Transformer Training (SNC Lavalin - District Cooling Project) - R01

Transformer Training
ELECTRO ELECTRIC SYSTEMS 1 www.hyundai-elec.com

CONTENTS
1. Training Schedule ------------------------------------------------------------- I
2 C
2. Company Profile
P fil -------------------------------------------------------------- 3
3 Power Transformers ----------------------------------------------------------- 13

3.
4. Operation
p & Maintenance of oil-immersed Transformer ---------------- 37
5. Specification for Power Transformer --------------------------------------- 159

2. Company Profile
 Location
 Sales & Marketing
140-2,
140 2, Kye-Dong,
Kye Dong, Chongro
Chongro-Ku,
Ku, Seoul, Korea
 Design & Production
1, Cheonha-Dong, Dong-Ku, Ulsan, Korea
 Factory Acreage :
 HHI Complex CHINA
Area : ,
2,025 Acres
Building : 1,215 Acres
 Electro Electric Systems(“EES”)
Area : 65 Acres
Building : 40 Acres
 Employees : 26,000(EES : 3,000)

AERIAL VIEW AND YARD LAYOUT
MAIN YARD

History
 1973 - Established as Hyundai Shipbuilding & Heavy Industries Co., Ltd.
 1978 - Renamed as Hyundai Heavy Industries Co., Ltd.
 1994 - Restructured Comprising Six Business Divisions

History of EES
 1973 Established as Electrical Department of Hyundai Shipbuilding &

Heavy Industries Co.,
Co Ltd.
Ltd
 1978 Establishment of Hyundai Electrical Engineering Co., Ltd.
as an Independent Company
 1989 Award of ISO 9001 Certificate
 1994 Merged into Hyundai Heavy Industries Co., Ltd.
 1997
199 Acquisition
A i i i off State-run
S C
Company Elprom Trafo
f CCo., Bulgaria
i
Award of ISO 14001 Certificate
 1999 Completion of 765kV Class Apparatus Factory
 2003 Establishment of HITC(Hyundai-Enova Innovative Technology
Center) in California, USA

Business Areas
HYUNDAI HEAVY INDUSTRIES CO., LTD.
Electro Electric Industrial Plant

Systems Ship Building Engine & Machinery & Engineering
E i i
Offshore & Engineering Construction Green Energy

Equipment
Manufacturing Plants of EES
STATIONARY ROTATING
MACHINERY PLANT MACHINERY PLANT

Introduction of Products
 Transformer
 Switchgear
 SF6 Gas Insulated Switchgear & Gas Circuit Breaker
 Power Automation
 M.V/L.V
M V/L V Circuit Breakers
 Rotating Machinery
 Inverter
 Electric Vehicle (EV) Purpose Equipment
 Automation System
y
 Traction Power Supply and Propulsion System
 Turnkey Solution

PRODUCTS
TRANSFORMER
 Power Transformer
( tto 765kV/ 1300MVA)
(up
 Distribution Transformer
 Cast
C t Resin
R i Transformer
T f
 Reactor
 Mobile
M bil Transformer
T f
 SF6 Gas Insulated Transformer
 Phase Shifting Transformer
 Furnace Transformer
 Rectifier Transformer
Transformer ( 1 / 2 )
Power Transformer Distribution Transformer Cast Resin Transformer
Reactor Traction Transformer Tap Changer

Transformer ( 2 / 2 )
SF6 Gas Insulated Transformer Mobile Transformer
Furnace Transformer Rectifier Transformer Phase Shifting Transformer

3. Power Transformers
1 The Physical Background of Transformer Operation ------------------------------------------------------------------14
2 Constructions of Transformers -----------------------------------------------------------------------------------------------17
2 1 Cores
2.1 C ------------------------------------------------------------------------------------------------------------------------- 17
2.2 Windings --------------------------------------------------------------------------------------------------------------------- 20
2.3 Core & Coil Assembly -----------------------------------------------------------------------------------------------------24
. Drying
2.4 y g & Assembly
sse b y -------------------------------------------------------------------------------------------------------- 26
2.5 Transformer Tanks --------------------------------------------------------------------------------------------------------- 28
2.6 Cooling System ------------------------------------------------------------------------------------------------------------- 30
2.7 Cooling Class Designation ------------------------------------------------------------------------------------------------ 36

1 The Physical Background of Transformer Operation
The operating principle of transformers originates in the law of electromagnetic induction such as Faraday’s Law and
Lenz’s Law. The induced voltage of each secondary winding is proportional to the rate of change of flux linkage in
a core, which links the primary winding. Essentially, a transformer consists of a magnetic core built up of insulated
silicon steel laminations upon which are wound two or more distinct sets of windings suitably located with respect to
each other and termed normally the primary and secondary windings respectively.
Fig. 1-1 Basic Diagram of Transformer
The primary winding is that winding to which the supply voltage is applied irrespective of whether it is the higher or
lower-voltage winding ; the other winding to which the load is directly connected is termed the secondary winding.

Such a combination may be used to drive a voltage higher or lower than that immediately available, and in case the
voltage of the secondary winding is higher than that of the primary winding, we call the transformer a step-up
transformer which is usually installed in a power plant and on the contrary the voltage of the secondary winding is
lower than that of the primary winding, we call the transformer a step-down transformer which is usually installed
in a substation of transmission lines.
As the phenomenon of electromagnetic induction can only take place in static apparatus when the magnetic flux is
continually varying, it is clear that static transformers can only be used in electrical circuits having such characteristics,
that is, in Alternating-Current circuits. It means that transformers can not be used in Direct Current circuit
because there is no variation of magnetic flux in the circuit.
circuit
If an alternating Electromotive Force so called e.m.f is applied to the terminals of the primary windings of a
transformer with the secondary winding open circuited,
circuited a very small current will flow in the primary circuit only,
only
which serves to magnetize the core and to supply the iron loss of transformer.
We call the current no-load current.
Thus an alternating magnetic flux is established in the core which induces an e.m.f in both primary and secondary
windings. The magnetizing ampere-turns are given by the product of the magnetizing current and the primary turns.
Therefore, the no-load current is given by the total no load ampere turns divided by the primary turns.

As primary and secondary windings are wound on the same core, and as the magnetizing flux is common to the two
windings, the formula related to induced voltage, flux and number of turns can be expressed as below and the voltage
induced in a single turn of each winding will be obviously the same as follows.
E1
Primary induced voltage E1, E1 = 2 x π x f x N1 x Ф = 2 x π x f x N1 x B x S (V)  =2XπXf XBXS
N1
E2
S
Secondary
d iinduced
d d voltage
lt E2 E2 = 2 x π x f x N2 x Ф = 2 x π x f x N2 x B x S (V)  N2 = 2 X π X f X B X S
E2,
E1 E2
Therefore, above two formula can be expressed like this ; = N2 = 2 X π X f X B X S.
N1
As described in above formula, the induced voltage in a single turn of the primary and secondary windings is
exactly same and the induced voltages in the primary and secondary windings are proportional to the number
of turns of those windings,
g , correctly.
y
Where, f = Frequency (HZ)

N1 = Number of turns in the primary winding
N2 = Number of turns in the secondary winding
Ф = Maximum value of magnetic flux (wb) = ( Flux density of core B ) X ( Core cross section area S )
B = Flux density of core (Gauss)
S = Core cross section area (Cm2)

2 Constructions of transformers
2.1 Cores
The core is constructed of cold rolled grain oriented sheet steel laminations with a high magnetic permeability
and a very low no load loss. Each lamination is insulated on each side with magnesium-silicate-phosphate coating
to reduce the eddy current loss.
Hyundai’s standard core construction is the so-called core form type with a single phase, two leg core or a three
phase, three leg core. Furthermore the core form type with a single phase, three or four leg core and a three phase,
five leg core or other special types can be manufactured. The oriented silicon steel strip is cut by computerized
machinery, thus minimizing air gap in the joint during assembly. Oriented silicon steel strips are generally cut at 45°
angle
l and
d also
l V-cut
V and
d / or rectangular
l cut are adopted.
d d This
Thi enables
bl the
h core to minimize
i i i core lossl andd soundd level
l l
during operation.
Raw material of core Cutting Slitting

Lamination Completed core
2/0 1/2 2/2 3/0 3/2

a) Single Phase Transformers b) Three Phase Transformers
Fig. 2-1 Core form

The core is assembled in the following manner in order to be tightened uniformly without unbalance of strength.
- The leg cores and yoke cores in which hard wooden bars are inserted, are tightened with synthetic resin
impregnated glass tape.
- The yoke cores are pressed with a rigid steel frame so called core clamping device.
- The above mentioned structures reduce inner vibration and noise level.
In the core of large power transformer, suitable insulation paper and / or rubber plate are inserted between some
l i i
laminations to reduce
d eddy
dd current andd to minimize
i i i magnetic
i short
h circuit.
i i Also
Al suitable
i bl cooling
li ducts
d are provided
id d to
obtain effective cooling. Followings show Hyundai’s standard core form for a single phase and a three phase
transformer, respectively.
Core Construction (3/0) Core Cross Section View

Where,
HF ; Window Height
BF ; Window Width
HF HEK ; Core Height
SSN
SS1
DS ; Core Diameter
HEK
(H i h )
(Height) SS ; Lamination Height
BS BF BS BF BS BS ; Silicon Steel Sheet Width
BSN
ES ES Fig. 2-2
BS1
Basic construction of core

2.2 Windings
Windings consist of copper conductors and solid insulation materials such as insulation paper, press board and so
on. Hyundai usually selects copper conductors considering transformer capacity, permissible current, temperature
rise limits and mechanical strength to withstand the electromagnetic force produced by a short circuit current.
Conductor Round type
Flat type Single
Twin
R di l Twin
Radial T i
Triple
CTC (Continuous Transposed Conductor)
CTC
Fig. 2-3
The type of conductor

In manufacturing transformers, the most suitable winding method has to be employed according to the capacity,
voltage and tap range of each transformer. According to the winding method, Hyundai generally uses three kinds of
windings such as layer windings, helical windings and disc windings.
The type of windings used is determined by the following situation.
- Layer windings for low voltage and large current such as 22 KV and below class voltage and 1000 amperes and
below, respectively.
- Helical
H li l windings
i di f llow voltage
for lt up to
t 33 KV and
d the
th magnitude
it d off currentt such
h as some thousand
th d amperes.
- Disc windings for high voltage of 33 KV and above and low current.
Fig. 2-4
Layer winding Helical winding Disk winding 3 kinds of windings

The low voltage winding is usually positioned nearest to the core, the high voltage winding and tap winding are
usually positioned the outside of the low voltage winding.
Fig. 2-5
Basic construction of windings
g
Manufacturing the winding Sizing the winding

Key words
Pressing wood
Insulating block
Electro static shield ring
Insulating cylinder
Oil duct
Core
Yoke
Low voltage winding
High voltage winding
Tap winding
Fig. 2-6 Winding Construction

2.3 Core & Coil Assembly
For insulation, all Hyundai transformers have a concentric winding structure. One or more insulating cylinders are
placed around the core legs. The number of insulating cylinder depends on the voltage stress between the leg and the
winding itself. Vertical spacers are provided to produce an oil duct for cooling windings. Between the low and high
voltage winding, several insulating cylinders are provided at fixed distance from each other by using vertical spacers.
Fig. 2–7 Inserting the winding Fig. 2–8 a) Core & coil assembly

The high voltage winding is wounded on the outer cylinder. The bottoms of windings rest on the supporting system of
the lower yoke. And a large wooden press ring called “ pressing wood “ is provided at the top of windings.
The windings are pressed by means of the pressing wood and bolts on the upper clamp device. All leads and bus bars
are tightly supported to withstand short circuit force.
After the core and coil assembly of transformers is

completed it is dried in the vapor phase drying
completed,
plants under high vacuum condition for the purpose
of eliminating moisture content.
Fig. 2–8 b) Core & coil assembly

2.4 Drying & Assembly
The internal parts of the transformer are given primary vacuum drying with the heat in Hyundai’s vacuum drying oven
at a temperature of about 110 °C and a vacuum level of 0.2 Torr. During the primary vacuum drying process, the
temperature and vacuum level of the drying oven vary hour by hour in accordance with moisture quantity evaporated
from the insulation material of transformer active parts. The variation ranges of the temperature and vacuum
level are +/- 10 degree C and 0.2 Torr to 65 Torr, respectively.
After the primary vacuum drying, core and coil assembly is pulled out of the vacuum drying oven to retighten the
loosed core and coil assembly caused by removing the moisture from the insulation material of the core and coil
assembly.
y
Furthermore after the insulating material has been retightened securely, the internal parts are given secondary vacuum
drying under the same conditions as mentioned previously because the insulation material of the core and coil
assembly absorbs some moisture of atmosphere during the retightening work up to a few percent
percent.
On the completion of the vacuum drying the core and windings are tanked and the transformer is filled with insulation
oil under high vacuum. The completion of the vacuum drying process can be judged by measuring insulation resistance,
tangent delta and hourly rate of extracted water from the transformer internal parts.
Since the insulation material is retightened firmly after complete drying through these both vacuum drying processes, it
iss abso
absolutely
u e y free
ee from
o further
u e sshrinkage
age due to
o yea
year round
ou d usage.

As described in international regulation,
tangent delta so called power factor is
defined as the ratio of the power
dissipated divided by the input voltage
ampere times 100.
If the internal p
parts have to be dried at the
installation site because of restrictions on
transport, One of the methods of degassing
and drying transformers can be employed.
The methods are described in Clause 6.9
Degassing and drying transformer of
Hyundai’s manual titled Shipment, Storage
and Erection.
Fig. 2–9 Vacuum drying

2.5 Transformer Tanks
The Protection of core and coil assembly in the transformers
are very important, especially in case of high voltage and
large current transformers. While achieving the optimized
size of transformers to suit the site conditions for installation,
the main role of the tank is to protect the core and coil
assembly
bl andd th
the ttank
k is
i fabricated
f b i t d to
t have
h sufficient
ffi i t
strength to withstand internal and external faults that may
occur during operation. And the various ancillary devices
such as lifting lug
lug, jack pad,
pad and skid base are designed and
provided on the tank so that the completely assembled
transformer unit can be moved in any direction without
damage
g when using
g rollers, plates
p or rails.
Hyundai strict welding procedure and leak test assure 100%
leak-proof seams and maximum mechanical strength.
After finishing the welding work, all the tank surface will be
strongly blasted with shot balls to remove all dust and
spatters before painting.
Fig. 2–10 Transformer Cover & Tank

Fi 2–11
Fig. 2 11 IIn-Tanking
T ki Fi 2–12
Fig. 2 12 Fi
Finall A
Assembly
bl

2.6 Cooling System
A transformer in service has losses which are transformed as heat to
be dissipated and thus leading to a temperature rise in the
transformer. In order not to allow the temperature to rise above
the permissible level, a suitable cooling method should be
considered and adopted. Generally, the cooling methods suitable for
th ttransformer
the f iis ddetermined
t i d bby th
the customer
t after
ft ddue th
the
consideration of transformer capacity and the circumstances at the
installation site.
Since the expectation of transformer life of some ten years is highly

related to the hottest temperature of transformers which is 98 ºC on
yyearlyy average
g ambient temperature
p of 20 ºC,, Hyundai
y decides
radiator specification, the number of cooling fans and the cooling
No. Description No. Description
capacity of unit coolers with care.
1 Pipe 6 Lifting hook
2 Element 7 End plate
In case of the design of forced oil cooling, Hyundai also considers 3 Round bar 8 Drain plug
maximum speed of oil flow inside the active part of the transformer 4 Rad. flange 9 Gasket
so not to create streaming electrification. 5 Air vent 10 Radiator valve
Fig. 2–13 Radiator

Hyundai can design and manufacture transformers with various types
of cooling systems according to the customer’s requirement.
ONAN ; Natural Oil cooling ( ON ), Natural Air cooling ( AN )
ONAF ; Naturall Oil
il cooling
li ( ON ),
) Forcedd Air
i cooling
li ( AF )
OFAF ; Forced Oil cooling ( OF ), Forced Air cooling ( AF )
ODAF ; Directed Oil cooling ( OD), Forced Air cooling ( AF )
OFWF ; Forced Oil cooling ( OF)
OF), Forced Water cooling ( WF )
When transformers are equipped with panel type radiators, radiator

valves are usually welded on transformer side wall as shown in figure
2-14. The main advantage of radiator valve is for easy removal of
the radiator from transformer tank during transportation or for
Fig. 2–14 Radiator Valve
repairing the radiators without draining insulating oil from the main tank when a small defect occurs on the radiator.
Th transformer
The t f can remain
i energized
i d during
d i radiator
di t removal.
l The
Th damaged
d d radiator
di t can be
b removedd from
f the
th tank
t k
after closing the upper and lower radiator valves and then draining out the oil from the radiator. When a radiator is
removed, blind flanges have to be fixed on the valves because only very small quantities of oil come out from the
valves After repairing,
valves. repairing remove the blind flanges and assemble the radiator at the original position.
position For oil filling,
filling
connect the filtering machine to the drain valve and fill the oil into the radiator until some of oil flows over through
the air cock on the upper side of the radiator. Insulating oil to be filled must have enough dielectric strength and
radiator valves must be closed during
g filling.
g After filling
g the oil, close the air cock and drain valve and then open
p the
radiator valves after stabilizing the oil, sufficiently.

In case of cooling fan as shown in figure 2-15, Hyundai has two ways to attach the fans on the radiator. One is to
attach the fans to the flank of the radiator and the air is blown horizontally. The other is to attach the fans to the
bottom of the radiator and the air is blown vertically.
Fig. 2–15 Cooling Fan Fig. 2– 16 Attach to the flank Fig. 2–17 Attach to the bottom

A photograph and the inner parts of oil to air cooler are shown in figure 2-18. In this cooling system, the cooling effect
per unit is improved to a great extent. The heat transmission rate of oil is about 4 times higher than that of air.
It means that the air contact area is about 4 times larger than the oil contact area. Finally, the cooling unit in which the
radiation area of air is increased by fixing a thin fin on the oil pipes is used.
Fig. 2–18 Oil to Air Cooler

The thin fins of coolers are hot dip galvanized and provide a good thermal contact with oil pipe and excellent
protection against corrosion. As the cooler has large air ducts, it is not sensitive to the ingress of foreign
substances and therefore is maintenance free. A large number of different fan speeds make it possible to meet the
requirements of low sound level. This cooling method has a simple structure and can be installed in a small space
because of its small size. The cooler is generally fixed onto the transformer main body. As the case may be, the cooler
can be installed separately from the transformer main body.
In case of oil to water coolers as shown in figure 2-19, it

has a great cooling effect than any other cooling systems.
The
h diff
difference from
f the
h OOFAF
A cooling
li system iis that
h water
is circulated around the oil filled pipes of the cooler, thus
make heat exchanged. In this case, special care must be
taken to ensure that the pressure of the oil is higher
than that of water.
The reason is that when a water cooling pipe is eaten
away with rust and cooling water is mixed up with
insulating oil, severe electrical damage can be caused by
water entering into the transformer tank.
Fig. 2–19 a) Oil to Water Cooler

Therefore, Hyundai uses double tube type
OFWF coolers to protect transformers from this
phenomena.
In case of double tube type OFWF coolers,
transformers can be fully protected from the
danger of a leak of cooling water because
H
Hyundai
d i can iinstall
ll an alarm
l signal
i l in
i the
h
double tubes of each cooler for detecting
a leak of cooling water.
Fig. 2–19 b) Oil to Water Cooler

2.7 Cooling Class Designation
Designation Explanation
ONAN 1. First letter : Internal cooling medium in contact with the windings ;
-. O : Mineral oil or synthetic insulation liquid with fire point ≤300℃
ONAF -. K : Insulating liquid with fire point ＞300℃
-. L : Insulating liquid with no measurable fire point
ONAN/ONAF/ONAF
2. Second letter : Circulation mechanism
ONAN/ONAF/OFAF -. N : Natural convection flow through cooling equipment and in
windings
ONAN/ODAF -. F : Forced circulation through cooling equipment, natural
ONAN/ODAF/ODAF convection flow in windings
-.. D : Forced circulation through cooling equipment, directed from
OFAF the cooling equipment into at least the main winding
3. Third letter : External cooling medium
OFWF
-. A : Air, W : Water
ODAF 4. Fourth letter : Circulation mechanism for external cooling equipment
-. N : Natural convection
ODWF -. F : Forced circulation

OPERATION & MAINTENANCE / HHIS-WZ-TE-300 (06)
4. OPERATION & MAINTENANCE OF OIL-IMMERSED TRANSFORMER

Transformers are often subjected to heavy electrical and mechanical stress because of their electrical location in a
power system.
system To avoid failures and problems,
problems it is essential to conduct a program of careful supervision and
maintenance.
The life of a transformer is highly dependent upon the heat prevailing in the windings and core of the transformer.
International standards consider average transformer life to be 20 to 25 years.
years This estimation is based on continuous
operation at rated load and service conditions with a maximum ambient temperature of 40 ºC and a temperature rise of
65 K. The heat is caused by internal losses due to loading, high ambient temperature, and solar radiation. It is
important to understand how your particular transformers are cooled and how to detect problems in the cooling
systems. Therefore, it is important that the temperature of the transformer should be periodically or continuously
monitored. And also, the characteristic of insulating oil is extremely important and should be maintained at a high
quality according to the standard.
In case of On Load Tap Changer, it is important that the tap changer should be maintained in accordance with the
manufacturer’s recommendations. It is generally accepted that all new On Load Tap Changers are inspected internally
at the end of the first year of service, regardless of the number of operations.
There are the two important purposes of this internal inspection ;
First, it is to ensure that the internal mechanism is functioning properly.
Second, it is to measure switching contact wear so that the time interval between subsequent inspections may be
estimated.
For the first few days, daily inspections are recommended for recently energized transformers.

