and installation
55
56
4.1 Locating a transformer • Proper transformer ventilation (roughly

speaking, transformers with cooling fans under
The instructions below are meant as a guideline to the radiators need a minimum clearance to the
move a transformer and its accessories safely and ground of approximately the diameter of the
with a minimum of risk for damages. fan).
4.1.1.2 Inspection of equipment to move

4.1.1 Preparation to move a
transformer Equipment that is to be moved to its final position
has to be ready.
A number of items need to be prepared and
• Newly received transformers that are to be
checked before a transformer is moved to its final
moved, must first be inspected according to
position on site:
the procedures listed in section [3] before final
• The site has to be prepared correctly and must positioning on its foundation.
be ready for receipt of the unit • Equipment that has been in temporary storage
• The transformer itself has to be declared fit to has to be re-packed or prepared, so that is
move. suitable for the specific movement.
• The transformer has to be prepared to move. ° This refers especially to the disconnection
• The transportation route has to be prepared for of all equipment, accessories or power
the move. that might have been attached for storage
purposes.
° If the transformer is under pressure or
vacuum for storage purposes, relieve the
4.1.1.1 Inspection of the final location pressure (or the vacuum to atmospheric
pressure by using dry air or nitrogen with
0
Before the transformer is moved to its permanent a suitable low dew point less than -51 C).
foundation or to a temporary storage area, the site
must be carefully inspected. Always:
Inspect the foundation the transformer will be • Disconnect all power supplies.
placed on. Ensure that its size and structural
properties are correct for the transformer load. You
might also confirm with the foundation engineering
DANGER
personnel to be sure. Also ensure that control
If there is any power to be disconnected, do not
wiring conduits or channels are in the correct
take any further steps until this has been
position for the transformer control box(es),
properly done.
especially if supplied from underground (through
the foundation surface).
Ensure that there are proper clearances around the • Unbolt any bolts, nuts or cables that may be
transformer for: fastening the transformer to its current location
• Fire prevention equipment, fire walls, (or carrier). Carefully check that all wires,
personnel safety. cables and groundings (earthings) have been
removed and that there are no parts stopping
• Noise barriers, fences, water deluge systems,
the free transportation of the transformer.
ladders, etc...
• Check the transformer for any equipment or
• Cabling to control cabinets and for opening the
accessories that must be removed before
cabinet doors
moving it to the new location (in order to clear
• Proper personnel access for construction and
any obstacles along the route). For equipment
maintenance purposes
or accessories which must be removed:
57
° Matchmark the pieces • The roadway: ensure that the roadway can
° Disconnect them support the load of the moving equipment and
° Store them carefully in a clean dry place its load. Make sure that it is level enough not to
until they are required for re-assembling cause interference. Ensure that any slopes,
(see also the storage chapter [3]) either up grade or down grade are within the
° Clean all remaining openings limits of the moving equipment to handle. The
° Seal the openings carefully, using transformer must never be tilted more than 15
blanking plates and gaskets. NEVER re- degrees from the vertical, side-to-side or front
use shipping gaskets for the final to back. This rule also applies to skidding a
assembly transformer to a pad. For steeper slopes, use a
° Tighten all blanking plates and covers crane.
carefully • Traffic: sometimes transportation routes will
cross other routes such as roads, loading
docks, railway tracks etc. Make arrangements
Remarks: to block, keep clear or divert other traffic if
• Should any equipment be missing or damaged required.
upon arrival, contact Pauwels immediately.
• If any equipment is damaged or lost during Finally, expect the unexpected. Bad weather may
(dis-) assembly, order replacement parts make an otherwise smooth surface soft or slippery.
through Pauwels. A change in weather can cause a firm surface to
turn to mush. Moving equipment may break down.
Expect that some delays will occur.
4.1.1.3 Inspection of the route
Prior to the movement of the transformer a

provisional route inspection must be performed. 4.1.2 Positioning a transformer on its
The route is investigated to determine its suitability final destination
for the movement of the transformer and to assess
whether the removal of street furniture is required. 4.1.2.1 General handling notes, lifting a
On completion of the route survey, the movement transformer by crane and jacking
must be communicated to all relevant authorities.
Inform the local police if escorts are required. Information on general handling notes, lifting a
transformer by crane and jacking can be found in
A number of items must be inspected along the
entire route. These items include: the transport section [3].
• Overhead obstructions: verify that there is

sufficient clearance for the transformer and its
moving equipment to pass under all overhead
4.1.2.2 Moving a transformer on wheels or
obstructions. Check for clearance to any
steel rods
overhead electrical equipment that may require
electrical clearances much larger than just
physical ones. a) Moving a transformer on wheels (if available)
Transformers supplied with wheels can be moved
• Side-to-side obstructions: verify that there is
in directions at right angles to the tank base.
sufficient clearance between buildings, gates,
Usually these movements are executed on ground
fences and other equipment. Ensure that
level on special tracks.
sufficient clearances are available for the
moving equipment and any turning circles Assembling the wheels:
required. Check for appropriate clearances to
energized electrical equipment and carefully • Jack up the transformer using the jacking
mark these for safety. steps. Raise the transformer the height
required just to install the rollers. Block the
58
transformer with suitable timbers or support Remark: The estimated force to start horizontal
blocks (for safety purposes) placed near the movement is 15-20% of the weight to be moved.
jacking steps under the lateral skids or
Steel rods must all be the same diameter, evenly
stiffeners.
and closely spaced. Refer to the table below for the
• Attach the wheels to the mounting pads
minimum required number of rods in relation to the
located under the tank using the necessary
weight being moved.
four bolts (a center bolt may also be provided
to easily turn the rollers by 900 on itself). The • Use at least three sets of rods side by side.
wheels are quite heavy. Therefore, the smaller The rods must be of sufficient width to suit the
the distance they have to be lifted, the easier transformer being moved. Do not use a single
the installation will be. row or two rows of rods.
• Once the wheels have been attached, use the • Rods are preferably iron-pipe profiles, double
jacks to raise the transformer just enough to extra strong IPS pipe.
remove the blocking. • If rods are to be used with timbers, the timbers
• Gently lower the transformer until it is resting must be steel faced. Each set of rods must
on the rollers. have its own set of timbers.
• The transformer may be now rolled into
position.
Diameter (mm)
Weight to be
Moving at right angles 25 50 75 100 125 150
moved (tons)
• Place a jack under each of the jacking steps, 45 - 70 52 26 18
and ensure that the surface under the jacks is 70 - 90 70 34 24 18
solid and suitable for the weight to be lifted. 90 - 115 86 44 30 22 18
Raise the transformer the height required just 115 - 135 52 36 26 20
to clear the rollers above the ground. Block 135 - 160 30 24 20
both ends of the transformer by placing 160 - 180 34 28 24
suitable timbers or support blocks (for safety 180 - 210 39 33 30
purposes) placed near the jacking steps under 210 - 240 45 36 33
the lateral skids or stiffeners. 240 - 270 51 42 36
0
• Unbolt each roller and turn 90 . Bolt each roller 270 - 300 57 48 39
into the new position using all available bolts.
• Raise the transformer slightly, and remove the Table 11 Minimum number of rods required
blocking. per set under the transformer
• Lower the transformer gently until it is resting
on the rollers. Remarks:
• The transformer may now be moved in the • The table above assumes the use of 3 – 300
new direction. mm (3 - 12 inch) wide steel faced timbers
• The table above gives the number of rods per
To remove the wheels: set under the transformer.
• Follow the guidelines to assemble the wheels

in opposite order. Different steps in moving a transformer on steel
rods:
b) Moving a transformer on steel rods • The first step is to prepare the route for moving
A transformer is moved by "skidding" whenever the transformer:
lifting and moving by crane is impossible or ° The truck bed, the railcar deck or the
unpractical. Transformers with a skid base are transfer car bed must be jacked up and
made to be skidded in directions at right angles to blocked so that it is level and firm
the tank base using steel rods. Transformers with a
flat base can be moved in any direction.
59
° Ensure that the supporting surfaces are designed for a specific site, as well as a for specific
firm enough to support the weight of the electrical network. Hence they usually are of a
transformer completely unique design. For this reason, every
° Assemble the necessary tools (such as transformer installation will to be a unique event as
jacks, "tow and drag" winches etc..), well. People involved in the installation have to
support blocks, rods, greased turning study the specific design and have to use their
plates or greased skids etc…, required for experience and this IOM-manual for the installation.
all events of the movement. A well-prepared installation is the first condition to
• Connect appropriately sized cables to the make it a successful event. Furthermore the
haulage eyes located near the transformer installation of a transformer requires specialized
base. Only pull a transformer by the correct equipment as well as services. These services may
attachment points. Haulage eyes are be sourced internal in your organization or may be
mentioned on the general arrangement sourced externally (eventually by the service
drawing. Utilize a spreader bar if required to department of Pauwels). Accurate scheduling is
limit the strain on the haulage eyes. required in order to make efficient use of these
• Raise the transformer using four hydraulic sources. We assume in below text that the
jacks. Place the rods on the steel faced timber transformer is correctly positioned on its foundation
(or on the rails in the event of using a transfer according to the instructions in the previous chapter
cart with embedded rails) and roll them under and that all necessary transformer components and
the transformer. The longitudinal skid accessories are available for installation.
members serve as stops for positioning the
rollers. When all of the rollers are in place,
carefully lower the transformer onto them.
• Move the transformer into the next position. 4.2.1 Planning of the installation
• Once the transformer is situated on its
foundation:
As some equipment or resources are not always
° Remove the haulage cables readily available it is advised to start some weeks
° Jack the transformer to remove timbers or even months in advance depending on the
and/or rollers from under the transformer available experience. A graphical planning tool (e.g.
° Set the transformer onto its foundation. MS-Project) can be useful in accomplishing a good
installation program including all necessary steps
Remarks: and resources.
For flat base type transformers, timbers and rods

must be positioned in such a way that they support
core and windings during movement. The rollers
must therefore be centered at one-third the width 4.2.2 Recommended assembling and
and two-thirds the width of the base plate, seen energization sequence
from the movement direction.
If the transformer is to be moved on greased Although situations can be different from one case
timbers or by machinery movers, the same kind of to another, below sequence is recommended
procedures and/or precautions should be followed. during installation and energization of the
transformer. This sequence guarantees the best
result with the minimum effort, minimum risk for
damages and (oil) contamination.
1. Installation and preparation of the transformer
4.2 General installation topics tank
2. Inspection of availability of all parts and
Although power transformers are designed and
equipment
manufactured to National or International
3. Installation of main accessories:
Standards, every transformer ends up being
60
a) metal parts.conservator, radiators, pipes, • Clean rags for cleaning.

pumps,... • Methyl Hydrate (or equivalent) for cleaning
b) bushing turrets and bushings. When all bushings.
metal parts have been installed the risk for • Powdered talc and/or gasket-glue for use on
damaging bushings while installing these gaskets.
parts is minimized. • Dry air cylinders, with pressure regulators and
c) cable boxes inlet hose if internal work is to perform.
4. Oil treatment (if necessary)
5. Vacuum processing and initial oil filling
6. Topping up the oil
7. Installation of remaining accessories: fans, 4.2.3.2 Oil filling and processing tools and
measurement devices, control cabinets, wiring equipment
on the transformer. When the transformer has
been completely filled there is no more risk to Once the transformer accessories are installed, it
spill any oil on electrical accessories. must be filled. In addition, the following filling and oil
8. Pre-operational tests and checks treatment equipment will be required:
• Oil processing and pumping equipment, with
filters etc. This equipement may include:
4.2.3 Collecting and preparing the ° vacuum degassing and drying function
required equipment ° filtering function
° pumping function
4.2.3.1 Assembling tools and equipment • Vacuum pump (can be a part of the oil
treatment equipment)
The following equipment is recommended to have ° Capable to obtain the required vacuum
on hand during installation. By collecting the ° (recommended 0,2 mbar or lower)
following equipment prior to the start of installation, ° Required capacity depends on
you eliminate many of the possible delays: transformer oil quantity
• All necessary safety equipment, such as

hardhats, flashlights, fire extinghuisers, plastic Oil quantity Recommended vacuum pump
overboots (for internal inspection), etc,... capacity
• A set of large socket wrenches and optional < 25 m3 ± 250 m3/h
compressed air tool for the use of the sockets. < 50 m3 ± 500 m3/h
These will be needed for opening and closing < 100 m3 ± 1000 m3/h
manhole and handhole covers, for removing
blanking plates etc.. Table 12 Required vacuum pump capacities
• Crowbar and claw hammer for opening
accessory crates etc.. • Vacuum gauge
• A set of large open end wrenches. • Pipes and valves of suitable size depending on
• Cable cutter(s) the capacity
• Strong nylon ropes and slings for bushing • The right quantities of transformer oil
installations. • A Megger (500 – 5000 V DC)
• Strong strings for installation of draw leads (to • Transformer Turns Ratio meter (or use
pull leads through bushings) and for tying tools voltmeter system).
taken inside of the transformer tank. • Oil dielectric tester.
• A crane for installation of heavy components • Dewpoint tester.
and or correctly sized blocks and tackle
assemblies.
A dielectric test set especially if benchmark tests
• Normal tools for an electrician (for – external –
are to be taken prior to in service
wiring and connection).
• CLEAN tarpaulins, plastic sheeting etc..
61
DANGER
4.3 Installation of the transformer Do not attempt to enter a transformer or do not
body put your head inside, until:
The tank has to be evacuated using a vacuum
pump to 50 mm of mercury (absolute); and then
4.3.1 Grounding the tank to be filled with dry air;
The tank has finally been checked for sufficient
Once the transformer has been placed on its oxygen to support life. The check should be
foundation, it is important to ground the tank before performed with an approved gas detector. A
any more work is done. For positioning of the minimum of 19.5% of oxygen is required.
grounding pads, refer to the General Arrangement Failure to comply with this warning can be fatal.
Drawing No. 115. The grounding leads must be of
suitable dimension to be effective. Refer to section
[1]: Danger and safety notes and section [2] for
When opening a transformer:
general information on transformer grounding.
• Try to open only one manhole or handhole at a
time to prevent cross breathing of the tank
(which lets in moisture).
CAUTION
• Do not open a transformer if bad weather
Correctly ground the transformer tank before
threatens, and try not to open the tank during
doing any assembly or commissioning work.
periods of high humidity. Temporary weather
shields may be necessary as a last resort.
• Besides following the above measures, always
limit the exposure time of core and windings to
4.3.2 Preparation of the transformer 24 hours. This is the total allowable time the
active part may be exposed to atmospheric
before assembling accessories
conditions. If exposure time exceeds 24 hours,
the vacuum pulling process has to be
While working on an inert gas-filled transformer,
extended.
pay attention to the internal overpressure. It could
be up to 0.3 bar at any time. This is especially so
while opening valves or removing blind flanges. In case of any doubt about humidity of the
Also bushing turrets are under pressure. insulation:
To install certain accessories, the transformer tank • Fill the transformer with dry nitrogen or air
will have to be opened. Depending on the specific (dew point < -51 ºC) and wait for 48 hours.
shipping or storage conditions: • Take a sample and perform a dew point
measurement. If requirements are not met,
• Oil has to be (partially) drained and the
perform an extended vacuum processing. [see
removed oil has to be stored in dry and clean
further in this section]
containers
• Decide whether the insulation is dry or not.
• Inert gas has to be replaced with breathable
dry gas
In case of any doubt, contact Pauwels before
energization.
4.4 Installation of accessories

