VENDOR DOC. NO.

D211-EKA-TTCL-004

TOTAL 197 SHEETS

(Included this page)

SERVICE : Power, Distribution, Unit Auxiliary, Auxiliary Transformer and NGR

DOCUMENT TITLE : Installation, operation and maintenance instruction manual

EGCO COGENERATION SPP REPLACEMENT PROJECT

EGCO Cogeneration Company Limited

TMSP SDN. BHD.

TTCL JOB ACCOUNT

NO. D-211 ___________

P/O No. : D211-520000-P0000002

21BAT10, 20BAT10, 20BBT10/ 21BBT10, 20BFT10/20BFT20,

Item No. :
20BBS10/ 21BBS10

Project Doc. No.: V-D211-21BAT10-YA-001 Rev. 3

FINAL

3 19-Dec-23 FINAL JITTIYA S. JITTIYA S. KORAKOD R. KORAKOD R.

2 28-Nov-23 FOR FINAL PORNTEP T. JITTIYA S. KORAKOD R. KORAKOD R.

1 10-Apr-23 FOR INFORMATION PORNTEP T. JITTIYA S. KORAKOD R. KORAKOD R.

0 19-Jan-23 FOR INFORMATION PORNTEP T. JITTIYA S. KORAKOD R. KORAKOD R.

REV. DATE DESCRIPTION PREP' D CHECKED APPROVED AUTH' D

VENDOR NAME : EKARAT ENGINEERING PUBLIC COMPANY LIMITED

Installation, Operation and maintenance

Service : Gas Turbine Generator Transformer

Tag no. : 21BAT10

Description : Gas Turbine Generator Transformer

11/118 kV, ONAN/ONAF 52/73 MVA, Oil Immersed, Conservator tank with
rubber bag

Ekarat Engineering Public Company Limited

9/291 U.M Tower, 29 Fl., Ramkamheang Road.,Suanluang Dis., Bangkok 10250
Tel : (+662) 719-8777 Fax : (+662) 719-8760
Website : http://www.ekarat.co.th
 CONTENT

SECTION TITLE
1 Transportation 6
1.1 Cautions for Transportation
1.2 Inspection and instruction on
Arrival at site
2 Before Installation 12
2.1 Storage
2.2 Inspection of packages and unpacking
 CONTENT

SECTION TITLE
3 Installation 18
3.1 Caution for transformer installation
3.2 Supervisor for work and safety measures
3.3 Preparation of tools, instruments and material
3.4 Flow chart for installation
3.5 Setting of the transformer on a bed
3.6 De-aerated oil filling up to the level above coil
3.7 Fitting of radiators
3.8 Fitting of mounts for bushing
3.9 Fitting of conservator
3.10 Fitting of cooling fan
3.11 Oil piping
3.12 Piping and wiring of electrical system
3.13 Fitting of bushing
3.14 Fitting of condenser type bushing
3.15 Fitting of solid type bushing
3.16 Oil filling and draining process
3.17 Caution for thermometer lead line
To enter in local control cabinet
 CONTENT

SECTION TITLE
4 Transportation 67
4.1 Inspection and test after installation
4.2 Field test after installation
4.3 Painting
4.4 Re-drying of the transformer at job site
4.5 Caution when energizing transformer
 SECTION 1
TRANSPORTATION
 Ref.No. : IE-12101
1.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSPORTATION Date : 24-Nov-09
CO., LTD. Page : 1 / 3

(1) Transportation on boat

Boat

The transformer and parts shall Transformer

be placed under deck of boat. (Fig. Fig. 1
1)

(2) Unloading at the port

Transformer shipped by boat will be unloaded at the main port of destination

using cranes, etc. Such unloading work should be executed by skilled workers and
it is desirable that a representative of the ultimate user should be present during
unloading operations.

Check against the following:

Fig. 2 (a) Contact of transformer against quay.

Fig. 3 (b) Radical contact of transformer against ground.
(c) Check if the nitrogen gas pressure inside the transformer
Fig. 4
is positive or not by the attached pressure gauge.

Use a steel wire having sufficient strength to lift the transformer, etc.
Hoist it by the lifting lugs specified by the transportation drawing.

Transformer

Boat
Transformer

Fig. 2

Designed by : I.TEERAWAT Checked by : M.Ochi Approved by : M.Ochi

 Ref.No. : IE-12101
1.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSPORTATION Date : 24-Nov-09
CO., LTD. Page : 2 / 3

Pressure gauge

Transformer

Transformer

Fig. 3 Fig. 4

(3) Transportation from the port to the substation. etc.

The transformer is transported to substation etc. by trailer or by other means.
It is undesirable to give severs shock to the transformer during transportation.
The traveling speed of the trailer should be regulated according to the conditions of
the road surface.

The normal speed is as follows:

- Completely paved road : 40 km/h, 25 mph or less
- Insufficiently paved road : 30 km/h, 19 mph or less
- Unpaved road : 5-10 km/h, 3-6 mph or less

When the transformer is shipped by rail, there is no problem while the train is
running, however attention should be paid to prevent shock during loading and
unloading work. It is undesirable to incline the transformer too sharply. The angle
of slope should be within 10° as illustrated in Fig. 5.
 Ref.No. : IE-12101
1.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSPORTATION Date : 24-Nov-09
CO., LTD. Page : 3 / 3

Transformer

Cargo train

10º

Fig. 5

It is better to install a tachometer on the trailer or the train or attach a shock meter to
the transformer itself. To measure the angle of slops of the transformer, use a plum
bob.
 1.2 INSPECTION AND Ref.No. : IE-11101
INSTRUCTIONS
Rev. : D
DAIHEN ELECTRIC Date : 23-Jan-07
CO., LTD. ON ARRIVAL AT SITE Page : 1 / 2

The transformer is transported in some sections, the main tank, bushings,

conservator, radiators, and other accessories. the dismantled accessories are
packaged in crates or boxes.

Immediately on arriving at site, the following examination should be made for any
damage sustained in transport, and a check for lost parts.

If injury or rough handling is evident, a damage claim should be filled.

(1) Check for gas pressure :

In order to prevent moisture impregnation, the main tank is filled with dry nitrogen gas.
(Approx. 0.2 kg./sq. cm. At 30 degree Celsius)

Remove the protective cover for the compound gauge mounted on the tank, and
open the connecting valve, and check the gas pressure. (After checking the
pressure, close the valve tightly.) Positive indication shows that air and / or water has
not entered into the tank.

If the point read zero, air ingress might happen. At this occasion, measure the
insulation resistance of windings to know the degree of moisture impregnation refer
to the "INSTRUCTIONS FOR INSPECTION AND MAINTENANCE" for the criterion
of moisture impregnation.
Measurement in low humidity atmosphere is preferable to prevent the live parts
from moisture impregnation. If the measured value is lower than the criterion, a
drying treatment will be required.

(2) Inspections for exterior :

(2.1) Check for damage
Check if the transformer was dropped accidentally, or reinforcements and
piping were distorted.

When a shock recorder is provided, check the records carefully after arrival at
site. If the recorded figures at all axis exceed 3 G, please contact DAIHEN
ELECTRIC CO.,LTD.

(2.2) Rust
When the painting is damaged or the metal parts are rusted, remove the rust
with a sandpaper, and coat with touch-up paint.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 1.2 INSPECTION AND Ref.No. : IE-11101
INSTRUCTIONS
Rev. : D
DAIHEN ELECTRIC Date : 23-Jan-07
CO., LTD. ON ARRIVAL AT SITE Page : 2 / 2

(2.3) Bolts and nuts

Check if the bolts and nuts are loosed. When the bolts fastening the covers or
valves are loosed, make measurement for insulation resistance mentioned above
(1).

(2.4) Inspection of impact recorder chart

Check the impact recorder chart before transferring the transformer and after the
arrival to the destination. If the recorded figure exceeds the following value,
please ask manufacture for further information.

- Vertically : 3 G
- Length-wise : 3 G
- Short-wise : 3 G
(3) Transport at site and unpacking
Refer to IE-12101 and IE-14101 in this instruction manual.

CAUTION :

Before removing a manhole cover, shipping plate, or other device, vent the
transformer to atmospheric pressure. Do not enter the transformer until the gas
space has been flushed with dry air, or a suitable oxygen (not less than 18% of
oxygen in the tank) supply is available for safety working.
 SECTION 2
BEFORE INSTALLATION
 Ref.No. : IE-21102
Rev. : A
2.1 STORAGE 18-Dec-09
DAIHEN ELECTRIC Date :
CO., LTD. Page : 1 / 1

It is recommended that the transformer will be put into service immediately in its
permanent location. If this is not possible, the following precautions must be taken
to insure the proper storage of the transformer.

(1) The transformer tank has been filled with dry nitrogen gas totally . When
stored for more than 4 months from the date of shipment, the transformer tank
should be filled with insulating oil up to the level lower than the tank cover by
about 25 cm. The gas space between the cover and the oil should be filled with
dry nitrogen gas.

As to the oil filling method , refer to clause IE - 41201 in this instruction . The
gas pressure must be checked periodically .
After fill with insulation oil up to the level lower than the tank cover by about
25 cm,the nitrogen gas will dessolve into insulation oil .
When nitrogen gas pressure deteriorated less than 0.1 kg/cm², the nitrogen
gas shall be supplemented.
The gas filling pressure ,refer as following.

(2) It is recommended that the transformer tank and accessories will be stored
indoor. The accessories would be stored in the boxes to avoid the loss of them.
When the accessories are taken out from the boxes, vinyl sheets covering the
accessories should not be removed.
When stored outdoor, cover totally the tank and accessories with strong water
proof sheets to prevent the water ingress. And lay wooden beams under the
tank and boxes. The tank and accessories should be stored in a dry and clean
location, free form corrosive gases or fumes.

(3) When painted surface is damaged, retouch with attached paint.

Designed by : S.Winyou Checked by : TEERAWAT Approved by : M.OCHI

 Ref.No. : IE-14101
2.2 INSPECTION OF Rev. : -
DAIHEN ELECTRIC PACKAGES AND UNPACKING Date : 20-Jan-04
CO., LTD. : 1 / 4
Page

It is necessary to inspect the number of packages and unpack these in the presence
of a representative of your company and our technical staff in the
following manner.

(1) Checking of the number of packages

When the packages etc. are brought into the installation site it is necessary to
inspect the number of packages and the appearance of each, before unpacking
them. Check the number of packages against the packing list prepared by our
company or our agent.
If any package is missing; take steps to have it found or replaced.
(2) Inspection of the appearance of package
At the time of inspection of the number of packages, also inspect their
appearance. Check the damage to packing, exposure of contents etc. visually.