CONTENTS
1. GENERAL ---------------------------------------------------------------------------------------------------------------------- 40
2. SAFETY REGULATIONS -------------------------------------------------------------------------------------------------- 41
2.1 General ----------------------------------------------------------------------------------------------------------------------- 41
2.2 Safety ------------------------------------------------------------------------------------------------------------------------- 42
3. OPERATION AND CHECK ITEMS ------------------------------------------------------------------------------------- 44
3.1 Normal Operation ----------------------------------------------------------------------------------------------------------- 44
3.1.1 Conditions of valves ----------------------------------------------------------------------------------------------------- 44
3.1.2 Fan and pump operation ------------------------------------------------------------------------------------------------- 44
3.2 Emergency
g y operation
p ------------------------------------------------------------------------------------------------------ 45
3.2.1 Loading guide ------------------------------------------------------------------------------------------------------------- 45
3.2.2 Over excitation operation ------------------------------------------------------------------------------------------------ 45
3.3 Inspection and check ------------------------------------------------------------------------------------------------------- 46
3.3.1 Protective accessories and pre-set values ----------------------------------------------------------------------------- 46
3.3.2 Inspection and check items before operation ------------------------------------------------------------------------- 47
3 3 3 Inspection and check items of transformers in service -------------------------------------------------------------- 62
3.3.3

4. MAINTERANCE -------------------------------------------------------------------------------------------------------------- 88
4.1 Forwards --------------------------------------------------------------------------------------------------------------------- 88
4.2 Classification of maintenance and inspection -------------------------------------------------------------------------- 90
4.3 Daily maintenance and inspection --------------------------------------------------------------------------------------- 91
4.4 Periodical maintenance and inspection ---------------------------------------------------------------------------------- 95
4.5 Maintenance and inspection standard ----------------------------------------------------------------------------------- 115
4.5.1 Inspection of transformer insulation ----------------------------------------------------------------------------------- 115
4.6 Gas analysis
y on transformer oil ------------------------------------------------------------------------------------------ 123
4.6.1 Analysis method ---------------------------------------------------------------------------------------------------------- 123
4.6.2 Assessing the test results ------------------------------------------------------------------------------------------------ 123
5. TROUBLE SHOOTING ----------------------------------------------------------------------------------------------------- 126
6. RECOATING ------------------------------------------------------------------------------------------------------------------- 156
6.1 Recoating cycle ------------------------------------------------------------------------------------------------------------- 156
6 2 Method of recoating ------------------------------------------------------------------------------------------------------- 156
6.2
6.2.1 Outdoor service equipment --------------------------------------------------------------------------------------------- 156
6.2.2 Indoor service equipment ------------------------------------------------------------------------------------------------ 157
7 FACTORY REPAIR PROCEDURE -------------------------------------------------------------------------------------- 157
7.

1. General
This instruction manual is prepared as a guide to the operation and maintenance of Hyundai transformers.
Every man who works on the operation and maintenance of the transformer should be constantly aware of what he
should do and should not do to maintain the high quality and reliability of the transformer.
All work-operation, inspection and maintenance should be done according to this manual.
All
ll off possible
ibl contingencies
i i which
hi h may arise
i during
d i operation
i andd maintenance
i are not coveredd with
i h this
hi manual.
l
When further information is necessary or a particular problem not covered with this manual, contact the manufacturer
about that.
Hyundai Heavy Industries Company LTD. would furnish sufficient information willingly.
Before dealing with transformer, one must read and remember this manual especially clause 2. Safety
Regulations.
Not following these instructions may cause personal injury or property damage.

2. SAFETY REGULATIONS
2.1 General
Safety regulations are intended to alert personnel who are in charge of transformers with possible personal injury,
d h or property ddamage. One must avoid
death id improper
i working
ki mentioned
i d ini this
hi manual.
l Safety
f levels
l l quotedd in
i this
hi
manual are defined in three levels, have a mark of and are printed in bold characters as follows ;
Extreme hazardous working that can cause severe personal injury, death or property damage.
Hazardous or unsafe working that has possibility of injury, death or property damage.
Unsafe or improper working, which can result in minor personal injury or property damage.
All safety regulations with the symbol have to be strictly observed to prevent person from related hazard or
property damage. Each person, operator or who is in charge of a transformer, has to read and be aware of the
regulations.
g The whole pparts of clause 2 is related with safety.
y These instructions must be obeyed
y during
g working
g on a
transformer.

2.2 Safety
The following safety precautions must be observed while the transformer is in service.
1) Working near a energized transformer.
Never climb on any part of a transformer while it is energized.

Injury or death can occur due to an electric discharge.
2) Liquid level
Do not open any valve or pull any plug on a transformer or any of its accessories while the
transformer is energized because the liquid level inside the transformer can drop below the minimum
level except gas or oil sampling valves.
A iinternal
An t l flashover
fl h may occur if the
th liquid
li id level
l l isi lowered
l d below
b l minimum
i i level.
l l
3) Control circuits
Caution must be used when operating any of the switches or breakers because the control circuits,
inside and outside the control cabinet, utilize voltages that can be dangerous to personnel.
If it is necessary to work on the circuits,
circuits the power supply must be switched off
off.

4) Cooling equipment
When the transformer is energized,

g , the proper
p p cooling g equipment
q p must be in operation.
p
If not, dangerous pressures can occur inside the transformer and possibly result in injury to personnel.
5) Jacking
When unloading the transformer or placing it in position, make sure that the jack lugs or places
designated for jacking it on the outline drawing are used when jacking the unit.
The use of jacks on any other part of the transformer may require costly repairs.
6) Pulling eyes
Always pull the transformer with pulling eyes supplied on the unit.
Check the outline drawings for the proper fittings to use.
7) Current transformers
The secondary terminals of any current transformers not connected to auxiliary circuits must be shorted
and
d grounded.
d d

8) Electrical grounding
The transformer tank must be solidly grounded at one point.
3 OPERATION AND CHECK ITEMS

3. ITEMS.
3.1 Normal operation
3.1.1 Condition of valves
Prior to operating
p g transformers,, the operating
p g positions
p of all transformer valves should be checked whether theyy are
correct or not in accordance with Table 6-6 of Hyundai’s another instruction manual HHIS-WZ-TE-100 (6) titled
“ SHIPMENT, STORAGE & ERECTION OF OIL IMMERSED TRANSFORMERS” .
3 1 2 Fan and pump operation (If provided)

3.1.2
Fans and pumps can be operated either manually or automatically. Transformers must be operated under the automatic
control condition of the fans and pumps, normally. It means that the selector switch of the fans or pumps installed in
the local control panel must be set at an “AUTO”
AUTO position. Under this condition, when the winding temperature
reaches at the pre-set value, the fans and pumps will be operated automatically. The pre-set value may be subjected to
change according to site condition. In case of transformers with water cooler or unit cooler, the pumps and fans of the
cooler can be operated by the signal of Potential Transformer fitted in switchgear (Refer to local control panel
drawing).

3.2 EMERGENCY OPERATION
Under emergency condition, the transformer can be operated beyond its rated value.
3.2.1 Loading guide

The transformer can be operated under the permissible load described in IEC publication 60354 ( ANSI/IEEE C57.92 )
or applicable standards.
3 2 2 Over
3.2.2 O excitation
it ti operation
ti
The transformer can be operated under over excitation condition as shown in Fig. 1. If a different permissible curve
was submitted, refer to that curve instead of Fig. 1. The great care must be taken to minimize the over excitation
period to avoid giving excessive thermal stress to the transformer.
transformer As explained in the Fig.
Fig 1 of permissible over-
voltage characteristics, the transformer can be continuously operated at 110 % of rated voltage and also operated at
about 140 % of rated voltage for 10 seconds after energizing the transformer.
150
140
Fig 1
130
P
Permissible
i ibl
120
over-voltage
110
100
Characteristic
Excitation [%] 0.2 1 10 100 ( Typical )
Time [ min ]

3.3 INSPECTION AND CHECK

3.3.1 Protective accessories and pre-set values
Protective accessories listed in Table 1 are equipped with the transformers. Pre-set values of their alarm and trip
contacts are shown in Table 1. If any troubles occur or alarm and trip signals are detected, counter measures should be
taken according to the “trouble shooting” which is shown in this manual.
Table 1 Protective accessories and p

pre-set values of the alarm and the trip
p contacts
Name of Pre-set values ( Special Requirement )

No.
protective accessories Alarm Trip
1 Buchholz relay ( EE3 of CED - ASPE ) Volume of gas : 250㎤ Oil velocity : 0.9 m/sec.
2 Protective relay for OLTC ( M Type of MR ) - Oil velocity : 1.2m/sec.
3 Oil temperature indicator 85 ( 95 ) ℃ 95 ( 105 ) ℃

4 Winding temperature indicator 95 ( 110 ) ℃ 105 ( 120 ) ℃
5 Oil level indicator for main tank Low oil level ( Low-Low oil level )
6 Oil level indicator For OLTC Low oil level ( Low-Low oil level )
7 Pressure relief device for main tank ( 0.7Kg/㎠ ) 0.7Kg/㎠
8 S dd pressure relay
Sudden l ( 00.035kg/㎠/sec.
035k /㎠/ ) 0 035k /㎠/
0.035kg/㎠/sec.

- These pre-set values may be changed according to the applied accessories and site conditions.
For more detail, refer to attached instruction of each component.
3 3 2 Inspection and check items before operation ( 1 / 15 )

3.3.2
Followings are inspection or check items of each accessory to be made before energizing transformers.
No. Accessories Inspection or Check Items Normality Result Remarks

1) Main tank When oil level indication is within
±10 ºC of oil temperature indication, it is
Oil level 2) OLTC compartment
1 acceptable. If not, the oil level should be
indicator
adjusted according to explanation as the
3) Other oil compartment (s) below part of this table.
1) Valve (s) between When opening up or locking valves

conservator and main according to the instructions described in
t k or other
tank th auxiliary
ili Table 6-6 of Hyundai’s another manual
2 Valve tanks. HHIS-WZ-TE-100(6) titled “SHIPMENT,
STORAGE AND ERECTION OF OIL
2) Radiator valves IMMERSERED TRANSFORMERS”, it is
3) Other valves normal.
When oil level indication is not within ±10 ºC of oil temperature indication, adjust the oil level correctly in accordance
with calculation results from the temperature difference between oil level indication and oil temperature indication, the
coefficient of oil expansion of 0.78 X 10-3 / K as well as the total volume of transformer oil.

3.3.2 Inspection and check items before operation ( 2 / 15 )

Same as that of above item No. 1 oil level
1) Oil level
indicator.
When there is no oil leaks on the bushing, it
2) L
Leaks
k i normal.
is l If not, anti-oil
i il paste can be
b usedd
for repairing oil leaks on the bushing.
When the porcelain does not get any damage
Oil-filled
Oil filled and the surface of porcelain is clean, it is
3 normal. If not, clean up the surface of
Bushing
3) Porcelain bushing porcelain with insulating oil and the
insulating oil should be cleaned out from the
surface
su ace of
o bushing
bus g porcelain
po ce a by using
us g
mineral water after cleaning up.
When the taps are connected to a relay or
4) Test taps or
solidly grounded through their caps, it is
potential taps
normal.l If not, don’t
d ’ energize
i transformers.
f
When the inside of the Buchholz relay is
Buchholz completely filled with oil, it is normal.
4 Oil level
relay
e ay If not,
o , air
a bubbles
bubb es sshould
ou d be eeliminated
a ed by
using its gas release cock.


When the selector switches of fans
installed in the local control panel is set at
1) Electrical operation automatic operation positions, it is normal.
If not
not, set it at automatic operation
Cooling fan, positions.
5
if provided When the rotation direction of fan is same
as an arrow marked on fan motor, it is
2) Fan rotation normal. If not, change two wire
positions out of 3 phase power lines each
other.
Same as that of above item No. 5 cooling
1) Electrical
l i l operation
i
Oil pump, fan.
6
if provided Same as that of above item No. 5 cooling
2) Motor rotation
fan.
Transformer operation must be done under the automatic control conditions of cooling fans and oil pumps as well.
It means that the cooling fans or pumps must be automatically operated at the winding temperature indication of 85
and 95°C or presetting value under the condition that the selector switch installed in the local control panel is set at
automatic operation position.


Followings are inspection and check items to be made before energizing transformers.
No. Accessories Check Items Normality Result Remarks
When the tap changer runs through the
entire operating cycle without any
1) Manual operation obstruction excepting switching off at both
through all tap positions end tap positions, it is normal. If not,
request a factory engineer if a mechanical
fault in the tap-changer is suspected
When the tap position of motor drive unit

is same as that of the tap position indicator
2) The indications of motor
installed in the diverter switch chamber of
On-load tap drive and tap changer
the tap changer, it is normal. If not, make
7 changer, if
request for factory engineer service.
provided
p
When the current position of the control
3) Driving motor rotation cam fitted in motor drive unit is set at the
(Raise and lower center tap position before energizing
direction) motor it is normal.
motor, normal
If not, set it at the center tap position.
When the tap changer switches off after

4) Upper and lower limit
reaching
g at both end tapp positions,
p , it is
switches
it h
normal. If not, request a factory engineer.


No
1) When the inside of the protective relay

is completely filled with oil, it is normal.
If not, air bubbles should be eliminated
by using its breather.
2) When a stop valve between the relay
5) Protective relay and oil conservator is opened up, it is
On-load
O l d tap normal.l Iff not, open the
h valve.
l
7 changer, if 3) When the flap valve of the relay has a
provided vertical position in the middle of
inspection window, it is normal.
If not, replace
l it
i with
i h a new one.
When the switch fitted in motor drive unit

6)) Control selector switch is set at the remote p position,, it is normal.
If not, set it at the remote position.
When oil level is on the red line marked

1) Oil level in the glass oil
8 Breather on the glass oil cup, it is normal.
cup
If not, adjust the oil level to the red line.


When silica gel has blue color more than

2) The color of silica gel its one third, it is normal.
If not, replace it with a new one.
8 Breather When air is drawn in the breather, or

expelled out of the breather without any
3) Breathing obstruction, it is normal. If not, clean out
an air passage way between glass oil cup
and breather main body.
Breather consists of glass oil cup and silica gel chamber

chamber.
Glass oil cup shall be filled with insulating oil up to the red line marked on the cup.
When air is drawn in through intake slots between the glass oil cup and the silica gel chamber of the breather, the air
flows through the silica gel to the connection pipe of the breather.
When about 70 % of new silica gel has been discolored from the bottom of the silica gel, the silica gel should be
replaced with a new one.


No. Accessories Check Items Normality

y Result Remarks
When the resistance values are more than
Hyundai’s recommendation of Fig 7-2
insulation resistance at 20 ºC described in
clause 7 of another instruction manual
HHIS-WZ-TE-100 (6) titled “ SHIPMENT,
STORAGE AND ERECTION OF OIL
IMMERSED TRANSFORMERS”, it is
1) Insulation resistances of
normal
normal.
windings and auxiliary
If not, the transformer should be dried out
circuits
Electrical according to Hyundai’s recommendation
9 described in clause 6.9 Degassing and
tests
drying transformer oil of another
instruction manual HHIS-WZ-TE-100 (6)
titled “ SHIPMENT, STORAGE AND
ERECTION OF OIL IMMERSED
TRANSFORMERS .
TRANSFORMERS”
1) When the ratio error is within the
permissible tolerance of ±1 / 200,
2) Ratio and polarity
it is normal.
If not, request a factory engineer.


2) When the polarity is subtractive,
2) Ratio and polarity it is normal.
If not, request a factory engineer.
When the
Wh th dielectric
di l t i strength
t th is
i higher
hi h
than the instructions described in Table 6-
8 breakdown voltage, water content and
gas content of oil of Hyundai’s another
Electrical instr ction man
instruction manualal HHIS
HHIS-WZ-TE-100
WZ TE 100 (6)
9
tests titled “ SHIPMENT, STORAGE AND
3) Dielectric strength of oil ERECTION OF OIL IMMERSED
TRANSFORMERS”, it is normal.
If not
not, dry out the transformer according
to the procedure described in normality
column of above check item 1) Insulation
resistances of windings and
auxiliary circuits.
circuits
Insulation resistance value expresses the quality of insulation material inside the transformer. The measurement
sshould
ou d be made
ade betwee
between each
eac winding
w d g and
a d ground
g ou d as well
we as between
betwee windings
w d gs themselves
t e se ves by means
ea s of
o a megger
egge
tester of more than 1000V.


4) Polarity of BCT
When the polarity is subtractive, it is
( Bushing Current
normal. If not, request a factory engineer.
Transformer )
1) Wh
When transformers
t f are energized,
i d the
th
secondary circuits of BCT including
heating coil circuits for winding
temperature indicator shall never be
5) The secondary
secondar circuits
circ its of open circ
circuited.
ited If not
not, the BCT can be
BCT including heating burned out due to high potential induced.
Electrical coil circuits for winding 2) When the secondary circuits of bushing
9
tests temperature indicator current transformers are connected to
the relay concerned or shorted at the
terminal board of local control panel, it
is normal. If not, the BCT can be burned
out due to high potential induced.
1) When wired according to Hyundai’s
local control panel drawings,
6) Alarm and control
2) When all contacts are open or closed
circuits.
according to Hyundai’s local control
panel drawings,


3) When insulation resistance values

between terminals themselves as well
Electrical 6) Alarm and control as between each terminal and ground is
9
t t
tests circuits
i it more than
th 10 meg ohms, h it is
i normal.
l
If not, dry out the terminals by using
compressed air.
When the alarm circuits and control

circuits of all relays are correctly wired in
1) Control circuits, alarm or
accordance with the connection diagram
trip circuits
of Hyundai’s local control panel drawings,
it is normal. If not,, correct them.
Local When the secondary circuits of bushing

10 control current transformers are connected to the
2) The secondary circuits of
panel concerned relay or shorted at the terminal
BCT
C
b d off llocall control
board t l panel,
l it is
i normal.
l
If not, correct them.
1) When insulation resistance is more than

3) Humidity or dust inside
10 megg ohms at 20 ºC between relayy
th cabinet
the bi t
terminals and ground,


2) When hygrograph stat for heater with
the designation of 23H in the
component list of local control panel
drawing is set at the previous setting
Local
3) Humidity or dust inside value 80%,
80%
10 control
the cabinet 3) When thermostat with the designation
panel
of 23T in the component list of local
control panel drawing is set at the
previous setting value 18 ºC, it is
normal. If not, set them for the values.
1) When the waiting period between
releasing the vacuum from the
transformer and putting the transformer
in service is longer than Hyundai’s
1) Waiting period between recommendation described in Table 6-7
releasing the vacuum vacuum treatment and oil filling
11 Others
and putting requirements after complete assembly
transformers in service of Hyundai’s another instruction manual
HHIS-WZ-TE-100 (6) titled
“ SHIPMENT, STORAGE AND
TRANSFORMERS”,


2) When all vent plugs are closed after
1) Waiting period between
opening them up for several seconds to
releasing the vacuum
release air bubbles from inside the
and putting
transformer, the transformer is ready to
transformers in service
energize.
1) When all components are clean,
2) When the control circuits of all
components are correctly wired in
11 Others
accordance with the connection diagram
2) All components
of local control panel, it is normal.
If not, correct them in accordance with the
connection diagram of Hyundai
Hyundai’ss local
control panel drawings.
When there is no damage on the outside
3) Touch up paint surface of the transformer, it is normal.
If not, paint the damaged part.
When there is some damage on the outside surface of transformer, the damaged parts are painted with touch up paint
according to instructions described in clause 6.11 touch-up painting of Hyundai’s another instruction manual HHIS-
WZ-TE-100 (6) titled “ SHIPMENT, STORAGE AND ERECTION OF OIL IMMERSED TRANSFORMERS”.



y Result Remarks
When the transformer has been stored
4) All sealing joints and more than two months after assembly, it is
electrical connections normal that all joints and connections must
be retightened
retightened.
When temporary grounding system had
been used during transformer assembly, it
5) All temporary is normal that all the temporary
grounding system groundings system must be removed from
the transformer prior to energizing the
transformer.
11 Others
If possible
possible, the transformer should be
energized in such a way that the voltage is
increased step by step up to the rated
voltage.
This may be done by connecting
6) Energizing transformer
the transformer to a generator which the
voltage can slowly increase.
If not, the transformer may be connected
directly to a live transmission line at no
load.



y Result Remarks
After energizing, the transformer has to be

kept under careful observation for the first
12 hours. Check and record the oil
temperature, the winding temperature, its
instrumentation and ambient temperature.
Watch particularly for their any sudden
changes.
When the transformer is successively
loaded, observe carefully the transformer
for a few hours, especially temperature,
11 Others 6) Energizing transformer.
gauges and gas relays.
The observation should be continued on a
daily schedule for seven days and then
weekly for the first month of operation.
An oil sample should be taken after the
first and twelfth month of their operation
for Gas Analysis on transformer oil.
The results of these two analysis should be
reviewed and checked in accordance with
instructions described on Table 3.6.1 gases



y Result Remarks
to be analyzed and criteria as well as
Table 3.6.2 gas content in oil by faults of
this manual and international regulations
such as IEC 60599 and IEEE standards
concerned with dissolved and free gases
11 Others 6) Energizing transformer
analysis.
After the transformer has been in service
at normal working temperatures for
several weeks, all sealing joints have to be
retightened.