There are a lot of different accessories that can be
used on power transformers. Some guidelines
62
always apply, whatever the type of accessory to 4.4.2 Preparing accessories

install. Other guidelines are more specific. We will
start by providing general recommendations Before finally assembling the accessories, make
concerning installation. Next, we will provide an sure all bolts, nuts, gaskets, etc. are at hand. Put
overview of the most frequently used accessories the accessories in the order in which they will be
and their mounting instructions. assembled. This will make the installation easier.
Although not all provided information will apply to
the scope of delivery of the transformer, it might be
useful to have it at hand for other transformers or
for future extensions.
4.4.3 Equipment safety during
Always have a look at the drawings in section [part installation
C] and documentation in section [part B] to learn
about the specific accessories used and to apply Whatever the equipment or accessories to install
the correct instructions. always make sure nothing drops into the
transformer tank. Especially during installation of
bushings one must be careful not to drop any parts
into the tank.
4.4.1 Unpacking accessories Bolts, nuts and washers can easily be dropped and
even a small washer can cause a permanent
Unpack the shipping boxes or crates (except for oil- transformer breakdown. Entering a transformer to
filled bushings), identify and inspect the parts. It is recover the lost parts is a serious job, especially
important to handle all accessories with care. when the transformer is already oil-filled (draining
oil, looking for the part, …). The worst case is when
things have been dropped and one doesn’t know
what was dropped or how many parts were
NOTES ON OIL-FILLED (CONDENSER) dropped.
BUSHINGS:
Oil-filled bushings may not be immediately
unpacked. The reason for this is that the top
must remain higher than the bottom so that the CAUTION
air space does not travel into the insulation. At Be very careful when handling bolts, nuts and
this point, only identify each bushing. During washers inside the tank or on a transformer
assembly, unpack only one bushing at a time: cover with open manholes. You should be
unpack the bushing when it is needed for careful so as to avoid dropping these items into
assembly. the windings or other insulation structures. We
strongly advice you to use a drop cloth under
the internal bushing terminals to collect
dropped parts as well as to count the number of
The bushing porcelain is fragile and must be components taken into the tank. If any parts are
protected from damage during unpacking and dropped and cannot be retrieved, contact
installation. Be careful with the tools used to Pauwels and do not try to energize the
remove the packing-cover and the clamps used transformer.
for shipment of the bushing. Bushing deliveries
can be quite long and if you damage a bushing,
it may take months to replace it.
4.4.4 General assembling instructions

for accessories
These general instructions should be used for all
accessories, especially when no detailed
63
information is available in the documentation [part

B] or in other assembly instructions. However, not 9 7 1 5 11
all possibilities can be addressed in this IOM-
manual, therefore general rules for good
workmanship should always be taken into account. 3 4
12 6 2 8 10
4.4.4.1 Tightening bolts
1
Bolted assemblies are generally used for: 6
7
• Mechanical assemblies without gaskets
(supports) 3 4
• Mechanical assemblies with gaskets (oil pipes,
valves, flanged covers, devices in contact with 5 8
oil, bushings, etc..) 2
• Electrical assemblies (busbar connections,
internal connections to bushings and/or
Figure 5 Sequence of tightening bolt – nut
terminal boards, ground connections, etc..)
connections (1 -> 2 -> 3 -> 4 -> …)
Every bolted assembly must utilize the following

hardware sequence: the bolt with a flat washer
under the head, and on the other side a flat washer
against the flange and a nut. Lock washers or lock 4.4.4.2 Gasket systems
nuts are provided for some of the connections (in
certain cases the external paint locks the nut a) Used gasket systems on transformer
correctly).
Typical bolt tightening sequence: tighten pairs of
bolts on diagonal lines and in two steps to avoid
overstressing: tighten each of the bolts twice,
snugly in the first pass and bring them to the final
tightness in the final pass.
64
apparatus or in the flange. The gasket may be an

O-ring or a flat gasket. The gasket material is
usually high quality nitrile. For some specific
components, other base material can be used. The
gasket is powdered (with talc) or treated with acid-
free Vaseline. The surface of the flanges is treated
to prevent corrosion. The gaskets might be
considered re-usable after accurate inspection of
the used gasket.
System D: This system is used where metal gasket
stops must be present (for ANSI and CSA
standards). The gasket material is nitrile or
impregnated cork. The gasket stops prevent
overstressing of the gasket material. Sealing
compound may not be used. The gaskets may be
considered re-usable after accurate inspection of
the used gasket. Depending on the expected
lifetime of the gasket system, special gasket
material can be provided.
b) Handling re-usable gaskets (C – D)

• Dismantling
° Make sure not to damage the gaskets
when an element is removed from the
main tank.
• Replacement
° Gaskets and metal surfaces have to be
free of dust, oil and other impurities
Figure 6 Different types of gaskets before installation.
° The cleaning can be done with a
Non re-usable gasket types (A – B) degreasing product (a solvent based
System A: This is the system that is normally used degreaser).
for flanged joints on IEC transformers. The gasket • Additives
material is impregnated cork. Joints are treated with ° No glue or other additives may be used
a typical sealing compound. The surface of the between gaskets and metal surface.
gasket material that is exposed to the ambient air
and/or sunlight is treated and painted to prevent
degradation of the gasket material. NOTE
Vaseline is sometimes used for easy mounting
System B: This is the system that is normally used
of the gaskets. Please note that the use of
for flanged joints which are mechanically loaded by
vaseline is only allowed (however not required
the weight of (or force to) the mounted component
and not recommended) on gaskets that are fully
(radiators, etc..). The gasket material is a high-
located in a chamber or groves. In case vaseline
density-fiber plate (IT) (based on aramid fibers).
is used on non-groved or non-chambered
Joints may be treated with a sealing compound to surfaces, the friction towards the compression
become a safer joint. The gaskets are not re- surfaces is no longer sufficient and therefore
usable.
not allowed.
Re-usable gasket types (C – D)
System C: This system is used for typical
c) Lifetime of gaskets
components that have gasket-grooves on the
65
The re-usability of the re-usable gaskets is

influenced by time and temperature. However,
within a period of approximately 10 years, normal • Nitrile rubber gasket joints
re-use of gaskets is allowed. Therefore, we ° In case the joint between two pieces is
recommend renewing the gaskets when a gasket is not broken during dismantling, no special
removed after 10 years from date of manufacture. precautions have to be taken.
° In case the joint is broken, then the
connections have to be cleaned by
d) Making a gasket joint (A – D) peeling–off the sealing compound (e.g.
Sometimes, gaskets are made from two or more with a knife) and after cleaning, a new
pieces in order to cover the whole gasket surface. If sealing compound can be used such as
this is the case, the following instructions have to ”Curil K2” or ”AEG Sealing Compound” or
be taken into consideration. equivalent.
• Impregnated cork gasket joints
Replacement or spare gaskets for systems A and D ° Cork gasket joints can be reproduced in
may need to be cut and/or adjusted on site as the required shape with sealing
follows: compound. When tightening the
connection, the cork material will expand
and close the joint.
4.5 Installation of Conservator and

Pipes
Figure 7 Gasket joint
66
Figure 8 Conservator and pipes assembly
67
1. Unpack all components, check them and clean • completely assembled including radiators: no
all gasket surfaces. special installation or filling is required
2. Mount the conservator support(s). • (partially) filled with oil: the radiators have to be
3. Mount the conservator on its supports (bolts filled with oil by the transformer tank one by
are not to be tightened at this time). one. Remarks: As small amounts of oil may
4. Mount the oil pipes on the cover, including new leak out of closed throttle valves, make sure
gaskets (bolts are not to be tightened at this that an oil can is placed underneath the throttle
time): valves. Connect the radiators as soon as
• The oil connection between tank and possible.
conservator. • with an inert gas and without any oil: the
• The oil connection between bushing turrets radiators should be filled during the vacuum-
and the oil pipe (if any). filling process of the main tank.
• The oil connection between the tap changer
head and its conservator.
5. Mount the vertical oil pipes and their
components including new gaskets (bolts are
not to be tightened at this time):
• The oil drain valve(s) (LTC and main
conservator).
• The pipe to the silica gel breather and the
breather itself.
• If all components are in place, tighten the bolts
on the pipe connections in the same sequence
as you have mounted them. Then tighten the
bolts on the conservator support(s).
CAUTION
Before final tightening of oil connections, check
the position of the valves: full oil filled
chambers may not be entirely closed by any
valve, because thermal oil expansion may
produce high internal pressures possibly
damaging the transformer or its components.
Figure 9 Example of radiator No. 92
If the oil (vacuum) filling process cannot follow

immediately, insert dry air or nitrogen (dew point < -
510C) into the transformer and keep a slight positive
pressure (± 0.2 bar) to prevent moisture ingress. 4.6.1 Mounting instructions
Unpack and check each radiator carefully; remove
blind flanges (the inside should be dry, clean and
free from foreign objects): clean gasket surfaces.
4.6 Installation of radiators For filled transformer tanks, check whether the
throttle valve(s) No. 93 is (are) closed.
Every transformer uses custom designed radiator
assemblies to provide proper cooling for the Remove the blind flanges on the throttle valves:
specific design. clean the gasket surfaces.
The transformer might be shipped: Mount the radiators (one by one) to the tank with
the right side up (top-side = lifting lug); use new
gaskets. Tighten all bolts. Retighten after 24 hours.
68
4.6.3 Filling radiators for (partially) oil-

filled transformers
CAUTION
Never lift radiators by the spotwelded side rods. Fill the radiators one by one as follows:
Always use the lifting lugs on top.
1. Open the air-vent screw No. 94 on the top of
the radiator and valve No. 123 between the
Mount stiffener bars (if any) between the radiators. conservator and the tank.
2. Partially open the lower throttle valve No. 93.
If necessary, touch up the damaged/scratched 3. When oil escapes from the air-vent screw,
radiator surfaces. close the air-vent screw.
Remarks: 4. Completely open the upper and the lower
throttle valve.
The same instructions apply for mounting radiators
on a cooler bank. For connecting the cooler bank to
the transformer we refer to the General Remarks:
Arrangement drawing. During this process, the oil level in the transformer
tank must be checked regularly; the oil level may
never sink under the radiator inlet / highest point of
the windings to avoid moisture, air, or gas ingress.
For this reason, it could be necessary to fill-up oil
4.6.2 Different types of gaskets used immediately (refer to oil filling instructions).
4.6.2.1 High-density-fiber gasket (IT):
This gasket type does not use gasket-stops (see

also section [3] for different gasket types) 4.6.4 Draining oil from a radiator
Always mount two new gaskets together (2x2mm)
and position them on the valves between the stud- 1. Close valve No. 123 between the conservator
bolts. Using a small amount of a correct sealing and the main tank and close both throttle
compound will help to keep the gaskets in place valves No. 93 of the radiator No. 92.
during installation and will limit the risk for leaks. 2. Unscrew the protection cover of the drain plug
No. 95
3. Make sure that the air vent No. 94 is fully
closed.
4. Unscrew entirely and make sure that
4.6.2.2 Impregnated cork gaskets or O-rings: outcoming oil does not drip on the ground.
5. After a while, the oil flow stops due to a
These types of gaskets need a gasket stop (usually vacuum created in the radiator.
by positioning the gasket in groves at the valve- 6. Connect a flexible hose or another device to
side, see also earlier in this section for different the drain plug so that oil spillage is avoided.
gasket types). 7. Open the air vent No. 94
8. Remove the protection cover.
• Inspect the O-ring for any damage prior to 9. Open the air vent by turning the screw in a
reusing it in the final installation. counterclockwise direction.
• Use fresh cork-gaskets to the radiator valve. A 10. Incoming air in radiator results in a rapid oil
small amount of petroleum jelly will help to draining via the drain plug.
keep the gaskets in place during installation. 11. After draining :
° close vent plug No. 94
° remount protection cover of vent plug
° close drain plug No. 95
° remount protection cover of drain plug
69
4.6.5 Disassembling a radiator from a

filled transformer
It might be necessary to disassemble one or more
oil-filled radiators during installation activities.
Follow below guidelines.
1. Remove the fans and fan supports
2. Close valve No. 123 between conservator and
main tank.
3. Close throttle valves No. 93 and drain oil.
4. Unscrew nuts underneath and on top of the
throttle valves.
5. Remove radiators by means of a lifting device.
6. Place a blank flange on the throttle valves of
the transformer when the radiators are Figure 11 Vent plug No. 94
removed for longer than 1 hour. If the radiators
are to be used again, provide them also with a
blank flange.
Figure 12 Throttle valve No. 93 open
Figure 10 Drain plug No. 95 ∗
∗
Part numbers refer to DIN 42558
70
4.7.1.2 Mounting
Reverse procedure.
4.7.2 Current transformers for draw

lead bushings (phase / neutral)
4.7.2.1 Dismounting
1. Disconnect bushing leads from network.

2. Close valve No. 123 between conservator and
Buchholz.
3. Drain oil in main tank.
4. Disconnect cables in terminal box No. 32 on
front- and backside of terminal
Figure 13 Throttle valve No. 93 closed 5. Remove HV bushing.
6. Unscrew nuts on base plate.
7. Disconnect grounding connection between
base plate and cover.
8. Remove base plate.
4.7 Installation of CTs Turn base plate over so that current
transformer arrangement is on the top side.
4.7.1 Current transformers for bottom– 9. Unscrew 4 nuts.
Remove Bakelite base plate, protecting cork
connected bushings (phase / ring, distance tubes and fixing blocks.
neutral) Disconnect grounding connection between
current transformer core and base plate.
4.7.1.1 Dismounting 10 Remove current transformer from base plate.
1. Disconnect bushing leads from network.