Especially to the packages opened at the time of custom clearance, this should
be carried out most carefully, As to the packages damaged or packages whose
contents are missing, take the necessary action regarding an insurance claim and
take pictures to cover a future claim for insurance money.
(3) Unpacking

When the checking of the number of packages and inspection of the appearance
is over, open the packages. Unpack the wooden boxes carefully by using pincers
so that the contents are not damaged. As far as possible avoid the use of a crow
bar. After unpacking a wooden box, or cardboard box etc. inspect the number
and appearances of the parts according to (1) and (2).

Crow bar
Pincer

Fig. 1
Unpack the package holding bushing carefully according to the following
method, and using care not to damage the contents.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-14101
2.2 INSPECTION OF Rev. : -
PACKAGES AND UNPACKING 20-Jan-04
DAIHEN ELECTRIC Date :
CO., LTD. Page : 2 / 4

Ceiling
When the package is longer in
Cover the upright position as shown by
the figure at left, do not lay it down
Inner partition in a horizontal position but open it
board in upright position according to the
following.

Use pincers but not crow bars.

- Remove the ceiling.
Fig. 2 - Remove the cover.
- Draw out the inner partition board.

As for the handling of bushing

after unpacking refer to the
" instructions for bushing"

Cover

inner partition boad

inner partition boad

Support
- Do not cut
Fig. 3

When the packing is an inclined package as shown above, do not cut off the
supports but draw out the nails by pincer and remove the cover and inner
partition board while keeping it in the inclined position. Do not use a crow bar.
As for the handling of bushing after unpacking, refer to the instructions for
bushing.
 Ref.No. : IE-14101
2.2 INSPECTION OF Rev. : -
DAIHEN ELECTRIC PACKAGES AND UNPACKING Date : 20-Jan-04
CO., LTD. Page : 3 / 4

Cover

Inner partition board

Fig.4

When the package is a horizontal type as shown above, draw out nails by pincers
and remove the cover and inner partition board. Do not use a crow bar.

(4) Rearrangement and accommodation

When the parts are taken out of the packages, rearrange them and
accommodate them in a safe place to prevent damage. Radiator, pipes, etc.

May be stored out-doors with sufficient protection to preclude the possibility of

damage but small parts such as a thermometer should be stored inside a building .
The drums of insulating oil for the transformer should be stored out -doors in a
horizontal position with their filling holes aligned horizontally . (to see Fig.5)

No good No good

Fig.5 Fitting holes should

be aligned horizontally

Good
 Ref.No. : IE-14101
2.2 INSPECTION OF Rev. : -
DAIHEN ELECTRIC PACKAGES AND UNPACKING Date : 20-Jan-04
CO., LTD. Page : 4 / 4

In storing the radiators vertically, do not arrange them in more than 3 levels.
Prevent damage by inserting wood blocks in between the radiators. (Fig.6)

Wood

Aligned vertically
Fig.6
 SECTION 3
INSTALLATION
 Ref.No. : IE-13404
3.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSFORMER INSTALLATION Date : 20-Jan-04
CO., LTD. Page : 1 / 4

1) Work in the tank

When opening the transformer tank, precaution must be taken to prevent the moisture.
If wet air enters the transformer, it may be cooled by the tank wall below its dew point
and condensed, so it will lower the dielectric strength of the transformer.
Do not enter the transformer tank until the nitrogen gas has been entirely dissipated.
When working in the tank, take care especially not to drop tools or foreign substances.
It is recommended that tools used in the tank are tied to worker with a cord. Worker
should not carry anything unnecessary in the tank.
Care should be taken to see that all nuts, bolts, and lead connections are tight and all
parts in their right places.
Check the internal terminal connections.
When the work in the tank is completed, the inside of the tank should be inspected.
Check that it is clean and no foreign substances are left behind. For inside cleaning,
the dry, clean, and lint-free clothes should be used.

2) Lifting and transportation of the main tank

The main tank must be lifted by the same manner as IE-12101. When the transformer
is skidded, moved on rollers or jacked up, take care not to injure the base and not to tip
over the transformer. The transformer is also equipped with jacking bosses . Jacks
should be placed under the jacking bosses . The transformer should never be lifted or
moved with jacking up the radiators or other accessories . When rollers are used , skids
must be placed between the base and the rollers to distribute the stress .

3) Lifting of accessories
Position and direction of the accessories and other parts should be according to the
transformer drawing exactly. Before fitting them, read the instructions completely.
Mishandling will result in damage to the accessories.

Treatment of gasket joints at site

In order to perfect the seal effect of gasket joints, following treatments should be
done at site.

3.1) Gasket of Cork - Nitrile - Rubber (CN-PG)

a) Clean the flange surface with thinner and clothes and remove the moisture, oils
and fats, stains and others.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-13404
3.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSFORMER INSTALLATION Date : 20-Jan-04
CO., LTD. Page : 2 / 4

b) Apply the liquid gasket (Super Three Bond 1215) to both sides of CN-PG,
smoothly and uniformly.
c) Then, attach the separated parts to their positions with gasket.
d) Start of oil filling should be more than 24 hours after applying the liquid gasket .
e) If temporary fixing of gaskets are needed for vertical or inclined joints , apply the
adhesive ( Cemedine 501 ) around the gasket (refer to Fig.1) Cemedine 501 is
included in our packing .

Super Three Bond 1215

( x maker )
CN - PG 5 5 5 5
xxxx
CN - PG
xxxxxxxxx

xxxx
xxxxxxxxx

Flange (mm.) 5 5
5 5
(mm.)
Cemedine 501
( o maker ) Fig. 1

3.2) Gasket of Nitrile - Butadiene - Rubber (NBR-PG)

a) The liquid gasket ( Super Three Bond 1215 ) should not be applied to NBR -PG.
b) Clean the flange surface with thinner and clothes and remove the moisture, oils
and fats, stains and others.
c) Then, attach the separated parts to their positions with gasket.
d) If temporary fixings of gasket are needed for vertical of inclined joints , apply the
adhesive ( Cemedine 501 ) around the gasket by spot-applying and after 2 or 3
minutes drying, attach them to the flanges. (refer to Fig.2)

NBR - PG

Flange Fig. 2

Cemedine 501
( o maker )
 Ref.No. : IE-13404
3.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSFORMER INSTALLATION Date : 20-Jan-04
CO., LTD. Page : 3 / 4

4) Fastening with bolts and nuts

Each bolt and nut should be screwed rigidly. But in order to avoid the bolts and
nuts broken, pay attention not to over tighten.
Fasten the bolts and nuts under suitable torque as follows by measuring torque
wrench or torque meter.

Size of Bolt Suitable Torque for Fastening

M10 249 ~ 303 (kg.cm)
M12 434 ~ 529 (kg.cm)
M16 1080 ~ 1310 (kg.cm)
M20 2100 ~ 2560 (kg.cm)
M22 2860 ~ 3490 (kg.cm)
M24 3620 ~ 4420 (kg.cm)

5) Fastening of stud-bolts
Each stud-bolt should be screwed rigidly. But in order to avoid the stud-bolt broken,
fasten the stud-bolt under suitable torque as follows by measuring torque wrench or
torque meter.

Size of Stud-Bolt Suitable Torque for Fastening

M12 500 ~ 600 (kg.cm)
M16 1100 ~ 1300 (kg.cm)
M20 2100 ~ 2500 (kg.cm)
 Ref.No. : IE-13404
3.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSFORMER INSTALLATION Date : 20-Jan-04
CO., LTD. Page : 4 / 4

6) Water protection by the silicone

6.1) Radiator valve position

Upper side Silicone

Tank side Radiator side

Lower side

6.2) Thermometer position

Thermometer

Silicone

Terminal box

Silicone
 Ref.No. : IE-15101
3.2 SUPERVISION FOR WORK Rev. : -
DAIHEN ELECTRIC AND SAFETY MEASURES Date : 23-Dec-03
CO., LTD. Page : 1 / 6

(1) Supervision of work

To execute assembly work of transformer at site smoothly and accurately
the supervision of work must be clearly established.
For reference purpose, we illustrate below the supervision of work we have
been adopting.

Customer like
Our company
your company
Supervisor Engineer, Person-in-charge

Leader of working party

Work chief

Workmen

As illustrated above, our supervisor makes arrangements with your engineer,

person-in-charge, on details of field assembly of transformer and determines
how to proceed with field work. Then the supervisor explains to the leader of
working party details on how to proceed with work, method, cautions, etc.

The leader in turn assigns a specific part of the work to each workman, and
then the working party executes.

It is not desirable that an instruction is given to a workman directly from the

supervisor, without informing the leader.
In the case of large work, when several leaders are to be arranged,
supervision of work should follow the illustrated pattern.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-15101
3.2 SUPERVISION FOR WORK Rev. : -
DAIHEN ELECTRIC AND SAFETY MEASURES Date : 23-Dec-03
CO., LTD. Page : 2 / 6

(2) Safety measures for working

It is necessary to take safety measures in order to secure personal safety
during field work and to prevent machine parts from being damaged. We
shall deal with matters that demand special attention, mentioning some major
items.

a) Work at an elevated place

In the case of assembling the transformer much work is done at elevated

places.
Therefore, it is necessary to take the following measures in order to prevent
an accident such as a fall by a workman, or an accident caused by a falling
object or collapsing scaffold.

For work to be done at an elevated place, build up a strong scaffold with

metallic pipe or timber, and be sure to provide it with a means of safe ascent
and descent.
For such work in which a scaffold can not be used, it is necessary for the
workman to use a safety belt.
When the transformer tank cover gets covered with oil, rainwater, etc., it is
necessary to clean it, otherwise a workman might lose his footing and fall.
Because work at elevated places is always dangerous because of the
possibility of falling, this has the danger of causing more serious accidents.
Therefore, it is necessary to take a forward-looking attitude of taking positive
safety measures even if these measures may be troublesome when work is
going smoothly.

b) Work inside the transformer tank

Lack of oxygen
Shortage or lack of oxygen may take place inside the transformer tank
because nitrogen gas which is sealed into it for the purpose of transportation
still remains there or ventilation inside the tank is insufficient.
 Ref.No. : IE-15101
3.2 SUPERVISION FOR WORK Rev. : -
DAIHEN ELECTRIC
AND SAFETY MEASURES Date : 23-Dec-03
CO., LTD. Page : 3 / 6

Therefore, when connection work or inspection work is to be done inside the

tank, it is necessary to takes measures against accidents caused by lack of
oxygen.

