Hyosung Power Transformer

Site Installation & Maintenance Training

(Mar. 2023)
Contents
1.Principle of the transformer
2. Transportation
2.1. From port to Foundation
3. Site Installation
3.1. Transformer Installation Flow Chart
3.2. Supervisor Check Point during assembly
3.3. Receiving Inspection
3.4. Prepare Work
3.5. External Assembly
3.6. Internal Connection
3.7. Torque
3.8. Vacuum Process
3.9. Oil Pre heating and Circulation
3.10. Dielectric Strength Test
3.11. Oil filling Under Vacuum
3.12. Adjusting Oil Level
3.13. Oil Circulation
3.14. Site Test (According to STP)
3.15. LCP

4. Protective Relays

5. Maintenance
1.Principle of the transformer
 Structure of the transformers

General oil immersed transformers are composed of these components

core
- composition of the magnetic circuit

windings
- composition of the electric circuit

oil
- cooling and insulating

tank
- packing the main body and oil

radiator & cooler

- control of the temperature by losses

tap changer
- compenstion for the voltage regulation

· bushing
- connetion windings of transformer and
transmission lines

insulator
- insulation between high-voltage conductors
- supporting the constructure of transformer
main body
Principle of the transformer

Ideal transformer 
i1 i2

V1 e1 e2 V2

1. Input sinusoidal voltage(V 1) at the primary winding

2. Sinusoidal magnetic field(Φ) in the core is producted

3. Elecrtomotive force(e2) is induced secondary winding linking with magnetic field

by Faraday’s induction law .

Voltage, current and winding ratio is related by these equations.

V1 N 1 e1 i1 1
  a 
V2 N 2 e2 i2 a
capacity V1 I 1 V2 I 2 [ VA ]
So, capacity of the primary and secondary winding is same.
Transformer main components

Conservator
HV Bushing

XV
Bushing OLTC
HVN
Radder Conservator
Bush-
ing

Arrestor

Radiator

Motor
Drive Unit

Control
Panel
Transformer main components

1.1 OLTC [ On-Load Tap Changer)

OLTC is device that it is possible to change

tap position, when transformer was
operating

Control device can be installed both

transformer side and remote by
customer’s demand

It is mainly used substation that voltage

variation is too high.
Transformer main components

1.2 Radiator

The fin radiator is an ideal heat-emission ele-

ment
for power transformer with its characteristics of
excellent emission on performance.

It can be easy install and maintenance as well

as
its good appearance.
Transformer main components

1.3 Bushing
Oil to Air Type Bushing
Transformer main components

1.4 Air Seal Cell Type Conservator

Conservator is device used to keep transformer oil proper level

It protect to insert air inner transformer

2. Transportation
From Port To Foundation

• Transformer mainbody Unload-

ing

• Transportation to site.

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From Port To Foundation

• Unloading Mainbody beside

Foundation.

• Prepare to move mainbody to

foundation

·
From Port To Foundation

• Move Mainbody on the founda-

tion

• Setting On the foundation

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From Port To Foundation (By Using Crane)

• If possible, mainbody can be set-

ted
by using crane

·
3. Site Installation
Transformer Installation Flow Chart

• Examination with the naked eye on main body and parts

Initial Sight Inspection • Inner Pressure, Impact Recorder, Dew Point, Core Megger,
P/L
• Man Power : at least 10 Workers
Prepare Work • Instruments set up : Dry air, Tools, Crane, Manlift, etc.
• Checked Power Supplier : 3P 380/440V, 200kW

Bushings Test • C1 & C2 test prior to assembling bushing (If Required)

• Insulation Resistance Test

Parts Assembly • Radiators, Conservator, Arresters, Bushings, etc

• Insulation Resistance, Ratio, Polarity (In case of CT Turrets

CT’s Test prior to vacuum
are shipped as disassembled with mainbody)

Internal Lead Connection • Refasten Bushing bottom and winding Lead Connections
• Examination with the naked eye

Vacuum and Filling • As per technical manual determine Torr, Keep up duration
• Under 10℃, core, coil and hot oil circulation is needed.