2. Remove HV bushing.
3. Disconnect cables in terminal box No. 32 on 4.7.2.2 Mounting
front- and backside of terminal.
4. Unscrew nuts on base plate. Reverse procedure.
5. Disconnect grounding connection between
base plate and cover.
6. Remove base plate.
Turn base plate over so that current
transformer arrangement is on the top side. 4.8 Wiring on the transformer
7. Unscrew 4 nuts.
Remove Bakelite base plate, protecting cork The wiring on the transformer is always completed
ring, distance tubes and fixing blocks. and checked during assembly in the factory.
Disconnect grounding connection between However, the connection between transformer and
current transformer core and base plate. remote control cabinets is only made as a
8. Remove current transformer from base plate. temporary base for testing.
During disassembly for shipment of the transformer,
some parts with an electrical connection must be
disconnected. This will result in free cable-ends (or
free plug-ends) that can be situated on the
71
dismantled part or on the transformer. Free cable- 4.9 Oil quality requirements
ends will be coiled and protected by plastic bags or
another protection and tied to the transformer tank The oil quality is very important for the reliability of
or assemblies. The wires of free cable-ends are the transformer. Oil filling and oil treatment
marked with the same terminal number as the procedures have an enormous impact on the oil
terminal to which they have to be connected during quality. This is why the procedures below should be
the final wiring on site. followed strictly.
Current transformer circuits have been short- The specific filling and treatment procedure to
circuited before and during transportation for safety follow depends on:
purposes. This short circuit wire has to be removed
at the time of final wiring and/or testing. • The transformer design
• The oil supply method
The following wiring types are used: • The voltage class (Un < 70 kV – Un > 70 kV)
• Cabling with a certain cable type. The cables • The method of shipment of the transformer
are mounted into stainless steel cable
channels (possibly with covers) that are fixed In the explanation below we assume that:
to the transformer tank or assembly. This is the
normal standard for IEC transformers. • The transformer has been assembled
• Wiring into conduits (galvanized or in according to the previous guidelines.
aluminum) that are fixed on the transformer • The transformer is filled with an inert gas and
tank or assembly. This is the normal standard does not contain any oil.
for ANSI and CSA transformers.
• Plug-in cable connections, used for some
Remarks:
typical accessories (Qualitrol apparatus, fans,
etc.). Starting from an empty, inert gas filled transformer,
vacuum filling can be performed in one step
(commonly used for small transformers and for
sealed transformers or for transformers with a
4.8.1 Mounting instructions positive pressure system) or in two steps
(commonly used for large transformers): first filling
After mechanical installation of the parts that are to the tank and then filling up the conservator.
be electrically connected: • All necessary oil filling and oil treatment
1. Remove the protection on the cable-end and equipment is available.
check the wire marking with the wiring • New transformer oil of the right quality is
diagram. available (see below).
2. Clean wire ends (and contact-pins of cable-
plugs, if any).
3. Fix the cable in the cable channel. NOTE
4. Introduce the cable into the cable gland. Oil quality and care in handling are extremely
5. Check with the wiring diagram. important for the proper functioning of the
6. Connect the wires to the right terminal. transformer.
7. Tighten the cable gland.
Once again, make sure that the right connection

has been established. 4.9.1 New transformer oil
New transformer oil can be available in drums or in
containers. Normally, new transformer oil is not
degassed and has to be treated (streamlined)
according to the processing parameters below.
72
Before using any transformer oil to fill (or top up) a

transformer, the oil quality should be in accordance
See section [5].
with the applicable standards:
Required oil quality after oil treatment:
• IEC 60296
• ASTM D 3487-88 Dielectric strength: ≥ 75 kV (IEC 60156)
Water content: see section 5
Tangent δ (90 ºC): ≤ 0.5 %
4.9.2 Oil treatment (degassing, If temporary storage of the oil is required, prevent
streamlining) air and water from entering the container. Test the
oil again just before filling.
Oil treatment is used to improve the oil quality by
Remarks:
filtering and degassing the oil.
Some filling installations are equipped with
Transfer the oil from the barrels into a dry and clean
integrated degassing features and do not require
container of suitable size (preferably the same size
separate degassing. In this case, oil samples
as the amount of oil to be treated). Connect the
should be taken at a regular basis before the oil
treatment installation in a closed loop to the
enters the transformer.
container and circulate the oil volume 3 times. The
vacuum should be 1 mbar or less.
Non-inhibited transformer oils: treatment should be
performed at a temperature of 60 ºC 2 (maximum
65 ºC). 4.9.3 New treated transformer oil in
new equipment
Inhibited transformer oils: due to the volatile
character of the inhibitor one should limit the
Oil quality should be in accordance with the
temperature in order to prevent loss of inhibitor.
applicable standards and Pauwels specifications:
Conditions that have been found satisfactory for
most inhibited mineral oil processing can be found • IEC 60422
in the table below. In general, one should limit the • ASTM
treatment temperature for inhibited transformer oils • Pauwels specifications: see further in this
to 50 ºC. section and section [5].
3
Minimum Pressure
T (ºC) Pa Mbar Torr 4.9.4 Transformer oil for transformers
40 5 0.05 0.04 in service
50 10 0.1 0.075
60 20 0.2 0.15 Same as above (4.9.3) applies.
70 40 0.4 0.3
80 100 1.0 0.75
90 400 4.0 3.0
100 1000 10.0 7.5
4.10 Pulling vacuum
Table 13 Oil treatment
The purpose of pulling vacuum is to lower the
pressure inside the transformer tank below the
partial pressure of water vapor at the temperature
2
Temperature at the outlet of the degassing of the insulation. The more the vacuum is lowered
installation below the partial pressure, the better the removal of
3 the surface moisture will be.
Reference: ASTM D 3787
73
CAUTION
Mount the necessary equalizing pipes between
all hydraulic chambers that cannot resist full
4.10.1 Before pulling vacuum vacuum by itself before drawing a vacuum or
before starting any filling process. Check the
Test if there are any leaks. This can easily be done General Arrangement drawing, the
by applying a pressure of 0.15 up to 0.2 bar with documentation and nameplate for more details
dry air or nitrogen. If leaks are detected, close on vacuum resistance. Especially have a look at
them. the tap changer and its conservator, membrane
Ensure that all radiator valves are opened. type conservators etc.
If the transformer is equipped with non-
vacuum/pressure tight accessories (such as a gas B Transformercompartment
detection apparatus, drycol breathers, pressure OLTC-compartment
relief devices, etc.) block these until the vacuum
process is completed or remove them. Expansion tank
vacuum installation
A
CAUTION
In case a Drycol dehydrating breather is
installed on the conservator, or if a gas analyzer OLTC
tank
and electronic devices such as a “Hydran” is
installed on the tank, do NOT allow either a
vacuum to be drawn on, or oil to be injected into
the apparatus. Ensure that either the valves on
Figure 14 Equalizing pipe connections
this apparatus are closed off on both inlet and
outlet sides or that the devices are removed for
the period of pulling vacuum and filling.
DANGER
Never perform an electrical test on a
If the transformer is equipped with a(n) (on) load
transformer under vacuum. Internal flashovers
tap changer, refer to the appropriate (O)LTC
may occur at voltages as low as 200 V, causing
documentation included in this IOM. Prior to pulling
severe damage.
vacuum or performing a leak test using
Do not attempt to climb on a transformer, or
overpressureing be aware that, an equalizing pipe
walk around on any part of the cover, while the
(A) is installed between the (O)LTC compartment
transformer is under vacuum. This is unsafe for
and the tank during transportation. Maintain this
connection untill starting to pull vacuum. In case a personnel and equipment.
connection with valve is used, the valve should be
open while pulling vacuum and closed when the
transformer is energised.
If the conservator is of a membrane type, the 4.10.2 Establishing connections
membrane is NOT capable of withstanding a
vacuum or overpressure. Install the necessary Connect the vacuum connecting point on the
pressure equalizing pipe (B) between the conservator No. 125 with the internal part of the
expansion membrane, the conservator atmoseal bag (via dehydrating breather connection
compartment of the transformer and the flange, on top of conservator). The vacuum
conservator compartment of the (O)LTC. connection should be made as short as possible.
Ensure that a shut off valve is installed. Please
refer to the Figure in "Filling Procedures" included
in this IOM.
74
• Connect a vacuum proof transparent hose (L3) • There is significant moisture in the tank and
between the oil sampling device on the bottom the vapor pressure of the moisture is limiting
filter valve No. 112 and the connecting line of the vacuum to drop to the specified level.
the vacuum pump (L2) on top of the
conservator (or tank if no conservator is
Try the following procedure to determine the cause
present) to visualize the oil level during filling.
of the problem. While the vacuum pump is running,
This transparent hose should be at least 50 cm
close the valves (for a minimum of 30 min.)
(20”) longer than necessary.
between the vacuum pump and the transformer
• Connect the oil pump installation (VP, F) to the
tank.
bottom filter valve (No. 112 - L1). A filter and
degassing installation (if non-degassed oil is • Compare the level of vacuum on the tank and
used) should be part of the installation on the pump side of the valves that are closed.
procedure in order to filter out all the water If the tank pressure increases quite fast, the
particles and impurities. transformer is leaking.
• Open all the cooling systems’ isolation valves • If the vacuum pump side of the valves does
No. 93 if this has not been done already. not drop down quickly, the pump capacity is
too small or probably requires servicing.
• If the vacuum pump side of the valves drops
down quickly and the transformer tank
4.10.3 Pulling vacuum pressure increases slowly, then there is
excess moisture in the tank.
Start the vacuum pump, open all the vacuum lines
to the transformer tank (and other vacuum proof Correct the problem and restart the vacuum
compartments) and then draw a vacuum 6.7 mbar procedure. Should repair on the vacuum pump or
or less, absolute. Hold this vacuum for at least 8 on the vacuum connections take some time, then
hours (increased with 1 hour per 8 hours exposure refill the transformer with dry gas. Should the
time) to assure all gas is removed from the transformer require repairing, then the tank MUST
insulation structures. be refilled with dry gas before attempting repairs.
If the problem is excessive moisture, an extended
vacuum procedure can be applied and special
DANGER attention should be paid to the oil quality before
Never leave a transformer under vacuum energization. See end of this section.
unattended.
4.11 Oil filling standard

4.10.4 Troubleshooting
4.11.1 Oil filling
If the specified vacuum cannot be reached or
maintained, one or more of the following may be A vacuum of minimum 13 mbar must be maintained
the case: during the entire filling process. This means the
• The vacuum pump is too small for the size of valve of the oil supply pipe has to be throttled to
the transformer. maintain this vacuum. This is necessary because,
• The vacuum pump requires servicing and/or while entering the tank, the oil will give off dissolved
new sealing oil. gasses that must be evacuated by the vacuum
• The vacuum connections or the transformer pump. The oil-filling valve must be adjusted to
itself are leaking. maintain a positive pressure up to the throttled
valve.
75
If degassed oil is used to fill the transformer, the Unblock items that were blocked for overpressure
quantity of oil flowing into the tank should not protection.
exceed 12 mm (0.5 inch) per minute, even if the
If the transformer is equipped with oil pumps, vent
required vacuum can be held at a higher filling rate.
these pumps. Furthermore, it is recommended to
This rule should be followed to ensure all voids are
occasionally run the pumps. The procedure is to
correctly filled with oil.
run the pumps for an hour or so, then stop the
The use of oil treatment equipment (streamliner) pumps and about 15 to 30 minutes later, bleed all
with an integrated vacuum degassing chamber is bleeder points on the transformer. Restart the
preferable. In this way residual dissolved gasses pumps and proceed with a number of cycles.
are removed while the oil enters the transformer
Ensure that the (O)LTC compartment (and its
tank. The risk for a process interruption will be
conservator) is correctly filled.
limited as well.
In the case of a conservator design transformer,
Remarks:
bleed air from manholes, bushing turrets, cooling
Certain transformers with a maximum voltage class component systems etc., using the bleeder screws
of 34 kV may be filled with non-degassed oil. The or valves on the equipment. Mount the air
oil should be entered on the top of the tank using a breather(s).
special spray-nozzle. The rate of oil admitted to the
Recheck the transformer oil level and top up if
tank should not exceed 33 liters or 12 mm per
necessary (see further).
minute, even if the required vacuum can be held at
a higher rate. This rule should be followed to
ensure degassing of the oil during filling and to
ensure all voids are correctly filled with oil.
Check the dielectric strength of the oil during filling
in samples taken from the transformer side of the
oil treatment equipment. If a test indicates a
lowering of strength, the filters must be replaced
before continuing.
Continue to fill under vacuum until the oil level
gauge reads the correct level.
Remarks: Figure 15 Transformer filling (without
In case of first step filling of a transformer equipped conservator)
with a conservator (refer to Figure 15) fill up to
approx. 100 mm below the highest point of the
cover. The main insulation must be covered with oil V = Oil storage tank
completely. F = High vacuum filter (streamliner)
VP = Vacuum pump (streamliner)
When the oil level in the transformer main tank (or S = Sampling device (drain plug) of installation
in the conservator) is correct, stop the oil filling and L1 = Filling line of the transformer tank
stop the vacuum pump. Break the vacuum using L2 = Connecting pipe of the vacuum pump
dry air or nitrogen, whichever is available. The gas L3 = Vacuum proof, transparent hose
supply should be 0.15 bar or less, until a pressure T = Transformer Tank
of about 0.15 up to 0.2 bar is obtained in the M = Vacuum measuring device
transformer. Dismantle the vacuum and oil-filling C = Conservator with atmoseal bag
equipment from the transformer. Mount silica gel air
breathers (if there are any).
Open the valves on the non-vacuum/pressure tight
accessories (such as a gas detection apparatus,
drycol breathers, pressure relief devices, etc.).
76
CAUTION
The purpose of vacuum filling is to remove all
gas from the insulation structure. The presence
of gas in the insulation may cause failures
and/or may develop partial discharges that can
develop into an internal failure. In addition, the
interpretation/analysis of dissolved gasses will
be not correct. Therefore, it is very important
that the vacuum filling is performed strictly in
accordance with these instructions.
Figure 16 Transformer filling with conservator 4.12 Topping up oil after initial vacuum
filling
This procedure can be used after the initial vacuum
filling of the main tank (leave filling line L1
4.11.2 Filling procedure in the event of connected to the bottom filter valve No. 112) or for
process interruption transformers that are shipped (partially) oil-filled
(connect the filling line L1 to the top oil filter valve
The procedure of pulling vacuum and oil filling is No. 111). Please note that initial filling of an empty
meant to be a smooth and uninterrupted process. transformer should always be done following the
Should the process be interrupted for any reason, vacuum filling procedure described above or by
then: using the “oil-spray-system”. In certain
circumstances only topping up the oil might be
Stop the flow of oil into the transformer tank. done without following the vacuum filling procedure.
Attempt to return power to the process equipment However if vacuum filling equipment is available,
as soon as possible. Upon the resumption of vacuum filling is to be prefered in any case as this
power, inspect the vacuum gauge. method prevents air bubles to be trapped in the
If the internal tank pressure is below 13 mbar: transformer.
proceed with the filling process.
• Conservator design type transformers and Un
If the tank pressure is between 13 and 32 mbar: < 70 kV may be topped up with degassed oil,
first pull vacuum below 6.7 mbar, then continue directly pumped through a suitable filter (1 to 5
with the filling process. μm) into the conservator without drawing
vacuum.
If the tank pressure is above 32 mbar: drain the oil
• Conservator design type transformers and Un
from the tank and begin the vacuum filling process
> 70 kV must be topped up under vacuum; the
all over again (from the start).
same procedure applies as for initial vacuum
filling. However, the vacuum hold time before
filling may be reduced to 4 hours.
• Non-conservator design type transformers only
need correction of the oil level using degassed
oil.
• If radiators are not mounted before the initial
vacuum filling, mount and fill them according to
the mounting and filling instructions for
radiators (see earlier in this section).
77
Remarks: air should be trapped in the conservator or