3.3.3 Inspection and check items of transformers in service ( 1 / 26 )

Followings are inspection and check items of transformer in service.
No. Items Contents and Notes Judging Standard Action in case of abnormality
1) In case oil and winding

temperatures are much higher or
lower considering transformer load
and ambient temperature,
2) Correctly adjust the temperature
1) After checking and
indications by turning bolt fitted on
recording the indications of
When the indications the needle or face of the indicators
oil and winding
Transformer are in proper range after calibrating them according to
temperature indicator,
temperature considering the explanation on the next page.
ambient temperature,
1 indicator and transformer load and 3) If not, replace the indicators with
transformer load (MW,
load ambient temperature,
temperature new indicators and put the
MVAR) and voltage,
indicator the indicators are indicators back into service.
2) compare the indications
operating, correctly. 4) Measure the temperatures of
with the data previously
potential parts by using an infrared
obtained.
detecting device to determine loose
connections, overloading of
conductors, localized overheating in
transformers before they get into
serious condition.
condition


Transformer
5) Some more details for other type
temperature
infrared detecting devices are
1 indicator and
described at the below part of this
load
table.
indicator
Calibration of temperature indicators.
Each temperature indicator had been already calibrated by its manufacturer or transformer manufacturer
manufacturer. It means that
no further calibration is required in principle. But if necessary, take following procedure to calibrate the temperature
indicators when error is less than 5 ºC.
1. To check calibration, put the bulb of the temperature indicator in boiling
g water (100 ºC) or in a well stirred bath with
a control thermometer and read the indication of the indicator after 15 minutes.
2. If necessary, adjust the pointer by carefully turning the screw on its pointer or on its face.
3. If error is larger than 5 ºC, Hyundai recommends you to contact its manufacturer or transformer local agent.
4. Refer to another Note and Calibration Method for Resistance thermometer and Temperature monitor described in
clause 5. TROUBLE SHOOTING of this manual.
Somee more
So o e deta
detailss for
o ot
other
e type infrared
a ed detect
detecting
g dev
devices.
ces.
Since all matter emits infrared rays in proportion to its temperature, an infrared detecting device can be used to

determine loose connections, overloading of conductors, localized overheating in equipment, or similar conditions
before they become serious. Some equipment is sensitive to a fraction of a degree. Infrared inspection can be done
from a distance, since touch with the item being measured is not required. Substation equipment, such as bare bus,
disconnect switches and connections, can be checked without being de-energized. The inspection is made by aiming
the infrared detector at various area of the substation and everywhere the hot spots are.
Several types of infrared detectors are available. These vary from a simple hand held instrument similar to a gun,
through which the operator can detect hot spots and note their locations, to complex equipment requiring qualified
operators
t andd product
d t photographs
h t h as a permanentt record
d off th
the area bbeing
i checked.
h k d Th
The simpler
i l ddetectors
t t are usually
ll
sold outright, while the complex items are usually used by infrared detection services which contract to do the work.
Having an instrument readily available can be justified for a large installation with several substations, while a contract
to have a survey performed would probably be better for a small installation
installation. However
However, as a low cost alternative,
alternative a
camera with infrared sensitive film may be used, or a self calibrating portable indicating unit can be coordinated with a
polaroid camera.
At maximum rated current, the bushing outer terminal normally takes a temperature of about 35 to 45 K above the
ambient air. Significantly higher temperatures, especially at lower current loading, can be a sign of bad connections.
For bushing terminals and connections, maximum values of temperature and temperature rise above ambient air are
given
i in
i a table
t bl as described
d ib d on nextt page.

Maximum Maximum
Comments
Description of component temperature rise temperature
Note a
i K
in i ºC
in
Copper and copper alloys, uncoated Note d
In air 45 75
In SF6 60 90
In oil 50 80 Note b
Spring contacts Tinned in air, SF6 or oil 60 90
Silver / nickel plated

In air or SF6 75 105
In oil 60 90 Note b
Copper, aluminum and their alloys,

Uncoated
In air 60 90
In SF6 75 105
Screwed
S d In oil 70 100 Note b
contacts
Tinned
In air or SF6 75 105
In oil 70 100 Note b

Maximum Maximum
Comments
Description of component temperature rise temperature
Note a
in K in ºC
Silver / Nickel plated
Screwed In air or SF6 85 115
contacts In oil 70 100 Note b
Terminals to be Copper, aluminum and their alloys,

connected to
exterior Uncoated 60 90
conductors by Tinned 75 105 Note c
screws or bolts Silver or nickel plate 75 105
Insulation class
A ( OIP ; Oil IImpregnated
dPPaper ) 75 105
E ( RBP ; Resin Bonded Paper or 90 120
RIP ) 100 130
Metallic parts in B ( GIF ; Gas Impregnated paper or
contact with plastic
l i Film
Fil )
SF6 e Note e
Oil e N t e
Note


Notes
a. The temperature rise values are based on IEC 60943-1998 with a maximum daily mean temperature of 30 ºC.
F ffurther
For th iinformation
f ti reference
f should
h ld be
b made
d to
t IEC 60943-1998
60943 1998 G Guidance
id concerning
i ththe permissible
i ibl
temperature rise for parts of electrical equipment, in particular for terminals , Table 6.
b. For synthetic insulating liquids ( silicone, esters ), higher values may be agreed between purchaser and supplier.
c If heavy oxidation is to be expected
c. expected, the temperature rise shall be limited to 50 K.
K
d. A spring contact is a connection maintained by spring pressure, for example a plug-in connection.
e. The temperature limits shall be stated by the supplier.
N
No. It
Items C t t andd Notes
Contents N t J d i St
Judging Standard
d d A ti in
Action i case off abnormality
b lit
1) When the indication is much lower
considering transformer load and
ambient temperature, it is possible
When oil level that there are some leaks on the
oil level indicator, ambient
indication is within transformer caused by poor joints or
temperature, transformer
±10 ºC of oil temp. wrong welding parts.
2 Oil levels load (MW, MVAR) and
indication, the oil 2) After repairing them, fill the
voltage
voltage,
level indicator is transformer with insulating oil
operating, acceptably. according to calculation results
by using format described in the
obtained.
normality column of accessories oil
level indicator of clause 3.3.2


Inspection and check items before

operation.
3) In case the oil level is much higher
ambient temperature, some oil
should be drained from the
transformer.
When oil level The oil quantity, to be drained from
oil level indicator, ambient
indication is within the transformer tank, can be
temperature, transformer
±10 ºC of oil temp. calculated same as the explanation
2 Oil levels load (MW, MVAR) and
indication, the oil described in the normality column
voltage
voltage,
level indicator is of accessories oil level indicator of
operating, acceptably. clause 3.3.2 Inspection and check
items before operation.
obtained.
4) If the abnormal oil level indication
is caused by the damaged rubber
bag or diaphragm of transformer oil
preservation system, the rubber bag
or diaphragm should be replaced
with a new one.


1) When cooling fans or oil pumps

make abnormal sound or vibration
When there are no comparing them with those of other
1) After checking the sound
abnormal sound units due to a loose fan blade
blade, a
and vibration of cooling
or vibration damaged winding of motors or
fans, oil pumps or
comparing them with damaged bearing, the units should
3 Noise transformer tank,
those of other units, be repaired or replaced with a new
2) Compared them with those
those cooling fans or one according to manufacturer’s
manufacturer s
of other units
pumps are well recommendation.
operating, now. 2) When some supporters, pipes or
other parts make vibration due to
loose bolts and nuts
nuts, tighten them
them.
1) After checking loose 1) When bushing terminal temperature

connections at bushing When there is no is higher than maximum values
terminals,, ggrounding g discoloration at described on pprevious pages,
p g ,
Loose circuits, auxiliary circuits all potential parts, 2) When some parts of bushing
4
connections and others, all the parts of the terminals has been discolored,
2) Compare conductor color transformers are well 3) The transformers should be
with other p parts of them or operating,
p g, now. disconnected from the transmission
that of other units. lines and solidly grounded,


4) The contact surface of the terminals

should be cleaned out by using steel
wire brushes, thinlyy coated with
conductive grease by using lint free
cloths to prevent them from
oxidizing in the atmosphere and to
1) After checking loose improve
p the conductivity
y between
connections at bushing When there is no both contact surfaces,
terminals, grounding discoloration at 5) Tighten the bolts and nuts of the
Loose circuits, auxiliary circuits all potential parts, terminals according to
4
connections and others, all the parts of the manufacturer’s recommendation.
2) Compare conductor color transformers are well 6) In case of grounding circuits,
with other parts of them or operating, now. above procedure should be taken
that of other units. excepting disconnecting the
transformers from the transmission
lines.
li
7) In case of auxiliary circuits and
others, above procedures should be
taken to them after isolating them
from power sources
sources.


1) In case some oil leaks had been
founded, clean out the dirty oil
traces of leaks on transformer prior
to
o taking
a g thee repair
epa procedure,
p ocedu e,
2) And check if the traces are made by
oil leaks after applying the N2 gas
pressure to above oil level by using
breather ppipe
p line for more than 12
Check
Ch k visual
i l oilil leaks
l k in i
When there is no hours.
connections such as the joint
oil leaks on 3) If oil leaks are caused by damaged
parts of valves, meters, pipes,
5 Oil leaks transformers, the gasket, replace the gasket with a
radiators, especially in the
transformers are well new one according g to the repair
p
gasket
k t joints
j i t as well ll as
operating, now. procedure of the gasket.
welding parts of transformer.
4) If oil leaks are caused by a wrong
welding, apply metal bond to the
leaks or welding g procedures
p again
g
to the leaks while the transformer is
under vacuum after cleaning out the
dirty oil traces of leaks on the
transformer and then waiting g period
p
should be taken according to the


description of Table 6-7 vacuum
treatment and oil filling
Check visual oil leaks in
When there is no requirements after complete
connections such as the joint
oil leaks on assembly of Hyundai’s another
parts of valves, meters, pipes,
5 Oil leaks
l k t
transformers,
f the
th i t ti manuall HHIS-WZ-
instruction HHIS WZ
radiators, especially in the
transformers are well TE-100 (6) titled “ SHIPMENT,
gasket joints as well as
operating, now. STORAGE AND ERECTION OF
welding parts of transformer.
OIL IMMERSED
TRANSFORMERS .
TRANSFORMERS”
1) When silica gel
1) When silica gel has been discolored
has blue color
more than two thirds of the silica
more than one
1) After checking the ambient gel, dry it out or replace it with a
third
hi d off its
i andd the
h
humidity, the load variation new one.
oil cup had been
of transformer, 2) When the oil level is lower than the
filled with oil up to
Dehydrating 2) Pay attention to the red line marked on the cup, fill new
6 the red line marked
breathers discoloration of silica gel. oil up to the red line.
on the cup,
cup
3) Check oil level and 3) When there is some obstruction in
2) And there is no
breathing action in the breathing action, clean up inside the
obstruction in
glass oil cup. oil cup and replace the oil with a
breathing action,
new one after disassembling the cup
breathers are under
f
from the
h bbreather.
h
normal operation.


1) When radiator surfaces are dirty,
1) When radiator
the surface should be clean up by
surfaces are clean
using compressed air, not mineral
and have not
water.
1) Af
After checking
h ki the h l k
leaks,
2) When there are some leaks on
cleanliness and leaks of 2) When the
radiator surfaces, disassemble the
radiator surfaces and indications of oil
damaged radiator from the
joint parts among radiator temperature
transformer after closing butterfly
fl
flanges, butterfly
b fl valves
l i di
indicators are in
i
valves and draining out insulation
and transformer tank as proper range
oil from the radiator and the leaks
well, considering
7 Radiators should be repaired by means of
2) After checking if radiators transformer load
metal
eta bond
bo d or
o a suitable
su tab e welding
we d g
are plugged
l d up with
i h sludge
l d andd ambient
bi
procedures. After repairing the
or foreign debris, temperature,
leaks on the radiator completely, the
3) Compare the indications of 3) When there is no
radiator can be reassembled at the
oil temperature indicators plugged radiators
original
g pposition and filled with new
with
ith the
th data
d t previously
i l with
ith sludge
l d or
insulating oil by using the oil drain
obtained. foreign debris,
valve and air vent of the radiator
4) The radiators are
and oil purifier as well.
operating,
3)) When the indications of oil
normally.
ll
temperature indicators are high


No. Items Contents and Notes Judging

g g Standard Action in case of abnormality
y
1) When radiator considering transformer load and

surfaces are clean ambient temperature, check if
and have not butterfly valves are opened.
1) After checking the leaks, If not, open the valves.
cleanliness and leaks of 2) When the 4) If radiators are plugged with sludge
radiator surfaces and indications of oil or foreign debris, inside the
joint parts among radiator temperature radiators should be cleaned up by
flanges, butterfly valves indicators are in means of hot oil flushing method
and transformer tank as proper range after disassembling the radiators
well, considering from transformer tanks according to
7 Radiators
2) After checking if radiators transformer load the second item of the action in case
are plugged up with sludge and ambient of abnormal of this item, the
or foreign debris, temperature, insulating oil of the transformer
3) Compare the indications of 3) When there is no should be cleaned up and inside the
oil temperature indicators plugged radiators tank as well.
with the data previously with sludge or 5) If not, the power factor of
obtained. foreign debris, transformer will be increased in the
4) The radiators are future because the sludge has
operating, conductive and good thermal
normally. isolation characteristic.


6) And also the thermal aging of solid
insulation material will be rapidly
7 Radiators
developed due to the good thermal
isolation characteristic of the sludge.
1) When there are some leaks on the
coolers, take the second item of the
action in case of abnormal column
1) After checking leaks 1) When there is no
of above item No.
No 7 Radiators
Radiators.
caused by corrosion and a leaks, foreign
2) When there are some foreign matter
foreign matter inside the matter, abnormal
inside the coolers, eliminate the
cooler due to contamination, rotating sounds
foreign matter from the coolers by
abnormal rotating sound and vibration,
using compressed air or hot oil
and vibration, 2) There is no
8 Unit coolers flushing method.
2) After checking whether plugged coolers
3) When the indications of oil
radiators are plugged with with sludge or
temperature indicators are high
sludge or foreign debits or foreign debris,
not, 3) The coolers are
ambient temperature, check if
3) Compare them with those operating,
butterfly valves are opened.
of other units normally.
If not, open the valves.
4) If coolers are plugged with sludge
or foreign debris, inside the coolers


should be cleaned up by means of
hot oil flushing method after
disassembling the coolers from
transformer tanks, take the
second item of the action in case of
1) After checking leaks 1) When there is no
abnormal column of above item No.
caused by corrosion and a leaks, foreign
7 Radiator, the insulating oil of the
foreign matter inside the matter, abnormal
transformer should be cleaned up
cooler
l due
d to contamination,
i i rotating
i sounds d
and inside the tank.
abnormal rotating sound and vibration,
5) If not, the power factor of
and vibration, 2) There is no
8 Unit coolers transformer should be increased
2) After checking whether plugged coolers
and also the thermal aging of solid
radiators
di are plugged
l d with
ih with
i h sludge
l d or
insulation material will be rapidly
sludge or foreign debits or foreign debris,
developed due to same reasons
not, 3) The coolers are
of the fifth and sixth items of the
3) Compare them with those operating,
action in case of abnormal column
off other
h units
i normally.
ll
of above item No. 7 Radiators.
6) In case of abnormal rotating sound
and vibration, refer to all items of
the actions in case of abnormal
column of above item No. 3 Noise.


1) When oil level indication is not

within ±10 ºC of oil temperature
indication, refer to the second and
third items of the action in case of
abnormal column of above item No.
1) When oil level
2 Oil levels.
indication is
1) If the bushing has an oil 2) When bushing terminals had been
within ±10 ºC C of
level gauges, check oil discolored due to loose connections,
oil temperature
level, oil leaks. refer to the first and second items of
indication,
2) Check the loose connection the actions in case of abnormal
9 Bushings 2) And there is no
of bushing terminals. column of above item No. 4 Loose
loose connections
3) Evaluate the extent of connections.
and no much dust
the porcelain contamination 3) When there is much dust on the
on the porcelain of
by appropriate method. porcelain surface of bushings, the
bushings,
surface can be rinsed out by using
3) The bushings are
insulating oil, water jet or by wiping
well operating.
with a moist cloths as well as
compressed air.
4) If necessary, ethyl alcohol or ethyl
acetate may be used.


5) If not, corona discharge will be

begun with bushing terminal and
flashover will finally occur on the
bushings after the corona discharge
1) When oil level is more and more developed due to
indication is the much dust on the porcelain
1) If the bushing has an oil
within ±10 ºC C of surface of the bushings.
bushings
level gauges, check oil
oil temperature Particularly in areas where there are
level, oil leaks.
indication, contaminants such as salts or
2) Check the loose connection
9 Bushings 2) And there is no conducting dusts in the air,
of bushing terminals.
loose connections flashovers may be caused by
3) Evaluate the extent of
and no much dust deposits of dirt on the bushings.
the porcelain contamination
on the porcelain of 6) The bushing terminals will be eaten
by appropriate method.
bushings, away and can be finally cut or
3) The bushings are melted by the corona discharge and
well operating. the load current of the bushings as
well.
7) The corona discharge can be easily
observed in the night.
night


1) When there are some abnormal
phenomena in the indications and
function of the relays, check if the
control circuits of all concerned
relays are normal and insulation
1) When there is no resistance value among terminals
abnormal and ground is more than 10 Meg
phenomenon in the Ωat 20
20ºC
C.
1) Check the indications of indications and If measurement temperature is not
the instruments and relays. function of the 20ºC, the measured insulation
10 Instruments 2) Check dew inside the relays, resistance can be corrected to 20ºC
control panel or cable 2) When there is no by multiplying the measured value
boxes. dew inside the by the correction factor
panel, it is normal. corresponding to the ambient
3) All instruments are temperature described in clause 7.1
well operating. Insulation resistance measurement
of Hyundai’s another instruction
manual HHIS-WZ-TE-100 (6) titled
“ SHIPMENT, STORAGE AND
TRANSFORMERS”.


2) If not, correct the circuits according

to the circuit diagram of Hyundai
Hyundai’ss
local control panel drawings.
1) When there is no
3) And also, the terminals shall be
abnormal
cleaned up by using compressed air.
phenomenon in the
4) Or the terminals shall be isolated
1) Ch
Checkk the
h indications
i di i off i di i
indications andd
from the ground by using insulation
the instruments and relays. function of the
material to make the insulation
10 Instruments 2) Check dew inside the relays,
resistance value more than 10 MΩ
control panel or cable 2) When there is no
at 20 ºC
C for the terminals.
b
boxes. d iinside
dew id theh
5) When there is some dew inside the
panel, it is normal.
panel, dry out moisture inside the
3) All instruments are
panel by means of compressed air
well operating.
and lower the setting value to 80 %
of hygrograph stat for heating inside
the panel and of 18 ºC of thermostat.