First of all, measure the concentration of oxygen inside the tank by means of
the oxygen densitometer, confirm that the oxygen concentration is more than
18% and record the concentration value.
Working lamp
Next, it is necessary to use working lamp having a sufficient intensity of
illumination for safety and to facilitate work inside the tank.
A working lamp with guard is recommended in order to prevent a workman
from receiving an electric shock as well as to protect the bulb from damage
due to unintentional knocks. Oil proof lead wire is recommended.
The lower the voltage of working lamp the better it is, for safety.
Pay attention to the above-mentioned points, and carry out work inside the
transformer tank.
Moreover, prohibit one man work inside the tank, and station a watch at a
place from where he can see workmen.
Finally, consider the fastening of a rope to each workman who enters the
transformer tank.
This can be used in an emergency. The rope would be the means of
rescuing a workman and would be pulled form the outside.

c) Lifting and lowering of heavy parts

Usually a crane car is used to raise and lower the parts at the time of
assembling the transformer.
Our company adopts a practice of requiring the operator of crane car to
submit to us the operator's license and maintenance check list of his crane
car.
The sling work, we likewise require this work to be executed under the
command of a qualified sling workman who has a license to this effect.
We think that the control corresponding to our practice stated above is
necessary in your country, too.
Prior to the work being done with the crane car, be sure to try a trial
suspension.
 Ref.No. : IE-15101
3.2 SUPERVISION FOR WORK Rev. : -
AND SAFETY MEASURES
DAIHEN ELECTRIC Date : 23-Dec-03
CO., LTD. Page : 4 / 6

In the case of a large article to be suspended or in the case of suspension in

a narrow place, it is recommended to attach a long rope to the suspended
article so it does not spin in suspension and so as to guide it into the desired
place.

In the case of lifting an article under the horizontal condition or in the case of
fine adjustment in lowering, it is recommended to use a chain block together
with crane car.

Chain
block

d) Clothes for workmen

d.1) Clothes for workmen
- The head : Put on The prescribed helmet marked with The name of
Our company and name of workman, and be sure to fasten The chin
strap.

- Eyes : When work is to be done with a grinder or when a chemical is

to be used, put on the prescribed protective glasses made of acrylic
resin.
- The upper half of the body : Wear the long-sleeve jacket prescribed
by our company, and put the workman's name card on the left breast.
- The lower half of the body : wear the trousers prescribed by our
company.
- Hands : It is in order to put on a pair of working gloves; however,
when touching the transformer interior, tap-change, etc., do so with
naked hands.
- Feet : Wear the leather laced boots prescribed by our company, and
put the cuffs of trousers into the boots.
 Ref.No. : IE-15101
3.2 SUPERVISION FOR WORK Rev. : -
DAIHEN ELECTRIC AND SAFETY MEASURES Date : 23-Dec-03
CO., LTD. Page : 5 / 6

d.2) Clothes for welding work

In the case of welding work, a welder should wear a protector in
addition to the above-mentioned clothes for field workmen.

d.3) Clothes for special works

In the case of work to be done inside the transformer and work on the
indoor panel, it such work is difficult to do wearing the above-
mentioned clothes, it is in order to put on the cloth working cap and
canvas shoes instead of the helmet and leather laced boots with
permission of customer's person in charge and field work responsible
person of our company.

It is also recommended to wear in addition a dry vinyl waterproof

when working inside the transformer tank.

d.4) Clothes for painting work

When engaging in painting work, it is in order to put on a cloth

working hood an rubber boots instead of the helmet and leather laced
boots after obtaining permission from the customer's person in charge
and field work responsible person of our company to carry out painting
work with painter's mask.

e) Electric shock preventive measures

Field work responsible person is required to call workmen's attention to
the following :

e.1) Not to handle anything long in the neighborhood of the high-tension

charging part. However, in case such handling is unavoidable, carry
anything long by two or more persons with the permission of the field
work responsible person.

e.2) A workman should not come within a less distance than show in the
following table from any high-tension part:
 Ref.No. : IE-15101
3.2 SUPERVISION FOR WORK
Rev. : -
AND SAFETY MEASURES
DAIHEN ELECTRIC Date : 23-Dec-03
CO., LTD. Page : 6 / 6

In cases where approach as to the high tension part is unavoidable, he

should take the necessary measures to be safeguarded against an
electric shock following instructions from a field work responsible
person prior to working near a high-tension area.

Nominal Voltage (kV) Off-limits Distance (cm)*

3-6 80
11-22 100
33-44 120
60-70 140
154 250
257 400

* Distance from the high-tension part for workmen to whom a warning

should be given by field work responsible person.
 Ref.No. : IE-81101
3.3 PREPARATION OF TOOLS, Rev. : A
DAIHEN ELECTRIC INSTRUMENTS AND MATERIALS Date : 21-Dec-03
CO., LTD. Page : 1 / 6

The items, specifications and requirements for all tools and materials
required for assembling, inspection and testing of transformer are listed below.

(1) Tools required for assembling

(a) Crane car

It is convenient to use crane car to fix
radiator, conservator, etc. Crane car having
hoisting capacity of 10 ton and beam length
of about 10 m is suitable. Skilled operator
must operate the crane car.
Before hoisting the parts, suspend a cargo
having similar weight as the part to be
suspended to check if it operates correctly.

(b) Oil bath made of steel sheet

Before oil filling of the transformer, transfer
the oil in a drum into the oil bath. The proper
capacity of the oil bath is about 20 % of the
total quantity of oil for the transformer when
the rated voltage of the transformer to be
assembled is less than 100 kV.
When the rated voltage of the transformer is
100 kV and above, it is better to use an oil
bath having a capacity equivalent to the total
oil quantity, because it is preferable to drain
the entire quantity of oil from the transformer
following a total filling.
When the capacity of one oil bath is
insufficient, use several of them.
The internal surface of the oil bath should
be clean being free from moisture and dirt. It
should be a sealed bath which prevents
infiltration of rain or outside air even when it
is installed outdoors.
Transparent pipe If the oil bath allows entry of air, attach a
container holding silica-gel at the air passage
to prevent entry of moisture air. It is
convenient if an oil level indicator or a
transparent pipe is attached.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-81101
3.3 PREPARATION OF TOOLS, Rev. : A
DAIHEN ELECTRIC INSTRUMENTS AND MATERIALS Date : 21-Dec-03
CO., LTD. Page : 2 / 6

(c) Oil filter press

Use oil filter press to transfer oil from the
drum to oil bath. Use a thoroughly dried
fresh filter paper for the oil filter press as the
duty of the press is to remove fine dirties or
moisture contained in the oil.
Usually a capacity of 5-10 kl/h is
appropriate for such an oil filter press.

(d) Oil purifier

Use oil purifier to transfer oil from oil bath to
VC the transformer.
The main duty of the oil purifier is to

VP SP eliminate gas contained in the oil.

It also eliminates moisture and dirt.
F
Therefore the oil purifier must comprise
vacuum pump, heater, filter, injection pump,
etc.
H
Usually the purifier having a capacity of
2000 - 5000 Lt./h is used.
EP FP
Carry out test run before oil filling into the
Oil bath transformer to drain residual oil in the oil
Trans. purifier and clean up the inside.
VP : Vacuum pump
VC : Vacuum chamber
SP : Spray pump
EP : Extraction pump
F : Filter tank
H : Heater
FP : Filter pump
 Ref.No. : IE-81101
3.3 PREPARATION OF TOOLS, Rev. : A
DAIHEN ELECTRIC INSTRUMENTS AND MATERIALS Date : 21-Dec-03
CO., LTD. Page : 3 / 6

(e) Vacuum pump

Usually the vacuum pump with
displacement of about 3000 l/min is used.

Transformer (f) Nitrogen gas cylinder

Nitrogen gas cylinder should be equipped
with reducing valve, meter and rubber hose.

(2) Instruments for inspection and testing

Conduct inspection and testing during and
after assembling work of the transformer by
using the following apparatus.

(a) Oil tester

Test all item are as appendix 1

The measurement should be roughly as

follows :
* Select several drums out of drum pool and
test them.
* After filling oil bath with oil and
immediately before it is pumped into the
transformer.
* After transformer is filled with oil. Take
sample from the bottom of the drum. Judge
the test results against ASTM, BS or other
equivalent standard.
Appendix 1 Page 1/2

1. Transformer oil test : Dielectric breakdown, Neutralization

number, Interfacial tension. Moisture content, Power factor
and Colour check
- After electrical test
1.1 Dielectric breakdown
Objective Before and after oil filling, and intermediately before the induced overvoltage and
separate source voltage withstand tests

Acceptance criteria
More than 30kV for average value

Standard reference
IEC 60156 (1995)

1.2 Neutralization number ( Sampling by Ekarat and submit to EGAT Lavatories)

Standard reference ASTM D 664-95

Acceptance criteria
Limit (Max) 0.20 mg KOH/g

1.3 Interfacial tension ( Sampling by Ekarat and submit to EGAT Lavatories)

Standard reference ASTM D 971

Acceptance criteria
Limit (Min) 25.0 mN/m

1.4 Moisture content

Objective For checking water mixed in transformer oil

Procedure 1 Sampling oil from main tank into water content tester
2 Set timer 10 – 15 Sec for testing
3 Test result will be record by tester ( PPM)

Acceptance criteria
< 35 PMM

Standard reference
ASTM D 1533

1.5 Power factor

Standard reference ASTM D 924

Acceptance criteria
< 0.5% @ 25 ºC

1.6 Colour test ( Sampling by Ekarat and submit to EGAT Lavatories) Standard
reference ASTM D 1500

Acceptance criteria
Limit (Max) 2.50
Appendix 1 Page 2/2

2. Transformer oil test : Dissolved gas analysis (DGA) test

- After electrical test
- After energized 1 month and 6 month

Objective Dissolved gas in oil shall be analyzed by automatic dissolved gas in oil analyzer. Oil
shall be collected from filter valve at time of before any tests and after dielectric
tests and temperature rise tests.

Standard reference
ASTM D3612-02 (2009)

Acceptance criteria
No C2H2
 Ref.No. : IE-81101
3.3 PREPARATION OF TOOLS, Rev. : A
DAIHEN ELECTRIC INSTRUMENTS AND MATERIALS Date : 21-Dec-03
CO., LTD. Page : 4 / 6

(b) Volt meter

An A.C. Voltmeter is required for the
following test.
* Ratio test
* Polarity test
* Sequence test of control circuit
One set of each of the following double
range precision meters for AC are required.
AC 150/300 V ......................... 1 set
AC 30/75 V ......................... 1 set

(c) Ammeter
One set each of the following precision
double range ammeter are required for
measurement of exciting current when low
voltage is impressed on the transformer and
for measurement of current of auxiliary
apparatus of the transformer such as cooling
fan, oil pump, etc. If they are equipped on
the transformer.
AC 20/100 mA ...................... 1 set
AC 10/50 A ...................... 1 set

(d) Double bridge

This is required to test the winding
resistance etc. of the transformer.
Measuring range of 0.001Ω - 10 Ω is required.
Kelvin double bridge as appropriate.
Batteries should also be made ready.
 Ref.No. : IE-81101
3.3 PREPARATION OF TOOLS, Rev. : A
DAIHEN ELECTRIC INSTRUMENTS AND MATERIALS Date : 21-Dec-03
CO., LTD. Page : 5 / 6

(e) Megger
Megger is used for measurement of
insulation resistance.
Manually operated megger having rating of
about 2000V and 2000MW as appropriate.

(f) Universal tester

This is the portable tester which can
measure AC voltage, resistance and DC
current by changing the range.