other parts of the transformer.
If no degassed oil is available, use streamlining
• Do not re-open the vent plugs No. 99 on the
equipment and apply the correct processing
conservator after filling and venting has been
parameters (depending on the oil type used).
done as described above. If you do re-open
the vent plugs, air can enter the conservator
and the filling or topping up procedure should
CAUTION be repeated.
Never attempt to top up a transformer with oil 2. Transformers with forced oil circulation using
that has not first been tested for adequate pumps should be vented a first time after
dielectric strength. Special care should be taken complete oil filling. Have the pumps run for at
for oil that has been stored outside in drums. least two hours. The oil has to stabilize for
several hours and a second venting sequence
should be performed.
3. After completion of the venting procedure:
° Securely close all vent plugs and replace
protection caps (if present).
4.13 Air venting ° Clean all spilled oil around the vent plugs
so that it cannot be mistaken for oil leaks.
Once the filling process has been completed, all
vent plugs should be opened until all air bubbles
have been evacuated. The most appropriate
venting sequence is first opening the lower vent 4.14 Pre-operational tests
plugs and then the higher ones.
At this point, the transformer has been installed,
For example: completely filled and should be ready for
• Radiators energization. However, in many cases, energization
• Cover will not directly follow completion of the installation
• Overpressure valve and filling process. This is so because other related
• (O)LTC equipment (such as circuit breakers, remote
control, …) has to be ready first. It can take weeks
• Bushing turrets
to complete the entire substation after completion of
• Bushings
the transformer installation.
• Buchholz
• Conservator Whatever the time in-between, we recommend
proceeding with the installation and filling procedure
as soon as possible for the following important
Remarks: reasons:
1. If an expansion membrane of the conservator • Equipment safety: the best practice to store a
type No. 96 has been used and topping up has transformer is completely assembled, filled and
been done without applying vacuum: put well maintained.
overpressure on the pipe to the dehydrating
• Equipment completeness: during erection
breather No. 23 on the membrane, open the
activities one can easily check whether all
vent screws and wait until oil runs out. If
necessary materials are available. Missing and
required, adjust the oil level by using the lower
defective parts will be discovered and can be
filter valve No. 112. Install the dehydrating
replaced in time.
breather (according to the specific installation
procedures available in the documentation
section[7]). To ensure Equipment functionality both mechanical
• When complete filling or topping up has been and electrical tests on the transformer and its
done following the vacuum procedure, no more accessories are recommended as soon as
installation and filling have been completed. This
78
will allow you to perform all necessary tests without Special tests are only to be performed if there are
exceeding the available time limits. Please use a indications of potential problems or defects.
copy of the “Site commissioning report” in section
If Pauwels is doing the erection and commissioning,
[9] to register all applicable test results.
contractual specifications concerning site testing
If immediate energization is possible after testing have precedence over the sequence below.
this is, of course, to be recommended and will
Remarks:
result in the highest efficiency.
Tests and checks related to the specific network or
Section [4], “Putting into Operation”, provides an
to remote controls, as well as cable tests are not
overview of the periods a transformer is allowed to
included in this section.
wait for energization. Depending on the length of
the waiting period, some or all tests should be
repeated.
Once the transformer has been fully assembled and DANGER
oil filled, a number of tests and checks are required - Never perform DC tests other than the ones
to ensure safe energization of the transformer. described below. These types of tests may
overstress the insulation system and/or disturb
the magnetic features and may cause damage
to the transformer.
- Never perform an electrical test on a
4.14.1 Mechanical tests and checks transformer under vacuum.
First of all, a thorough inspection of the transformer

and its accessories should be performed to ensure Required tests:
safe electrical tests and reliable test results.
• Megger test
° Winding megger test
° Core grounding megger test
• Voltage ratio test
4.14.2 Oil sampling and testing
Optional test:
At the end of the mechanical inspection of the
transformer it is required to take the necessary oil • Vector group test
samples for oil testing.
Special tests:
• Insulation power factor test
• Bushing power factor test
4.14.3 Electrical tests • Winding resistance test
• Continuity / impedance check
If the oil quality meets the specifications, you can
proceed with the electrical tests. Before starting any
voltage tests, make sure that the current
transformers are correctly short-circuited.
4.15 Pre-operational tests and checks
Required tests have to be performed in all cases. of accessories
Although the optional test, the vector group test, is
an often performed field test, it is not necessary. In
General items
the “Site commissioning report” section [9] test
sheets are available for the required and optional • Check for remaining equipment or tools on the
tests. transformer cover or other parts
• Check for leaks or other damages
• Check for damaged painting
79
• Check the presence of the Nameplate (or Pressure devices

Ratingplate)
• Pressure relief devices are set in the factory;
• Check grounding connections
check that the device is unblocked. Do not
open the device; strong loaded springs inside
The transformer tank, all external metal parts and it may endanger the personnel.
accessories should be permanently grounded • If pressurized gas equipment is supplied,
according to the correct safety and operation check the regulator for correct operation.
practice and in accordance with instructions for the
specific equipment being used.
Current transformers
All bushings have to remain grounded until final
energization of the unit (except to perform the • All current transformers’ secondary windings
electrical tests). must either be connected to a load or be
shorted out.
• All cables that are connected to the • If it is suspected that the current transformer
transformer should be adequately grounded. core has become magnetized, this must be
corrected, as it will adversely affect the
operation of connected loads, especially
Valves and associated items
protective relays.
• Check that all bolted joints are correctly • Connect a 100 ohm variable resistor of
tightened and that there are no leaks. sufficient wattage based on the secondary
• Make sure that all valves (including radiator output voltage at 150 % secondary current
valves) are in the operation position. across the secondary winding, then slowly
• Ensure that all venting openings are closed. reduce the current to zero. Remove the
resistor and connect the current transformer to
its load or short it.
(Air) breathers
• Check the color of the silica gel and replace if Load tap changers
necessary. Check oil locks.
• Check the protective relay.
• Check the motor drive after it has been
Gas detector / Buchholz relays
electrically connected. Check at least the
• De-block floaters (if applicable). following:
• Bleed the air from the appropriate device. ° Overcurrent motor protection.
° Step by step function.
° Mechanical and electrical overrunning
Bushings
protection.
• Ensure that all bushings and bushing turrets ° Other trip and alarm functions as per
are correctly air bled. Check for leaks, specification.
especially on bolted flanges and the bushing ° Remote control function (if present).
top terminals.
• Ensure that capacitive test taps on condenser
De-energized tap changer
type bushings are correctly grounded or
connected. • Check the trip contact (if present).
• Check for sufficient voltage clearances. • Check and padlock the tap changer into
position.
Temperature gauges
Cooling system
• Temperature gauges are set in the factory at
the values indicated on the documentation or • Check oil pumps, fans and their control
to customer requested values. system. Check for leaks. Observe operation for
at least one hour.
80
• Check if all condensation release plugs are 4.16.3 Oil quality requirement
removed on electrical motors.
• Overcurrent motor protections. Minimum dielectric strength of transformer oil must
• Check and set temperature controllers. be met: see section [5].
• Check the flow indicators for the correct flow
Maximum moisture content as a function of the
direction.
temperature must be met: see section [5].
• Other trip and alarm functions as per
specification. More detailed oil specifications are given in the
• Remote control function (if present). applicable standards IEC 60422 and ASTM.
CAUTION
For transformers with OFAF cooling (Oil Forced
Air Forced), oil pumps always have to be in
4.17 Megger test (Required)
operation if the transformer is energized, even
at no load: pumps always have to run. The purpose of the megger test is to detect internal
movement of parts that may have shorted out some
of the insulation on the core and on the windings
and leads, as well as to check for excessive
moisture contamination.
4.16 Oil sampling and testing Remarks:
• For all megger tests a good estimate of the
4.16.1 Sampling inner transformer temperature is required. For
oil-filled transformers the oil temperature
For the sampling procedure we refer to the gauge can give a good estimation. Be aware of
maintenance section [5] further on in this IOM the atmospherical influences.
Manual. • Multiply the measured insulation resistance by
the correction factors, given by the table in
section [0], to bring the measured value back
0
to a 20 C reference temperature.
• Insulation resistances measured without oil
4.16.2 Required oil quality tests filling on a nitrogen-filled transformer are not
comparable with the measured values in the
After oil filling and before performing electrical tests factory. Below values are given for an oil-filled
two oil tests are required. Write the test results on a transformer.
copy of the “Site commissioning report”.
• Dielectric strength
• Moisture or water content
4.17.1 Winding insulation megger test
More information on these oil tests and additional
A megger test on a transformer winding is a single-
oil tests is provided in the maintenance section [5].
phase test. When testing the HV winding, ground all
The additional tests may be necessary if there are
LV and TV bushings, connect all HV bushings
indications of potential problems or if specific
together, and megger the HV bushings to ground.
maintenance procedures require reference values
Wait for one minute and repeat the test. Do this for
(e.g. DGA analysis).
10 subsequent measurements. Follow the same
way for all megger tests of all windings. The
polarization index is the measurement after 10
minutes divided by the one after one minute.
Use a megger voltage of 5000 V DC (1000 V DC
for a nitrogen-filled transformer). The bushings
81
must be cleaned and dry. Do not use pieces of The test is conducted by using a megger voltage of
strings etc.., to hold leads apart, as they may damp 1000 V DC. All windings must be shorted and
and introduce a leakage path sufficient to greatly grounded before starting this test.
distort the true readings. High atmospheric humidity
Both core grounding and clamp grounding megger
will also influence the test results.
values should exceed 100 Mohms corrected to
In the case of a two-winding transformer, the 20°C according to the correction table in the table
following winding megger tests should be section [0].
performed:
1. Open the access hole towards the terminals
• HV windings to ground, with LV windings No. 137 by unbolting the access cover. The
grounded. atmosphere in this box is ”air”.
• LV windings to ground, with HV windings 2. Disconnect the core grounding link by
grounded. unscrewing the bolts on the core bushing and
• Connect all HV and LV windings together and grounding point. The core is now disconnected
megger to ground. from ground potential.
3. Perform a megger test between bushing and
grounding point.
Complete the “Insulation resistance measurement”
part of the site commissioning report for 2-winding
transformers .
NOTE
In the case of a three-winding transformer, the Some transformers have more than one core in
following winding megger tests should be the main tank.
performed:
• HV windings to ground, with LV and TV
• Each core grounding is brought out to a
windings grounded.
separate insulation bushing and the purpose is
• LV windings to ground, with HV and TV
marked near each bushing.
windings grounded.
• The measurement has to be done for each
• TV windings to ground, with HV and LV
individual core.
windings grounded.
• Connect all HV, LV and TV windings together
and megger to ground. After testing:
1. Reconnect the core grounding link between
Complete the “Insulation resistance measurement” the core bushing and grounding point.
part of the site commissioning report for 3-winding
transformers. on bushing on grounding point
stud
Required values: Maximum torque 40 Nm (30 20 to 30 Nm (14.8 to
spanner value lbf.ft) 21.1 lbf.ft)
• Megger values: minimum 10 Mohm/kV with a
minimum of 400 Mohm.
• Polarization index: minimum 1 2. Put the nitrile rubber gasket back into place on
the box frame.
3. Put the cover back into place and tighten with
bolts/nuts
4.17.2 Core grounding megger test
The core grounding megger test is used to
determine the state of the core clamping structure,
core to ground and/or clamp to ground insulation.
The core is tested by accessing the core ground
bushing located on the cover of the tank No. 137.
82
4.17.3 Accessories insulation megger measured values should be within the tolerances
test given in the Test Reports in section [8].
For transformers with tap changing equipment, on
The insulation of accessories should be meggered load and/or de-energized, it is recommended that
with a megger voltage of 500 V DC. the ratio be measured on all taps. Do not change
taps whilst the voltage is being applied to the
transformer.
Access cover Bolts / nuts
Nitrile gasket
with retainers Bushing
4.18.1 Ratio meter method
Follow the instruction that comes with the
AIR instrument you will be using. The turns ratio
between the transformer windings can be obtained
from the transformer nameplate. Remember to take
into account the phase relationships of the windings
that are being measured. The measured ratio must
Grounding be within the tolerance as specified in the
point standards.
The null meter on the ratio instrument should be
OIL IN MAIN TANK Transformer steady while the test is performed. If the needle on
cover
the instrument jumps about or if it is not possible to
null the meter, this may indicate incorrect
Core grounding lead TO CORE instrument use, incorrect or poor measurement lead
connection, open or shorted turns in one or more
windings.
Figure 17 Core grounding assembly
4.18.2 Voltage ratio test for turns ratio

4.18 Voltage ratio test (Required) Connect the voltage power supply to the HV
windings. Two voltmeters must be used; one
connected to the HV windings and one to the LV
windings. They should be read simultaneously. The
DANGER ratio of the readings of both voltmeters should
Always use a low voltage power supply correspond with the nameplate ratio. The values
(maximum 400 V) and connect it to the HV must be within the tolerance as specified in the
windings so that ALL OTHER INDUCED standards (taking into account the accuracy of the
VOLTAGES WILL BE STEPPED DOWN. Pay used voltmeters).
special attention to the bushings during this
test.
The voltage ratio test is used to ensure that internal 4.19 Vector group test (Optional)
connections have been made correctly. The test
can be performed with a transformer turns ratio The vector group test is used to ensure that the
meter or by using the voltage ratio check. The internal connections have been made correctly. The
83
vector group can be checked by using the 4.20 Insulation power factor test or TAN
alternating voltage method. δ (Special)
Connect one point of the HV windings to one point
of the LV windings (see the figure below for The insulation power factor test is also called
example). tangens delta test (tan δ). The test results are used
to help determine the dryness of the insulation
Connect a low voltage power supply to the full HV system in the main transformer and the bushings
windings. Record readings of the applied voltage (see further).
and the superposed voltages (as shown on the
figure below for example). Compare the measured The measuring method depends on the equipment
values with the calculated values applicable for the used. We refer to the guidelines of the specific
transformer vector group. Check if all values are equipment.
correct.
Remarks:
Example: vector group Yd1; Three-phase voltage
1. The bushings have to be clean and dry. Do not
supply on HV windings.
use pieces of strings etc. to hold leads apart,
as they may damp and introduce a leakage
path sufficient to greatly distort the true
reading. High atmospheric humidity will also
influence the test results.
2. There may be problems to test in the field if
power frequency interference is nearby. Some
test sets work at a higher frequency to reduce
the interference problem.
3. Considering the potential lack of experience,
the number of intervening factors and the
absence of standards relating to measuring
instruments, you have to be careful with the
interpretation of insulation power factor tests.
Therefore, when site tests are comparably
performed, the changes observed from one
test result to the next are more important than
the absolute values of the individual tests.
Perform the test between:

• HV and LV with TV windings grounded (if
present).
• LV and HV with TV windings grounded (if
present).
• TV (if present) and HV with LV windings
grounded.
Normal values for transformers in service have to

Figure 18 Vector group test ∗ be below 1 % (50 Hz and corrected to 20°C); for
factory new transformers even below 0.5 % is
recommended. Values above 2 % call for
immediate examination.
∗
connect these points together
84
4.21 Bushing power factor test (Special • Remove the test cap with the grounding spring
test) and connect the power factor test equipment.
• The power factor test should be performed at
HV bushings require attention during the whole life about the same temperature as the factory test
of a transformer. The bushing power factor test can to allow correlation of test results. The power
be performed using a dissipation/power factor factor reading depends on the temperature,
bridge or a Doble test set. The transformer lead and the less correction that has to be applied,
must be disconnected from the bushing for this test. the better. Test from the test cap to the top
It is relatively simple to do this for draw lead cap, from the test cap to ground and from the
bushings, but oil must be drained for bottom top cap to ground. The values of C1 and C2
connected bushings. can be derived. Expect to have a difference
between the factory test values and the field
test results (commonly ~ 10 %).
Grounding
spring CAUTION
The bushing test terminal grounding cap MUST
Tap be put into place at the end of the test.
electrode
Operation of the bushing without grounding the
tap electrode will very likely cause flashover
Insulating
bushing
due to the high open circuit voltage produced at
the tap.
Figure 19 Bushing testtap 4.22 Winding resistance test (Special

test)
Bushing Measuring of resistances is not required. It may

center
conductor however be a practical test in the field, although a
continuity impedance check is a better test (see
C1
further).
Test cap
Please note that resistance measurement results
C2 may be influenced by:
Ground • Heating up of the windings during the test.
• Contact resistance of all connection points
during the test.
• Contact resistance of a tap changer. In case of
important deviations, operate the load tap
Figure 20 Capacitive bushing representation changer many times with about 10 % current
(as described below under "continuity check"):
Evaluation of the test results should be based on this will clean the surface contacts. De-
the bushing test certificates in the documentation energized tap changers should be operated
section [7]. only mechanically!
Some testing notes and suggestions:

If the measured resistance values change by using
• The bushings must be clean and dry. High another measuring current, this indicates that the
atmospheric humidity will also influence the measuring system is influenced by one of the
test results. above points.
85
The resistance of the windings may be measured Rm = measured resistance

by using a resistance bridge. There is a large Ts = desired reference temperature
number of bridges on the market, but the two most Tm = temperature at which resistance was
known are: masured.
For aluminum windings, change the factor 235 to
• The Kelvin bridge, for the measurement of 225.
resistances lower than one ohm.
• The Wheatstone bridge, for the measurement
of resistances of one ohm or higher.
Some modern bridges can cover a wider resistance 4.23 Continuity impedance check
range than these traditional bridges. (Special test)
The operation of the bridge will be explained in the The continuity impedance test is meant to check
instructions that come with it. However, there are the impedance and all internal connections,
some points to watch out for when measuring including the continuity of the current for the
transformer resistance. windings and all tap connections. At the same time,
All CTs in the transformer must be shorted so that the main function of the load tap changer can be
no remanence is introduced into the CT-core. This checked. The current should be limited to a
would adversely affect the operation of the maximum of 10 % of the rated current.
transformer protection system. Use an AC power voltage supply. The needed
supply can be defined as follows:
DANGER
Read the following points concerning the • Supply voltage = 10 % or less of the
energy stored in the winding during this test. impedance voltage. (expressed in % of the
rated voltage on the Nameplate or
Ratingplate).
Although a power supply of only 12 volts is used, • Current supply = 10 % or less of the rated
the amount of energy stored in the inductive current (refer to the Nameplate or Ratingplate).
reactance of the windings is quite large. Switching
the circuit on is safe, but interrupting the current at The power may be supplied to the HV windings or
the completion of each test can be dangerous. to the LV windings, depending on the available
Please pay attention to the following: power supply. The not supplied windings are to be
• Use a resistance bridge that is specifically shorted with adequately sized shorting leads. Refer
suitable for measuring highly inductive loads. to the transformer Nameplate (or Ratingplate).
• Break the circuit slowly dissipated in an arc, or Once all connections are made, switch the power
shunt the winding through a resistance before on and read the supply voltages and currents.
opening the circuit. Switch off the supply and repeat the test for each
• Before disconnecting the leads from the position of the de-energized or load tap changer.
transformer, ensure that all stored energy has Do not operate the load tap changer while the
been dissipated. supply is switched on.
In the case of unbalanced currents, voltages or
Failure to do this may endanger personnel and the discontinuity, something is wrong with the internal
transformer. connections or there is a malfunction on the load
tap changer.
Temperature conversions can be calculated as
follows:
Ts + 235
Rs = Rm ( ) Where:
Tm + 235
Rs = the resistance at desired temperature
86
4.24 Removal of surface moisture amount of air infiltration and the temperature at the
time the vacuum is applied. Unfortunately, the
If the dew point test that was performed (at arrival relative humidity and the amount of infiltration is a
or for exposure times > 24 hours) indicates an very difficult thing to monitor. Extending the vacuum
unacceptable dew point temperature, an extended hold time for longer than the table below suggests
vacuum processing can be used to flash off surface is recommendable.
moisture. This can be done to see if this improves
the situation before attempting more complicated Relative Hold time Hours
and costly drying out procedures. humidity Expo- Insula- Insula- Insula-
of sure tion tion tion
ambient time temp temp temp
air (hours) 21ºC or 10ºC to under
4.24.1 Removal of surface moisture by higher 21ºC 10ºC
10 6 9 12
vacuum 20 12 18 24
10 to
30 18 27 36
The purpose behind the application of vacuum is to 25%
40 24 36 48
lower the pressure inside the transformer tank to
something below the partial pressure of water vapor 50 30 45 60
at the temperature of the insulation. The more the 10 15 23 30
vacuum is lowered below the partial pressure, the 25 to 20 25 38 50
better the removal of the surface moisture. This 50% 30 40 60 80
process does not work well for moisture deep within 40 55 83 110
solid insulation, as it would take an extremely long 50 to 10 20 30 40
time for the moisture to work its way out to the 70% 20 40 60 80
surface from deep in the interior. Table 15 Vacuum hold times for flashing
The vacuum to be drawn depends on the surface moisture
temperature of the insulation (removal of moisture
by vacuum of moisture in freezing weather is After the required hold time has been achived,
unpractical without the application of heat). The break the vacuum with dry air or nitrogen that has a
drying process will be accelerated by providing a dew point lower than desired for the transformer.
lower vacuum than listed. Repeat the dew point test after a period of at least
24 hours – this period is needed for the moisture
content of the gas and insulation to stabilize. If the
Insulation Partial Required dew point is satisfactory, proceed with the final
Temperature Pressure of vacuum vacuum for filling. If the dew point is still not
ºC water vapor Microns satisfactory, contact Pauwels for further
Microns instructions.
25 105 100 or lower
20 85 80 or lower
15 50 45 or lower
10 36 32 or lower 4.24.2 Removal of surface moisture by
5 26 23 or lower
2 22 20 or lower
dry air recycling
Table 14 Required vacuum for flashing A simple method for removal of surface moisture
surface moisture can be useful in some cases: i.e. when vacuum
equipment is not directly at hand.
The hold time, or the duration that the vacuum must
• Recycle transformer with dry air and maintain
be held, depends on the relative humidity of the
at all times a positive pressure on the tank
ambient air that entered the transformer during the
(minimum 0.05 bar and maximum 0.2 bar)
exposure period, the time of the exposure, the
87
• Inflation point and bleeding point of dry air is

preferably diagonally located.
• Total quantity of dry air required is about three
times the tank volume of transformer.
• The total tank volume can be taken from oil
content as shown on the nameplate.
• After passing–through a volume of dry air,
equal to 3 times the tank volume, the bleeding
point has to be closed and a positive pressure
as mentioned above, has to be maintained for
at least 3 days.
Re-measure dew point as described above.
88
5 Commissioning
89
90
5.1 Repeating pre-operational tests If applicable, check also if all connections of the
ELASTIMOLD or PFISTERER type have been
The transformer should now be in operational sealed voltage proof. Otherwise the transformer
condition with all related equipment (circuit may not be energized.
breakers, remote control,…) installed and tested.
Pre-operational tests and checks on the
transformer have been performed to section [3]
Repeating these tests and checks is not necessary 5.1.3 Energization follows later than 6
if energization follows within a few days or months after installation and
maximum within a few weeks. testing
However, depending on the works that are
performed after assembling and testing the In this case all tests and checks as well as the air
transformer and depending on the time to venting procedure should be repeated before
energization, it may be required to repeat some energization.
tests and checks just before energization.
5.2 Operational system tests

5.1.1 Energization follows within 4
weeks after installation and Once the transformer has been (re-)checked and
testing (re-)tested, some operational tests on the complete
system – transformer, network and remote control
facilities – are required.
It is important to know if in this short period no other
activities have been performed on the transformer Below instructions are meant as a general
that could possibly influence the fitness for use. guideline. For more information, refer to the
General Arrangement drawing, the Nameplate,
• In case no such activities took place, proceed
Schematic drawings and documentation included in
with the commissioning procedure.
this IOM manual. Also use the information about
• In case some activities took place: repeat the the network configuration, remote control and
necessary tests and checks according to protection system.
section [3]
Write down the test results on a copy of the “Site
commissioning report” section [9]
If applicable, check also if all connections of the
ELASTIMOLD or PFISTERER type have been
sealed voltage proof. Otherwise the transformer
may not be energized.
5.2.1 Alarm circuits and contacts
Alarms are mentioned as a warning for an
abnormal situation on the transformer or its
5.1.2 Energization follows 4 weeks to 6 accessories that needs observation, action and
months after installation and follow up. There is no need to place the transformer
testing out of service.
The most commonly used alarms are:
Repeat:
• Slow gas production (Buchholz or gas relay).
• Air venting procedure according to section [3]
• Temperature alarms (first stage oil and/or
• All pre-operational tests and checks of
winding temperature).
accessories according to section [3]
• Oil level alarms (low and/or high level).
91
• Internal pressure alarms.

• Alarms on the cooling circuits (supply failures,
oil flow failures, etc.). 5.2.4 Temperature settings
• LTC alarms (supply failures, etc.).
Make sure all temperature settings are correct and
equal to or lower than the values on Pauwels
Please consult also the Nameplate and Schematic drawings (Nameplate and/or Schematic drawings).
drawings in the drawing section. Never use higher settings than the ones indicated
on these drawings, as this can cause too slow
If an alarm is generated on the transformer, it
reaction (or no reaction at all) of the protective
should be checked if this alarm switches on the
devices. Needless to say that serious damage may
related alarms on the entire system (such as signal
occur.
lamps, flag relays, buzzers, remote indicators, etc.).
CAUTION
Temperature settings ≤ values on Pauwels
5.2.2 Trip circuits and contacts
drawings
Trip contacts on the transformer or on accessories
immediately place the transformer out of service in
any abnormal situation that can damage the Carefully check the settings of:
equipment or its environment. • The thermostat(s)
The most commonly used trip contacts are: • Oil thermometer(s)
• Winding Temperature Indicators (WTI’s) for the
• Quick gas production (Buchholz or gas relay). different windings
• Quick internal pressure rises.
• Network protection relays (fed by current
and/or voltage transformers on the
transformer). 5.2.5 Verification of overpressure relief
• (O)LTC failure. etc. devices
If a trip is generated on the transformer, it should be The same remarks apply as for the temperature
checked if this trip immediately switches off the settings.
transformer from the network.
5.2.6 Voltage relation check

5.2.3 Remote control
Before switching on, a final check of the voltage
Depending on the actual network control system, it relation between all incoming and outgoing voltages
should be checked that all functions work should be performed.
satisfactory both on the transformer (in the control
cabinets) and in the remote control mode. The “Site
commissioning report” is indicating both:
• M.K.: Marshalling Kiosk or Transformer Control 5.3 Energization
Cabinet
• Client: All remote control equipment from the Once the transformer is fully assembled, checked
client and tested as described above, and after final
checks and testing of the protection equipment, the
92
transformer may be energized. If the ambient

temperature is not lower than -20ºC.
5.3.1.2 Transformers without forced oil
circulation using pumps.
DANGER Wait for :

If the ambient termperature is very low or can
• minimum 16 hours if high voltage ≤ 245 kV
be expected (below -20ºC), special precautions
• minimum 48 hours if high voltage > 245 kV
should be taken before energanization. Contact
Pauwels for further instructions.
It is usefull to start here with a log-book, recording 5.3.2 First energizing at no load
all important readings and observations for each conditions.
transformer, will be helpfull for the maintenance and
for identifying problems during the life time of the Set the (O)LTC/DTC for the right voltage ratio. Lock
transformer. It is highly recommended to take an oil the DTC drive against mal-operation while the
sample for DGA prior to energisation. This analysis transformer is under voltage.
forms a benchmark for all future DGA’s. To reduce the inrush-current during the first
energizing, it is advisable to set the (O)LTC two or
three steps out of the voltage ratio, so that more
turns are in service (refer to the Nameplate). This
5.3.1 Minimum oil stabilising period can only be done if the transformer is of a variable
flux design.
after final oil filling
1. Switch on the voltage:
The transformer oil should be stabilised after final 2. Check the secondary voltage (and eventually
oil filling. This condition will be normally fulfilled if the tertiary voltage).
the transformer has been filled some days or weeks 3. Check the no load current.
before energisation.
NOTE
During the first energizing, a noise-peak can be
detected. This peak will be dissapear after a few
5.3.1.1 Transformer with forced oil circulation
minutes upto an hour.
using pumps
Have the pumps run for at least 2 hours and wait

for : A general observation of and around the equipment
is suggested and should include a general
• minimum 8 hours if high voltage ≤ 245 kV awareness of what is happening to all the
• minimum 24 hours if high voltage > 245 kV equipment located in the electrical substation.
Unusual noises and disturbances should be
investigated. such as :
CAUTION • Fans, pumps, etc.. operating when they should
The pumps may not be switched on if oil not
temperature is below –10 ºC. In this case follow
• Circuit breakers or other equipment operating
the required waiting times for transformers
at odd moments.
without pumps, energise at no load conditions
• LTC taps changes too frequent or no changes
and wait until oil temperature raised above -
at all.
10ºC. Proceed with pumps running.
• Oil leaks. Small quantities of oil can spread
over large areas and can collect a lot of dust
very quickly.
93
5.3.3 Loading the transformer
DANGER
Do not energize the transformer at operation
load within 24 hours after putting at no load
condition.
Set the (O)LTC in the right position and check the

outgoing voltage. (If parallel-operation with other
transformers is provided, the voltage ratio should
be the same for all transformers). If an AVR
(automatic voltage regulator) is provided, the tap
changer will automaticly run to the right position.
1. Switch on the load
2. Check and record the following:
° Voltages and load currents
° Ambient temperature, oil and winding
termperatures and oil level(s).
Condition of accessories (as dehydrating breathers,

fans, pumps etc...)
94
6 Maintenance
95
96
6.1 Transformer maintenance c) Unusual service conditions: It happens

sometimes that units have to be relocated
6.1.1 Safety during maintenance to another location. Due to this new
environment, it may happen that the
originally agreed upon performances of the
Remember that hazardous voltage is present on an
unit are not 100 % as designed for.
energized transformer, so proper safety precautions
Therefore, the intention of having a
must always be observed when working on this
transformer operated under unusual
equipment. Consult the safety instruction in section
operating duty, frequency of operation,
[0] before starting any maintenance activities.
difficulty of maintenance, parallel operation,
reverse power operation, unbalanced
voltage conditions, or special insulation
DANGER requirements must be brought to the
Never perform maintenance or attempt to climb attention of your nearest Pauwels
on any part of a transformer unless all proper Transformers Representative.
safety precautions have been taken, including
de-energizing and proper terminal grounding.
6.1.3 External cleaning