1) In case severely corroded spots
1) Check excessive corrosion
should be brushed with steel wire
and oil leaks.
and painted with rust inhibition
2) Pay special attention to When there is no
Transformer paint.
11 the flanges and gaskets of corrosion and oil
tank 2) In case of oil leaks, refer to the third
bushing, valves, and leaks, it is normal.
and fourth items of the action in
radiators as well as the
case of abnormality column of
lower section of main tank.
tank
above item No. 5 Oil leaks.
1) When the needles of the oil flow

indicators do not indicate ‘ON’
under the pump operation, check if
When the needles of
the operation position of valves is
1) When oil pumps are under the oil flow
closed.
Oil flow operation, indicators indicate
12 2) If yes, open the valves.
indicators 2) Check the oil flow ‘ON’
ON under the pump
3) Wh
When theh indicators
i di are suspectedd
indicators. operation, it is
to be out of order, repair them after
normal.
disassembling them from the
transformer or replace them with
a new one.
one


1) When there is some dirty oil trace
on the transformer tank or the
indication pin is not at the original
position,
i i cleanl up the
h trace, reset the
h
pin at the original position and
make the following measurements
after disconnecting the transformer
1) Check if there are dirty oil 1) When there is no f
from ttransmission
i i lines
li ;
traces around the pressure dirty oil traces, (1) Measure the insulation
Pressure relief device. 2) And the indication resistance value between each
13 winding and ground as well as
relief device 2) Check if the indication pin pin is at the
between the windings
of the device is at the original position, it
themselves.
original position. is normal.
(2) Ratio measurement either with
measuring kit or by applying low
voltage to the HV side.
(3) Measure the winding resistance
by using DC power.
(4) Measure the no-load current by
applying
pp y g low voltage g to the HV
side.


2) Compare the results with the test

certificates attached to the
transformer instruction manual.
3) When the difference between both
results is not within permissible
1) Check if there are dirty oil 1) When there is no
tolerance, the transformer should be
traces around the pressure dirty oil traces,
internally inspected with care to
Pressure relief device. 2) And the indication
13 eliminate it after finding out the
relief device 2) Check if the indication fin fin is at the
fault.
of the device is at the original position, it
4) When the difference between both
original position. is normal.
results is within permissible
tolerance put the transformer back
tolerance,
into service after resetting the
indication pin at the original
position.
1) If inside the relay is filled with

If inside the relay is
Check if inside the relay is some air bubble, take the air bubble
Buchholz fully filled up with
14 filled up with insulating oil, from the relay by using gas
relay insulating oil, it is
fully.
y sampling
p g device fitted on the side
normal.l
wall of the transformer tank or the


gas release cock fitted on its top and
analyze the sample.
2) If there is abnormal gas in the gas
analyzing results,
results the transformer
If inside the relay is should be internally inspected with
Check if inside the relay is
Buchholz fully filled up with care to eliminate the fault after
14 filled up with insulating oil,
relay insulating oil, it is disconnecting the transformer from
fully.
normal. transmission lines and draining
insulating oil from the transformer.
If not, continuously operate the
transformer after venting the gas
from
o tthee relay.
e ay.
1) When a mechanical fault in the tap-
1) Check mechanical 1) When there is no changer is suspected, make request
mechanism such as the mechanism for factory engineer service.
drive shaft with bevel gear
gear, problem of the tap 2) When there are some oil leaks due
Off circuit
15 the motor drive unit and the changer, to a damaged gasket, replace the
tap changer
safety interlock circuit, if 2) When there is no gasket with a new one after
provided. oil leaks, it is disconnecting the transformer from
2) Check oil leaks. normal.
o a. transmission
a s ss o lines es aand
d ddraining
a g


1) When a mechanical fault in the tap-
1) When there is no
changer is suspected after checking
mechanism
all the contacts, make request for
problem of the tap
factoryy engineer
g service.
changer,
h
2) When there are some oil leaks due
2) When there is
to a damaged gasket, replace the
1) Check mechanical no oil leaks,
gasket with a new one after
mechanism such as the 3) When oil level
disconnecting g the transformer from
d i shaft
drive h ft with
ith bevel
b l gear, i di ti is
indication i same
transmission lines and draining
the motor drive unit and the as that of oil
On load tap safety interlock circuit, if temperature
16 3) When the level is not within ±10ºC
changer provided. indication,
of oil temperature
p indication,, refer
2) Ch
Checkk oil
il leaks.
l k 4) Wh
When there
th is i no
to the first item through the fourth
3) Check oil level in the air bubble inside
item of the action in case of
conservator. the relay and the
abnormality column of above item
4) Check the protective relay. flap valve of the
No. 2 Oil levels.
relay
l has
h a vertical
ti l
4) When there are some air bubbles
position in the
inside the relay and the flap valve
middle of
of the relay will not have a vertical
inspection window,
position in the middle of inspection
p p
it is
i normal.l
window, vent the air bubble from


the relay by using the air release
On load tap cock so called breather fitted on its
16
changer top and put the relay back into
service.
1) When the transformers have dry
nitrogen gas supplying system as a
N2 gas sealed type oil preservation
and N2 gas pressure is lower than 2
N2 gas psi (0.14KG/cm 2) at ambient
sealed type temperature 20 ºC, replace nitrogen
oil When transformers have N2 If N2 gas pressure is gas bottle with a new one according
preservation gas sealed type oil 2 psi (0 14KG/cm 2)
(0.14KG/cm to the procedure described in
17 system preservation system, measure at ambient clause 3.6 Equipment of dry
without dry the nitrogen gas pressure and temperature 20 ºC, it nitrogen gas or dry air for
nitrogen gas check gas leakage. is normal. transportation of Hyundai’s another
supplying instruction manual HHIS-WZ-TE-
HHIS WZ TE
system 100 (6) titled “ SHIPMENT,
STORAGE AND ERECTION OF
OIL IMMERSED
TRANSFORMERS”.
TRANSFORMERS
2) When the transformers have N2 gas


sealed type tank without dry
nitrogen gas supplying system and
N2 gas pressure is lower than 2
N2 gas psi (0 14KG/cm 2) at oil
(0.14KG/cm
sealed type temperature
oil When transformers have N2 If N2 gas pressure is indication of 20 ºC, refill the oil
preservation gas sealed type oil 2 psi (0.14KG/cm 2) preservation with new dry N2 gas.
17 system preservation system
system, measure at ambient If the temperature indication is not
without dry the nitrogen gas pressure and temperature 20 ºC, it 20 ºC, N2 gas should be filled by
nitrogen gas check gas leakage. is normal. Boyle’s law and Charles’ law as
supplying below ;
system P2 = ( P1 × T1 ) / T2
= [( 2 psi × 293 ) / ( 273 + oil
temperature indication in
Celsius )] in psi
Other periodical inspections and test items are as below ;

After 1 month of service and once every year, make an in-depth inspection of oil-filled transformers.
Before beginning the inspection, look carefully at temperature and oil level data sheets.
To find out all kinds of faults inside the transformer, Dissolved Gas Analysis is recommended.

4. MAINTENANCE
4.1 FORWARDS ( 1 / 2 )
No
No. INSPECTION CAUTIONS
1) The utmost attention should be given to ensure that human life is not endangered, and to
protect the transformer or associated equipment from damage.
2)) The ppower supply
pp y must be isolated from the transformer to pprotect pperson from no
electric shock and malfunction of the equipment.
1 General
3) Every work must be properly planned to ensure that the necessary tools, spare parts and
person are available.
4)) The necessary y tools used in transformer tank should be tied to worker with a cord
and the dry, clean and lint free cloths should be used inside the transformer.
1) Before commencing every work on the transformer it must be isolated from power
supply and a work permit must be issued. This will involve isolating the relevant
breakers, checking that the supply is off by testing with correct electrical detectors or
instruments and ensuring that the switches are properly padlocked.
2) In addition, transformer terminals must be earthed by means of grounding switch.
Prior to
2 3) No one must be allowed to work on the transformer without a work permit signed by an
working
authorized person.
Be certain that auxiliary power supply is off and all the terminals are grounded before
all of the work. Not doing those can cause severe personal injury or property damage.

4. MAINTENANCE
4.1 FORWARDS ( 2 / 2 )
N
No. INSPECTION CAUTIONS
1) If it is necessary to take an internal inspection, this should first be discussed with the
manufacturer Hyundai in ULSAN, KOREA or in the local representative.
Th workk should
The h ld onlyl be
b done
d either
i h byb a service
i engineer
i off the
h manufacturer
f or under
d
the supervision of an engineer of the manufacturer.
2) During an internal inspection it is essential that no foreign material or items are dropped
in the transformer tank and hence special precautions must be taken to prevent this.
Internal Before opening a transformer or removing any part of cover, make sure that the
3
inspection internal pressure is zero.
zero The oil level has to be lowered
Do not enter the transformer or do not breathe the inside air of the tank unless the
oxygen content of the gas inside the transformer is 19.5% ∼24%.
Oxygen contents less than this can cause drowsiness, injury or death.
Whenever anyone is inside the tank, other personnel must be near to the manhole on
the cover
cover.

4.2 CLASSIFICATION OF MAINTENANCE AND INSPECTION
No. ITEM CONTENTS
Daily maintenance and inspection during operation together with checking a transformer at
regular intervals and visual inspections are as below ;
1) Read and record the indications of all gauges provided on the transformer.
transformer
Daily 2) These values should be compared with the values obtained previously to detect for any
1 maintenance
abnormalities.
and inspection
3)) Duringg the inspection,
p pay
p y attention to anyy abnormalities such as noise, irregular
g
vibration, discoloration, smoke etc.
4) Some more detailed daily maintenance and inspection are described in clause 4.3.
Following maintenance and inspection are to be carried out periodically.

1) Some more detailed maintenance and inspection are given in clause 4.4 in accordance
Periodic
with
ith man
manufacturers’
fact rers’ guidelines
g idelines or international gguidelines.
idelines
2 maintenance
2) From the historical information obtained during this maintenance and inspection as well
and inspection
as operating conditions, the interval of the periodical maintenance and inspection may
need to be increased or could be decreased depending on its condition.
condition

4.3 DAILY MAINTENANCE AND INSPECTION ( 1 / 4 )

According to Hyundai’s recommendation described on this page through next several pages, carry out daily
maintenance and inspection. These daily maintenance and inspection items will make another important historical
information of transformers in the future along with periodical maintenance and inspection. When some faults and
abnormalities are founded out during daily maintenance and inspection, the faults should be treated in accordance with
action in case of abnormality of the clause 3.3.3 inspection and check items of transformers in service.
No. ITEM CONTENTS AND NOTES
1) Check and record oil and winding temperature.

2)) Record
eco d ambient
a b e t temperature,
te pe atu e, load
oad and
a d voltage.
vo tage.
EXPLANATORY NOTES :
Transformer 1) The transformer temperature directly affects the life time of insulation material.
1 temperature and 2) Maximum temperature rise limits are specified for both oil and winding temperature.
load During
i theh daily
d il maintenance
i andd inspection,
i i check
h k not onlyl these
h temperatures are
within the maximum limits, but also that these temperatures lie within a satisfactory range
by comparing their values with the test results of manufacturer’s test report, load
conditions and ambient temperature.
1) Check and record the oil level shown by the oil level indicator.
2 Oil level
2) Check that the glass of oil level indicator is not dirty.
After checking
g the sound and vibration of cooling
g fans,, oil ppumps
p or transformer tank,,
3 N i
Noise
compare them with those values of other units.


EXPLANATORY NOTES :
Learn by hearing an average & regular sound ;
3 Noise
If the noise of the transformer is not regular sound compared with remembered normal
sound, further investigation should be done immediately.
Check visual oil leaks on connections such as a joint part of valves,
valves meters,
meters pipes,
pipes radiators,
radiators
4 Oil leaks
especially at the gasket joints as well as a welding part of transformers.
Dehydrating 1) Pay attention to the discoloration of silica gel.
5
breathers 2) Check oil level and breathing action in the glass oil cup.
1) Check if there is any crack of the device.
Pressure relief 2) Check if there is any damage of the device.
6
device 3) Check if there is dirty oil trace around the pressure relief device.
4)) C
Check
ec if thee indication
d c o fin iss at thee original
o g position.
pos o .
1) Check the leaks of radiator surfaces as well as joint parts of radiator flanges,
butterfly valves and transformer tank.
7 Radiators
2) Check the cleanliness of radiator surfaces.
3) Compare the indications of oil temperature indicators with the data previously obtained.
obtained
1) Check the leaks of unit coolers as well as joint parts of cooler flanges, butterfly
valves and transformer tank.
8 Unit coolers
2)) Check abnormal rotatingg sound and vibration.
3) Check contamination inside the unit coolers.


4)) After checking
g leaks caused by
y corrosion and a foreign
g matter inside the cooler due to
8 Unit coolers contamination, abnormal rotating sound and vibration, compare them with those of other
units.
1) Check operating sound.

2) Check whether the tap position is correct or not.
On load tap 3) Record the number of tap changing operations.
9
changer 4) Check the oil level gauge of On Load Tap Changers.
5) Check the protective relay of On Load Tap Changers.
6) Check if the external mechanism of tap changers is functioning properly.
1) Check whether the tap position is correct or not.

2) Check if the external mechanism of tap changers is functioning properly.
Off circuit tap
Off-circuit
10
changer
Do not operate tap changer when the transformer is energized.
1) If the bushing has an oil level gauges

gauges, check oil level and oil leaks.
leaks
2) Evaluate the extent of the porcelain contamination by appropriate method.
11 Bushings
3) Check the loose connection of bushing terminals by means of measuring the temperature
of the terminals.
12 Buchholz relay Check if inside the relay is filled up with insulating oil, fully.


1) Check loose connections at grounding circuits

circuits, auxiliary circuits,
circuits foundation bolts,
bolts
Loose
13 bushing terminals, and others by appropriate method.
connections
2) Compare conductor color with that of other units.
Check the positions of all valves according to our recommendation described in Table 6-6 of
14 Valves Hyundai’s another instruction manual (6) titled “SHIPMENT, STORAGE AND
ERECTION OF OIL IMMERSED TRANSFORMERS”.
When transformers have N2 g gas sealed type

yp oil preservation
p system,
y , measure the nitrogen
g
15 G lleaks
Gas k
gas pressure and check gas leaks.
1) Check the indications of all instruments and the operation condition of all relays
16 Instruments connected to instruments.
2) Check dew inside the control panel or cable boxes.
1) Check excessive corrosion

Transformer
17 2) Check oil leaks at every flange and gasket of bushing, valves, and radiators.
tank
3) Ch
Checkk especially
i ll oil
il leaks
l k at the
h under
d part off main
i tank.
k
Oil flow
18 Check the indications of oil flow indicators.
indicators
19 Others Check abnormal exciting noise and vibration.

4.4 PERIODICAL MAINTENANCE AND INSPECTION ( 1 / 13 )
According to Hyundai’s recommendation described on this page through next several pages, carry out periodical
maintenance and inspection. As described on the previous page, it is very important that the frequency of the periodic
inspections may need to be increased or decreased in accordance with the historical information obtained during these
maintenances, inspections and the operating conditions as well. When some faults and abnormalities are found
d i periodical
during i di l maintenance
i t andd inspection,
i ti the
th faults
f lt should
h ld be
b treated
t t d ini accordance
d with
ith action
ti ini case off
abnormality of the clause 3.3.3 inspection and check items of transformers in service.
PERIOD
INSPECTION
No. CONTENTS AND NOTES CRITERIA
ITEMS 1 month
Annually
(service)
1) Di
Dielectric
l t i strength
t th
O More than 40KV / 2.5mm gap.
( IEC 60156 )
Less than 0.2 mg KOH/g

2) Neutralization number. O
at 100 ºC
C for 164 hours
hours.
1 Insulating oil
To be carried out only when the
3) Tests specified in IEC
dielectric strength and acid value are
60296 -
lower than Hyundai’s
y
; refer
f tto clause
l 3.6.
36
recommendation.


PERIOD
INSPECTION
No. CONTENTS AND NOTES 1 month CRITERIA
ITEMS Annually
(service)
Measurement of the insulation

The insulation resistance values
resistance between windings
Insulation of 2 or 3 of each windingg are more than
2 and between a winding and
winding years Hyundai’s recommendation of
the ground with a 2000 V
Fig. 2.
megger.
1)) Insulation resistance More than 10 MΩ.

2) Abnormal sound and 6 months
Fan motor / oil No abnormal sound and vibration.
3 vibration
pump motor
The current is within a p
permissible
3) L
Loadd current.
t O O
tolerance.
1) Check mechanical
mechanism such as the
d i shaft
drive h ft with
ith bevel
b l gear, No iinterruption
N t ti excepting
ti both
b th endd
Off circuit tap O
4 the motor drive unit and the tap positions.
changer safety interlock circuit, if
provided.
2) Check oil leaks O No oil leaks.

Off-circuit tap changers which are installed and operated in network transformers only barely need to be inspected in
regular intervals
intervals, because the mechanical operation of the off-circuit
off circuit tap changer does not involve any significant
contact wear. If after several years of service in one position, an off-circuit tap changer is to be operated in another
one, several switching operations must first be performed. In order to remove possible tarnish on the contacts, switch
the off
off-circuit
circuit tap changer from the previous position to the new one and also to the adjacent positions. Experience
shows that up to 25 switching operations on each contact are necessary for this purpose. It is recommended that the
efficiency of this measure is verified by resistance measurement. For more details, refer to IEC 60214 or IEEE
tap changer standards.
PERIOD
INSPECTION
ITEMS A
Annually
ll
(service)
1) No tarnish such as conductor

discoloration.
2) In case of off-circuit tap
Off circuit tap After 400,000 to
4 3) Contact wear changers for furnace
changer 500,000 operations
transformers, the tap changer
should be inspected after each
100,000 operations at the latest.


PERIOD
INSPECTION
ITEMS Annually
(service)
1) Check mechanical
mechanism such as the
No interruption
p excepting
p g both
drive shaft with bevel gear
gear, O
end tap positions.
the motor drive unit and the
safety interlock circuit.
2)) Check oil leaks O No oil leak.
On load tap
changer for More than 4 mm (More than 50%
3) Contact wear of diverter
MIII 500 Y of original thickness 8 mm).
switches
5 without oil
filter of MR, 4) Measure water content of
only ; refer to Less than 40 ppm
oil
Note 1. After
5) Measure dielectric strength 150,000 operations 30 KV/2.5 mm g
gap
p (IEC60156)
( )
off oil
il
6) Clean the diverter switch
oil compartment, diverter No carbon powder in insulation
switch unit and tap
p changer
g oil
oil conservator tank.


PERIOD
INSPECTION
ITEMS Annually
(service)
7) Check the diverter switch
oil compartment and No damage.
diverter switch unit.
unit
Same as the original values of the
8) Measure the transition resistors marked on the
resistor values. nameplate of On Load Tap
On load tap Changer.
changer for
No air bubble inside the relay and
MIII 500 Y
After the flap valve of the relay has a
5 without oil 9) Check the protective relay
150 000 operations
150,000 vertical position in the middle of
filter of MR,
inspection window.
only ; refer to
Note 1. 10) Check the pressure
Less than working pressure of 3.5
difference of the pressure
bar at oil temperature of 20 ºC.
C.
gauge off the
h oil
il filter
fil unit
i
When a function key is pressed,
11) Check the voltage the display must show the
regulator.
g previous setting
p g values of the
corresponding parameters.