It is used for the checking of control wiring

or electric items.

(g) Testing transformer

It is used for dielectric test of the
transformer. The capacity of testing
transformer is determined by a calculation
based on the ground static capacity
described in the table of test results supplied
It is better to use one having ample
allowance.
Impressed voltage and impressing time
shall be determined by ANSI standards, BS
standards, etc. Which apply to the
transformer.

(h) Phase rotation meter

This is the meter to check the direction of
phase rotation of three-phase electric motor,
etc.

(i) Vacuum gauge

It is necessary to have a vacuum gauge for
the measurement of the degree of vacuum
raised during the operation of the vacuum
pump.
Macleod or Pirani gauge should be used.
-2
It should be able to measure up to 10 mmHg.
 Ref.No. : IE-81101
3.3 PREPARATION OF TOOLS, Rev. : A
DAIHEN ELECTRIC INSTRUMENTS AND MATERIALS Date : 21-Dec-03
CO., LTD. Page : 6 / 6

(j) Pressure gauge

To inspect the leakage of pressurized oil

after assembling of transformer, a pressure
gauge is required. Borden tube type gauge
(compound gauge) having a measuring
range of 0-1.0 kg/cm2 is required.

(k) Others
Instruments necessary of executing a
temperature rise test, measurement of
dielectric loss tangent (d), noise test
and High voltage test should be
obtained.

(3) Tools
(a) Drum opener
(b) Screw driver for cross recessed head screws
(c) Screw driver for slotted head screws
(d) Scissors
2
(e) Compression pliers (for 2.0, 3.5, 5.5, 8.0mm )
(f) Pliers
2
(g) Wire stripper (for 2.0, 3.5, 5.5, 8.0mm )
(h) Jack with capacity of 10 t
(i) Monkey wrench 6", 8", 10", 12"
(j) Spanner
(k) Pincer.
 Ref.No. : IN-10013
3.4 FLOW CHART Rev. : C
DAIHEN ELECTRIC
FOR INSTALLATION Date : 19-Jan-09
CO., LTD. Page : 1 / 1

Order of installation for transformer is shown bellows.

SET TRANSFORMER ON BASE

Yes
Note
No
FIT COMMON PIPES OF RADIATOR Note :
In case of oil filling
VACUUM TREATMENT under vacuum up to level
above coil from factory.
(#1) OIL FILLING UP TO LEVEL ABOVE COIL

FIT MOUNTING BRACKETS

FOR ACCESSORIES
Caution :
FIT RADIATOR On process (#1) to (#2).
Every day before finish the
FIT MOUNTING FOR ALL BUSHINGS
day work, the transformer
FIT CONSERVATOR tank shall be filled with dry
nitrogen gas to prevent
ASSEMBLY PIPES OF OIL CIRCUIT moisture inside.

FIT ALL BUSHINGS

VACUUM TREATMENT FIT OTHER ACCESSORIES

OIL FILLING UP TO ASSEMBLY WIRING PIPES

OIL LEVEL-OIL TEMP CURVE

CHECK OIL TIGHTNESS FIT COOLING FANS

DRAIN OIL AND FILL NITROGEN GAS CONTROL WIRING

VACUUM TREATMENT TOUCH UP PAINT

(#2) FINAL OIL FILLING

CHECK FOR INSTALLATION

ELECTRIC FIELD TEST

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : ED-IM 17111
3.5 SETTING OF THE Rev. : -
DAIHEN ELECTRIC TRANSFORMER TANK ON A BED Date : 17-Dec-03
CO., LTD. Page : 1 / 1

(1) On bed

Install the transformer at the specified location at a substation or power station.

Take care not to incline the transformer too sharply, and prevent it from shocking
during installation work. The foundation should be able to bare the load and the
vibration of an earthquake. Since the center of the transformer is marked ( ↓ ) at the
bottom side, line it up to the center of the specified installation site. To adjust the
perpendicular alignment of transformer, use the markings at the top and bottom of the
transformer and check with a plumb bob, etc. If it is not perpendicular, insert thin iron
plates at an approprite point to adjust it perpendicularly.

(2) Fixing of transformer (when anchor bolts are attached)

Install the transformer with attached anchor bolts at the correct position in the way
previously stated and then fix the anchor bolts with cement. After a few days, when
the cement is sufficiently dry, again clamp the anchor bolts and secure them.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref. No. IE-41201
3.6 DE-AERATED OIL FILLING Rev. A
DAIHEN ELECTRIC
UP TO THE LEVEL ABOVE Date : 15-Jan-09
CO., LTD. THE COIL Page 1 / 2

To prevent direct contact of coil and insulator with atmosphere during

assembling of transformer, it is desirable to fill with the insulating oil first up to
the level about 25 cm below the tank cover.

It is necessary to carry out dielectric strength test of insulating oil stored in the
drums before oil filling.

Take samples from each drum and check whether they have specified
dielectric strength. If the oil does not have specified dielectric strength, filter the
entire oil content. Oil filling should be carried out only after its dielectric strength
reaches the specified value.

There are two methods to carry out oil filling. The first method is to fill with oil
through the drain valve while discharging gradually the nitrogen gas filled in the
tank. (see Fig. 2) The nitrogen gas pressure in the transformer tank should be
kept the value of from 0.05 to 0.2 kg/cm2 during oil filling.

The second one is to do oil filling after vacuuming the transformer. (See Fig. 3)
This method is superior to the first one.

approx. 25 cm
Insulating oil

Tank
Coil

Fig. 1

Designed by : S.Winyou Checked by : I.TEERAWAT Approved by : I.TEERAWAT

 Ref. No. IE-41201
3.6 DE-AERATED OIL FILLING Rev. A
UP TO THE LEVEL ABOVE
DAIHEN ELECTRIC Date : 15-Jan-09
CO., LTD. THE COIL Page 2 / 2

Discharging N2 gas
Compound gauge

Oil purifier with

de-aerator Oil filter press
Transformer

Oil tank Drum

Drain valve

Fig. 2

Compound gauge

Transformer

Connect to oil line

Vacuum (same as above)
pump
Fig. 3
 Ref.No. : IE-61202
Rev. : A
3.7 FITTING OF RADIATORS
DAIHEN ELECTRIC Date : 24-Dec-03
CO., LTD. Page : 1 / 4

1. Fitting of radiators :

Radiators are shipped separately. Blank covers are attached to the openings
of radiators and radiator valves to prevent moisture. Radiator valve is located on
each radiator connection so that any individual radiator may be removed in time
of necessity without lowering the oil level of the transformer tank.

As each radiator has an oil drain plug and an air relief plug, it is easy to drain
the oil individually.
The radiator withstands the same vacuum (full vacuum) and pressure condition
as the main tank.
Radiators should be handles carefully to prevent bending or puncturing the
panels.

Position number is stamped on the upper header of each radiator and this
should be matched with the position number stamped on the flange on the main
tank side. Fit the radiator according to the following procedures.

(1) Hoist the radiator from the stored position, and pay attention not to
damage other radiators with the hoisting tools.
(2) Remove the blank cover and gasket on the radiator.

(3) Inspect the inside of the radiator visually.

(4) Clean the fitting flange surface of the radiator.

(5) Remove the blank cover and gasket on the radiator valve of the
transformer.
(6) Clean and paint the flange surface of the radiator valve (See Fig. 1)
(7) Clean the gasket groove of the valve. Apply a small amount of adhesive
to the groove and fit the specified new gasket.
(8) Hoist the radiator by crane car with the side of the flange on which the
number is stamped showing upward.
(9) Pull the radiator by hand, incline it and drain the residual oil inside the
radiator. (See Fig. 3)
(10) Fit the radiator to the radiator valve.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-61202
Rev. : A
3.7 FITTING OF RADIATORS
DAIHEN ELECTRIC Date : 24-Dec-03
CO., LTD. Page : 2 / 4

(11) Match the radiator valve and the flange surface of the radiator and
clamp them by nuts. (See Fig.2)
(12) Clamp the pair of nuts located diagonally one after another in order to
clamp evenly. (See Fig. 4)
(13) Clamp them tightly until the radiator valve and radiator flange closely
match with each other.

2. fitting of the radiator supports :

When radiator fitting is over, attach the supports and the fasteners of the
radiator symmetrically as shown in fig. 5 and 6

(1) Fit the supports (E) at the transformer tank wall. (since the radiator in
outer and obstacle for fitting the supports (E) , it is preferable of fitting the
radiator) before.

(2) Put the fasteners (A) and (B) on the upper side of the radiators and put
(C) under the lower side (see Fig.7)
(3) Set jacks under the support (C) and jack up until the radiator may be
vertical (see Fig.6)
(4) Keeping the radiators vertical, joint the supports (E) to the support (C)
and fix with nut.

(5) Tank off the jacks.

Clean and repair with rust-

proof paint if the paint is
defoliated

Clean surface

Fig. 1
 Ref.No. : IE-61202
Rev. : A
3.7 FITTING OF RADIATORS
DAIHEN ELECTRIC Date : 24-Dec-03
CO., LTD. Page : 3 / 4

Match this surface

Transformer side Radiator side

Radiator valve
Fig. 2 Clamp it until there is
no clearance

Stemp of number
Radiator

Fig. 3

Incline and
drain residual
oil.

Clamp the pair of nuts located diagonally

one after another as shown left.
So that they should be clamped uniformly.

Fig. 4
 Ref.No. : IE-61202
Rev. : A
3.7 FITTING OF RADIATORS
DAIHEN ELECTRIC Date : 24-Dec-03
CO., LTD. Page : 4 / 4

(B)
(A)

Radiator
(C)
(E)

Transformer Wooden block

Jack
(C)

Fig. 6

Fig. 5 (A),(C)

(B)

Fig. 7

3. Operation of radiator valve :

Remove the protective cap located on the side of the valve. Turn the valve
stem with a spanner to desired position. Then attach the cap and bolt it. It is
desirable to change gasket with new one every time the cap is removed.

O S O S

Shut (Close) Open

Fig. 8
 Ref.No. : IE-62701
3.8 FITTING OF MOUNTS Rev. : -
DAIHEN ELECTRIC FOR BUSHINGS (GENERAL) Date : 20-Jan-04
CO., LTD. Page : 1 / 2

The mechanism of the transformer which may be equipped with the mount is
showing Fig. 1.
Do not give severe shock to the mount since the current transformer is often
located in it.

(1) Check the stamp indicate which phase the mount is fitted to . (See Fig. 2)
(2) Open the CT terminal box attached to the mount and measure the insulation
resistance of CT. It should be 200 MΩ and above.
(3) Remove the top and bottom blank cover of the mount, pass the insulated
wire into CT and check the polarity of CT for all taps . (See Fig. 3) The
polarity is shown in the nameplate .