Use an oil solvent to thoroughly remove all oil that
6.1.2 General maintenance guidelines appears on the outside of the tank or on the
gaskets. This oil, later showing up on the painted
Transformers are very reliable electrical equipment surface, often gives the false impression of a leak.
if well maintained and working under normal
operation conditions. Nevertheless, failures due to The bushing porcelains must be kept free from dust
improper maintenance or abnormal operation and dirt and have to be inspected at least once a
conditions may cause the transformer to be out of year. Abnormal conditions such as sandstorms, salt
service for a long time. This will especially be the deposits, dust, or chemical fumes require regular
case when custom made parts have to be ordered cleaning to avoid accumulations to the external
and installed. As power supply may often be critical, surface. Accepted methods of hot line washing or
it is absolutely worth spending the necessary time cleaning with solvents may be used.
on a good maintenance program. Keep the heat radiating surfaces of the transformer
Remarks: clean. External surfaces of forced oil heat
exchangers should be periodically cleaned as a
1. Transformer logbook: It is recommended to particular dusty location may dictate. Transformers
record readings and observations for every near the seacoast or in corrosive atmosphere areas
transformer in a logbook. This should not only should be painted regularly to prevent corroding or
be done during the warranty period but during rusting of metal parts.
the complete lifetime of the transformer.
2. Special service conditions: Special attention If it becomes necessary to remove a radiator or air-
must be paid when the transformer operates cooled oil cooler, first close the valves, top and
under abnormal conditions. bottom, and bolt them in the closed position. Next,
a) Bushings exposed to dust or chemically drain the oil from the radiator by removing the drain
laden air must be kept clean to prevent plug from the bottom header and the vent plug from
flashovers from occurring due to the the top. After draining the oil, remove the radiator. If
formation of conducting deposits on the the radiator/cooler is removed for any length of
porcelain. time, the transformer valves should be sealed with
b) Transformers installed near a seacoast gaskets and covered with suitable plates. This also
must be kept well painted to avoid corrosion applies to the radiator-cooler openings.
by salt air. All breathers and small openings in pressure relief
valves (and pressure vacuum bleeders on sealed
97
tank system and inert gas system units) must be • venting is only allowed on places filled with oil.
kept clean and in operating condition. This is not always the case when related to
nitrogen cushioned sealed tank systems.
All ground buses and wiring leads to ground must
be kept in good condition. Proper relay operation
depends on low ground resistance. Ground Venting is also required when components are
resistance must be measured annually replaced which are situated in places where oil is
involved.
6.2 Periodic Inspection of

transformers in service 6.2.4 External circuits and control
equipment
6.2.1 Oil levels and silica gel
The following must be inspected 30 days after
The oil levels in the tank and load tap changer installation and once a year after that.
mechanism compartment should be checked at • Control circuit voltage.
two-week intervals during the first month of
• Excess heating of parts - evidence by
operation and annually after that.
discoloration of metal parts, charred insulation,
Check the condition of the silica gel in the air or odor.
breathers weekly. Replace if necessary. • Freedom of moving parts (binding or sticking is
not allowed).
• Excessive noise in relay coils.
• Excessive arcing in opening circuits.
• Proper functioning of timing devices,
6.2.2 Oil quality sequencing of devices, relief device alarm
contacts, thermometer contacts, etc.
Regular testing of the oil quality is required. • Check the heaters in the control cabinets.
Dielectrical strength and water content are standard
• Also check temperature settings. These
oil tests to be performed on an annual basis. DGA
settings can be lower than the ones indicated
is highly recommended as well.
on the schematic diagrams but never higher.
• Evidence of water or liquids in control cabinets
and in air-filled cable boxes.
6.2.3 Venting
At moments when the transformer is not energized, 6.2.5 (On) Load tap changer – (O)LTC
it is advised to use this opportunity to vent the air or
gas bubbles from the different places where air We refer to the specific documentation of the
vents are installed. Like on top of radiators, (O)LTC for maintenance instructions. Also check
manholes, pipes, conservators with atmoseal bag, the oil quality and oil level on a regular basis.
etc., wherever applicable.
The basic conditions that must be fulfilled before
venting is allowed are the following:
• the transformer is de-energized and suitable 6.2.6 De-energized tap changer – DTC
grounding has been done
• the internal pressure is higher than the Beside the specific maintenance instructions in the
ambient pressure documentation, the DTC has to be switched over its
total range for at least ten times and this has to be
done minimum twice a year.
98
6.2.8.3 Other
6.2.7 Cooling system Make sure that the drain holes (closed with a plastic
plug upon delivery) are open (to allow draining of
Regarding naturally cooled transformers and condensation) and check also that the fan blades
transformers equipped with air-cooled oil coolers, can rotate without any obstruction of foreign objects
there is, in general, no need for taking special steps (like bird’s nests etc.).
to keep the inner side (oil circuit) of the cooling
surfaces clean, as long as the oil is in good
condition. If, however, formation of sludge in the oil
has set in, the sludge may deposit in horizontal
surfaces in radiators and coolers. In such a case, 6.2.9 Temperature
the radiators and the coolers should be rinsed in
connection with the changing of oil and overhauling The life of a transformer is highly dependent on the
of the transformer. If the sludge does not loosen by temperature prevailing in the windings and the core
flushing with oil, use benzine, trichlorethylene, etc., of the transformer under operation. It is therefore
and afterwards flush with oil. important that the temperature is continually kept
The other side that is exposed to the elements by under observation (e.g. via a remote sensing
system towards a dispatch center).
dust, sand, etc., has to be cleaned as mentioned
before. Even with a low temperature of the cooling medium
(ambient air), the transformer can be overloaded.
Hence the permissible overload must not be judged
only from the temperature rise of the oil above the
cooling medium, because the temperature drop
6.2.8 Fans winding-oil increases with the 1.6th power of the
increase of load. The ANSI/IEC Loading Guide may
6.2.8.1 Bearings be used on condition that the ”assumed
characteristics at rated load” as mentioned in the
Fan motors are executed with sealed ball bearings applicable standard, will be replaced by ”actual
lubricated with heavy-duty grease that do not characteristics after testing”. This means that the
require any maintenance as experienced by our fan actual ratio for no load and load losses including
suppliers and also by Pauwels’ after service the actual top oil and average winding rise has to
engineers during many decades. The bearings are be used for good judgment on allowable overload
from the so-called “maintenance free” type; it is situations.
advisable to know the general maintenance
instructions on bearings as mentioned by bearing, In case of doubt, Pauwels has to be consulted.
motor and fan manufacturers. Normally, it is not possible to place a temperature
measuring device directly on the windings of a
transformer, except in a few special cases where
fiber optics are mounted in the windings to measure
6.2.8.2 Periodical fan operation direct temperatures. Pauwels uses a method by
means of which an artificially obtained temperature
During extended periods of reduced transformer is measured, which follows the temperature in one
capacity not requiring fan operation, it is required or more of the windings of the transformers.
that the fans be activated on a periodical base (bi This device is installed if the design specifications
weekly for 1 hour), to assure satisfactory operation called for a Winding Temperature Indicator or
when required. This is valid for all electrical motors ”WTI”. In case a ”WTI” is not installed, the top oil
of fans, pumps etc. temperature indicator related to the ambient
temperature will give a reasonable indication about
the load conditions.
99
If, without an increase in load or change in 6.2.11 Periodic electrical testing

environmental conditions, there is a tendency for
the temperature of a transformer to rise, the reason 6.2.11.1 Power factor test
may be that in some way the cooling is reduced
(e.g.: fans out of service). It is recommended to perform a power factor test
Another reason for abnormal temperature may be whenever the unit has been de-energized for longer
that the oil has started to form sludge deposits in periods (> 1 month) or when the unit is opened for
the radiators, on the windings and/or on the core of any reason. In addition, it is recommended to
the transformer. The cooling of the active part is perform the test on an annual basis.
then reduced, and its temperature will increase. We refer to section [3] for more information about
However, the latter situation is considered to be a this test and the required values.
very abnormal one.
If abnormal temperature rises have been found, the
thermometer should first be checked for proper
functioning. 6.2.11.2 Accessories
The overload capacity is sometimes limited by the
accessories of the transformer (e.g. bushings, tap Test all accessories once a year. Examine all
changers, etc.) After every continuous overload of instruments, electrical cables and conductors,
20 % or more, an investigation is recommended. signaling and operating devices to the control room
or control board. Megger testing is also
recommended once a year.
6.2.10 Inspection of tank, cover, gaskets

and valves
6.3 Periodic inspection of
Tank, cover, gaskets and valves require annual transformers in storage
inspection for leakage, etc. All required
replacements or adjustments should be 1. Keep the bushings and the external surfaces
accomplished as soon as possible. clean.
2. Check the gas pressure if a gas pressure
Groundings: Check the transformer grounding installation is still connected.
connections and all groundings of accessories. 3. Keep the unconnected valves closed.
Painting: Check the transformer painting and 4. Check the silica gel air dryer at least once a
repaint (parts) if necessary. month; replace the silica gel if necessary.
Check also the level of the oil lock. The color
Gaskets: We refer to the installation chapter, change must start at the oil lock side of the air
section [3] for advice on whether to re-use gaskets breather, otherwise air is coming in through a
or not. leak.
Valves: In case leakage is detected on the driving 5. Check the oil level of the transformer once a
shaft, re-tighten the compression gland. Use only month (in case of a dropping oil level, inspect
graphite-free sealing material when changing the tank for possible leaks).
packings. 6. Check whether the panel heater in the control
cabinet is functioning, especially before and
during wintertime.
7. Check the external painted surfaces and the
cable box for paint damage or corrosion once
a year.
100
In case of any irregularity, repair it as soon as energization)

possible or contact the manufacturer Pauwels. W = weekly
M = monthly
S = semi-annually (6 months)
A = annually
CAUTION WR = when required
Store the transformer in a dry, cool and properly F = according to the (O)LTC documentation
ventilated area. section [7].
6.4 Maintenance inspection chart 6.4.2 Maintenance activity to perform
The maintenance inspection chart (see table below) 1. Visual inspection and reading
lists suggested rules for performing inspections, 2. Cleaning and examination
recordings and maintenance. 3. Taking oil sample, testing for dielectrical
strength, water content and DGA.
Remarks: 4. Filtering
Not all items necessarily apply to the specific 5. Lubrication
transformer, because some accessories or features 6. Operating test
may not be available. 7. Testing electrical circuits
8. Megger test electrical circuits
9. Inspection / cleaning of contacts
10 Changing contacts
6.4.1 Frequency indications

D = daily (especially during the first weeks of
101
Maintenance activity to perform
COMPONENT 1 2 3 4 5 6 7 8 9 10
Painting of tank, cover and metal

A
parts: repaint if necessary
Condition of gaskets, absence of oil
leaks: retighten or replace gaskets if A
necessary
Conservator A
Radiators: similar temperature on
bottom side of all radiators (indication A
for formation of sludge)
Fans attached on radiators A S A A A
Fans: plugs on drain holes removed? A
Coolers with fans incorporated A S A A A
Coolers water-cooled, (oil side) WR
S-
Coolers water-cooled, (water side)
WR
Valves WR
Oil pumps with motor WR A A A
4
Oil of transformer main tank A WR
Bushings A
Magnetic oil level indicators D WR A A A
Buchholz relay W WR A A A
Temperature indicator(s) D WR A A A
Thermostats WR A A A
Flow indicators for oil and water D WR A A A
Pressure gauges for oil and water D WR A A A
Pressure relief device M A A A A
Dehydrating breather for main tank W WR
Nitrogen cushion on sealed tank 5
D
system
Nitrogen equipment for units with inert
gas pressure system (positive D WR A A A
pressure nitrogen system)
Manual driving mechanism for de-
A A A A A
energized tap changer (DTC)
Load tap changer: F
6
- Main contacts of LTC F S
7
- Oil of LTC compartment A WR
- Oil level indicator of LTC D WR A A A
Remarks indicated in the table

4
If the transformer is operating in extremely high ambient temperatures and/or high loads or overloads, sampling and analysis should be
performed on a more frequent basis.
5
During cold ambient temperatures the nitrogen pressures will drop. The first weeks after putting the nitrogen blanket on the top of the oil
are critical as well, since the nitrogen will dissolve in oil and the nitrogen pressure tends to drop below the minus 5 PSI setting of the
pressure/vacuum bleeder on the main tank. It is required to adjust the nitrogen pressure up to + 5 PSI.
6
The (O)LTC and DTC have to be switched over the total range for at least 10 (ten) times.
7
First oil check has to be performed after about 20.000 tap changes, regardless of which (O)LTC-type is used in the transformer. More
detailed information on (O)LTC maintenance can be found in the available documentation.
102
Maintenance activity to perform
COMPONENT 1 2 3 4 5 6 7 8 9 10
- Thermostat WR A A A
- Pressure relief device M A A A A
- Motor drive unit A S A A A
- Automatic system for operation A A A
- Dehydrating breather for LTC W
Lightning arresters A A
Protective relays A A A A
All groundings (including CT
A A
groundings)
Re-tightening of all bolts + nuts at
S
electrical connections
De-energized tap changer (DTC) (3)S
Table 16 Maintenance inspection chart
103
6.5 Troubleshooting
6.5.1 Electrical malfunction
Electrical malfunction. Observations made

The power supply tripped while switching on the transformer.
↓ Abnormal high noise after several hours of service.
↓ Overheating at no load
↓ Overheating at normal load
↓ Unequal or unstable voltages on phases at equal load on all phases.
↓ Trip by internal transformer fault (Buchholz, Pressure relay, Load tap changer,…)
↓ Trip by external protection relays during normal service (Time current, ground fault, etc.)
↓ Possible cause of malfunction Rectification measures
X Supply voltage is too high, leading to Do not exceed 105% of the ref. voltage;
excessive inrush current / core loss. reset the tap changer in the right position.
X X Wrong protection relay setting. (inrush Check and reset protection relays.
current, etc.)
X X Circulation current between parallel Check all parallel operation conditions; set
transformers. tap changers for the same voltage ratio.
X Loose parts on the core/windings; Switch off; consult the manufacturer.
possibly caused by transport damage.
X Cooling system is insufficient. Check that valves of all coolers are in the
right working position. Check air, oil and
water supply. Check fan / oil pump
operation.
Note:
At OFAF cooling, oil pumps always have to
be in operation (even at no load)
X X Overloading. Reduce load.
Fault on the thermometer. Check the thermometer.
Ambient temperature is too high. Check for faults in the secondary network.
X X Heavy peek loads, start currents etc. Check for change of the load.
Bad contacts on internal or external Consult the manufacturer for further actions.
connections. Internal transformer or tap
changer fault.
X Malfunction of the measuring instrument. Check the measuring instrument.
Internal transformer fault. Switch off; consult the manufacturer.
X Fault or short-circuit in the secondary Check the secondary network.
network. Repeat all checks and tests as if it were the
Internal transformer fault. first energization. Consult the manufacturer.
Table 17 Electrical malfunction troubleshooting chart
104
6.5.2 Mechanical malfunction or malfunction of accessories
Observations made
Oil level is not correct.
↓ Alarm on Buchholz, gas relay.
↓ Alarm on temperature devices.
↓ Fans or oil pumps do not work.
↓ Insulation resistance is too low.
↓ Power factor is too low.
↓ Visual oil leaks.
↓ Possible cause of malfunction Rectification measures
X Level indicator is defective. Repair or replace level indicator.
Low oil level due to oil leak(s). Locate oil leak(s); repair leak(s).
Replace leaking device or gasket(s).
X Insufficient air venting during erection. Gas analysis is recommended.
Fault gas production. Consult manufacturer for further actions.
X The ambient temperature is too high. Reduce load.
Overloading.
Malfunction of the temperature devices. Check / replace temperature device.
Malfunction of the cooling system.
X Defect on temperature detecting system. Check detecting system.
Devices are defective. Replace defective devices.
X Contamination on bushings, etc. Clean-up external bushings, terminals,…
Penetration of humidity in the insulation Consult the manufacturer.
system.
X Degradation of the insulation system. Clean-up external bushings, terminals,…
Consult the manufacturer.
X Defective gaskets. Tighten bolts.
Replace gaskets.
Table 18 Mechanical malfunction troubleshooting chart
105
6.7 Oil sampling