The tap selector of the On Load Tap Changer is generally maintenance-free. In special cases, however, for example in
industrial transformers where a great number of tap change operations are to be expected, On load Tap Changer must
be contacted after about 1,000,000
1 000 000 operations.
operations The diverter switch unit of the tap changer has to be replaced by a new
one after about 800,000 operations the least. If the number of operations per year exceeds 15,000 operations, paper
filter type oil filter unit is recommended and combined filter cartridge type oil filter unit is recommended if the highest
voltage for equipment is higher than 245 KV
KV. Regardless of the number of tap changer operations listed in Note 1,
1
inspection must be carried out after 6 to 7 years. In case of On Load Tap Changer with insulation to ground according
to Um ≥ 245 KV, the first inspection must be performed after 20,000 switching operations or after 2 years of service
respectively,
p y whichever comes first. In case of other type
yp tap
p changer,
g the concerned manual should be referred to the
periodical maintenance and inspection. For more details, refer to IEC 60214 or IEEE tap changer standards.
Note 1 ; Following are technical data for M and MS type On Load Tap Changers of MR in Germany ( 1 / 2 ).
On Load Tap Changer Inspection inter
intervals
als (Operations) Water Dielectric
No.
Type Current Without oil filter With oil filter content strength
1 MIII 350 Y / MSIII300 Up to 350 A
100,000
,
Up to 350 A
2 MIII 500 Y More than
Less than
Up to 500 A 80,000 150,000 30 KV
40 ppm
(IEC60156)
Up to 350 A 100,000
3 MIII 600 Y
Up to 600 A 80,000

Note 1 ; Following are technical data for M and MS type On Load Tap Changer of MR in Germany ( 2 / 2 ).
On Load Tap Changer Inspection intervals (Operations) Water Dielectric
No.
Type
yp Current Without oil filter With oil filter content strength
4 MIII 350 D Up to 350 A

40,000 80,000
5 MIII 600 D Up to 600 A
6 MS I 301 / MS II 302 U tto 300 A
Up
7 MI 351 / MII 352 Up to 350 A
8 MI 501 / MII 502 Up to 500 A 100,000
9 MI 601 / MII 602 Up to 600 A 150,000
Up to 500 A More than
Less than
10 MI 802 40 KV
Up
p to 800 A 30 ppm
(IEC60156)
80,000
Up to 800 A
11 MI 1200
Up to 1200 A
70,000 140,000
U tto 1200 A
Up
12 MI 1500
Up to 1500 A
60,000 120,000
Up to 1500 A
13 MI 1800
Up to 1800 A 50,000 100,000


PERIOD
INSPECTION
ITEMS Annually
(service)
1) Check the external 2 or 3 No oil traces dirtied by dust on

O
porcelain for cracks
cracks. years porcelain surface
surface.
2 or 3 No oil traces dirtied by dust on

2) Check oil leaks. O
years porcelain surface.
3) Check the bushing oil level 2 or 3 The oil level is within ±10 ºC of oil
or the oil level gauge. O years temperature indication.
Bushings
6 ; refer to 4) Bushing terminal 2 or 3 The terminal temperature is less
O
Note 2. temperature years than
h 70 0 ºC at ratedd current.
5) Dissolved Gas Analysis in 2 or 3 No abnormal gas such as CO, CO2,

O
bushing oil. years CH4, C2H6, C2H4 and C2H2.
The terminal should be grounded by

6) The terminal of bushing 2 or 3 the means of a spring clip in the tap
voltage tap years cover or connected to bushing
potential
i l device.
d i

PERIOD
INSPECTION
ITEMS Annually
(service)
1) Th
The power factor
f off the
h
capacitance or potential tap will
generally be about 1.0 % or less.
2) The measurement will vary from
the original values according to
the loading history and
Bushings environment condition of the
2 or 3
6 ; refer to 7) Bushing capacitance values bushings
bushings.
years
Note 2. 3) Bushings showing signs of
deterioration should be tested at
intervals of 6 months to 1 year
andd removedd from
f service
i if the
h
test show a dangerous condition.
4) Regarding to Maintenance Tests
g refer to Note 3.
for Bushings,


PERIOD
INSPECTION
ITEMS A
Annually
ll
(service)
1) Moisture content less than 5 ppm.
2) Neutralization less than 0.02 mg
8) Insulating oil inside the 2 or 3
KOH / g at 100 ºCC for 164 hours
hours.
bushing years
6 Bushings 3) Dielectric breakdown min. 45 KV.
4) Power factor less than 0.05 %.
9) Check the external 2 or 3 No carbon tracking on the external
porcelain for contamination. years porcelain.
Note 2 ; Followings are additional information for condenser type bushings, only ( 1 / 3 ).
There is no perfect insulator ; a small amount of leakage current always exists. This current leaks through and along
the bushing surface from the high voltage conductor to ground. If the bushing is damaged or heavily contaminated,
leakage current becomes excessive, and visible evidence may appear as carbon tracking (treeing) on the bushing
surface. Flashovers may occur if the bushings are not cleaned periodically.
Carbon tracking may occur more often in atmospheres where salts and dust deposits appear on the bushing.
Refer to the bushing manual for detailed instructions on cleaning and repairing your specific bushing surface.
Different solvents, wiping materials, and cleaning methods may be required for different bushings.

When the bushing has a gage with a pointer, look carefully, because the oil level should vary a little with temperature
changes. If the pointer never changes, even with wide ambient temperature and load changes, the gage should be
checked at the next outage. A stuck gage pointer coupled with a small oil leak can cause explosive failure of a
bushing, damaging the transformer and other switchyard equipment.
If th
the oil
il level
l l isi low
l andd there
th is i an external
t l oil
il leak,
l k check
h k the
th bolts
b lt for
f proper torque
t andd the
th gasket
k t for
f proper
compression. It is very important that the correct type gasket should be installed and the correct compression should
be applied. A leaky gasket is probably also leaking water and air into the transformer, so check the most recent
transformer Dissolved Gas Analysis for high moisture and oxygen.
oxygen If the oil level is low and there is no visible
external leak, there may be an internal leak around the lower seal into the transformer tank. After repairing the gasket,
the bushing should be passed with an internal oil pressure test and tightness tests in accordance with IEC 60137 or
IEEE bushing
g standards at the bushingg terminal capp and the bottom of the bushingg center tube,, respectively.
p y
Never open the fill plug of any bushing if it is at an elevated temperature because pressurized hot oil may suddenly
gush from the fill plug. Generally, bushings have a nitrogen blanket on top of the oil which pressurizes as the oil
e pands When oil temperat
expands. temperature
re is bet
between
een 15 ºC and 35 ºC,
ºC the bbushing
shing ma
may be safel
safely opened
opened.
If one phase bushing terminal shows markedly higher temperature, there is probably a bad connection. The
connection at the top is usually the poor one ; however, a bad connection inside the transformer tank will usually show
a higher temperature at the top as well. In addition, a bad connection inside the transformer will usually show hot

metal gases ( ethane and ethylene ) in the Dissolved Gas Analysis.
As a convenient accessory, condenser type bushings have its terminal of bushing voltage tap for measuring the power
factor and capacitance of the bushing.
Corona (air ionization) may be visible at tops of bushings at twilight or night, especially during periods of rain, mist,
f
fog, or high
hi h humidity.
h idit At the
th top,
t corona is
i considered
id d normall ; however,
h as a bushing
b hi becomes
b more andd more
contaminated, corona will creep lower and lower. If the bushing is not cleaned, flashover will occur when corona
nears the grounded transformer top. If corona seems to be lower than the top of the bushing, clean the bushing as
quickly as possible.
possible
Note 3 ; Maintenance Tests for Bushings ( 1 / 5 ).
Common maintenance tests are power factor,

factor RIV ( Radio Influence Voltage ),
) DC insulation resistance,
resistance and testing
oil or compound for moisture. Descriptions of these various tests are as below ;
1. Power factor Doble Tests.
The p
power factor test is the most effective known field test procedure
p for the earlyy detection of bushingg contamination
and deterioration. This test also provides measurement of AC test current which is directly proportional to bushing
capacitance. Bushings may be tested by one or more of four methods depending upon the type of bushing and the
power factor test set available. For more complete detailed instructions on the method of test and test procedure, please
see the appropriate power factor test set instruction book. The four test methods are as follows ;

1) The GST ( Ground Specimen Test ).

This test measures the insulating
g qualities
q of the insulation between the current carrying
y g or center conductor and the
mounting flange of a bushing. The application of such a test is necessarily limited to bushings out of the apparatus
such as spare bushings, or bushings which have been isolated from connected windings and interrupters.
Large variation in temperature have a significant effect on power factor readings on certain types of bushings. For
comparative purposes, readings should be taken at the same temperature, or corrections should be applied before
comparing readings taken at different temperatures.
2) The hot guard test

test.
The test measures the insulation between the current carrying or center conductor and the mounting flange of a bushing.
The test was designed specially for “draw lead” type bushings but is applicable to any bushing in apparatus which can
be isolated from connecting
g windings
g and bus but not sufficientlyy to withstand test potential.
p Both the bushingg and the
draw lead, winding, and bus are energized at the same test potential, but only the current and losses of the bushing are
measured.
3) The UST ( Ungrounded Specimen Test ).

)
This test measures the insulation between the current carrying or center conductor and the capacitance tap, power
factor tap, and/or ungrounded flange of a bushing. This test may be applied to any bushing in or out of apparatus which
is either with capacitance or power factor taps or the flange of which can be isolated from the grounded tank in which
the bushing is installed. The insulation resistance between the taps or insulated flanges and ground should be 0.5 meg-
ohm or better. While in this case, anything that is attached to the bushing ( such as contact assemblies or transformer
windings ) would also be energized ; only the insulation of the bushing between the center conductor and the
ungrounded tap or flange would be measured. In the case of bushings equipped with capacitance taps, a supplementary
test should always be made on the insulation between the tap and the flange.
4) The hot collar test.

This test measures the condition of a specific small section of bushing insulation between an area of the upper
porcelain rainshed and the current carrying or center conductor. It is performed by energizing one or more electrodes
( collars
ll ) placed
l d aroundd the
th bushing
b hi porcelain
l i with
ith the
th bushing
b hi center
t conductor
d t grounded.
d d This
Thi test
t t is
i usedd to
t
supplement the three tests described above or to test bushings in apparatus when the above mentioned three tests are
either inapplicable or impractical. Hot collar tests are effective in locating cracks in porcelain, deterioration or
contamination of insulation in the upper section of a bushing,
bushing low compound or liquid level,
level or voids in compound,
compound
often before such defects are noticeable with the tests outlined in subparagraphs 1), 2), and 3).
When bushings with capacitance or potential taps are tested by the ungrounded test specimen method described in the
above subparagraph 1), it is recommended practice to include a separate power factor test on the tap insulation as well.
The exception to the separate power factor test is condenser type bushing which have tap outlets designed to operate at
less than 100 voltages. On all other capacitance or potential taps, tests are performed at several voltage levels from 2 to
5 KV.
KV It means that the maximum permissible test potential should be limited to bushing instruction manual and

specification for test instrument as well. The procedure is to energize the tap with the bushing center conductor and
flange grounded.
grounded The power factor of a capacitance or potential tap will generally be around 1.0
1 0 % or less.
less There are
the principal exception to this in some bushings because the inherent properties of the fibrous Bakelite material used
for the tap insulator have resulted in power factors up to 10 % for apparently satisfactory taps. In such cases, field
measurement, particularly ungrounded specimen tests, should compare with and the bushings be rated on the basis of
nameplate power factors. In general, any bushing that exhibits a history of continuous increase in power factor should
be questioned and scheduled for removal from service. Measured power factor values should be temperature corrected
to 20 ºC. The table of correction values are given in the Table 7-2 Temperature corrections for insulation power factor
test of Hyundai’s another instruction manual HHIS-WZ-TE-100 (6) titled “ SHIPMENT, STORAGE AND
2 The RIV test

2. test.
The RIV test can provide detection of corona in resin bonded, solid core no condenser bushings. Methods of
measurement of RIV are described in NEMA Publication No. 107.
Liquid
q filled bushings
g ggenerallyy have a low RIV value. A high
g RIV value on this type
yp of bushings
g which can not be
reduced by cleaning the porcelain indicates the level of the filling liquid and should be checked.
3. The DC insulation resistance test.

Th DC insulation
The i l ti resistance
it test
t t generally
ll cannott be
b relied
li d ( trusted
t t d ) on to
t detecting
d t ti early
l contamination
t i ti off bushings.
b hi

When bushing deterioration can not be detected by DC insulation resistance, it is generally in an advanced stage
requiring immediate attention. A 2500 voltage insulation resistance meter may be used for an insulation resistance
check, but a high reading should not be completely relied upon as indicating a good bushing. Any bushing testing less
than 20,000 meg ohms has questionable insulating value.
4 Hot
4. H t wire
i test
t t for
f moisture.
it
Plastic type compound used to filled bushings may absorb moisture if there are leaks through the shell or cap.
A moisture content of as little as 0.15 % in soft compounds can be detected by pushing a red hot rod into the
compound If moisture is present
compound. present, a crackling,
crackling sputtering,
sputtering or hissing sound will be heard.
heard If no moisture is present
present, the
compound will melt quietly. Another test is to put some compound on a wire and melt it in the flame of a match.
If moisture is present, there will be a sputtering sound and small sparks will be thrown off. Dry compound will melt
without disturbance.
5. Testing oil for moisture.

Whenever the presence of moisture in the oil of an oil filled bushing is suspected or found by a bushing power factor
t t the
test, th oil
il should
h ld be
b drained
d i d outt andd a sample
l should
h ld bbe ttested
t d bby a di
dielectric
l t i or power ffactor
t ttest.
t Si
Since th
the quantity
tit
of oil in a bushing is small, the old oil should be discarded and new oil put in. If moisture is found in the oil, the
bushing should be dried out before being back into service.

PERIOD
INSPECTION
ITEMS A
Annually
ll
(service)
1) There is any air bubble inside
the relay.
2) Th
The flap
fl valve
l off the
th relay
l has
h a
vertical position in the middle of
1) Visual inspection. inspection window.
3) The pipe connected to the OLTC
Protective 2 or 3 conservator is placed with an
7 inclination of at least 2%.
relays years
2) Check operating and
insulation resistance of
thermometer, level gauge,
More than 10 ㏁.
flow indicator, gas detector,
pressure relay, vacuum
gauge etc
etc.
If necessary, replace the gasket with
Control panel 1) Check waterproof.
2 or 3 a new one
8 and terminal
2) Check the tightness of all years
box If necessary, tighten
i h theh connections.
i
connections.


PERIOD
INSPECTION
ITEMS Annually
(
(service)
i )
3) Operation of all switches,
annunciates and lamps to
If any part malfunctions,
Control panel observe p
proper
p functions O
adjust or exchange it with a new one.
one
8 and terminal according to schematic
box diagrams.
2 or 3 More than 10 ㏁ at ambient
4) Insulation resistance.
years temperature of 20 ºC.
C.
Check the discoloration of When silica gel has been discolored
9 Breather silica gel in breathers due to 6 months more than two thirds of its, replace it
the moisture of breathing air. with a new one.
1) Check transformer tank and
1) Repair the leaks,
its accessories for finding
O 2) Coat the damage with
External of out oil leaks, rust, coating
10 paint after cleaning up rust.
transformer damage.
2) Check if all connections are
O Tighten all the loose connections.
in a good condition.
When silica gel had been discolored more than two thirds of its, the silica gel can be heated with the temperature
between 120 ℃ and 130 ℃ for several hours to recover it it’ss moisture absorbing ability
ability.
When the color of the silica gel is changed from pale pink to blue, it’s moisture absorbing ability has been recovered.


PERIOD
INSPECTION
ITEMS Annually
(service)
No oil traces dirtied by dust on
1) Small leaks. O O
the surface of them.
h you touchh pipe
When i lines
li or
2) Plugs. O O radiators, there is no noticeably
cooler part.
The neutralization number of
Tanks
T k andd
11 insulating oil is less than
radiators. 3) Sludge. O O
0.2 mg KOH / g at 100 ºC for
164 hours.
No ddamaged
N d painting
i ti partt andd no
4) Paint and rust. O O
rust.
5) Check if all connections are
O Tighten all the loose connections
in a good condition.
1) Loose blades. O O No vibration.
12 Cooling fans. Motor load current is within

2) Motor bearing. O O permissible tolerance and no
abnormal noise.


PERIOD
INSPECTION
ITEMS Annually
(service)
Motor load current is within
1) Motor bearing. O O permissible tolerance and no
13 Oil pumps.
pumps abnormal noise.
noise
Motor load current is within
2) Valves. O O
permissible tolerance.
Transformer 1)) Winding
g resistances. 3 to 5 The measurement is within ±5%
14
testing. 2) Core insulation resistance. years of the original resistance values.

4.5 MAINTENANCE AND INSPECTION STANDARD
4.5.1 Inspection of transformer insulation.

The transformer insulation will be deteriorated over a period of time even if the transformer has not been subjected to
any accidental fault. The life of transformer is considered the same as the life of insulating material in the transformer.
The followings explain what inspection method should be taken in order to prevent insulation material from
premature
t deterioration.
d t i ti
There are two kinds of the deterioration of transformer insulation material as below ;.
The first is the deterioration of transformer
transformer’ss solid insulation material
material.
The second is the deterioration of insulating oil.
1)) Determination on the deterioration of transformer’s solid insulation material.

The determination on the deterioration of the insulation material must be done carefully with the insulation test
results and historical information previously obtained.
2) Determination on the deterioration of insulating oil.

The measurement of the dielectric strength, acid value, resistivity and tangent δ is an excellent guide to determine
if the oil has deteriorated. Generally the dielectric strength and acid value are normally employed during maintenance.
If these give unsatisfactory results,
results further tests must be carried out on the insulating oil by authorized party.
party

(1) For details of insulating oil test method and testing apparatus, refer to IEC-60296 or IEEE oil test standards such as
ASTM D1816 or ASTM D877 .
(2) When sampling insulating oil, utmost care should be taken to ensure no foreign objects such as water or dust are
mixed with the oil. Sample the insulating oil directly from the sampling valve on the transformer. Leave the
sampled oil in the test container for the specified period of time and conduct the test as soon as possible afterwards.
All testing and sampling apparatus should be cleaned and dried prior to oil sampling and testing.
Table 3.5.1 are standard test items to determine the first deterioration of transformer’s solid insulation material.
As explained in Table 3.5.1, there are inspection items such as insulation resistance, dielectric loss factor and other
method.
method
Refer to the explanatory notes and judging standards of each inspection items as below ;

[ Table 3.5.1 ] Standard test to determine the deterioration of transformer insulation.
INSPECTION JUDGING
No. EXPLANATORY NOTES
ITEMS STANDARD
The measurement of the insulation resistance is a very helpful guide to

initially detect any deterioration in the insulation, though it does not
determine the quality of the insulating oil.
The insulation resistance is very sensitive to any moisture absorbed by
Insulation
1 the oil and hence can give early warning if moisture is present in the oil. Refer to Fig. 2
resistance
To give an accurate measurement of the transformer insulation
resistance, the transformer must be isolated from the power supply and
cables and also the bushings thoroughly cleaned.
(The use of transformer oil is recommended for cleaning the bushings.)
The tangent δ relates closely to the moisture content of the transformer

winding (including insulating oil) ;
Dielectric loss 1) As the value of tangent δ increases the more sharply, the insulation
2 Refer to Fig. 3
factor (tan δ) resistance declines.
2) The use of shearing bridge is highly recommended for the
measurement and it is also important to use a single meter for years.
Corona measurement is also available for the determination of

3 Other methods
insulation resistance
resistance.

In case of insulation resistance, please refer to Fig 2.

As described on the figure,
figure the good condition of the
insulation resistance means the right side of each line
drafted on the voltage of transformer winding.
The left side of each line means the poor condition of
th insulation
the i l ti resistance.
it
[ Fig 2 ] Insulation resistance of transformer at
measuring temperature of 20℃.
In case of Dielectric loss factor, please refer to Fig 3.

In this case, the good condition of the insulation
power factor means the below part of below line
drafted on the oil temperature of transformer.
The upper part of upper line means the poor condition
of the insulation power factor.
Middle area between both lines is fair but precautious
for insulation power factor of judging transformer
deterioration.
[ Fig 3 ] Standard of judging transformer
deterioration by tan δ

In connection with determination of insulating oil deterioration as the second deterioration of transformer insulation
material, refer to this judging standard for each inspection item of insulating oil.
[ Table 3.5.2
3 5 2 ] Determination of insulating oil deterioration ( 1 / 2 )
INSPECTION JUDGING
ITEMS STANDARD
Moisture absorption affects the insulating performance.