(4) Carefully remove the blank cover on the mount fitting flange, and also
remove gasket. (On the transformer side).
At this time, pay attention not to let bolts, nuts, tools and dirt fall into the
transformer.
(5) Clean the flange part by sand paper, and apply a small amount of adhesive
to the surface, and fix the new gasket.
(6) Hoist the mount by crane car and pass the lead wire through the central
hole of it. (See Fig. 6)
The lead wire is fixed in the transformer by tape during transport. When
drawing up it, remove the tape and pay attention not to damage the lead
wire and not to apply external force to the transformer coil.

(7) Clamp the bolts and nuts uniformly until the stopper on the flange matches
to the mount flange. (See Fig. 4).
(8) when fitting is over, tie the lead wire at the nut which welded below the
blank cover. (See Fig. 5)

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-62701
3.8 FITTING OF MOUNTS Rev. : -
DAIHEN ELECTRIC FOR BUSHINGS (GENERAL) Date : 20-Jan-04
CO., LTD. Page : 2 / 2

Bushing Stamping
Insulated wire
Mount CT terminal
box terminals

Trans-
former CT
CT G
Fitting flange
Fig. 1 Fig. 2 Fig. 3

Nut Wind the lead

wire and tie it by
Match this Bolt Mount string
surface
Gasket
Stopper
Tank cover
Spring washer side

Nut

Fig. 4 Fig. 5

Mount
Lead wire
Tank cover

Core

Transformer coil

Fig. 6
 Ref.No. : IE-63401
3.9 FITTING OF CONSERVATOR Rev. : C
DAIHEN ELECTRIC Date : 20-Jan-04
CO., LTD. Page : 1 / 3

(1) The rubber cell type conservator is shipped separately and filled with
nitrogen gas to prevent from moisture.
When mounting the conservator on the transformer, it is necessary to take
care of the followings.
Don't heat the conservator by welding or grinding, as the rubber
diaphragm is installed in.
Please refer to the instruction of rubber cell type conservator in detail.

(2) Fitting the protective relay

If the transformer is provided with a buchholz relay or other protective
relay, install them to the conservator before mounting it on the transformer.
The relay is connected to the conservator through a connecting valve.
Remove a blank cover of the flange surface, change the gasket to new one.
Install the relay to the conservator and clamp bolts tightly and uniformly,
Be sure to sets the relay in the direction indicated on the nameplate fitted
to it
Fitting of the protective relay should be referred to the instruction
manual in detail.

(3) Setting an oil level indicator on the conservator for OLTC

The conservator for OLTC with a dial oil level indicator is equipped on that
for the main tank.
The indicator is packaged separately from the conservator during transport.
Attach it to the conservator according to the following procedure.
(3)-1. Manually shift the float up and down , and check the operation of
alarm contact. Make sure of the arm length. (See Fig. 3).
(3)-2. Remove a blank cover and a gasket on the indicator fitting flange
of the conservator.
Attach the indicator to it carefully using a new gasket. Screw
bolts tightly and uniformly.

(4) Mounting the conservator on the transformer.

When the above fitting is over , hoist the conservator using lifting lugs and
mount firmly at the specified location . Pay attention not to incline in the
when hoisting. (to see fig. 4).

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-63401
Rev. : C
3.9 FITTING OF CONSERVATOR
DAIHEN ELECTRIC Date : 20-Jan-04
CO., LTD. Page : 2 / 3

Handhold
Oil level gauge Conservator

Rubber cell

Protective relay

Elbow Connecting valve

Drain valve

Fig. 1

Oil filling hole

Oil level gauge

Arm

Float

Fig. 2 Conservator for OLTC.

 Ref.No. : IE-63401
Rev. : C
3.9 FITTING OF CONSERVATOR
DAIHEN ELECTRIC Date : 20-Jan-04
CO., LTD. Page : 3 / 3

Conservator Float

Arm To check that the float does not

stop between upper and lower part.
If the float stops in its half way,
adjust the arm length again.

Indicator

Fig. 3 Check for float (operation) & contact.

Lifting lug

Conservator

Mounting bracket

Fig. 4 Hoist conservator horizontally

 Ref. No. : IN-05001
3.10 FITTING OF Rev. : A
DAIHEN ELECTRIC COOLING FAN Date : 14-Aug-08
CO., LTD. Page : 1 / 2

(1) Fitting
The cooling fans attached to the radiator panel The radiators, which provided
with fan fitting supports, are located at the end of each cooling bank.

The fans will be installed to the supports by nuts fastened surely. The fan
motors should be placed so that their cable outlets will be at the bottom of a fan
motor.

(2) Cabling

The terminal boxes, to which fan motor cables are to be connected , are
attached to the fitting supports on the radiator panel . After terminating the
cables as shown in Fig.1, connect them with the terminal blocks with confirming
to match the wire color to the block mark, i.e. The black covered wire is
connected to the blue mark U, the grey to V, the red to W and the black to E .

(3) Checking
After wirings are completed, supply the proper power to the fan motors, and
make sure that the fans rotate in the normal direction and without abnormal
sound.

(4) Moisture protection in the motor.

If a fan is stationary for long periods in a humid atmosphere, it should be
switched ON for minimum of 2 (two) hours every month to remove any
moisture that may have condensed within the motor.

U V W E Terminal block

Blue Black
Red
Reinforced with vinyle tape
Grey

Bush Bottom of terminal box

Cable

Fig.1 Cable connection for terminal box

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref. No. : IN-05001
3.10 FITTING OF Rev. : A
DAIHEN ELECTRIC COOLING FAN Date : 14-Aug-08
CO., LTD. Page : 2 / 2

Radiator Cooling fan

Fig.2 Cooling bank

Rotation
Fan fitting Fan motor
supports Junction box

Radiator panel
Cable

Terminal box

Fig.3 Fitting of cooling fans

 Ref.No. : IE-66201
Rev. : -
3.11 OIL PIPING 20-Jan-04
DAIHEN ELECTRIC Date :
CO., LTD. Page : 1 / 2

The oil piping should be in accordance with the diagram of PIPING ROUTE and
PIPING SYSTEM shown in the instruction manual, and based on the number tag
attached to the each pipe.

(1) Remove the blank covers from the separated oil pipes
Oil piping is provided for connecting the oil circuit of various accessories, and
some oil piping is transported separately.
Prior to fitting the oil pipes, remove the blank cover from them. Then remove
old gaskets which used for the blank covers, and clean sufficiently the gasket
groove and the gasket face by means of sandpaper.

After cleaning, be sure to wipe off foreign matter with a dry waste. If the
painted face is found to be spoiled, repaint with rust-proof paint.

(2) Check the ventilation of oil pipes

When cleaning of oil pipes is finished, pass either dry air or nitrogen gas
through the oil pipe and make sure that removal of foreign matter is complete.

(3) Remove the blank cover from the oil pipes on the transformer side.
Remove the blank covers and clean the piping faces. Check that no foreign
matter is allowed to enter inside the transformer tank.

(4) Assembling
Apply a small amount of adhesive to the gasket groove and fit the new gasket.
Tighten the clamp bolts in diagonal order and evenly until the flange faces
match.

(5) The connecting valves are also joined to oil pipes by means of above
procedure.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-66201
Rev. : -
3.11 OIL PIPING 20-Jan-04
DAIHEN ELECTRIC Date :
CO., LTD. Page : 2 / 2

Flange without a
gasket groove

Flange with a gasket groove

Fig. 1

Match surface

Fig. 2
 Ref.No. : IE-66301
3.12 PIPING AND WIRING Rev. : -
DAIHEN ELECTRIC OF ELECTRIC SYSTEM Date : 25-Dec-03
CO., LTD. Page : 1 / 3

(1) Pipe matching

In accordance with piping system diagram shown in the instruction
manual and based on the number tag attached to each pipe, arrange
a number of pipes to various accessories over the ground.

(2) Temporary assembly

Remove the blank covers from each conduit pipe and terminal box .
Temporarily set the conduit pipes from the terminal box to accessories
in numerical order as shown on the number tag attached to each conduit
pipe, and check piping direction , keeping the pipe connecting bolts
under the temporary screwed condition. (See Fig. 1)

(3) Determination of length of wires to be put in the conduit pipes

Based on wiring diagram, check the required number of wires to
be put in the conduit pipes leading to various accessories.
Measure the length along the temporarily assembled piping from
the terminal boxes to accessories, and cut out the required
number of insulated wires accordingly.

(4) Installing wires into the conduit pipes

Install the insulated wires into the conduit pipes from the
terminal box side to accessories side . (See Fig.2) However
before putting the insulated wires into the conduit pipes , check to
see if the end of each conduit pipe is smooth . If not, smooth in
inner end of pipes with a file in order not to damage the insulation
of the wires. Replace all gaskets for pipe connections with new
ones. Apply a small amount of adhesive to the gaskets groove
before putting the gaskets.

(5) Tightening of conduit pipes

When connecting the conduit pipes in which the insulated wires
are installed, check if any wires are caught in between the
connecting faces (See fig. 4), then tighten until the face match .

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-66301
3.12 PIPING AND WIRING Rev. : -
DAIHEN ELECTRIC OF ELECTRIC SYSTEM Date : 25-Dec-03
CO., LTD. Page : 2 / 3

(6) Another method of installing the wires into a conduit

As shown in Fig. 5, pass a cotton tube through the conduit pipe
by nitrogen gas or dry air pressure . Tie a bundle of insulated
wires to one end of the cotton tube.

The cotton tube enables smooth pulling of wires into and

through a conduit pipe. Instead of cotton tube, a fish wire
(steel wire) is also useful.

Fig. 1 Arrangement of pipes (over the ground)

Fig. 2 Temporary assembling and installing the wires

(over the ground)
 Ref.No. : IE-66301
3.12 PIPING AND WIRING
Rev. : -
OF ELECTRIC SYSTEM
DAIHEN ELECTRIC Date : 25-Dec-03
CO., LTD. Page : 3 / 3

Protective relay

Transformer Terminal box

Thermometer

Fig. 3 Fitting of pipes on the transformer

wiring

WRONG GOOD
Fig. 4

Conduit pipe

Insulated wires

Fig. 5
Cotton tube
 Ref.No. : IE-62101
3.13 FITTING OF Rev. : -
DAIHEN ELECTRIC BUSHING (GENERAL) Date : 25-Dec-03
CO., LTD. Page : 1 / 1

Bushings should be installed lastly to minimize the possibility of their being

damaged while installing other parts.
Care should be taken in unpacking the bushing package to avoid damage of the
porcelain. Before fitting the bushings clean the porcelain and the live part
thoroughly.
Bushings should be mounted on their locations as shown in outline drawing.

Make connections to both ends of the bushings in such a manner that strain is
avoided. When heavy busbars are connected to bushings, flexible connections
should be used to prevent damage that might possibly result from expansion and
contraction due to temperature changes. Be sure that all connections are tight to
prevent local heat of the terminal.

When the bushings are installed on the transformer , change a gasket to new one
for the fitting seat. The flange should be fixed uniformly by nuts in such manner
as shown in Fig. 1.