• Megger, Voltage ratio, BCT polarity.

Site testing
• Bushings, Arresters, Winding Resistance, Relays, etc.

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Supervisor Check Point during Assembly

18
Receiving Inspection (Impact Recorder)

X Y Z
5 10 PM
AM

9 PM

4
8 PM
AM

7 PM

3
6 PM
AM

Zone A Zone A Zone A

Zone B Zone B
Zone B

Deflection from Center in Number of

Impacts Grids
X Y Z
3G 1.8 2.1 2.3
6G 3.8 4.5 4.9
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Receiving Inspection (Impact Recorder)

Lateral Longitudinal Vertical

· The Impact Recorder Check Point

- Longitudinal : Under ±3.0G
- Vertical : Under ±3.0G
- Lateral : Under ±3.0G
* G : Acceleration of Gravity

Analog Type

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Receiving Inspection (Impact Recorder)

Digital Type

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 Receiving Inspection [Dew Point Measurement( IF Required)]
DEWPOINT TEST
• Measure internal tank temperature and measure the Dew Point temperature of the air inside the tank.
• Use Figure 3.5 for pressure between 0 and 5 PSI
• Use upper and left axes for temperatures recorded in Celsius, use the lower and right axes for temperatures
recorded in Fahrenheit.

Figure 3.5
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Receiving Inspection (Check Internal Pressure)

Positive Pressure
OK

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 Receiving Inspection (Measure Insulation Resistance )

Insulation Resistance Check

• Measure Insulation Resistance between Core-Frame-Ground.

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Receiving Inspection ( Check Crates & Accessory )

· Check all crates for external damage.

· Open each crate and verify
contents against the packing list.
· Check the damaged components
· Store safely against fire, humidity, missing

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Prepare Work

• Oil purifier Machine (with hose)

- 6000L/hour [RVP : 3750L/min, MBP : 1500m3/hour]

• Vacuum Pump (with hose & vacuum chamber)

- [RVP : 3750L/min, MBP : 1500m3/hour]

• Vacuum gage(Up to 0.01Torr), Oil dielectric Tester(0~75kV), Hygrometer(0~100%)

• Manometer(-76mmHg~1.0kgf/Cm2), Dew point tester(-100C~30C)
- Check Calibration status

• Hydraulic Crane(5~50 ton), Oil storage Tank (20,000L), Compressor (5kg/Cm2)

• Man lift(if required), Dry air (> -55C , with hose& Fitting)
- Check Internal Status of Oil Storage Tank

• Spanner, Rachet Wrench, Box spanner, pipe wrench, Adjustable angle wrench
-> 10,11,13,14,17,19,22,24,27,30,32,36,42,46 mm

Insulation Resistance Tester, Multi-meter, BCT tester (or Galvano meter)

- Check Calibration Status

( According to Site Test Plan )

• Power Factor Tester, Winding Resistance Tester, SFRA TESTER ,,,,,etc.
- Check Calibration Status

• Ladder, rag, alcohol, Individual safety equipment,, fitting for connection ,,,,,etc.

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External Assembly

< Manifold & Bracket Assembly >

1) To assemble radiator, manifolds has to be

assembled in advance.
2) Brackets for external accessory also has to be
assembled in advance.

• Surface of manifold’s flange for mounting has

to be clean to prevent oil leakage

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External Assembly

< Radiator Assembly>

1) Before assemble radiator, Check Valve Status

2) Assemble radiator carefully

• Because radiator is easy to be broken during

lifting, operator of crane has to be experienced
person.
• Surface of radiator’s flange for mounting has to
be clean to prevent oil leakage

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External Assembly

< Conservator Assembly >

1) Before assembling conservator, it need to

be tested.
- Oil Level Gage float condition check
( Check its external apperiance)
- Oil Level Gage Operation test
- Air Seal Cell Pressure test
(0.1kgf/Cm2, hold 1hour or more)
2) After chek inside, assemble conservoaor