Breakdown Moisture content is checked by the measurement of the breakdown
1 Refer to Table 3.5.3
Voltage voltage, though it can also be calculated by the measurement of
resistivity, tangent δ and water content.
The interrelation between the acid value and insulation deterioration

is delicate.
Sludge caused by oxidation hinders cooling functions.
functions
2 Acid value Refer to Table 3.5.4
Acid value of about 0.2 mg KOH/g rarely allows sludge
development, 0.3 mg KOH/g allows sludge to form and above 0.3
mg KOH/g accelerates sludge development.
The resistance of insulating oil directly relates to the insulation

property of the transformer.
3 Resistance Refer to Table 3.5.5
The resistance decreases according to increase of transformer
t
temperature
t as the
th insulation
i l ti resistance
it does.
d

[ Table 3.5.2 ] Determination of insulating oil deterioration ( 2 / 2 )
INSPECTION JUDGING
ITEMS STANDARD
Moisture
4 Karl fisher reagent method. Refer to Table 3.5.6
content
5 Gas analysis Gas chromatograph analyzer. Refer to Table 3.6
The life of transformer is considered the same as the life of insulating material in the transformer tank such as
insulating oil and solid insulation material as well.
Especially insulating oil should be controlled in accordance with the requirements of following four tables described
Especially,
on next page because the characteristics of the oil can extend the life of transformer.
As an example, when the high voltage of a transformer is lower than 154KV, the breakdown voltage of insulating oil is
more than 50KV as a minimum requirement.
When the high voltage of a transformer is lower than 500KV and higher than 154KV, the breakdown voltage of
insulating oil is more than 60KV.
And the good condition of oxidation of the oil is less than 0.2mg KOH/g for 164 hours at 100℃
In case the good condition of resistivity of the oil is more than ten to 13th power ( = 1 X 1013 ) ohm - cm at 80℃.

[ Table 3.5.3 ]Standard of breakdown voltage
No. CLASSIFICATION OF ACCORDING TO APPLICATION JUDGING STANDARD

1 ≤ 500㎸ CLASS M
More th
than 60㎸
2 ≤ 154㎸ CLASS More than 50㎸
3 On-load tap changer More than 40㎸
[ Table 3.5.4 ]Standard of oxidation stability (100℃, 164hours)
No. CONDITION OF INSULATING OIL JUDGING STANDARD

1 Good Less than 0.2 mg KOH/g
2 Oil to be replaced or cleaned in an earlier stage 0.2 ∼ 0.3 mg KOH/g
3 Oil to be replaced or cleaned immediately More than 0.3 mg KOH/g
[ Table 3.5.5 ]Standard of resistivity, at 80℃
No. CONDITION OF INSULATING OIL JUDGING STANDARD

1 Good More than l x1013 ohm-cm
2 Fair, but precarious 1x1012 – 1x1013 ohm-cm
3 Poor Less than 1x1012 ohm-cm

[ Table 3.5.6 ] Standard of Water Content

CLASSIFICATION OF FAIR, BUT
No. GOOD POOR
ACCORDING TO APPLICATION PRECARIOUS
1 ≤ 500㎸ CLASS Less than 15 ppm 15 ∼ 20 ppm More than 20 ppm
2 ≤ 154㎸ CLASS, OLTC Less than 20 ppm 20 ∼ 30 ppm More than 30 ppm
As described in above table, when the high voltage of a transformer is lower than 154KV, the good condition of the
water content of insulating oil is less than 20 ppm.

4.6 GAS ANALYSIS OF TRANSFORMER OIL

Incipient faults in oil filled transformer are usually the result of electrical or thermal excess stress of either the
transformer oil or insulating materials.
It is known that such excessive stresses produce a mixture of gases in accordance with the type of faults and
associated materials.
It is recommended that analysis of dissolved gases in transformer oil by gas chromatographic equipment is made, at
initial stage of operation and at suitable intervals.
44.6.1
6 1 Analysis method
(1) Sampling of oil from transformer
Oil in transformer can be sampled through drain or sampling valve near bottom of the tank.
Special care shall be taken not to intrude air, foreign matter, or dirty oil into sampling container.
For this purpose
purpose, first 00.5
5∼1
1.00 liter of oil from the transformer shall be over
over-flown
flown through the oil container
container.
Sampling method shall be in accordance with Fig.4 and sampled oil shall not be exposed to air before analysis.
(2) Gas analysis
Gases to be analyzed and criteria for the gases found in transformer oil are tabulated in Table 3.6.1.
4.6.2 Assessing the test results
In case of typical faults in transformer active part, the models of gas contents are shown in Table 3.6.2.
Table 3.6.1 and Table 3.6.2 may be referred to evaluate transformer condition.
Quantitatively, total amount of combustible gases (TCG) of 0.06㎖/100㎖ oil excluding carbon dioxide (CO2) is
generally accepted to determine the presence of incipient fault in transformer.
However, rate of increase in combustible gases shall be regarded most important.

Therefore we recommend gas analysis to be made once or twice a year to monitor change in the gases.
If the transformer is suspected of some incipient fault, consult with HYUNDAI agent or specialists.
① Oil sampling valve

② Hose and connector
③ Sampling bottle
④ Vessel
[ Fig. 4 ] Taking an oil sample with a sampling bottle and vessel
[ Table 3.6.1 ] Gases to be analyzed and criteria
Description DECOMPOSABLE GASES IN TRANSFORMER OIL

1. Gases mean that a transformer is under normality. O2, N2, H2, CO, CO2, a little CH4
2. Gases mean that a transformer is under abnormality. H2, CH4, C2H2, C2H4, C2H6
3. Gases mean that a transformer is under deterioration. CO,, CO2, CH4

[ Table 3.6.2 ] Gas content in oil by faults

TYPE OF FAULTS DECOMPOSABLE GASES IN TRANSFORMER OIL
1 O
1. Overheat
h t off oil
il CH4, C2H4, H2(C2H6, C3H6, C3H8, C2H2)
2. Arcing in oil H2, C2H2, (CH4, C2H4)
3. Overheat of solid insulating materials CO, CO2, (H2, C2H4)
4. Overheat of oil and paper combination CH4, C2H4, CO, CO2, H2
5. Arcing of oil and paper combination H2, C2H2, CO, CO2, (C2H4)
* ( ) shows gas contents which appear rarely.

When C2H2 gas is found in the dissolved gas analysis results of insulating oil , the transformer should be
disconnected from a transmission line as soon as possible because the gas can make some explosion inside the
transformer sooner.
sooner

5. TROUBLE SHOOTING ( 1 / 30 )
Trouble shooting described on this page through next some ten pages are also very important for you to operate
transformers under emergency condition. In case of the trip signal of Buchholz relay and pressure relief device as well,
the transformer should be inspected closely after completely isolating the transformer from transmission line as soon as
possible. Especially when an accessory of the transformers makes alarm signal or trip signal, refer to the previous
paragraph of 4.6.Gas Analysis on Transformer Oil along with the dissolved gas analysis results of your transformers.
Please remember this table of trouble shooting described on this page through next some ten pages because the trouble
must be treated in accordance with Hyundai’s recommendation for each fault described in the column of remedial
measures. And refer to the possible cause described in another column of the table.
Accessories FAULT Possible Cause Remedial Measures

1) Check oil level inside the Buchholz relay.
2) Check leaks on the transformer.
3) After repairing the leaks on the transformer and filling
completely inside the Buchholz relay with insulating oil, put
the relay back into service.
Buchholz Buchholz relay
1) Oil loss. 1)) Check the ppositions of all valves.
relay
relay. - Alarm.
2) When the valve fitted between the transformer tank and the
conservator is closed, open the valve and put the valve
back into service after checking the positions of all valves
accordingg to Hyundai’s
y recommendation of valve operation
p
as described in clause 6.8.4 of another instruction manual

HHIS-WZ-TE-100 (6) titled “SHIPMENT, STORAGE
1) Oil loss. AND ERECTION OF OIL IMMERSED
TRANSFORMERS”.
1) Vent air bubbles from the Buchholz relay. The relay will be
automaticallyy filled with the oil duringg exhaustingg the air
2) Accumulation bubbles from the relay because there is sufficient insulation
of air. oil inside the conservator.
2) Put the relay back into operation when faults cannot be
found or the faults have been eliminated.
1) Check all the electrical connections.
Buchholz Buchholz relay 2) Check the signal mechanism of the Buchholz relay.
relay. - Alarm. 3) Signal fault.
3) After repairing the electrical connections and the signal
mechanism,, pput the relay
y back into service.
1) Take 1 liter oil sample from tank top and carry out a
4) Gas dissolved gas analysis in the sample.
generation due 2) Fill dry nitrogen gas into the Buchholz relay for 5 hours and
to inside analyze the gas for DGA.
DGA
failure. 3) When there is abnormal gas in analyzed results, the
transformer should be internally inspected with care to
5) Violent eliminate the fault.
vibration. If not, continuously operate the transformer after venting the
gas from the relay.

4) Gas
4) Take 1 liter oil sample from tank bottom and check the
generation due
dielectric strength of the oil. When the dielectric strength
to inside
is less than Hyundai’s recommendation as described in
failure.
Table 3.5.3 of this manual, the oil should be dried out in
5) Violent
accordance with the procedures of Degassing and Drying
vibration such
Buchholz relay Transformer Oil as described in clause 6.9 of Hyundai’s
as the
- Alarm. another instruction manual HHIS-WZ-TE-100 (6) titled “
mechanical
SHIPMENT, STORAGE AND ERECTION OF OIL
shock of
IMMERSED TRANSFORMERS”
TRANSFORMERS .
earthquake or
Buchholz other
5) If the oil has enough dielectric strength, continuously
relay. mechanical
operate the transformer.
shock.
1) Oil loss.
2) Violent oil 1) Maintain the shutdown status of the transformer.
surge due to 2) Make the following measurements :
2.1) Measure the insulation resistance value between each
inside
Buchholz relay winding and ground as well as between the windings
flashover.
- Trip. themselves.
3) Violent gas
2.2) Ratio measurement either with measuring kit or by
generation due applying low voltage to the HV side.
to inside 2 3) Measure
2.3) M th
the winding
i di resistance
it by
b using
i DC power.
failure.

2.4)) Measure the no-load current by y applying
pp y g low voltage
g
to the HV side.
1) Oil loss. 3) Take all remedial measures including tests and analysises
2) Violent oil described in the remedial measures column of Buchholz
surge
g due to relayy – Alarm.
inside 4) Compare the results with the test certificates attached to the
flashover. transformer instruction manual. When the difference
Buchholz Buchholz relay 3) Violent gas between both results is not within permissible tolerance, the
relay.
y - Trip.
p generation due
g transformer should be internally y inspected
p with care to
to inside eliminate it after finding out the fault. When the difference
failure. between both results is within permissible tolerance, vent air
4) Violent from the Buchholz relay and put the transformer back into
vibration. service.
5) Fault tripping. 5) When any faults cannot be found or faults have been
eliminated, vent air from the Buchholz relay and put the
transformer back into service.
When the Buchholz relay makes alarm signal, the transformer can be continuously operated but some tests and
examinations for fault analysis should be made as soon as possible.
While when the relay
y makes trip
p signal,
g , maintain the shutdown status of the transformer to eliminate the fault.

1) Maintain the shutdown status of the transformer.
2) Check the pipes and shut-off devices. When the valve
fitted between the transformer tank and the conservator is
1) Conservator
closed, open the valve after unscrewing the locking bolts of
pipe shut off
Pressure relief the valve and put the transformer back into service.
Pressure or clogged.
device Wh inside
When i id the
h pipe
i isi clogged,
l d clean
l out the
h inside
i id off the
h
relief device. pipe by using hot oil flush procedure, compressed air or
- Trip.
cylinder type steel wire brush.
2)) Electric Check the transformer accordingg to the pprocedure as
flashover described in the remedial measures column of Buchholz relay
inside the tank. – Trip.
Pressure 1) Maintain the shutdown status of the transformer.
relief device Pressure relief 2) Check the tripping mechanism of the relay.
relay
of diverter device 3) After removing the diverter switch from its chamber, check
switch - Trip. it and especially measure the resistance values of transition
chamber. Oil surge
resistors to compare the measurements with the original
produced by a
values marked on the name plate of the tap changer.
changer
Protective fault in the
If necessary, change it with a new one.
relay of Protective diverter switch
4) When main or auxiliary contact had been worn too much,
diverter relay chamber.
the contact should be replaced with a new one.
switch - Trip. 5)) After takingg above remedial measures,, reset the tripping
pp g
chamber. mechanism and put the transformer back into service.

Resistance 1) Transformer Reduce transformer load by using other transformers
thermometer. overload.
l d connected
d to the
h same load
l d in
i parallel.
ll l
Oil or winding 1) In case oil and winding temperatures are too much higher or
temperature lower considering transformer load and ambient temperature,
- Alarm or 2) Inadequate
Temperature correctlyy adjust
j the indications byy turningg the bolt fitted on
trip. li
cooling
monitor. the needle or face of indicators after calibrating them ( refer
equipment.
to calibration method described in Note as below ).
If not, replace the indicators with a new one.
Note ; Calibration
C lib ti method th d recommended
d d by
b one off thermometer
th t manufacturers.
f t
In principle, it is not necessary for you to calibrate any kind of the temperature indicators because each temperature
indicator had been calibrated in its factory, already. But sometimes the calibration can be required for the indicator due
to another heating source located near to the capillary tube of the thermometers, solar irradiation and etc.
Calibration Method
1) After putting the bulb of the temperature indicator in 100 ºC boiling water or in a well stirred bath with a control
thermometer, check the temperature indication of the indicator after 15 minutes.
2) If necessary, adjust the pointer by turning the screw fitted on the needle or face of the indicator with care.
3) If error is more than 5 ºC,
ºC Hyundai recommends you to contact the local agent or representative of the thermometer
manufacturer.
4) In case of winding temperature indicator, the calibration should be done on the result of transformer temperature rise
test. The gradient between average winding temperature and average oil temperature should be adjusted by means of
the secondary current of bushing current transformer connected to the temperature indicator and a temperature
compensation component fitted inside the temperature indicator as well.
Resistance 2)) When radiator surfaces are dirty, y, the surfaces should be
thermometer. clean out by using compressed air.
3) When there are some leaks on radiator surfaces,
disassemble the damaged radiator from the transformer after
closingg butterflyy valves and drainingg out insulatingg oil from
the radiator and the leaks should be repaired by means of
metal bond or a suitable welding procedure.
After repairing the radiator completely, the radiator can be
reassembled at the original
g pposition and filled with new
Oil or winding insulating oil by using the oil drain valve, air vent of the
2) Inadequate
temperature radiator and oil purifiers as well.
cooling
Temperature - Alarm or 4) When the indications of oil temperature indicators are too
equipment.
monitor
monitor. trip.
p high
g consideringg transformer load and ambient temperature,
p ,
check if butterfly valves of cooling equipment are opened.
If not, open the valves.
5) When there are some leaks on the cooling equipment, take
the same remedial measures described in above item 3)) of
this accessories.
6) When there are some foreign matter inside the coolers,
eliminate the foreign matter from the coolers by using
hot oil flush p
procedure,, compressed
p air or cylinder
y type
yp steel
wire brush.

Resistance 7)) Check control device for cooling g equipment.
q p
thermometer. If the device has been damaged, stucked, or contaminated,
repair it or replace it with a new one.
8) When the previous setting values for alarm or trip signal are
too lower considering g transformer operation
p condition and
ambient temperature, reset new setting values according to
Oil or winding manufacturer’s recommendation described in the instruction
2) Inadequate
temperature manual of each accessory.
cooling
Temperature - Alarm or 9)) Check current transformers connected to thermometers.
equipment.
i t
monitor. trip. When the current transformers have been burned out due to
disconnecting the secondary leads of the transformers from
terminals or the concerned relay, replace the current
transformers with a new one and filter insulatingg oil by
y
using oil purifier.
10) After taking above remedial measures, put the
thermometers or the transformers back into service.
1) When the indication is too much lower considering
transformer load and ambient temperature,
1) Not enough
Oil level Oil level 2) It is possible that there are some leaks on the transformer
oil caused by
indicator. - Alarm. caused by poor joints or wrong welding parts.
oil leaks.
3) After repairing them, fill the transformer with insulating oil
according to calculation results from the temperature

1) Not enough difference between oil thermometer indication and oil level
oil caused by indication, the total oil quantity of the transformer as well
oil leaks. as the coefficient of oil expansion of 0.78 X 10-3 / K.
2) Too much oil In case the oil level is higher than 10 ºC of oil temperature
due to indication due to overfilling transformers with insulating oil,
oil
overfilling some oil should be drained from the transformer according to
transformers the calculation result described in item 3) of above remedial
Oil level Oil level with insulation measures column for possible cause of not enough oil caused
indicator
indicator. - Alarm.
Alarm oil
oil. by oil leaks of this accessory.
accessory
1) If the oil level indicator indicates minimum oil level or
3) Too little oil make alarm signal caused by the damaged rubber bag or
due to the diaphragm of transformer oil preservation system, the
damaged rubber bag or diaphragm should be repaired or replaced
rubber bag or with a new one.
diaphragm. 2) After taking above remedial measures, put the relay back
into service.
If some oil should be added to the transformer tank, refer to oil filling procedure described in clause 6.8.6 of
Hyundai’s another instruction manual HHIS-WZ-TE-100 (6) titled “ SHIPMENT, STORAGE AND ERECTION OF
OIL IMMERSED TRANSFORMERS”.
If the oil level inside the transformer is insufficient
insufficient, some relays such as Buchholz relays or the protective relays of On
Load Tap Changer may make trip signal to protect the transformer from internal discharge due to the lower oil level.

1)) S
Slide
de vvalve
ve Ope thee slide
Open s de valve
v ve aftere uunscrewing
sc ew g thee locking
oc g cap
c p bolts
bo s of
o
closed. the valve and put the oil flow monitor back into service.
Clean up inside the pipe by using hot oil flush procedure,
compressed air or cylinder type steel wire brush after
2) Pi
Pipe clogged.
l d di
disassembling
bli the
th pipe
i from
f the
th transformer
t f andd assembling
bli it
at the original position, put the oil flow monitor back into
service.
Seal leaks on the p
pipe
p byy means of suitable weldingg procedure
p
3) Pipe leaked. or adhesive such as metal bond and put the oil flow monitor
Oil flow back into service.
No oil flow.
monitor.
4) The incorrect
When the direction of motor is not correct,, change
g two wire
di ti off
direction
positions out of 3 phase power lines each other.
rotation
5) Oil pump fault 1) Repair the oil pump according to the source of the trouble
such as no such as no voltage,
g , or too low voltage.
g
voltage, too 2) When the trouble is caused by defective windings or
low voltage, damaged bearings, replace the damaged motor with a new
the defective one.
windingg of 3)) Check the setting g value of over current relay.
y If necessary,
y,
motor, and etc. adjust the setting value according to the starting current and

5)) Oil ppumpp fault
starting
t ti time
ti off the
th pump motor t or replace
l existing
i ti over-
such as no
current relay with a suitable new one if necessary.
voltage, too
4) Check the electrical connections of the tripping
low voltage,
Oil flow mechanism of the oil flow monitor. If necessary, take the
No oil flow. the defective
monitor.
it di l measures ddescribed
same remedial ib d in
i item
it 1) off above
b
winding of
remedial measures column of this accessory.
motor, or
5) After taking above remedial measures, put the oil flow
damaged
monitor back into service.
bearing.
g
1) Protective Clean up the protective screens of fan blades by using
screen iced up. compressed air, put it back into service.
No air flow or 1) Remove impurities from the coolers or clean them out by
Air flow
reduced
d d 2) Cooler is too using compressed air, put the air flow monitor back into
monitor
airflow. much dirtied service.
or clogged. 2) If the coolers are too much clogged, replace the coolers with
a new one.
1) When the trouble is caused by the defective winding or
Difference No air flow or damaged bearing, replace it with a new one.
pressure reduced Fan motor fault. 2) Check the setting value of over current relay.
switch airflow
airflow. If necessary
necessary, adjust the setting value of the over current
relay according to the starting current and starting time of

the fan motor or replace existing over

over-current
current relay with
a new one if necessary.
3) Check wire connections and the tripping mechanism.
When the direction of motor is not correct, change two wire
Difference No air flow or
positions out of 3 phase power lines each other.
pressure reduced
d d F motor ffault.
Fan l
4) After taking remedial measures above, put the difference
switch airflow.
pressure switch back into service.
5) In case of others, repair fan motors or replace the motors
with a new one according to the instructions of
manufacturer, case by case.
1) Motor
1) Check the source of electric power of the motor drive unit.
protection
2) If necessary, repair the electric connection leads, the
switch
i h ( Q1 )
tripping mechanism, and the switches of the no-fuse
is not in
Motor-drive breakers of motor-protection switch ( Q1 ) and put the
The unit is out operating
unit of On motor drive unit back into service.
of service, position.
Load Tap
electrically. 2) When putting
Changer.
hand crank in After pulling out the hand crank from the drive shaft hole and
the drive shaft setting the crank at the original position inside the motor drive
hole of motor unit,, p
put the motor drive unit back into service.
drive unit.