Throughout the work, worker should not use the gloves and tools-monkey
wrench, spanner, etc., unless they are tied to the worker with hempen strings to
prevent them being dropped into the transformer tank.

3' 2
Each pair of stud bolt 1-1', 2-2' and 3-3'
should be tighten with nuts at same time
2' 3 in order to fix the flange uniformly .

1'
Bushing fitting flange
Fig.1

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IN-01001
3.14 FITTING OF Rev. : A
CONDENSER TYPE BUSHING
DAIHEN ELECTRIC Date : 22-Aug-11
CO., LTD. Page : 1 / 2

Before fitting the bushing, read the attached instruction manual in which
described bushing handling manner such as unpacking, lifting.

Connection of lead wire and installation of bushing.

1. Draw the lead wire from the transformer tank.

2. Insert a hamper or cotton string into the hollow conductor of bushing as

shown in Fig.1 .

3. Lift the bushing over the transformer.

4. Attach a ring screw (M12) to the top of the inner terminal stud, and then
tie the lower end of string to the ring screw as shown in Fig.2 .

5. Pass the lead wire through the bushing while pulling up the string and
bringing down the bushing gradually.

Do not pull the string too strong not to damage the transformer winding
and the lead wire.

6. Match the flange surface of bushing to the fixing part by tightened with
nuts. (See Fig.3)

7. Draw the inner terminal stud from the bushing head, and insert refraining
pin into bushing tube through inner terminal stud as shown in Fig.4 .

8. Fix the inner terminal stud to the outer terminal stud. It is unnecessary to
change the flat gasket to new one (See Fig.4)

9. Fix the top terminal to the outer terminal stud head with bolts as shown in
Fig.5 .

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

3.14 FITTING OF CONDENSER
TYPE BUSHING
 Ref.No. : IE-62303
3.15 FITTING OF SOLID TYPE Rev. : -
DAIHEN ELECTRIC BUSHING ( Plate type ) Date : 20-Jan-04
CO., LTD. Page : 1 / 1

(1) Tighten the nut (A) and (B) to porcelain slightly.

(2) Clean the gasket groove of bushing fitting seat, and apply a small amount of
adhesive in the groove in order to fix a new gasket.

(3) Put the bushing on the seat, and tighten nuts until the flange surface matches to
the seat.

Do not over-tighten.
(4) Connect the copper plate brought out from the transformer winding to the
bushing terminal tightly by using bolts, nuts and washers.

Gasket

Washer
Nut (A) Spring washer
Nut (B) Bolte
Lead terminal
Terminal Plate

Bolte
X X'

Lead
Nut

X - X'

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref. No. IN-09141
3.16 Oil filling and Rev. -
DAIHEN ELECTRIC draining process Date : 18/05/2015
CO., LTD. Page 1 / 4

1. Draini ng the ins ulati ng oil while filli ng w ith nitroge n ga s.

Supply nitrogen gas into the transformer to displace the insulating oil, then to drain off the
insulating oil. Do not allow the internal pressure inside transformer to become negative. Sealing
pressure of nitrogen gas should be from 0.05 to 0.2 kg/sq.cm. (Refer to item 3 "In case of oil
draining")
2. Filli ng of tota l qua ntity of ins ulati ng oil unde r vac uum.
After draining the total quantity of insulating oil from the transformer, arrange the machine parts as
illustrated in the last page of this cause (OPERATION OF VALVES), and carry out filling.
2.1 Cautions for va cuum ing a nd oil filli ng.
1) When opening drums of oil, care should be exercised to prevent moisture from condensing
within them. It is preferable that filling is done when humidity is low. Drums should be opened
only at the time when the oil is needed. Before filling the oil, take sample from oil tank/drums
as the following table A and test the dielectric strength as the following table B.
Table A
Number of Number of
Number of samples Number of samples
drums drums
2 - 5 2 101 - 200 10
6 - 20 3 201 - 400 15
21 - 50 4 more tha n 400 20
51 - 100 7 - -

Table B
IEEE C57.106 IEC60422
Voltage class Minimum voltage (kV) Voltage class Minimum voltage (kV)
(kV) at 1 mm gap at 2 mm gap (kV) at 2.5 mm gap
≤ 69 ≥ 25 ≥ 45 < 72.5 > 55
> 69 - < 230 ≥ 30 ≥ 52 72.5 - 170 > 60
> 230 - < 345 ≥ 32 ≥ 55 > 170 - 400 > 60
> 345 ≥ 35 ≥ 60 Note : Test metho d accor ding t o IEC60156
Note : Test metho d accor ding t o ASTM D1816

2) The oil filling apparatus should be clean and free from moisture, care should be taken to
prevent moisture from being introduced into oil though oil line.
3) Do not energize the transformer when vacuuming and filling oil.
4) In the case of transformer with resistor type on-load tap-changer the partition wall of diverter
switch compartment can not withstand full vacuum. Before exhausting air from the transformer,
open the equalizing valve located between the switch compartment and the transformer tank in
order to maintain same pressure as the transformer interior.
5) In the case of transformer with diaphragm type conservator. Before exhausting air from the
transformer, open the equalizing valve located with the conservator in order not to damage the
diaphragm.
6) In the case of transformer with nitrogen seal equipment. Before exhausting air from the
transformer, do not vacuum the nitrogen gas expansion tank, because the tank can not
withstand full vacuum.

Designed by : M.UTEN Checked by : S.Winyou Approved by : K.Nagai

 Ref. No. IN-09141
3.16 Oil filling and Rev. -
DAIHEN ELECTRIC draining process Date : 18/05/2015
CO., LTD. Page 2 / 4

2.2 Vacuum Treat ment

1) Connect the service tool to flange (13) and (21).
2) Close (1), (2), (5), (6), (8), (9), (11), (12), (14), (17), (18), (20)
Open (3), (4), (7), (10), (13), (15), (16), (19)
and exhaust air from the inside of rubber cell until the degree of vacuum is less than 10 mm.Hg.
3) Close (15)
4) Open (20), exhaust air from the main tank until the degree of vacuum is less than 10 mm.Hg.
5) Open (15), exhaust air from both inside rubber cell and transformer tank until the degree of
vacuum is less as specified in table C. Continue vacuuming to keep degree of vacuum as
specified in table D.
Table C : Vacuum level. (mm.Hg)
Capacity
< 20 MVA < 60 MVA < 200 MVA > 200 MVA
Rated Voltage
less than or equal 36 kV 5 5 5 --
36 kV < x < 84 kV 5 5 3 --
84 kV < x < 170 kV 3 3 1 1
more than 170 kV 1 1 0.5 0.5

Table D : Vacuum keeping hour for new transformer. (hour)

Capacity
< 20 MVA < 60 MVA < 200 MVA > 200 MVA
Rated Voltage
less than or equal 36 kV 2 2 4 --
36 kV < x < 84 kV 2 4 4 --
84 kV < x < 170 kV 6 12 12 18
more than 170 kV 12 18 18 24
6) After the vacuum degree was confirmed, stop the vacuum pump temporarily, and carry out
the stop test. Criteria for stop test is by degree of vacuum, and increment of vacuum is as
specified in table E by 15 minutes after stopping. If the result of stop test is satisfactory,
proceed with oil filling.
Table E
Rated Voltage of transformer Increment of degree of vacuum
less than or equal 77 kV less than 5.0 mm.Hg
more than 77 kV less than 3.0 mm.Hg
more than 154 kV less than 1.0 mm.Hg

2.3 Oil fil li ng

1) After the transformer has carried out vacuum treatment described in item 2.2, then close (4),
open (1) and pump degassed oil into the tank. The insulating oil should be through the oil filler
press and the vacuum oil preconditioned.
2) During oil filling, continue the operation of vacuum pump. When degree of vacuum become
more than vacuum level, temporarily suspend oil filling and operate only the vacuum pump in
order to achieve required degree of vacuum.
 Ref. No. IN-09141
3.16 filling and Rev. -
DAIHEN ELECTRIC dra ining pr oce ss Date : 18/05/2015
CO., LTD. Page 3 / 4

3) Start oil filling until the indication of oil level gauge of main conservator indicates the scale 3-4.
Then temporary stop oil filling.
4) Close (15), (20) and stop vacuum pump.
5) Take off the vacuum line from (16) and replace with nitrogen gas line, open (15) and fill
nitrogen gas into the rubber cell until it comes into atmospheric pressure. Take off the nitrogen
gas line from (16).
6) Take off service tool from (13) and (21), Then close (21) by blank cover, Open (20)

7) Open (18) and start oil filling again when oil come out (18), Close (18), Then adjust oil level
until oil level of main conservator indicated follow at oil level-temperature curve, Then close (1)

8) Oil filling for OLTC conservator.

Open (4), the insulation oil from main conservator flow to OLTC conservator through (7)
and (4) until oil level reach the level indicated at oil level-temperature curve, close (7).
9) Open (14) and fill nitrogen gas to OLTC conservator until it comes into atmosphere pressure.
10) Install the dehydrating breathers. (Refer to the instruction manual of dehydrating breather)
11) Residual gas release and oil level adjustment:
Allow more than 8 hours for oil to permeate into the
immersed parts after oil filling. Then release residual gas ! WARNING :
from various parts by loosening the air relief plugs or KEEP THE EQUALIZING VALVE CLOSE
valves until oil escape. AT ALL TIME, EXCEPT WHEN VACUUMING

After residual gas is released, carry out oil level adjustment according to "Oil level-Oil
temperature curve" attached to the transformer.