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External Assembly

< Bushing Turret Assembly >

1) Before assembling bushing turret, CT need

to be tested.
- CT Ratio, Polarity TEST
- CT Insulation Resistance TEST
- Check CT’s external appearanace

• The weather condition during turret as-

sembly has to be sunny day.
And must be caution to let things fall

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External Assembly

< Bushing Assembly >

1) Before assembling bushing, it need to be
tested.
- Check Bushing’s external appearance
- Insulation Resistance TEST
- Power Factor TEST (If required)
- Check Bushing’s external appearance

• In general, direction of bushing oil level

gauge is as shown below
(But always review the bushing
manufacturer’s manual and transformer’s
drawing to determine how the bushings
should be oriented)

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 External Assembly

< Bushing Handling >

• For lifting the bushing from box , apply **Lift the bushing to vertical position and to an angle according to the figures below.
two clean lifting slings as shown below When lift it , use a soft bedding under the bottom end of the bushing.
e.g. rubber mat,,,
Refer to HICO O&M Manual Section 4.13 (Rev 5)

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External Assembly

< Gas Pipe and the other accessory Assembly >

1) Assemble Gas Pipe, Protective relays, Copper
pipe, sampling device, Ground cable, Surge
arrestor,,,,etc

• When assemble gas pipe, do not assemble

it as forced status.

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Internal Lead Connection

< Bottom connection & Internal Inspection >

1) Check No. and type of tools bring in.
2) Connect the winding lead to bushing conductor.
-> Bottom connection, Draw lead, Draw rod Type
Bottom Connection Type 3) Inspect the condition of insulation and joint.

• Before internal work, check Oxygen content over

19.5%.
Draw Lead Type
• When connect winding lead with bottom of bush-
ing,
Use Torque Wrench.

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Torque

< bolts/nut Torque >

Internal Connections Only

Refer to HICO O&M Manual Section 4.8

This table applies to galvanized steel,

SAE grade 5 and stainless steel type
304 nut an bolts through an un-threaded
hole in steel, stainless steel, Copper or
Aluminum base material
Refer to HICO O&M Manual Section 4.8
Vacuum Process

< Vacuum Work >

1) Vacuum Pump maintenance is highly
recommended including hose, fittings and
Vacuum
pump vacuum tank (No Leakage)
2) Pull vacuum & hold vacuum as specified.
3) After required vacuum Level reached, perform
Vacuum Leak Test
4) All Equipment must be grounded
5) Keep monitoring not to lose vacuum
-> Record vacuum value every 1hour.

• Under vacuum, No work on the

transformer is permitted.
• During vacuum, it need to check leakage
of hose by separating it with Transformer.

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Vacuum Process

< Vacuum Leak Test during Vacuum work >

1) After required vacuum Level reached,
close valve between vacuum pump and TR.
Vacuum
pump Then check rising value of vacuum.
* Refer to HICO O&M Manual Section 5.7 (Rev 5)

1. Valve Close
2. Keep 10 Min
3. Check Torr Rise

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Oil Pre heating and Circulation

< Oil Pre-heating and Circulation >

1) Move Oil form drum to Oil tank
1 2) Beforer filling oil into the transformer, perform
OIL Drum
oil preheating and circulation in the oil storage
tank to remove water and reduce filling time.

Oil
Purifier OIL Tank • Before moving oil form drum to oil tank, clean
2
water and dust on the drum.
Oil Dielectric Strength TEST before filling oil into Transformer

• Prior to filling Oil into transformer, Oil Dielectric Strength Test has
to be performed in accordance with International Standard

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Oil Filling under Vacuum (Processing Parameters)
Close this valve
when Oil level
reaches 100mm < Oil Filling under vacuum >
below of top of
mainbody 1) Oil filtering machine maintenance is highly
recommended including filter and hose,
fittings and tank.
Vacuum
pump 2) Check the oil quality prior to Filling
-> By checking Certification and Oil dielectric
TEST in accordance with HICO Manual.
3) Filling oil as specified table.
4) If ambient temperaturer is less than 10C,
It need to perform an active part pre-heat
Oil
OIL Tank Purifier
-> Refer to HICO O&M Manual section 5.6 & 5.10
(Rev 5)

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Adjusting Oil Level according to Level-Temp
Curve.