Accurate sampling methods are extremely
6.6 Oil quality important for the reliability of the test results. Oil
sampling has to be in line with the applicable
One of the most important parameters in standards. The instructions below are a general
transformer maintenance is the oil quality. Testing guideline in oil sampling but do not replace the
the oil quality on a regular basis gives good applicable standards (see explanation given for the
indications on the oil quality itself and on the individual tests).
working conditions of the transformer. Before taking
any steps towards oil replacement, be sure that the
cause of the problem has been found and
eliminated. CAUTION
Sampling when the transformer tank is under
Remarks: negative pressure may cause an air bubble to
Changing the oil in a transformer has to be in line be drawn into the tank. This may result in
with the filling procedures described earlier in this catastrophic dielectric failure (and explosion).
IOM Manual. The change should be as complete as
possible, because usually a mixture of old and new
oil will soon acquire the properties of the poorer Since the test results of a sample may be very odd,
quality. we recommend taking a second sample at the
same time. In case of doubt the second sample can
Important oil characteristics to test: be used for confirmation.
• Color and appearance
• Dielectrical strength ( ∗)
• Water content (*)
• Neutralization value 6.7.1 Taking samples for general oil
• Sediment and/or precipitable sludge testing purposes
• Dielectric dissipation factor
• Resistivity The instructions below must be followed for
• DGA (*) dielectric strength, water content, power factor and
• Presence of inhibitor interfacial tension. Testing has to be in line with
• Presence of particles (*) ASTM D 923 or IEC 60475.
• Use a clean dry screw cap bottle with a
Testing and evaluating the above parameters has capacity of one liter for collecting samples.
to be in accordance with IEC 60422 or Clear glass bottles are considered best, as the
corresponding ASTM standards. visual characteristics and the condition of the
oil can be ascertained quickly. Store and ship
the oil sample in a dark box, as exposure to
bright light for prolonged periods may affect
certain properties.
• Samples are to be taken from the sampling
valve of the transformer tank (or from the outlet
of the treatment equipment) or from the bottom
of the drum. If the transformer has just been
filled, then it should be allowed to settle for up
∗
Pauwels gives more severe values than IEC to three days for a large transformer. Up to 8
60422 or corresponding ASTM standards and/or hours waiting time is required for a drum.
additional information. Further information about Samples taken too soon may produce
this can be found later in this IOM manual. incorrect test results (e.g. dielectric strength
106
will test low). If the transformer is or has been clean bucket without injecting air bubbles into
operating, samples can be taken at any time. the stream. Avoid bubbles in the sample by
• Drain off sufficient liquid to be sure that a true using the 3-way syringe.
specimen of the main tank oil is obtained, and • Flush the syringe by using the 3-way valve. Let
not one that has been stagnant in the pipework the oil in the syringe and push the oil to the
or in the valve. Therefore, drain off three or bucket, using the syringe plunger. Repeat this
four liters of oil into a clean bucket before procedure several times until the syringe is
taking the oil sample. Rinse the clean clean and filled with oil, completely free of gas
container several times with oil prior to taking bubbles. Close the 3-way valve to the syringe.
the actual sample. • Close the sampling valve and remove the
• The oil can contain a large amount of syringe. Place the syringe in the syringe box.
dissolved water, invisible to the eyes but easily
detected by test. If the sample bottle contains
Take the spare sample following the same
liquid water, contact Pauwels immediately. It is
procedure.
preferred that the temperature of the oil be
equal or warmer than the ambient air to
prevent contamination by condensation.
• A period of 12 hours should be observed
between taking the sample and performing 6.8 Dielectrical strength
tests, to allow the oil to stabilize and become
homogeneous. Oil sampling has to be in line with ASTM D 923 or
IEC 60475. The test should be performed in a well-
equipped laboratory according to the applicable
standards.
6.7.2 Taking samples for DGA tests
Required values for transformers in service:
For DGA tests it is always recommended to take a • > 60 kV/2.5 mm (as tested per IEC 60156)
spare sample. This spare sample can be used if • > 30 kV/2.54 mm (as tested per ASTM D 877)
something happens to the first sample, or if the
analysis is very odd. Testing has to be in line with
ASTM D 3613 or IEC 60567. If values are lower, the oil should be filtered or
streamlined. Test the oil annually or even more
• Use dry clean syringes, equipped with a 3-way frequently if the operation condition of the
syringe valve. Record the transformer serial transformer questions the continuity of the oil
number, the ambient temperature, the oil quality in general.
temperature and the date of sampling.
Low insulating oil strength may also be an
• The sample is to be taken from the oil
indication that the transformer insulation contains
sampling valve. The location of this valve is
excess moisture. Further evaluation should be
indicated on the General Arrangement
made such as power factor tests and taking oil
drawing.
samples to determine moisture content in oil.
• If oil circulating pumps are installed on the
transformer, they should be operated for a Remarks:
minimum period of one hour before taking any
If some work has been carried out on a transformer
oil samples.
and the oil has, during that time, been exposed to
• Allow 3 to 4 liters of oil to run into a clean
the humidity of the air, the breakdown value of the
bucket to ensure a true sampling of the tank
oil should be checked.
oil.
• Attach the 3-way syringe valve and the
sampling syringe to the sampling valve (using
an adaptor).
• Open the sampling valve very slowly and allow
the oil to flow through the 3-way valve into the
107
6.9 Moisture content strength of oil occurs when iron, copper, aluminum
or cellulose particles are situated in the oil and tests
Transformer oil is hygroscopic and therefore it in this field show that the dielectrical strength of the
absorbs moisture from the air. The absorption of oil is very poor in this case.
moisture is minimized by the oil preservation Larger and conducting particles decrease the
system. The oil conservator system with a silica gel breakdown voltage most, whereas fine particles can
breather also minimizes the entry of moisture as be agglomerated or be dispersed, so that particle
long as the silica gel is properly renewed or chains can be developed. It is also known that
regenerated as soon as its ability to absorb particles may cause partial discharges.
moisture begins to diminish. Check also whether
the oil lock in the silica gel breather is properly filled If severe formation of particles has set in, the oil
with oil (check maximum and minimum oil level changes its color and gets darker. The appearance
indications in lock). of the oil is usually muddy. By filtering, it is possible
to remove the sludge but, having once started, the
Moisture content in ppm is related to the operation formation of sludge will increase with time. Such oil
conditions of the transformer. Moisture in oil can should be completely changed as soon as the
lead to reduction of the dielectric strength in oil and service conditions permit it.
windings. The table below gives the maximum
allowable ppm of water in oil. For the reasons mentioned above, Pauwels has
produced its own criteria for particles in new
transformer oil. We take these criteria into account
Maximum water before testing a transformer. The same values can
Temperature (° C) ∗ be used for transformers in service.
content (ppm)
- 20 5
- 10 9 Maximum amount of
0 16 Particle size particles in 10 ml
10 20 sample (0.338 fl.oz)
all Particles ≥ 1.5 µm
Table 19 Water in oil 2500
of which :
Particles ≥ 5 µm 1500
Particles ≥ 20 µm 30
Example: Particles ≥ 30 µm 10
In case 50 ppm moisture is detected in oil that is Table 20 Particles in oil
sampled at 10° C oil temperature, free water has
been created already and this water might have Since each measurement will produce different
been absorbed inside the windings and other results, it is a practical matter to provide 5 or 6
critical parts of the transformer. This is a dangerous measurements. The average of measurements is
situation for the transformer. then the base for the determination whether the
particles are within the required limits.
Remarks:
Another process of ageing, associated with the
6.10 Particles in oil
formation of sludge, is the increase of the content of
free acids in the oil. If this content does not exceed
The breakdown strength of oil decreases when the
0.5 mg KOH per g (500 ppm) and apart from this
moisture content increases at the same sample
the oil shows good properties, then it is fit for use. If
temperature. A further reduction in the breakdown
this is not the case, the oil should be changed. New
transformer oil as supplied by Pauwels Trafo
∗ contains an acidity (free acids in the oil) lower than
The indicated temperature is the lowest 0.1 mg KOH/gr.
temperature the oil can reach, non-service
conditions considered as well.
108
Should the flash point, when tested according to V = volume of the transformer [I]
ISO 2719 or ASTM D92, be less than 130 degrees Δt = expired period between measurements [days]
and should the oil also smell burnt, then a †
To have a reliable rate, intervals should be longer than 2 weeks
decomposition (cracking) of the oil may have
occurred. In that case a DGA should be performed ‡ rates of production [ppm/day] = Δc/Δt
and/or the transformer should be inspected (lifted or Δc = difference in concentration over the observed period
the manholes opened) to make sure that there is no [ppm]
local overheating of core or windings. Δt = expired period between measurements [ period]
$
5000 ppm for transformers with sealed conservations system
(atmoseal…), 10000 ppm for transformers with open breather
conservation system
6.11 Dissolved Gas Analysis on ** If a communicating OLTC-conservator is in use, this value will
transformer oils from the main be 270ppm
tank of a transformer †† if a communicating OLTC-conservator is in use, this value
will be 1 ml/day
Sampling has to be done in accordance with IEC

60567 or ASTM 3613 Remarks:
Analysis has to be performed in accordance with • IMPORTANT: In many cases, acetylene
IEC 60567 (C2H2) is a sign of severe electrical
problems. Therefore, the presence of
acetylene always should be considered as
6.12 Frequency of analysis serious and treated as such.
DGA should be performed as frequently as • If C2H2/H2-ratio is higher than 2, a

possible, but at least once a year as long as the contamination from the OLTC-compartment is
values remain below the limits of Table 21. See probable. If this is the case, DGA of the main
also 6.13.1 for actions in case of values exceeding tank can be unreliable.
the limits of table 1.
• If CO2/CO-ratio is lower than 3, paper
deterioration is possible. This has to be
6.13 Evaluation checked with a FAL-analysis (specific analysis
for paper deterioration). For evaluation: contact
Compare the results with the values in table 1. Pauwels.
Symbol Concentrations
Rates of Rates of • Values for rates of production tend to be higher
Name gas production* † production †‡ in relatively new transformers and can exceed
Gas [ppm]
[ml/day] [ppml/day]
the values in table 1 for new transformers (<1
Hydrogen H2 150 5 year).
Methane CH4 130 0.33
Carbondioxide CO2 5000/10000$ 30
• When calculating rates of production, intervals
Carbonmonoxide CO 1000 3
should be longer than 2 weeks to provide an
Ethane C 2H 6 90 0.25
acceptable accuracy of results.
Ethylene C 2H 4 50 2
Acetylene C 2H 2 5 ** 0.1††
• Rates of new samples should be calculated
Table 21 Limits for normal values for relative to the latest historical sample, not to
Pauwels Transformers the sample that needed to be confirmed when
the period between the two successive
* Rates of production [ml/day] = (Δc x V) / (Δt x 1000) samples is too short for reliable evaluation of
Δc = difference in concentration over the observed period rates,
[ppm]
109
• ppm = µl/l
110
6.13.1 Actions
6.13.1.1 First DGA-sample of a transformer
NO
First DGA-sample of Evaluate with respect to
a transformer historical data
YES
NO
NORMAL-status
Concentration
Level gas > table
gas1?
> Resample ≤ 1 year
table 1?
YES
Level
Concentration
C2H2 > table
C2H21?
> NO ALERT-status
Alert condition
table 1? Check ASAP
Resample rate
immediately
YES
ALARM-status
Contact Pauwels
Check rate immediately
111
6.13.1.2 Historical DGA-data are available
NO Evaluate as first DGA-

Historical DGA data
available ? sample of a transformer
YES
NO
Concentration gas > table 1? NORMAL-status
Resample ≤ 1 year
YES
NO
Concentration
6.14 Replacement of defective parts C2H2 >
YES
Always follow the applicable safety instructions
when working on a transformer. NO ALERT-status
RateFollow
C2H2 > the
table 1? Contact Pauwels
installation instructions (section [3]), use the
available drawings (section [6]) and/or specific ASAP
YES R l ≤3 th
documentation (section [7]) for the part or
accessory to replace or repair.
ALARM-status
Contact
In case of any difficulty contact Pauwels
your Pauwels immediately
contact person or PTS for advice orResample immediately
assistance.
ALARM-status NO
Consider to shut down
6.14.1 Ordering NO
replacement ornew
spare
Contact Pauwels Rate sample > table
parts
Immediately 1?
Resample within 2-4 YES
Replacement
weeksor spare parts should be ordered
through the responsible Pauwels division:Shut down !
Inform Pauwels
• Warranty related aspects: contact your
immediately
Pauwels contact person.
• Non warranty related aspects: contact the
Pauwels Transformer Service Division. Their NO ALERT-status
coordinates are avialable in section
Rate[0].
gas > table 1? Resample ≤ 6 months
YES
Use the “Parts ordering form” in section [9], provide
all the relevant information (transformer serial ASAP
Take new sample
number, part description and numbers on General
Arrangement Drawing, …) and send it to either your
contact person or Pauwels Transformer Service.
NO NORMAL condition
Concentration gas > table 1?
Resample ≤ 1 year
YES
NO
ALERTstatus
Rate gas > table 1?
Resample ≤ 6 months
YES
ALERT-status
Contact Pauwels
ASAP for evaluation
and further actions
112
7 Forms, checklists
113
114
Receiving inspection report
Date of report:
Transformer Serial No:
1 Customer and Equipment information
A Customer information
Customer Name:
Contractor Name:
User name:
Purchase Order No:
Additional information:
B Equipment information
Rating: MVA KV
Arrival location:
Date of arrival:
Transport by: VESSEL TRAIN TRUCK PLANE
Additional Information:
2 Arrival conditions of the equipment

Equipment inspected by
(name and function):
Has the transformer been subjected to all recommended
YES NO
arrival inspections and tests?
Visual external inspection of the transformer: OK NOK
Inspection of all means for blocking and securing: OK NOK
Absence of oil leaks: OK NOK
Inspection of the impact recorder: OK NOK
Recorder type and serial number:
Highest readings or recordings:
Inspection of the inert gas pressure system OK NOK
Tank pressure (> 0.05 bar):
Pressure of gas bottle in use (> 3 bar):
Is the equipment (transformer and parts) undamaged and
YES NO
complete? (if No, specify below)
Remarks on arrival of the equipment:
3 Appendices
4 Date, name(s), function and signature(s)
Remarks: Complete this report and send it to your Pauwels contact person. If there is any damage
or missing material, follow the procedures mentioned in the IOM manual.
116
Energization Report
Date of report:
Transformer Serial No:
1 Customer and Equipment information
Customer Name:
Contractor Name:
User name:
Purchase Order No:
B Equipment information
Rating: MVA KV
Site location:
Delivery date:
Additional Information
2 Energization information
Energization date:
Energization hour:
Atmospheric condition:
Ambient temperature:
Additional information
concerning energization
conditions:
Have all the tests and inspections listed in the “Site commissioning report”
YES NO
been performed?
Has a copy of the “Site commissioning report” been sent to Pauwels (in
case erection and commissioning has not been done or supervised by YES NO
Pauwels)?
Has energization been successful and without any problems?
YES NO
Remarks on energization:
3 Appendices
4 Date, name(s), function and signature(s)
Remark: Pauwels will confirm receipt of this report.
117
118
Parts ordering form (1)
Parts price request
1 Customer information
Customer:
Customer P/O No (1):
Contact Person:
Tel:
Fax:
B Transformer information
Transformer serial No:
Rating: MVA KV
Date of energization:
2 Information on parts delivery

Type of parts: Replacement of defective parts Spare parts
Delivery terms:
Delivery address:
Tel:
Fax:
3 Parts
Item No (2) Description Type/Specifications # Unit Price Total Price
Currency: Total price:

4 Date, name, function and signature
Date Name and function Signature
(1) When ordering parts: an official Purchase Order with reference to our quotation is required.
(2) Item No’s are provided on the General Arrangement drawing and materials list (in IOM manual).
119
120
Site commissioning report
Cover sheet
Project
Customer
customer reference
Order number
SIte
Country
PTS reference
Serial number
MVA
HV
MV
LV
Vector group
Attached test result sheets
Date
121
Mechanical inspection Tx.Nr.
Before start of erection.

damage no damage
Visual inspection of main tank for transport damages
damage no damage
Visual inspection of crates containing transformer parts. If there is a
visible damage, write a report.
If possible, take photgraphs of this damage and notify the client/insurance company.
Remarks :
Inspection of shock indicator or shock recorder.