3. In c ase of all oil drainin g.

1) Connect the service tool to flange (13) and (21).
2) Status of valve before oil draining. (14) (16)
Close (1), (2), (5), (6), (7), (8), (9), (11), (12), (15), (20)
Nitrogen line
Open (3), (4), (10), (13), (14), (16), (17), (19) Pressure gauge
3) Connect the nitrogen line to flange (14) and (16), connect
the insulation oil line to valve (1).
4) Open (1), (15), (20), drain insulation oil and fill nitrogen ( Keep pressure 0.05 to 0.2 kg/sq.cm
) to displace the insulating oil untill the main tank without the insulation oil. Stop operation of
draining, close (1) .
5) Take off the insulation oil line from (1) and connect to (9).
6) Open (9) , drain insulation oil and fill nitrogen to displace the insulating oil untill the OLTC
without the insulation oil. Stop operation of oil draining and nitrogen filling, close (9).
 Ref. No. IN-09141
3.16 Oil filling and Rev. -
DAIHEN ELECTRIC
CO., LTD.
draining process Date :
Page
18/05/2015
4 / 4

(18) (21) (21)

Air
detector (13)
(13 (14) (20)
Flange for Flange for OLTC (15)
Dehydrating Dehydrating breather Main Tank Conservator
Cons.
breather and Nitrogen line

(17) To Vacuum pump

(4 (6) ( ) (5 and Nitrogen line
(16)
Oil flow Relay

(7) (3)
Buchholz
(3 (2) Serv ic e too l
Relay
(19)
Q S R E2 Sudden pressure

(8) Main Tank

(11 (10

Radiator
(9) OLTC
(12) (1)
(10)
To Oil Line
No. Description Vacuuming Oil Filling In Service Oil Drianing
close- open- close- open-
1 Drain valve for main tank close close
close close
2 Filler valve for main tank close close close close
3 Connecting valve for main conservator open open open open
open -close -
4 Connecting valve for OLTC conservator open open open
open
5 Drain valve for main conservator close close close close
6 Drain valve (plug) for OLTC conser. close close close close
7 Equalizing valve for OLTC. open open -close close close
8 Connecting valve for oil filter unit close close close close
close- open-
9 Connecting valve for oil filter unit close close close
close
10 Connecting valve for radiator open open open open
11 Gas release valve close close close close
12 Oil sampling valve ( If any) close close close close
To
13 Connecting flange for Air breather open open
Air breathe r
open

Connecting flange for fill nitrogen to To

14 close close- open open
OLTC conservator Air breathe r
Temporary valve for vacuum and fill open -close - open -close - open -close -
15 N/A
nitrogen to main tank open open open
Temporary flange for vacuum and fill
16 open open N/A open
nitrogen to main tank
17 By-pass valve for Buchholz relay close close close close -op en
close- open-
18 Gas release valve for Air detector close close close
close
19 Connecting valve for Sudden pressure open open open open
open -close open -close
20 Connecting valve for Air detector close -op en open
-op en -op en
21 Connecting flange for vacuum open open -close close close -op en
3.17
 1. Recomm ended set ting temp erat ure of Therm ometer

1.1) In the case of Alarm and / or Trip

Thermometer for Oil for Windi ng

Alarm 80 ° C 100 ° C

Trip 90 ° C 110 ° C

1.2) In the case of cooling fan control.

Thermometer for Windi ng

stop -°C
2 nd Stage
of Cooli ng
start-up 90 ° C
(NOTE) In the case of over load operation,there is a possibility
of alarm and / or trip contacts operating

2. Recomm ended to m oisture protec tion in the motor of cooli ng fan.

If a fan is stationary for long periods in a humid atmosphere.

It should be switched ON for minimum of 2 (two) hours every month to
remove any moisture that may have condensed within the motor.

Process No. Title Description Date Rev.

Sett ing for Transf ormer
PP0443B Acce ssory
Date : 28/04/2015 Scale : X
DES 'D M.UTEN
CHK 'D S.Winyou Reference No.
APP 'D S.Winyou DAIHEN ELECTRIC CO., LTD. FD-PP0443B-20-01
 SECTION 4
AFTER INSTALLATION
 Ref.No. : ED-IM-17112
4.1 INSPECTION AND TEST Rev. : -
DAIHEN ELECTRIC AFTER INSTALLATION Date : 25-Dec-03
CO., LTD. Page : 1 / 1

After assembling transformer, check it in accordance with the followings:

1) Construction
Make sure that all parts are located on their proper position, and clamping of
all bolts and nuts is complete.
2) Connection
Make sure that electrical connections are complete and wiring are without
mistake.
3) Cooling equipment
Make sure that all radiator valves are opened, and cooling control device,
cooling fans operates is normal condition.
4) Tap changer
Make sure that the tap-changer operates smoothly, and the tap position is
corresponding to the specified voltage. Control device for OLTC is in normal
condition.

5) Protective relays
Check the contact operation.
6) Indicators
Check the oil level gauges or thermometers indicate the proper position of the
scale.
7) Dehydrating breathers
Check the breathers operation.
8) Check air-release is complete.
9) Check the valves are in the proper position.
10) Grounding system
Make sure that the ground system of the transformer is perfect. Since the
surface of ground pads are painted to prevent it from rusting during transport;
remove the paint for good connection of ground cable.

11) Live parts of bushings and lighting arresters.

Make sure that phase to phase and phase to ground distance are sufficient.

When above inspections are complete, carry out the field test such as insulation
resistance measuring, ratio test angular displacement measuring. Execution of
applied potential test and temperature rise test is preferable.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-54201
4.2 FIELD TEST AFTER Rev. : A
DAIHEN ELECTRIC INSTALLATION Date : 22-Oct-10
CO., LTD. Page : 1 / 3

In the field test to be conducted during and after field assembly, there are the
following.
a) Insulation resistance measurement
b) Polarity, phase rotation & transformation ratio tests
c) Test of alarm devices and control units
d) High voltage test

a) Insulation resistance measurement

(i) Transformer body
Measure insulation resistances between two windings and between
each winding and earth by means of a megger of more than 1000 V,
and record the measured values. Because insulation resistance
values change according to temperature, be sure to record the
temperature of transformer.
According to the document no. NE-TC6-061, Fig 1. "Tolerance for
insulation resistance of transformer"

(ii) Accessories & wiring

Measure insulation resistances between two terminals of terminal box
and between each terminal and earth from terminal to terminal, and
record insulation resistance value and temperature. In the case of
bushing CT, be sure to measure insulation resistance between two
CTs in addition to insulation resistance between each CT and earth.
According to the document no. ED-IM-17154, Table 3. "Insulation
resistance values of the low-tension electrical works"

b) Polarity, phase rotation & transformation ratio tests

(i) Polarity & phase rotation tests
Perform the polarity and phase rotation test at the rated tap.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-54201
4.2 FIELD TEST AFTER Rev. : A
DAIHEN ELECTRIC INSTALLATION Date : 22-Oct-10
CO., LTD. Page : 2 / 3

Criterion Polarity
H V1 > V2 Subtractive
X1
V1 < V2 Additive

V1

X2
H
V2
H

X2
H X3 H
X1 H3-X3=H2-X2 < H3-X2=H2-X3
H2

X2
H1 H3
X1 X3

H2

X2
H1 H3
X1 X3 H3-X3=H3-X2=H2-X2 < H2-X3
H2

X2
H1 H3
X1 X3

(ii) Transformation ratio test

In the case of a three-phase transformer, measuring it with a single-
phase power source will give better precision. Measure transformation
ratio at all taps with regards to each phase.
 Ref.No. : IE-54201
4.2 FIELD TEST AFTER Rev. : A
DAIHEN ELECTRIC INSTALLATION Date : 22-Oct-10
CO., LTD. Page : 3 / 3

In the case of a delta-delta connection

V V

Primary Secondary

In the case of a star-delta connection

V
V

Primary Secondary

In the case of a delta-star connection

V
V

Primary Secondary

c) Test of alarm devices and control units

Actuate each accessory such as the temperature relay, Buchholz relay,
etc. or short-circuit the terminal of such an accessory and check its
performance from terminals in terminal box and alarm panel.

d) Others
Continuously pressurize the transformer with pressure of 0.3 kg/cm2
(preferably delivered by nitrogen gas) for more than 24 hours, and visually
inspect to see if there are any oil leaks. With reference to drawings, carry
out appearance, dimensional and other checks on the transformer,
Measure insulation oil for its measurable properties such as withstand
voltage, acid value, volume, specific resistance, water content, etc.
It is also recommended to measure the winding resistance.
 Ref.No. : IE-72101
Rev. : -
4.3 PAINTING Date : 25-Dec-03
DAIHEN ELECTRIC
CO., LTD. Page : 1 / 4

Painting procedures are as follows:

(I) Clean the whole transformer with use of thinner and rag.

(II) Polish with emerypaper any parts that have been scratched or marked, and
further clean each area lightly with emerypaper so that paint will adhere to
surface.

(III) By a brush, apply under coat (red primer) to the parts where flaws were found.

(IV) Cover up the following parts with paper or vinyl sheet so as to prevent them
from being fooled by paint. (See 2-3)

(V) By means of the spray gun, apply paint to the whole transformer.

(VI) After painting is over, remove the paper of vinyl sheet which is set out in the
above procedure (IV).

Further details of painting, including those parts that should not be painted, and
items that demand special attention when under coating and/or finish coating are
to be done after assembly of transformer is completed at site.

(1) Materials to be used

They are as follows; air compressor, spray gun, air reservoir, air hose, lead
wires, power source, switch, emerypaper, rag, painting brush, paint, thinner
and washing agent.

(2) Under coating

Under coating is anticorrosive painting to be executed prior to finish coating,
and using anticorrosive paint, apply it with brush.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-72101
Rev. : -
4.3 PAINTING Date : 25-Dec-03
DAIHEN ELECTRIC
CO., LTD. Page : 2 / 4

(2-1) Parts to be subject to under coating and finish coating

the following parts are to be subjected to an under coating and then a
finish coating:
a) Those parts where the painted face was flawed during transportation.
b) The parts separately shipped and assembled at site, where the
painted face was flawed during transportation.
c) Parts to which blank covers are attached for transportation purpose.

(2-2) Parts to be subjected to under coating only

The following parts are to be subjected to an under coating only as the
finishing coat is omitted when the transformer is to be assembled at site:
a) From the gasket face of radiator fitted flange to the flange face of
outer side.
b) From the gasket face of radiator valve to the flange face of outer side.
c) From the gasket face of oil piping flange to the flange face of outer side.
d) From the gasket faces of fitted flanges of other accessories to the
flange faces of outer side.
e) From the gasket effective face of opening flange of a handhold or
manhole to the flange face of outer side. (However, when the flange
face is made of brass or non-metal, under coating can be also omitted
there.)

Examples
Part to be
subjected to
foundation coating

Part not to be
subjected to
coating

Radiator fitting flange Opening angle of Handhold

Fig. 1 Examples of Parts to be Subjected to Foundation Coating Only

 Ref.No. : IE-72101
Rev. : -
4.3 PAINTING Date : 25-Dec-03
DAIHEN ELECTRIC
CO., LTD. Page : 3 / 4

(2-3) Parts not to be subjected to under coating

The following parts are not to be subjected to under coating.
a) Gasket face of radiator fitted flange and part of inner side from this
gasket face.
b) Gasket face of radiator valve and part of inner side from this gasket face
c) Gasket face of oil piping flange and part of inner side from this gasket
face.
d) Gasket faces of fitted flanges of other accessories and parts of inner
side from these gasket faces.
e) Gasket effective face of opening angle of a handhold or manhole.
f) Parts of ground terminal block where the ground conductor makes
contact. However, in the case of flange of a conduit pipe, it is in order
to apply under coat to the gasket face.

(3) Finish coating

Finish coating is a coating of final paint of designated color and is to be
applied by spraying by means of a spray gun. The following parts are not to
be subjected to finish coating.
a) Porcelain tube, terminals, oil level indicator and nameplate of bushing.
b) Glass part of oil level indicator of conservator and plated part of frame of
instruments.
c) The whole lightning arrester (except the lightning arrester fitted part.)
d) Dial type thermometer
e) Inspection window and needle valve of gas release plug of gas detector
and Buchholz relay.
f) All nameplates on the transformer.
g) Exposed charging part.
h) Ground conductor and ground terminal (However, the cleat for fixing
ground conductor is to be coated.)
 Ref.No. : IE-72101
Rev. : -
4.3 PAINTING Date : 25-Dec-03
DAIHEN ELECTRIC
CO., LTD. Page : 4 / 4

(4) Mixing of paint

In the case of under coating of finish coating, depending upon method of

paint application, that is bushing or spraying, and the kind of paint to be used,
mix the thinner with the paint by the appropriate ratio listed in the following
table, and then apply the resulted mixture.