3) Open circuit
on one or After correctly fixing motor phase connections to the source of
more motor electric power, put the motor drive unit back into service.
phases.
4) Motor current When the trouble is caused by defective windings or damaged
is excessive bearings, replace the damaged motor with a new one or repair
due to phase the motor according to the source of the trouble and put the
failure. motor drive unit back into service.
Motor-drive 5) One of the

The unit is out push buttons is
unit of On
of service, stuck.
Load Tap
electrically.
Changer.
g 6) Emergency
stop button is
stuck. After cleaning it up by using compressed air, repairing it
according to fault status or replacing it with a new one, put the
7) Motor motor drive unit back into service.
contactor is
i
out of order.
8) Relay
contactor is
out of order.

1) Relay
Motor-drive contractor is
stuck. After cleaning it up by using compressed air, repairing it
unit of On Drive keeps on
according to fault status or replacing it with a new one, put the
Load Tap running 2) Emergency motor drive unit back into service.
Changer.
g stop button is
stuck.
1) After checking all outside the mechanism, request a factory
1) Some engineer if a mechanical fault in the tap-changer is
components suspected.
d
defect from 2) The shield cap of the OLTC selector s/w part can make
operation partial discharge due to loosed bolts.
Operation mechanism 3) When insulation barrier touched to grounding parts, partial
T changer
Tap h mechanism
h i iis di h
discharge can occur
stuck.
2) Poor contact After checking all the contacts, request a factory engineer if a
making. mechanical fault in the tap-changer is suspected.
3) Carbon Clean out the carbon formation and perform the remedial
formation on measures of Buchholz relay – Trip fault as described in the
contacts. initial part of this trouble shooting.
When tap changers don

don’tt operate correctly, internal inspection should be carried out after disconnecting the
transformer from the transmission line. If not, serious internal discharge could occur inside the transformer.

After disconnecting the transformer from transmission lines

and grounding all transformer bushings by using the earthing
The screws of
The terminal Discoloration switch of transmission lines, the contact surface of the
the terminals is
lugs of of connecting terminals should be cleaned up by using steel wire brushes,
not tightened
bushings parts. coated with conductive grease and tighten the screws of the
enough.
terminals according to manufacturer’s recommendation and
put the transformer back into service.
1) After checking transformer operation condition such as

transformer load and ambient temperature,
Pressure 1) Improper
2) After disconnecting the transformer from transmission lines
gauge setting value
by using the earthing switch of transmission lines, adjust the
or monitor of the gauge.
setting value of the gauge according to site condition
of oil- correctly and put the transformer back into service.
Pressure gauge
immersed
- Alarm or
condenser
type bushing, Trip. 2) Too high oil
especially temperature
When the transformer is overloaded, reduce transformer load
oil to sf6 inside the
by using other transformers connected to the same load in
type bushing. bushing due to
parallel.
transformer
overload.

1) When the oil is overheated due to solar irradiation, increase

bushing cooling efficiency by using sunshades which must
keep minimum air clearance between the shades and the
3) Too high oil
bushing conductors.
temperature
p
2) The minim
minimum m air clearance is described in international
inside the
regulations such as IEC 60076-3-2000 or IEEE Std
Pressure bushing due to
C57.12.00-2000.
gauge solar
3) Increase bushing cooling efficiency by using effective
or monitor irradiation.
ventilation
ventilation.
of oil- 4) Reduce transformer load by using other transformers
Pressure gauge
immersed connected to the same load in parallel.
- Alarm or
condenser
Trip.
type
yp bushing,
g
especially 1) When there is some leaks on the bushing,
oil to sf6 2) Seal the leaks on the bushing and fill inside the bushing
type bushing. with insulating oil according to the procedure of bushing
instruction manual after disconnecting the transformer from
4) Oil loss. transmission lines and grounding all transformer bushings
by using the earthing switch of transmission lines.
3) When the manual does not allow to fill inside the bushing
with insulating oil, replace it with a new one and put the
t
transformer
f back
b k into
i t service.
i


1) Check bushing status such as pressure on the gauge and
leaks on the bushings,
2) When there is some damage on the bushings, follow the
repair procedure of bushing manufacturer and refer to
international standards such as IEC 62155 titled “ Hollow
pressurized and unpressurized ceramic and glass insulators
for use in electrical equipment with rated voltages greater
than 1000 V ” and IEC 60168 titled “ Tests on indoor and
outdoor post insulators of ceramic material or glass for
systems with
i h nominal
i l voltages
l greater than
h 1000 V. ”
3) The following is one of the recommendations of bushing
Bushing Damaged Mechanical
manufacturers for repairs under condition that glaze faults
porcelains porcelain. shock.
on the porcelain of bushings shall not exceed the limits
according to IEC 62155 and IEC 60168 ; refer to the end
part of Bushing porcelain for the limits.
(1) Additionally, there are 3 kinds of acceptable porcelain
damage for repairs as below ;
A Glaze defects,
A. defects scratches and scraping in the glazing.
glazing
Only faults which don’t exceed the limits according to
the relevant international standards can be repaired.
B. Smaller damage on the sheds.
When the broken p piece exists,, the size of the damage
g
must be less than the followings ;

Length = 10 % of shed diameter.

Width = 5 % of shed diameter.
Depth = 1.5 % of shed diameter.
When the broken piece is missing, the size of the damage
must be less than the followings ;
L
Length
h = 5 % off shed
h d diameter.
di
Depth = 1 % of shed diameter.
C. Smaller damage on the porcelain body and smaller chips
broken out from the flange surface.
The size of the damage must be less than the
Bushing Damaged Mechanical followings ;
porcelains porcelain. shock. Length = 4 % of shed diameter.
Depth
h = 3 mm ffor shed
h d diameter
di more than
h 50000 mm.
Depth = 2 mm for shed diameter less than 500 mm.
(2) Repairs ; The repair part shall be free from pores.
(2.1) Repair of porcelain with the broken piece available.
The damaged surface of the porcelain must be cleaned out
by using ethyl acetate.
The solvent used, must be of a pure quality, with no grease
residuals. Use clean and lint-free cloths.
To attach a broken piece of porcelain, use epoxy resin e.g.
CIBA GEIGY Araldite F and hardener HY 956 as well.

Mix 100 parts by weight ( p.b.w. ) epoxy resin in 20 p.b.w
hardener and the mixture shall be used within 45 minutes.
Brush the adhesive onto both surfaces.
The joint is hardened by means of contact pressure itself at
room temperature for 15 hours or at 70-80 ºC for 3 hours.
N t ;
Note
If the broken piece consists of several smaller porcelain
pieces, a polyacrylate adhesive can be used e.g. Lactate
401.
After cleaning out,
out brush the adhesive onto one surface of
two broken parts in a thin, covering layer.
Bushing Damaged Mechanical Place the two pieces in exact position as they were and
porcelains porcelain. shock. press the two pieces by hand together for 1 minute.
Excess adhesive is cleaned out. If necessary, y, fill voids
with epoxy paste as below ;
(2.2) Filling chips and voids where the piece is missed.
(2.2.1) Procedure ; Brown porcelain.
The damaged surface must be cleaned out by using ethyl
acetate.
This repair is performed by using epoxy resin, e.g. Araldite
121 P, and brown colored paste as well.
If necessary, the paste is mixed in Araldite coloring agent,
DW 0133 ( red ) to get the same color of the porcelain.

The color mix must be p performed byy usingg Araldite

hardener HY 956.
Mix ratio ; 100 p.b.w. epoxy resin, 10 p.b.w. hardener.
The mix must be used within 45 minutes.
The compound is applied to layers ( 1-5 mm ) and can be
held in position by using tapes.
After hardening it at room temperature for 15 hours or at
70-80 ºC for 3 hours, remove the tape, clean out the resin
surface and smooth the surface by using sandpaper.
A l more compoundd if necessary – clean
Apply l outt andd smooth
th
the surface.
Apply a brush to the mix of polyurethane varnish and
hardener.
The mix ratio shall be 2 pp.b.w.
b w varnish and 1 p.b.w.
pbw
hardener.
Apply the varnish coating twice for hardening time of 2
hours at room temperature after the first coating and a
finish hardening time of 24 – 48 hours at room temperature
or 70 – 80 ºC for 3 hours after the last coating.
(2.2.2) Procedure ; Grey porcelain.
This repair is performed by using epoxy resin e.g. Araldite
2014 mixed in white epoxy paste, e.g. Araldite DW 0131 to
a light grey color.

The Araldite 2014 consists of two kinds of epoxy resins
in a 200 ml cartridge and can be applied to a handgun with
a mixer.
Mix them with some blue paint paste e.g. Araldite DW
0135 to o get
ge thee same
s e color
co o of
o thee porcelain.
po ce .
The resin is applied to layers and can be held in position
by using tapes.
After hardening it at room temperature for 15 hours or 70 –
80 ºC for 3 hours,, remove the tape,
p , wash off the resin
Bushing Damaged Mechanical Apply more compound if necessary - wash off the resin
porcelains porcelain. shock. surface and smooth the surface by using sandpaper.
Apply
pp y the varnish coatingg twice for hardeningg time of 2
hours at room temperature after the first coating and a
finish hardening time of 24 – 48 hours at room temperature
or 70 – 80 ºC for 3 hours after the last coating.
((2.2.3)) Procedure ; Unglazed
g surface.
This repair is performed by using epoxy resin e.g. Araldite
2014.
The Araldite 2014 consists of two kinds of epoxy resins
in a 200 ml cartridge
g and can be applied
pp to a handgun
g with
a mixer.

The resin is applied to layers and can be held in position

by using tapes.
After hardening it at room temperature for 15 hours or 70 –
80 ºC for 3 hours, remove the tape, wash off the resin
surface and smooth the surface by using sandpaper
sandpaper.
Apply more compound if necessary - wash off the resin
Electric After disconnecting the transformer from transmission lines

The
insulation and grounding the bushing by using the earthing switch of
protective Frequent
distance between transmission lines, adjust electric insulation distance between
spark gap of operation
arcing horns is arcing horns, fix them and put the transformer back into
bushings
not enough
enough. service
service.
The limits of Glaze defects for repairs according to IEC 62155

The total area of glaze defected on each insulator shall be less than [ 100 + ( D X Lc ) / 2000 ] mm and the area of any
single glaze defect shall be less than [ 50 + ( D X Lc ) / 1500 ] mm.
Where, D is the greatest external diameter in millimeter of the insulator and Lc is the creepage distance in millimeter of
the insulator.
F some ddetails,
For t il refer
f tot IEC 62155 and
d IEC 60168.
60168

Following methods can be applied for repairing the leaks
under condition that the upper part of conservators is under
vacuum by means of vacuum pump and also the oil level of a
transparent vinyl tube connected to the drain valve of
transformer tanks is lower than the leaks,,
1) The small leaks through a pin hole on the transformer tank
wall possibly may be stopped by peening with a ball peen
hammer. Generally, the small leaks can occur after the
several yyear operation
p of a transformer without anyy leaks at
Hyundai’s factory or during transformer installation
Tanks and Mechanical including long storage because the pin hole is temporarily
Small leaks.
radiators shock. blocked due to the shoot ball blasting as well as painting on
the tank surface at Hyundai’s
y factory.
y
2) As an alternative, the small leaks may be stopped by using
metal bond or welding while the transformer filled with
insulation oil. When welding them, take an oil sample from
the transformers for Dissolved Gas Analysis
y jjust before and
just after welding as well as 24 hours later after transformers
are energized to check if gas increases due to the welding
work.
3)) When makingg vacuum inside transformer tank for the
welding procedures, the waiting period between releasing

the vacuum from the transformer and putting the
transformer in service is longer than instructions described
Mechanical
Small leaks. in Table 6-7 of Hyundai’s another instruction manual
shock.
HHIS-WZ-TE-100 (6) because a vacuum may cause
bubbles to be formed in the insulating oil and cause arcing.
1) When a transformer tank is ruptured, the internal inspection

of the transformer should be carried out with care after the
transformer is completely disconnected from transmission
lines and solidly grounded. If necessary, the transformer
may be repaired at manufacturer’s factory because the
Tanks and rupture must be caused by the serious internal faults of the
radiators transformer.
2) In case a ruptured radiator should be disassembled from
Mechanical
M h i l the transformer after closing butterfly valves and draining
Rupture
shock. out residual insulating oil from the radiator.
3) And then the ruptured radiator should be repaired by means
of a suitable welding procedures or replaced with a new
one, if necessary.
After being repaired completely or replaced with a new one,
the radiator can be reassembled at the original position and
filled with new insulating oil by using the oil drain valve, air
vent of the radiator and oil purifier as well.

Cooling water
Oil leakage
l k 1) M
Maintain
i i theh shutdown
h d status off the
h transformer.
f
leaks into oil
detector 2) Request factory engineer service if an electrical fault in the
circulation
- Trip. transformer is suspected.
Oil-water system.
cooler 1) Leaks in After temporarily sealing up the leaks on the pipe or
No water flow
cooling water permanently repairing the leaks by suitable welding
or reduced
supplying procedure, put the cooling water supplying system back into
water flow.
system. service.
1) Check whether there are some leaks in the cooling water

supplying system or not. If so, the leaks shall be sealed by
suitable welding procedure or replacing gasket at joint
2)) Reduction of
No water
N t flflow points
i t with
ith a new one.
Oil-water cooling water
or reduced 2) Request factory engineer service if a mechanical fault in the
cooler supplying
water flow. cooling water supplying system is suspected.
quantity.
3) When there are some faults in the electric connections or
the tripping mechanism of the system,
system fix them and put the
cooling water supplying system back into service.
1) First of all, tighten fan blade screws after disconnecting the

Fans are out of
Cooling fans. 1) Loose blades. damaged fans from their power source.
service.
i
2) After tightening the fan blade screws, balance the fan blades

to prevent the cooling fans from vibration and put the fans
1) Loose blades
blades.
back into service.
When fan motor load current is high due to impeded fan
Fans are out of 2) Damaged rotation or fan motor makes abnormal noise, replace the fans
Cooling fans. bearing.
g with a new one after disconnecting
g the fans from their power
p
service.
source and put the new fans back into service.
Repair the wires after disconnecting the wires from their
3) Broken wires.
power source and put them back into service.
Replace the starter with a new one and put the pumps back
1) Pump starter.
into service.
Pumps are out 2) Damaged
Oil pumps. Same as that of cooling fan.
of service. bearing
bearing.
3) Broken wires. Same as that of cooling fan.
1) High Replace dehydrating agent with a new one and put the breather
Silica gel has humidity
humidity. back into service.
service
been
Dehydrating 2) Glass cylinder Seal up the leaks on the glass cylinder, completely and put the
discolored, not
breather leaks. breather back into service.
from bottom to
top. 3) Moisture in Dry out inside the conservator by using dry air or nitrogen and
conservator. put the conservator back into service.

After temporarily sealing up the leaks on the pipe by using

4) Pipe leaks. sealant or permanently repairing them by means of welding,
put the breather back into service.
5) Glass cylinder Replace the cylinder with a new one and put the breather back
Silica gel has is cracked. into service.
been
Dehydrating 1) When the moisture content of insulating oil is less than
discolored, not
breather Hyundai’s recommendation as described in Table 3.5.6
from bottom to
standard of water content of this manual, the transformer
top.
6) Too long can be continuously operated.
maintenance 2) If not, the oil should be dried out according to the procedure
interval of Degassing and Drying Transformer Oil as described in
clause
l 6.9
6 9 off Hyundai’s
H d i’ another
h iinstruction
i manuall HHIS-
HHIS
WZ-TE- 100 (6) titled “ SHIPMENT, STORAGE AND
1) Excessive
After checking the electric air clearance among live parts and
current on the
transformer tank, eliminate foreign matter on the transformer
Grounding Grounding line transformer
tank and the live parts and make sure that the tank and live
connection interrupted. tank due to
parts have sufficient electric clearance.
external
.
flashover.

1) After removing all the unnecessary grounding lines

2) IImpermissible
i ibl
excepting one grounding line with a sufficient cross section,
current loops
clean out the contact surfaces between transformer tank and
on the
grounding wire terminal and then tighten terminal blots.
Grounding Grounding line transformer
2) Refer to Specification of earth wire as described in
connection
i i t
interrupted.
t d d to multiple
due li l
Table 6-4 and Table 6-5 of Hyundai’s another instruction
grounding
manual HHIS-WZ-TE- 100 (6) titled “ SHIPMENT,
connections.
STORAGE AND ERECTION OF OIL IMMERSED
TRANSFORMERS”.
Electrical Dry out the excessive humidity inside the panel by using
Excessive
apparatus does compressed air or dry N2 gas, lower the setting value of
humidity in
not operate hygrograph stat as well as that of thermostat and put the panel
control panel
panel.
properly. back into service.
After drying out water or blowing off dust from inside the
Control Contacts
Water or dust panel by using compressed air, seal up the panel door and if
ppanel corroded or
inside the panel
panel. necessary fit a dust filter and put the control panel back into
necessary,
contaminated.
service.
Excessive high After fixing the distortion of the panel, protect the panel from
Apparatus
temperature
p in solar irradiation byy using
g shading,
g, pprovide the p
panel with a
h i bent.
housing b t
the panel. better ventilation and put the panel back into service.

1) When
h theh moisture
i content iis more than
h Hyundai’s
d i’
1) Breather is not
recommendation as described in Table 3.5.6 standard of
suitable for
water content of this manual, take the second remedial
operation
measures of 6) too long maintenance interval in possible
condition
cause column
l off dehydrating
d h d i breather.
b h
considering
2) Shorten the maintenance interval of dehydrating breather or
transformer
add extra breathers to existing breather pipe line by using T
load variation
branch pipe.
and ambient
The
Th Breakdown
B kd 3) If possible,
ibl change
h oil
il preservation
i system from
f open type
humidity as
electrical voltage is too conservator system to rubber bag type conservator system
well.
break-down low due to high (close type) as an alternative method.
voltage of water content
oil.
il off oil.
il After temporarily sealing up the leaks in the system by using
2) Leaks in water
adhesive such as metal bond and permanently repairing the
cooling
leaks in the system or replacing it with new one, put the
system.
coolingg system
y back into service.
3) Water
1) After checking the water pressure, request factory engineer
pressure
service if a mechanical fault in the cooling water circulation
reducer is out
system is suspected
suspected.
of service.

The Breakdown 2)) If possible,
p temporarily
p y seal upp the leaks byy usingg a suitable
3) Water
electrical voltage is too adhesive such as metal bond and permanently repair the
pressure
break-down low due to high leaks in the cooling water circulation system or replacing a
reducer is out
voltage of water content of damaged water pump in the system with a new one, put the
of service.
oil. oil. cooling system back into service.
1) Improper
Correctly set the ball position in the bottom of the
floating ball
condensation globe and put the breather back into service.
position.
Silica gel is not
blue. 2) Improper Shorten or prolong the frequency of regeneration cycles by
regeneration turning the blue dial on the control timer as necessary, and put
cycle. the breather back into service.
Maintenance
Free 1) Ch
Checkk supply
l feeders.
f d
Silica gel is not No voltage
Dehydrating 2) After repairing the electrical connections and the tripping
blue. supply.
Breather. mechanism, put the breather back into service.
1)) Leaks on the After temporarily
p y sealing
g up
p the leaks on the ppipe
p or
Silica gel is not connection permanently repairing the leaks, put the breather back into
turning pink pipe line. service.
during normal 2) Improper
operation.
p Prolong regeneration interval by turning the blue dial on the
regeneration
controll timer
i andd put the
h breather
b h backb k into
i service.
i
cycle.

6. RECOATING.
6.1 RECOATING CYCLE.
Since a coating is influenced by circumstances, it is difficult to show exactly the service life of coating.
Therefore, refer to the coating period for your reference as follows:
TROPICAL AND HUMID ZONE, SEASIDE,

SITE CONDITION SERVICE ORDINARY ZONE
AND CHEMICAL PLANT
Outdoor 3 to 4 years 2 to 3 years
Indoor 4 to 7 years 3 to 5 years
6.2 METHOD OF RECOATING.

6.2.1 Outdoor service equipment.
After removing rust perfectly and peeling paint from recoating surfaces by means of sandpaper or steel wire brush.
All the surfaces to be painted shall be clean out by using lint free cloths and compressed air as well.
After drying out the surfaces by means of natural wind or air, the anticorrosive paint of primer must be coated on the
surfaces
f bby means off air
i spray gun or brush,
b h theth mixing
i i ratio
ti off primer
i – base
b : h
hardener
d iis 4 : 1 (b
(by volume).
l )
After the primer was dried out sufficiently, the finish paint should be coated by air spray guns or brushes, the mixing
ratio of final paint – base : hardener is 2 : 1 (by volume), but a little thinner should be added to the final paint in
order to use the air spray guns.
guns Several thin coatings is more effective than one thick coating.
coating

In case of bolt connecting point, primer is painted with heavy thickness and then finish coating should be done.
After the final coating is finished, it must be dried out for 2 hours at 25 degree C.
Repair work on touch up painting should be carried out only in dry weather and at the temperature of at least 5 ºC
because surfaces damped by dew must not be painted.
6.2.2 Indoor service equipment.