< Adjusting Oil Level >

Vacuum
pump 1) First Fill oil up to level 4 and Stop.
(Or fill oil 1 more LV compared with L-T
Curve)
2) Then break vacuum slowly by using dry air.
3) Perform air vent at top of conservator.
(Include OLTC)
Oil
OIL Tank Purifier 4) During breaking vacuum, Oil level will come
down. So It need to fill more oil into Tr after
air vent work.
-> Refer to HICO O&M Manual section 5.10
Oil Circulation

< Hot oil Circulation >

1) After Oil filling, perform Hot oil circulation
according with as shown below table.
2) After finishing all process, perform oil dielectric
Oil
Strength test according with as shown below
Purifier table.
(If result is no good, perform hot oil circulation
more times)
-> Refer to HICO O&M Manual section 5.8 & 5.10 (Rev 5)

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Site Test

< Site Test >

• Receiving Inspection
- SFRA, Dew point (if required)
- impact record. Insulation resistance(C-F-G)
• Wiring & Terminal Check of Protection (BCT, Neutral
CT and associated accessory terminal)
• Insulation resistance test (Hv -Xv- G)
• Voltage ratio / Phase relation
• Winding Resistance
• Power Factor
• PD measurement(If required)
• Oil Breakdown Test
• Functional Test
• OLTC Test
• Sequence TEST

* According to Site Test Plan

Site Test
Measurement of winding resistance

- Standards : IEEE Std C57.12.90, clause 5 “Resistance Measurements”

IEC 60076-1, clause 10.2 “Measurement of winding resistance”

- Description
1. The winding resistance will be measured by the DC voltage drop method with resistance
Measuring system.
2. This test shall be made on all windings and all tap positions.
3. The measured resistance will be corrected to reference temperature.

- Typical test circuit

Site Test
Voltage ratio measurement

- Standards : IEEE Std C57.12.90, clause 7 “Ratio tests”

IEC 60076-1, clause 10.3 “Measurement of voltage ratio and check of phase
displacement”

- Description :
1. The voltage ratio shall be measured by means of a voltage ratio measuring bridge and
on single phase, phase by phase.
2. The applied voltage to HV winding will be about 220V.
3. The test shall be made primary to secondary, primary to tertiary and secondary to tertiary

- Typical test circuit

Site Test
Polarity & phase relationship

- Standards : IEEE Std C57.12.90, clause 6 “Polarity and phase relation test”
IEC 60076-1, clause 6 “Connection and voltage displacement symbols for three
phase transformers”

- Description :
1. The polarity shall be checked at rated voltage tap connection.
2. 220V will be applied to HV winding and the voltage shall be measured between terminals.
3. Test circuit will be drawn and confirmed.

- Typical test circuit

Site Test
Insulation resistance measurement

- Standards : IEEE Std C57.12.90, clause 10.11 “Insulation resistance test”

IEC 60076-1, clause 10.1.3 : Power transformers-Part 1 “General”

- Description :
1. Transformer must be grounded and tie all terminals of each winding together.
3. Measured by means of Megger tester at 5000V dc between windings and ground.
4. Measured ㏁ unit. 1000V DC This is a function of the moisture and impurity contents of
the insulation.
5. Voltage should be increased in increments of usually one kilovolt to five kilovolts and held
for one minute while the current is read.

- Typical test circuit

Site Test
Insulation power factor measurement

- Standards : IEEE Std C57.12.90, clause 10.10 “Insulation power factor test”
IEC 60076-1, clause 10.1.3 Power transformers Part1 : General, “Measurement of
the dissipation factor of the insulation resistance capacitances”

- Description :
1. All insulation must be immersed in oil and all terminals of each phase must be connected.
2. Power factor between windings, winding and ground will be measured.
3. Doble test (capacitance and power factor) shall be performed on the each unit and all
condenser type bushings installed in each unit.
4. The measured power factor will be corrected to 20 ℃.