Type : Enregistreur Indicateur Electron.
Longitudinal dir. : ≤ 0.5 g Y/N Y/N Y/N
Transversal dir. : ≤ 0.8 g Y/N Y/N Y/N
Vertical dir: ≤ 0.3 g Y/N Y/N Y/N
If applicable, measurement of core-to-tank insulation (PTS IR or IR3))
After erection
General check
OK NOK NA
ground connections of all accessories mm mm
distance between lightning rods & ground
check position of all valves
Position of flap valves (radiators)
oil level transformer
oil level tap changer
desaeration of relevant parts
absence of oil leaks
absence of tools on transformer
markings, terminal plate, rating plate
air breather(s) : oil lock, silica gel condition
painting
Pauwels’s representative Client’s representative

Name Name
Signature Signature :
PTS MI
122
Mechanical & electrical checks Tx.Nr.
ON LOAD TAP CHANGER.

OK NOK NA
Are all the necessary supply voltages present ?
Synchronisation of motor drive / tap changer
Manual test of end posistions
Electrical test of end positions
Local electrical control of tap changer
Remote electrical control of tap changer
Heating : functioning and control
OFF LOAD TAP CHANGER
OK NOK NA
Synchronisation of drive / tap changer
Functional test
Funtioning of mechanical interlocks
LINKS INSTALLED UNDER TX COVER
OK NOK NA Voltage
Check position of links --> operating voltage
CONTROL CABINET
OK NOK NA
External wiring completed
Current transformers connected or short circuited
All wiring insulation tested with 500V (except remote)
position ind / AKM Trafoguard / DIGEM
Tightmess of connections
Phase rotation of incoming supply
Rotation of each fan
Rotation of each pump
Operational tests & checks of measuring andcontrolling devices
OK NOK NA
Manual control of fan operation
Thermal device control of fan operation
Manual coantrol of pump operation
Thermal device control of pump operation
Breaker contact operation of pump control
Oil flow indicator(s)
Automatic change over of supply voltage
Heating : functioning and control
Indication of “Fans working” and contact (if applicable)
Indication of “Pumps wordking” + contact (if applicable)
Indication of “Tap changer running” + contact (if applicable)

Nom: Name:
Signature: Signature:
PTS ME
123
ALARM CONTACTS Tx.Nr.
C.C. CLIENT NA
Buchholz transformer
Buchholz cable boxes
Oil level transformer minimum
Oil level tap changer maximum
Oil level tap changer minimum
Oil temperature alarms
Winding temperature alarms (primary)
Winding temperature alarms (secondary)
Winding temperature alarms (tertiary)
MCB cooling supply
C.C. supply-control relay(s)
MCB tap changer supply
Tap changer suppy-control relay
Aux.contacts of fan MCB’s
Aux. contacts of pump MCB’s
TRIP CONTACTS
C.C. CLIENT NA
Buchholz transformer
Tap changer protective relay
Buchholz cable boxes
Overpressure relief device 1
Overpressure relief device 2
Overpressure relief device on cable boxes
Oil temperature trip
Winding temperature trip (primary)
Winding temperature trip (secondary)
Winding temperature trip (tertiary)
Non return flap valve (Sergi)
INDICATION CONTACTS
C.C.. CLIENT NA
Check all applicable signalisation contacts

Name Name
Signature Signature
PTS ATC
124
Tx.Nr.
Temperature settings ≤ values on Pauwels drawings
Thermostat degrees C NA
start fans (pumps)
alarm
trip
Oil thermometer degrees C NA
stop fans (pumps) or alarm 1st stage
start fans (pumps) or alarm 2nd stage
alarm
trip
WTI (primary) degrees C NA

stop fans / pumps (1)
start fans / pumps (2)
alarm (1)
alarm (2) or trip
WTI (secondary) degrees C NA

sart fans / pumps (1)
alarm (1)
alarm (2) or trip
WTI (tertiary) degrees C NA

alarm (1)
alarm (2) or trip
Verification of overpressure relief device

mbar NA
overpressure relief device 1 on transformer
overpressure relief device 2 on transformer
overpressure relief device on cable boxes

Name Name
Signature Signature
PTS TS
125
Insulation resistance measurement Tx.Nr.
Date :
Atmospheric condition
Ambient temperature
Oil Temperature
Tap changer position
Megger
Make
Type :
HV – LV + Tank LV – HV + Tank
Applied voltage kV Applied voltage kV
1 min 1 min
2 min 2 min
3 min 3 min
4 min 4 min
5 min 5 min
6 min 6 min
7 min 7 min
8 min 8 min
9 min 9 min
10 min 10 min
Polarization Index (value 10 min / value 1 min)
Core – Tank insulation resistance measurement
Applied voltage max.. 5000 V.
Measured value MΩ
Make sure the link is re-established and tightened after measurement

Name Name
Signature Signature
PTS IR2
126
Insulation resistance measurement Tx.Nr.
Date :
Ambient temperature
Oil Temperature
Megger
Make
Type :
HV – MV + LV +Tank MV – HV + LV + Tank LV – HV + MV + Tank

applied voltage Applied voltage Applied voltage
kV kV kV
1 min 1 min 1 min

2 min 2 min 2 min
3 min 3 min 3 min
4 min 4 min 4 min
5 min 5 min 5 min
6 min 6 min 6 min
7 min 7 min 7 min
8 min 8 min 8 min
9 min 9 min 9 min
10 min 10 min 10 min
Polarization Index (valeu 10 min / valeur 1 min)
Core – Tank insulation resistance measurement
Applied voltage max.. 5000 V.
Measured valur MΩ
Make sure link is established and tightened after measure

Name Name
Signature Signature
PTS IR3
127
Oil test results Tx.Nr.
Sampling date
Atmosperic condition
Ambient temperature
Oil temperature
Testing date
Ambient temperature
Oil temperature
Dielectrical strength
Instrument used
Make
Type :
Sample 1 Sample 2 Sample 3

Sampling Location Sampling Location Sampling Location
1 kV 1 kV 1 kV
2 kV 2 kV 2 kV
3 kV 3 kV 3 kV
4 kV 4 kV 4 kV
5 kV 5 kV 5 kV
6 kV 6 kV 6 kV
Average kV/2.5mm Average kV/2.5mm Average kV/2.5mm
PPM water content
Sample 1 Sample 2 Sample 3
ppm ppm ppm
Pauwels’s representative Client’ s representative

Name Name
Signature Signature
PTS OT
128
Voltage ratio test Tx. Nr.
Test performed by bridge

Test performed by voltmeter
Instrument make :
Instrument type :
if V-metre A-B V B-C V C-A V
if by V-meter, note measured phases and volts

if by bridge, note injected phases, measured phases and values
tap.pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Name Name
Signature Signature
PTS VR
129
Vector group test Tx.Nr.
Applied voltage
A–B V
B–C V
C–A V
Measured voltage V
V
V
V
V
V
Equations
Vector group =
A
A a
a
b
c
b
c c
C B C B
A
A
C B
C B

Name Name
Signature Signature
PTS VG
130
Winding resistance measurement Tx.Nr.
note selected terminals

tap pos
1 _Ω _Ω _Ω
2 _Ω _Ω _Ω
3 _Ω _Ω _Ω
4 _Ω _Ω _Ω
5 _Ω _Ω _Ω
6 _Ω _Ω _Ω
7 _Ω _Ω _Ω
8 _Ω _Ω _Ω
9 _Ω _Ω _Ω
10 _Ω _Ω _Ω
11 _Ω _Ω _Ω
12 _Ω _Ω _Ω
13 _Ω _Ω _Ω
14 _Ω _Ω _Ω
15 _Ω _Ω _Ω
16 _Ω _Ω _Ω
17 _Ω _Ω _Ω
18 _Ω _Ω _Ω
19 _Ω _Ω _Ω
20 _Ω _Ω _Ω
21 _Ω _Ω _Ω
22 _Ω _Ω _Ω
23 _Ω _Ω _Ω
24 _Ω _Ω _Ω
25 _Ω _Ω _Ω
26 _Ω _Ω _Ω
27 _Ω _Ω _Ω
28 _Ω _Ω _Ω
29 _Ω _Ω _Ω
30 _Ω _Ω _Ω
Secondary winding ;
_Ω
_Ω Oil Temperature
_Ω
Winding temperature
Tertiary winding :
_Ω
_Ω
_Ω

Name Name
Signature Signature
PTS WR
131
Tg delta measurement Tx.Nr.
Date
Ambient temperature
Oil temperature
Test device
Make
Type
HV – LV + Tank % L-GND(CH- L&CG-G red)

HV – Tank % L-Guard(CH-G red)
HV – LV % (CH-L red)
LV – Tank % H-Guard(CL-G red)
LV – HV + Tank % H-GND(CH-L&CL-G red)
HV – MV + LV + Tank % MAKE THE NECESSARY CONNECTIONS ON THE TERMINALS
MV – HV + LV + Tank %
LV – HV + MV + Tank %
HV + MV - LV + Tank %
HV + LV - MV + Tank %
MT + LV - HV + Tank %

Name Name
Signature Signature
PTS TD
132
Current transformer checks Tx.Nr.
Location : Name
Specs. Ratio
Insulation resistance with 2500V P1=
Kneepoint voltage determination NA P2=
Voltage S1=
Current S2=
Connections tightened or shorted
Location Name
Specs. Ratio
Insulation resistance with 2500V P1 =
Kneepoint voltage determination NA P2 =
Voltage S1 =
Current S2 =
Location Name
Specs. Ratio
Insulation resistance with 2500 V P1 =
Voltage S1 =
Current S2 =
Location Name
Specs. Ratio
Insulation resistance with 2500V P1 =
Voltage S1 =
Current S2 =
Location Nom
Specs. Rapport
Insulation resistance with 2500 V P1 =
Voltage S1 =
Current S2 =

Name Name
Signature Signature
PTS CT
133
Zero phase sequence impedance determination Tx.Nr.
1) Short circuit on HV winding
3) LV winding open, no load
3) Apply single phase voltage between Hv winding and HV neutral (220 – 240 V)
4) Measure currents going to each phase
measured line current average current ZPS Impedance

tap pos applied V A B C (A+B+C)/3 applied V / av.Curr.
lowest
nominal
highest

Name Name
Signature Signature
PTS ZPSI
134
Automatic voltage regulation check Tx.Nr.
Device(Type)
Make
Serial Number
Simulate the P.T. voltage and balance the relay on this voltage (no presignal). While the bandwidth is set at 1%,
increase the voltage by approximately 1.2 %. After the set time delay the tap should move to a lower position
(more winding turns in primary).
Lower the simulated P.T. voltage to approximately 1.2 % below the desired P.T. voltage.
The tap should move to a higher position (less winding turns in primary).
Y N
Did the relay pass this function test ?
OK NOK NA
Check undervoltage blocking
Check overvoltage rapid return
Check various time delays features

Name Name
Signature Signature
PTS AVR
135
CONCLUSION Tx.Nr.
Corrections to be made.
Other remarks.
The transformer is / is not ready to be energized
Remark regarding minimum rest period before energizing.
Transformer equipped with oil pumps :

let the pumps operate for 2 hours
if HV is lower than 245 kV : minimum rest period of 8 hours
if HV is higher than 245 kV : minimum rest period of 24 hours
Transformer without oil pumps :

If HV is loweer than 245 kV : minimum rest period of 16 hours after filling
If HV is higher than 245 kV : minimum rest period of 48 hours after filling
Representative Pauwels Trafo Service Representative Client
Name : Name :
Signature Signature
Date : Date :
136
8 Special instructions
137
138
8.1 Special instructions
No special instructions applicable.
139

Pawels Trans A

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Manual Installation, Operation and

Part A Maintenance Instructions

Pauwels Power Transformers

PAUWELS TRAFO http://www.pauwels.com/

Year of manufacture: 2009

Manufacturer serial number: 4001158

Customer: SEC WOA

1 General information ...................................................................................................................15

2.2 Information on mechanical transformer parts.................................................................... 35

4.9.3 . New treated transformer oil in new equipment ....................................................... 73

4.24.2Removal of surface moisture by dry air recycling....................................................87

6.4 Maintenance inspection chart.......................................................................................... 101

Figure 1 Example of SEFCOR connector ....................................................................................... 25

1.1 General information 1.1.2 Safety instructions and notes

Please read this IOM-manual completely before

The General Arrangement Drawing: shows a side, 1.1.6 Special instructions

Tel: ++ 32 / (0) 15 / 283 333 (8 am – 5 pm)

The text refers to several checklists and forms that

Ensure that all electrical circuits to be worked on

1.2.1 Basic safety practice

1.2.3.2 Preventive measures Grounding cables are to be securely lashed to

Min. cable size per • Accidental Release Measures

c) Establishing the grounding (earthing) system

1.4.1 Actions to be taken at installation 1.5 Insurance

Further procedure or assessment of damages after

a) If you received an insurance certificate and/or TºC 5 10 15 20 25 30

1.6.3 Torque values for SEFCOR

Figure 1 Example of SEFCOR connector

1.7 Conversion tables

Quantity Unit of Symbol Formula

Multiplication factor Prefix Symbol

Quantity Multiply by to obtain

Ounce-force 0.278 014 Newton N

Quantity Multiply by to obtain

Mile (U.S.Statute) 1.609 347 Kilometer km

Table 9 Conversion table for pressure and stress

2 General transformer description

2.1.2 General Arrangement Drawing

2.3.4 Tank accessories

2.4 Non-membrane conservator 2.5 Transformer grounding (earthing)

Figure 2 Parts to be grounded (earthed)

coat (PUR). The minimum total thickness of the EP

The connection is made by means of stainless steel

a) Primer paint (EP)

2.6.1 Painting system Adhesion after polymerization: cross cut test in

2.6.1.2 Painting system Adhesion after polymerization on primer paint:

Corrosion resistance: salt spray test following

2.6.1.4 All inner transformer surfaces

Preparation: identical to outside structures

3 Packing, Transport, Receiving, Storage

3.1 Packing c) For details of dismounted parts for transport,

The packing type, dimensions, weights and degree

Each package is marked and contains a packing-

3.1.2 Transformer body

3.1.6 Conservator, pipes and cable DANGER

3.2 Transport and handling CAUTION

3.2.1 General transport and handling

2. The ground must be capable of supporting the 3.2.4 Shipping documents

3.2.3 Blocking and securing

3.3.2 Transformer inspection CAUTION

3.3.2.2 The external inspection

• Examine the tank for signs of oil leakage, paint