Method of recoating is same as the outdoor service.
A volatile and inflammable solvent should not be used for paint as its volatile matter that remains in the room may
cause fire.
7. FACTORY REPAIR PROCEDURE.

Advice and assistance in dealing with any problems in the operation of Hyundai transformers are readily available
from HYUNDAI HEAVY INDUSTRIES CO.,, Limited,, ULSAN KOREA.
Please note that when making any enquire concerning Hyundai transformers, or their associated equipment, it
is essential to quote the exact serial numbers.
The serial number positively identifies the equipment in question and the relevant technical data can be quickly
and easily referred to by Hyundai engineers.
The factory address is described on next page.

** HEAD OFFICE **
1) HYUNDAI HEAVY INDUSTRIES CO., LTD
ELECTRO ELECTRIC SYSTEMS,
SYSTEMS CUSTOMER SERVICE DEPARTMENT
1, CHEONHA-DONG, DONG-KU, ULSAN, KOREA, 682-792
2) HOMEPAGE: www.hyundai-elec.com
3) TEL: 82-52-202-7772
4) FAX: 82-52-230-8665
5) E-MAIL: [email protected].
** S
SEOUL
O O
OFFICE
C **
1) HYUNDAI HEAVY INDUSTRIES CO., LTD
ELECTRO ELECTRIC SYSTEMS, HYUNDAI B/D
140 2 KYE
140-2, KYE-DONG,
DONG JONGNO-GU,
JONGNO GU SEOUL
SEOUL, KOREA
2) TEL: 82-80-029-5555 (Collect Call)
3) FAX: 82-2-3668-0888

5. Specification for Power Transformer
5 1 Project Summary ---------------------------------------------------------------------------------------------------------------- 160

5.1
5.2 Specifications for Power Transformers --------------------------------------------------------------------------------------- 161
5.3 Main Accessories and Sub-Vendor List for Power Transformers --------------------------------------------------------- 162
5.4 Outline for Power Transformers ----------------------------------------------------------------------------------------------- 164

5.1 Project Summary
Project Name ; ARAMCO / District Cooling Project
Project Scope ; 1) Power Transformer
; 3 PH 60 Hz 115/13.8 kV, 22/29/36 MVA, 2 Sets.
Customer ; SNC LAVALIN UAE
End User ; ARAMCO
Training period ; February 02, 2013 to February 03, 2013 ( 2 Days ).

5 2 Specifications
5.2 S ifi i for
f Power
P Transformers
T f
ITEM Power Transformers
Ambient Temperature ( Maximum / Yearly Average ) 50 ºC / 30 ºC
ONAN 22 / 22 MVA
Rating of ONAF 1 29 / 29 MVA
HV / LV Winding
ONAF2 36 / 36 MVA
Rated Voltage of HV / LV Winding 115 / 13.8 KV
Tap Voltage at HV Winding Side 115 KV + 8, -12 x 1.25 %
Connection Dyn1
Temp. Rise ( Oil / Winding / Hottest ) 50 / 55 / 68
HV Winding 650 KV
Basic Impulse Level
( B.I.L. )
LV Wi
Winding
di / LV neutral
t l 110 / 110 KV
HV Winding 275 KV
P.F. Test Volt.
LV Winding / LV neutral 50 / 50 KV
% IZ between HV and LV Winding, at Principal tap 9 % ( at 22 MVA )
No-Load Loss at rated frequency, at 28 KW

Loss 100% rated voltage
Load loss at 75ºC at principal tap 66KW ( at 22 MVA )

5.3 Main Accessories and Sub-Vendor List for Power Transformers (1/2)
No Description Q’TY Specification Sub-Vendor
1 HV BUSHING (OIL to AIR) 3 COT 750-800

750 800 / 170KV
170KV-800A
800A TRENCH / FRANCE
2 LV BUSHING (OIL to AIR) 3 COT 125-2500 / 24KV-2500A TRENCH / FRANCE
3 LV NEUTRAL BUSHING (OIL to AIR) 1 COT 125-2500 / 24KV-2500A TRENCH / FRANCE
4 CORE EARTHING BUSHING 2 1.2KV-200A HYUNDAI / KOREA
1) ON LOAD TAP CHANGER 1 VV III 250D-145-12233W

5 2) MOTOR DRIVE UNIT 1 ED 100L MR / GERMANY
3) PROTECTIVE RELAY FOR OLTC 1 RS2001-2A
OIL LEVEL INDICATOR FOR MAIN TJD-0280G02H03

6 1 TAIJIN /KOREA
CONSERVATOR (MIN.25℃, MAX)
OIL LEVEL INDICATOR FOR OLTC TJD-0281G02H01

7 1 TAIJIN /KOREA
CONSERVATOR (MIN.25℃, MAX)
8 OIL TEMP
TEMP. INDICATOR 1 AKM34406-15X-12 0
AKM34406-15X-12.0 AKM / SWEDEN
9 WINDING TEMP. INDICATOR 2 AKM35406-15X-12.0 AKM / SWEDEN
BUCHHOLZ RELAY
10 1 EE3-ML WITH RG3.3 CEDASPE / ITALY
WITH GAS RELEASE DEVICE

5.3 Main Accessories and Sub-Vendor List for Power Transformers (2/2)
No Description Q’TY Specification Sub-Vendor
11 PRESSURE RELIEF DEVICE FOR MAIN 1 208 003 01 (10 PSI)

208-003-01 QUALITROL / U.S.A
USA
12 PRESSURE RELIEF DEVICE FOR OLTC 1 213-012-01 (20 PSI) QUALITROL / U.S.A
13 RUBBER BAG TYPE CONSERVATOR 1 RB220-HDD HANSOL TECH / KOREA
14 RADIATOR 10 VR520-H2200-P34 HYUNDAI / KOREA
COOLING FAN
15 88+2
2 3PH 60HZ 208V 1/2HP TAIJIN / KOREA
(INCLUDING SPARE COOLING FAN 25%)
SILICAGEL BREATHER FOR MAIN

16 1 TJD-0167 (5KG) TAIJIN / KOREA
CONSERVATOR
SILICAGEL BREATHER FOR OTLC

17 1 TJD-0167 (1KG) TAIJIN / KOREA
CONSERVATOR
18 B.C.T TERMINAL BOX 10 6 POLE TAIJIN / KOREA

5.4 Outline for Power Transformers ( 1 / 3 )
No. Accessory
3,4 LV / LVN Bushing
10 O.L.T.C
24 P.R.D for Main Tank
25 P.R.D for OLTC
67 Vacuum Valve
96,97
, Pocket for WTI / OTI Sensor
98 Pocket for Spare
133 Core / Clamp Earth Device
138 LVN Earthingg Device

No
No. Accessory
1 HV Bushing
3,4 LV / LVN Bushing
21 Buchholz Relayy
41 Local Control Panel
110 Jack Pad with Pulling Eye
111 Man Hole for Side
112 Hand Hole for Bushing
115 Inspection Hole for Bottom
117 TR Base
Grounding
G di Pad
P d ffor M
Main
i
131
Body

No
No. Accessory
Gas Release Device for

22
Buchholz Relay
Oil Level indicator for Main /

35 36
35,36
OLTC Conservator
Breather for Main / OLTC
38,39
Conservator
Oil Drain
D i andd Lower
L Filtering
Filt i
61
Valve
62 Upper Filtering Valve
Oil Sampling
p g Valve for
71 72
71,72
Lower / Top Part

The Thermal Distributions
for both Oil Temperature and Winding Temperature ( 1 / 3 )
Average Winding Top Oil Temperature ; Top Oil Temperature ᅀΘWO x 1.3
Temperature 40.17 K = Oil Thermometer Ind.
ᅀΘWO
Core
Average Oil Temp.
; 28.32 K
Radiator Radiator ᅀΘWO Hottest spot Temp. =
Height
Winding Ther.
Hot spot Ind ; 62.19
Ind. 62 19 k
H
Coil
Average Winding
Temperature ; 45.26 K
Temperature
Bottom Oil Temp. Hot spot temperature above yearly The life of
Cooling Fan ; 16.47 K average ambient temperature transformer
110 °C 5 Years
Description IEC 60076 THE TROPICS
Max. / Yearly Average / Min. 104 °C
° 10 Years
Ambient Temperature 40 / 20 / - 20 °C 50 / 30 / - 5 °C
98 °C 20 Years
Temperature Rise 60 / 65 / 78 K 50 / 55 / 68 K
( Oil / Winding / Hot spot ) 92 °C 40 Years
Hot spot temperature above yearly 98 °C
average ambient temperature 86 °C 80 Years

Comparisons of transformer life losses ( IEC 60354 )

Location Season Spring Summer Autumn Winter Remarks
Average ambient 42 = 30 + 6 X 2
30 °C 42 °C 30 °C 18 °C
temperature 18 = 30 – 6 X 2
Hot spot
Tropical regions 68 K Full load
temperature rise
Ambient temperature Hot spot
98 °C 110 °C 98 °C 86 °C
Max. ; 50 °C temperature
Yearly ; 30 °C
12 Months
Min. ; - 5 °C Operating date 3 Months 3 Months 3 Months 3 Months
( 20 years )
18.75 Months
Actual life loss 3 Months 12 Months 3 Months 0.75
( ≈ 13 years )
20 °C 32 °C 20 °C 8 °C
Hot spot
IEC 78 K Full load
temperature rise
Ambient temperature Hot spot
98 °C
C 110 °C
C 98 °C
C 86 °C
C
Max. ; 40 °C temperature
Yearly ; 20 °C
12 Months
Min. ; - 20 °C Operating date 3 Months 3 Months 3 Months 3 Months
( 20 years )
18.75
18 75 Months
Actual life loss 3 Months 12 Months 3 Months 0.75
( ≈ 13 years )

Comparisons of transformer life losses ( IEC 60354 )
Location Season Spring Summer Autumn Winter Remarks

30 °C 42 °C 30 °C 18 °C
If transformers are operated under light load,
Hot spot
Tropical
op c regions
eg o s The hot spot temperature rise will be 62 K less than Light load
i
temperature rise
68 K.
Ambient temperature
Hot spot
Max. ; 50 °C 92 °C 104 °C 92 °C 80 °C
temperature
Yearlyy ; 30 °C
Min. ; - 5 °C 12 Months
Operating date 3 Months 3 Months 3 Months 3 Months
( 20 years )
9.375 Months
Actual life loss 1.5 Months 6 months 1.5 Months 0.375
( ≈ 26 years )
When hottest temperature is 80 °C, actual life loss can be calculated as below ;
Hottest temp. = 92 °C life loss = 1.5 months instead of operating date of 3 months.
Hottest temp.
p = 86 °C life loss = 0.75 months instead of operating
p g date of 3 months.
Hottest temp. = 80 °C life loss = 0.375 months instead of operating date of 3 months.
Therefore if hottest temperature is 80 °C, the actual life loss should be 0.375 Months instead of operating date of 3
months.
When the tensile strength
g of insulation paper
p p is reduced upp to 50% of the original
g strength,
g , the IEC explains
p that the
transformer should be discarded due to the thermal aging of insulation paper.

Dissolved Gas in Insulating Oil ( 1 / 5 )
H H H
Hydrogen Methane Ethane
H H H C H H C C H Type of Fault Main gases in Oil
H H H
Corona Sparking
p g Corona Hydrogen H2
H H H H H H H H
Methane CH4
C C C C Sparking
C C C C C Ethane C2H6
H H H H H H H H H H Heating Ethylene C2H4
Heating Arcing
H
Arcing Acetylene C2H2
H
C C H C C H
H H
Eh l
Ethylene A
Acetylene
l T
Temperature M i gases in
Main i Oil
C≡O O=C=O ≥ 105 ºC H2O, CO, CO2
Carbon monoxide Carbon dioxide
Heating ≥ 150 ºC H2, CH4
H OH CH2OH ≥ 250 ºC C2H6

O H H O
O ≥ 350 ºC C2H4
OH H H
H OH H ≥ 500 ºC C2H2
O O
H H
CH2OH H OH Molecule construction
Heating of
H–O–H Oil & solid insulation material
Water

DISSOLVED GAS ANALYSIS

Dissolved gases in insulation oil mainly occur due
to the deteriorations of transformer insulation
material
t i l causedd by
b the
th result
lt off electrical
l t i l or
thermal excess stress as follows ;
The first is the deterioration of solid insulation

material in the transformer.
transformer
The second is the deterioration of insulation oil.
It is recommended that analysis of dissolved gases

in the oil by gas chromatographic equipment is
made at after 1 month of operation and once every
year, normally.
The life of transformer is considered same as the

life of insulation material in the transformer.
It means when the tensile strength of the insulation
material is decreased by around 50 % of its
original value,
value the life of the transformer is
normally considered as finished.
Combustible Gas Generation versus
Approximate
pp Oil Decomposition
p Temperature
p
above 150 ºC

Fault types described in below table is taken from IEC 60599 of key gases, possible faults, and possible findings.
This table is not all inclusive and should be used with other information.
Fault Types ( 1 / 2 )
Key Gases Possible Faults Possible Findings
H2, possible trace of CH4 Partial discharge Weakened insulation from aging and electrical
and C2H6,
C2H6 possible CO CO. ( corona ).
) stress
stress.
Pinhole punctures in paper insulation with
H2, CH4 (some CO if discharges carbon and carbon tracking.
Low energy discharges
involve paper insulation). ( sparking and may be Possible carbon particles in oil.
oil Possible loose
Possible trace amounts of C2H6. static discharge ). shield.
Poor grounding of metal objects.
H2, CH4
H2 CH4, C2H6
C2H6, C2H4
C2H4, and the key
Metal fusion ( poor contacts in tap changer or
gas for arcing C2H2 will be present
lead connections ).
perhaps in large amounts.
High energy discharges Weakened insulation, from aging and electrical
If C2H2 is beingg generated,
g , arcing
g is
( arcing ).
) stress
stress.
still going on.
Carbonized oil. Paper destruction if it is in the
If paper is being heated, CO will be
arc path or overheated.
present.

Fault types described in below table is taken from IEC 60599 of key gases, possible faults, and possible findings.
This table is not all inclusive and should be used with other information.
Fault Types ( 2 / 2 )
Key Gases Possible Faults Possible Findings
Thermal fault less than Discoloration of p

paper
p insulation.
300 ºC in an area close to Overloading and / or cooling problem.
H2, CO.
paper insulation Bad connection in leads or tap changer.
( paper is being eaten ). Stray current path and / or stray magnetic flux.
Thermal fault between Paper insulation destroyed.

H2, CO, CH4, C2H6, C2H4.
300 ºC and 700 ºC. Oil heavily carbonized.
All the above gases and acetylene in High energy electrical Same as above with metal discoloration.
large amounts. arcing 700 ºC and above Arcing may have caused a thermal fault.

Fault Example or Possible cause

Discharges in gas-filled cavities resulting from incomplete impregnation, high humidity in
Partial discharge ( PD )
paper, oil supersaturating, and leading to X-wax formation.
Sparking
S ki or arcing
i between
b bad
b d connections,
i shield
hi ld rings,
i adjacent
dj disks,
di k conductors
d off
winding, broken brazing, closed loops in core.
Discharges of low energy Discharges between clamping parts, bushing and tank, HV and grounding within windings,
( D1 ) on tank walls.
Tracking in wooden blocks,
blocks glue of insulating beam
beam, winding spacers
spacers. Breakdown of oil,
oil
selector breaking current.
Flashover, tracking, or arcing of high local energy or with power follow-through.
Short circuits between LV and ground, connectors, windings, bushings, and tank, copper
Discharges of high energy
bus and tank,
tank windings and core,
core in oil duct,
duct turret.
turret
( D2 )
Closed loops between two adjacent conductors around the main magnetic flux, insulated
bolts of core, metal rings holding core legs.
Overloading of transformer.
Thermal fault, t < 300ºC
Blocked item restricting oil flow in winding.
winding
( T1 )
Stray flux in damping beams of yokes.
Defective contacts between bolted connections, gliding contacts, contacts within selector
switch, connections from cable and draw-rod.
Thermal fault, 300ºC < t
Circulating currents between yoke clamps and bolts,
bolts clamps and laminations,
laminations in ground
< 700ºC ( T2 )
wiring, defective welds or clamps in magnetic shields.
Abraded insulation between adjacent parallel conductors in windings.
Large circulating currents in tank and core. Minor currents in tank walls created by a high
Thermal fault,
uncompensated magnetic field.
field
t > 700ºC ( T3 )
Shorting links in core steel laminations.

Transformer Training (SNC Lavalin - District Cooling Project) - R01

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Transformer Training (SNC Lavalin - District Cooling Project) - R01

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Transformer Training

ELECTRO ELECTRIC SYSTEMS 1 www.hyundai-elec.com

1. Training Schedule ------------------------------------------------------------- I

3 Power Transformers ----------------------------------------------------------- 13

5. Specification for Power Transformer --------------------------------------- 159

ELECTRO ELECTRIC SYSTEMS 2 www.hyundai-elec.com

ELECTRO ELECTRIC SYSTEMS 3 www.hyundai-elec.com

ELECTRO ELECTRIC SYSTEMS 4 www.hyundai-elec.com

 1973 - Established as Hyundai Shipbuilding & Heavy Industries Co., Ltd.

 1978 - Renamed as Hyundai Heavy Industries Co., Ltd.

 1994 - Restructured Comprising Six Business Divisions

ELECTRO ELECTRIC SYSTEMS 5 www.hyundai-elec.com

 1973 Established as Electrical Department of Hyundai Shipbuilding &

ELECTRO ELECTRIC SYSTEMS 6 www.hyundai-elec.com

HYUNDAI HEAVY INDUSTRIES CO., LTD.

Electro Electric Industrial Plant

Offshore & Engineering Construction Green Energy

ELECTRO ELECTRIC SYSTEMS 8 www.hyundai-elec.com

ELECTRO ELECTRIC SYSTEMS 9 www.hyundai-elec.com

Power Transformer Distribution Transformer Cast Resin Transformer

Reactor Traction Transformer Tap Changer

ELECTRO ELECTRIC SYSTEMS 11 www.hyundai-elec.com

Furnace Transformer Rectifier Transformer Phase Shifting Transformer

ELECTRO ELECTRIC SYSTEMS 12 www.hyundai-elec.com

2 Constructions of Transformers -----------------------------------------------------------------------------------------------17

2.2 Windings --------------------------------------------------------------------------------------------------------------------- 20

2.3 Core & Coil Assembly -----------------------------------------------------------------------------------------------------24

2.5 Transformer Tanks --------------------------------------------------------------------------------------------------------- 28

2.6 Cooling System ------------------------------------------------------------------------------------------------------------- 30

2.7 Cooling Class Designation ------------------------------------------------------------------------------------------------ 36

ELECTRO ELECTRIC SYSTEMS 13 www.hyundai-elec.com

Fig. 1-1 Basic Diagram of Transformer

ELECTRO ELECTRIC SYSTEMS 14 www.hyundai-elec.com

ELECTRO ELECTRIC SYSTEMS 15 www.hyundai-elec.com

Where, f = Frequency (HZ)

ELECTRO ELECTRIC SYSTEMS 16 www.hyundai-elec.com

Raw material of core Cutting Slitting

ELECTRO ELECTRIC SYSTEMS 17 www.hyundai-elec.com

2/0 1/2 2/2 3/0 3/2

Fig. 2-1 Core form

ELECTRO ELECTRIC SYSTEMS 18 www.hyundai-elec.com

Core Construction (3/0) Core Cross Section View

ELECTRO ELECTRIC SYSTEMS 19 www.hyundai-elec.com

Flat type Single

CTC (Continuous Transposed Conductor)

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ELECTRO ELECTRIC SYSTEMS 21 www.hyundai-elec.com

Manufacturing the winding Sizing the winding

ELECTRO ELECTRIC SYSTEMS 22 www.hyundai-elec.com

Fig. 2-6 Winding Construction

ELECTRO ELECTRIC SYSTEMS 23 www.hyundai-elec.com

ELECTRO ELECTRIC SYSTEMS 24 www.hyundai-elec.com

After the core and coil assembly of transformers is

Fig. 2–8 b) Core & coil assembly

ELECTRO ELECTRIC SYSTEMS 25 www.hyundai-elec.com

ELECTRO ELECTRIC SYSTEMS 26 www.hyundai-elec.com

Fig. 2–9 Vacuum drying

ELECTRO ELECTRIC SYSTEMS 27 www.hyundai-elec.com