- Typical test circuit

3.15. LCP
4. Protective Relays
Buchholz Relay For Main Tank

-> Refer to Buchholz Relay Manual

A. Function
: Make Alarm & Trip Signal
to Internal Fault

B. Operating Values (Model : Cedaspe EE3)

a. Alarm
- Gas Volume
: 250cc
b. Trip
- Oil Surge
: 90~160 cm/sec

C. Mounting Position
Main pipe between tank and conservator
Oil Level Gauge
-> Refer to Oil Level Gauge Manual
A. Function
: Make a Alarm Signal
: Check to
Main Tank/OLTC Oil level

B. Operating Value
a. Alarm/Trip (Up to Customer)
- 0 (Zero) Position
- Lo/HI
C. Mounting Position
Main conservator side
OLTC conservator side
Pressure Relief Device For Main Tank

-> Refer to Pressure Relief Device Manual

A. Function
: Make a Trip Signal
to Internal Fault

B. Operating Value
a. 10psi ± 10%
b. 0.7kg/ ㎠ ± 10%

C. Mounting Position
a. Trans. Upper Cover

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OLTC Protective Relay

-> Refer to OLTC Protective Manual

A. Function
: Make a Trip Signal
to OLTC Diverter Switch fault.

B. Operating Value
a. Oil Surge
1.2m/sec± 0.2

C. Mounting Position
a. Between OLTC Head cover
and OLTC Conservator.

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Rapid Pressure Rise Relay

-> Refer to Rapid Pressure Rise Relay Manual

A. Function
: Make a Trip Signal
to Internal fault.

B. Operating Value
a. Pressure Rate 1.0 ~ 200 psi-sec
b. Various Response Time Chart

C. Mounting Position
a. Side on the main tank.
Rapid Pressure Rise Relay
Temperature Indicator (OTI/WTI)
-> Refer to Temperature Indicator Manual
A. Function
a. Make Alarm & Trip Signal
to internal fault
b. Fan Motor Operation

B. Operating Values
a. O.T.I
- 95℃ : Alarm
- 105℃ : Trip
b. W.T.I
- 55℃ : Fan Motor Operation
- 40~45 ℃ : Fan Stop

- 105℃ : Alarm
- 115℃ : Trip
Temperature Indicator (OTI/WTI)

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5. Maintenance
Maintenanace

 Routine Inspections
The Routine inspections should be made preferably daily on every transformer in service. Oil
temperature and/or winding temperature, load current, ambient temperature and oil level in a
transformer should be daily checked and recorded
 Periodic Inspections
the periodic inspections should be made occasionally, once every six months or once every
three years in order to ascertain the good performance of a transformer and its parts. Most of
the periodic inspections should be made in detail when the transformer is de-energized.
 Periodic Testing
Some additional inspections or measurements of electrical characteristics of a transformer are
recommended as preventive maintenance actions and when any transformer trouble should be
investigated.

Repainting of radiators and transformer tanks, and exchange of parts, gaskets and bearings of
Motors should be planned and executed regularly as a part of an effective preventive maintenance
Program to ensure reliable performance.
Routine Inspection
Routine Inspection
Periodic Inspection
Periodic Testing
Periodic Testing
Regular Maintenance
Standard for gas dissolved Insulated Oil

Abnormal case Genesis gas

Low ( Over 300℃) C2H6, CH4, C2H4

Heating of insu- CH4, C2H4, C2H6

Medium ( 300 - 700℃ )
lation oil

High ( Over 700℃) C2H4, CH4, C2H6

Heating of solid insulation materials CO, CO2, CH4

( Over 200℃)

ARC on insulation ( Over 1,000℃) C2H2, H2, C2H4, CH4

CORONA on Insulation ( Over 1,000℃) H2, C2H2, C2H4, CH4

Heating of insulation oil and materials CO2, CO

HYOSUNG CORPORATION

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