Ratio of thinner relative to paint

Brushing Spraying
Paint
(%) (%)
Foundation
Daigo (#200) 5 20-30
coating
Finish Graston 10 15-25
coating Phtharon 10-20 30

(5) Cautions for coating

a) In the case a vinyl resin paint is used for finish coating, use a vinyl resin
paint for under coating. The finish coating is to be applied after 24 hours
from applying the under coating.

b) Whenever under or finish coating is to be applied, completely remove oil

and grease from the surface on which paint is to be applied.
c) Whenever under coating is to be applied, polish thoroughly the rusted
part of surface to be painted, and then apply under coating. Do not apply
under coating directly to a rusted surface.

d) When dirt, dust, etc. are found on the surface to be painted, apply coating
only after removing.
 Ref.No. : X-80-02
4.4 RE-DRYING OF Rev. : -
DAIHEN ELECTRIC THE TRANSFORMER AT JOB SITE Date : 21-Jan-04
CO., LTD. Page : 1 / 7

Re-drying
Drying the transformer at job site is necessary in the following cases :
- When air-tightness is broken during transport or during storage (if nitrogen
gas leakage is found after checking it's pressure, see IE-11101)

- When the transformer core-coil has exposed to air as follows :

Maximum operating Exposed time
voltage (kV) (hour)
to 72.5 30
from 73 to 170 16
from 171 to 300 12

Page 7/7 might be helpful to understand following explanations.

1) Principle
Hot oil and vacuum treatment method
- Heating Preliminary vacuum treatment to judge the degree of humidity.
Oil filling under vacuum.
Oil circulation during heating.

- Drying Oil draining, filling the tank with nitrogen gas.

Vacuum treatment of the transformer tank.

- Judgment Judgment of the drying degree from dew point, vapor pressure
and temperature.

2) Heating
2-1 Preparation
- Mount the bushings on the transformer to measure the winding temperature
by resistance method.
- Drain off the residual oil completely by pumping out from the drain valve.
- Open the upper filter valve so as to make the air in tank for draining the
residual oil.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : X-80-02
4.4 RE-DRYING OF Rev. : -
DAIHEN ELECTRIC THE TRANSFORMER AT JOB SITE Date : 21-Jan-04
CO., LTD. Page : 2 / 7

- Fit the transparent tube, as the oil level indicator, between the drain valve
and the flange located on the cover (or the flange on the conservator
connecting pipe). This tube must endure a vacuum and withstand hot oil.
Clamp the flange sufficiently.

- Connect the vacuum pump equipped with a vacuum gauge and a condenser
to the upper part of the transformer (to a flange on the cover, for example).
- After lead wire connections of all bushing are finished, take preliminary
measurements of winding resistance and temperature so as to get a basis of
comparison for the subsequent operations.

- Put the vacuum pump into operation until a vacuum of at least 3 torrs is
obtained in the tank.
- Every hour, measure the volume of water taken from the condenser of the
vacuum pump until not more than 500g of water per hour is drained off.
- Once this value is reached, connect the oil purifier through two pipes
(suction on the lower filter value and delivery on the upper filter valve). Close
the under filter valve, and open the upper filter valve, and start the oil filling
(treated, dried and deserted oil) through the upper filter valve to the
transformer under vacuum.
The oil is then raised to the temperature of 50~60°C approximately. When
the oil level is 15 cm. Below the tank cover stop the oil filling and close upper
and lower filter valves. Continue the operation of the vacuum pump.

2-2 Heating operation

- Take the temperature measurements (by resistance variation or by
interpolation) twice a day.

Note ;
For measuring temperatures, two alternatives are possible.
- by measuring the resistance variation of one of the windings (by using a
measuring bridge and a D.C. battery)
- by interpolation; the temperature of the core-coil assembly lies between
the oil temperature at suction and delivery.
These temperature measurements should be made as near as possible to
the transformer so as to prevent any error due to heat, losses in the piping.
The oil temperature difference between suction and delivery must not
exceed 5 to 10°C.
 Ref.No. : X-80-02
4.4 RE-DRYING OF Rev. : -
DAIHEN ELECTRIC THE TRANSFORMER AT JOB SITE Date : 21-Jan-04
CO., LTD. Page : 3 / 7

- Flit the temperature curve of the core-coil assembly as a function of time.

- Open the lower and upper filter valves.
Start up the oil circulating by oil purifier.
This apparatus must comprise vacuum pump , heater, filter, injection
pump, etc. This apparatus should produce oil which is perfectly clean,
dried, deserted and treated. Allow the oil temperature rise until 90-95°C

The oil temperature should not exceed at 100°C . During the whole
heating process, record the temperature indicated by the thermometer at
every hour.

3) Drying
3-1 Preparation
- Stop the vacuum pump and break the vacuum in the tank
- Close the upper and lower filter valves and remove the oil circulating apparatu
- Completely drain the total quantity of insulating oil through the lower filter
valves, filling the tank with nitrogen gas (Blow the nitrogen gas through the
orifice of the cover) .

3-2 Drying operation

- Close the orifice, upper and lower filter valves.
- Put the vacuum pump into operation.
- Plot the curve, as a function of time, of the volume of water taken from the
condenser of the vacuum pump at every hour.
- Also, take the hourly reading of the residual pressure of vacuum.
- Continue the operation until the vacuum is obtained at least 3 torrs in the
tank. Maintain this vacuum value throughout the drying operation (at least
for 48 hours) .

4) Judgment
- When the water volume curve reaches below 50g per hour ,stop the vacuum
pump operation.
- Measure the pressure in the tank at every minute and plot the pressure
curve as a function of time. Fig. 1 shows the typical pressure curve.
- Decide the end point of vapor generation from this curve.
 Ref.No. : X-80-02
4.4 RE-DRYING OF Rev. : -
DAIHEN ELECTRIC THE TRANSFORMER AT JOB SITE Date : 21-Jan-04
CO., LTD. Page : 4 / 7

- Decide the temperature of core-coil assembly from the measurement of the

winding resistance.
- Decide the water concentration in insulation materials from Fig. 2 .
- If the water concentration is under 0.5%, finish the drying work.

5) Oil filling
- Start the vacuum pump operation again, and continue the vacuum pump
operation until the vacuum degree is obtained at least 3 torrs in the tank
(Maintain this vacuum value at least for 1 hour.) .

- Start the oil filling to the transformer through the lower filter valve.
- Bring the oil level as up as possible to the cover. Close the lower filter valve.
- Maintain the vacuum operation for 4 hours.
Installation, Operation and maintenance

Service : Steam Turbine Generator Transformer

Tag no. : 20BAT10

Description : Steam Turbine Generator Transformer

11/118 kV, ONAN/ONAF 21/30 MVA, Oil Immersed, Conservator tank with
rubber bag

Ekarat Engineering Public Company Limited

9/291 U.M Tower, 29 Fl., Ramkamheang Road.,Suanluang Dis., Bangkok 10250
Tel : (+662) 719-8777 Fax : (+662) 719-8760
Website : http://www.ekarat.co.th
 CONTENT

SECTION TITLE
1 Transportation 6
1.1 Cautions for Transportation
1.2 Inspection and instruction on
Arrival at site
2 Before Installation 12
2.1 Storage
2.2 Inspection of packages and unpacking
 CONTENT

SECTION TITLE
3 Installation 18
3.1 Caution for transformer installation
3.2 Supervisor for work and safety measures
3.3 Preparation of tools, instruments and material
3.4 Flow chart for installation
3.5 Setting of the transformer on a bed
3.6 De-aerated oil filling up to the level above coil
3.7 Fitting of radiators
3.8 Fitting of mounts for bushing
3.9 Fitting of conservator
3.10 Fitting of cooling fan
3.11 Oil piping
3.12 Piping and wiring of electrical system
3.13 Fitting of bushing
3.14 Fitting of condenser type bushing
3.15 Fitting of solid type bushing
3.16 Oil filling and draining process
3.17 Caution for thermometer lead line
To enter in local control cabinet
 CONTENT

SECTION TITLE
4 Transportation 67
4.1 Inspection and test after installation
4.2 Field test after installation
4.3 Painting
4.4 Re-drying of the transformer at job site
4.5 Caution when energizing transformer
 SECTION 1
TRANSPORTATION
 Ref.No. : IE-12101
1.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSPORTATION Date : 24-Nov-09
CO., LTD. Page : 1 / 3

(1) Transportation on boat

Boat

The transformer and parts shall Transformer

be placed under deck of boat. (Fig. Fig. 1
1)

(2) Unloading at the port

Transformer shipped by boat will be unloaded at the main port of destination

using cranes, etc. Such unloading work should be executed by skilled workers and
it is desirable that a representative of the ultimate user should be present during
unloading operations.

Check against the following:

Fig. 2 (a) Contact of transformer against quay.

Fig. 3 (b) Radical contact of transformer against ground.
(c) Check if the nitrogen gas pressure inside the transformer
Fig. 4
is positive or not by the attached pressure gauge.

Use a steel wire having sufficient strength to lift the transformer, etc.
Hoist it by the lifting lugs specified by the transportation drawing.

Transformer

Boat
Transformer

Fig. 2

Designed by : I.TEERAWAT Checked by : M.Ochi Approved by : M.Ochi

 Ref.No. : IE-12101
1.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSPORTATION Date : 24-Nov-09
CO., LTD. Page : 2 / 3

Pressure gauge

Transformer

Transformer

Fig. 3 Fig. 4

(3) Transportation from the port to the substation. etc.

The transformer is transported to substation etc. by trailer or by other means.
It is undesirable to give severs shock to the transformer during transportation.
The traveling speed of the trailer should be regulated according to the conditions of
the road surface.

The normal speed is as follows:

- Completely paved road : 40 km/h, 25 mph or less
- Insufficiently paved road : 30 km/h, 19 mph or less
- Unpaved road : 5-10 km/h, 3-6 mph or less

When the transformer is shipped by rail, there is no problem while the train is
running, however attention should be paid to prevent shock during loading and
unloading work. It is undesirable to incline the transformer too sharply. The angle
of slope should be within 10° as illustrated in Fig. 5.
 Ref.No. : IE-12101
1.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSPORTATION Date : 24-Nov-09
CO., LTD. Page : 3 / 3

Transformer

Cargo train

10º

Fig. 5

It is better to install a tachometer on the trailer or the train or attach a shock meter to
the transformer itself. To measure the angle of slops of the transformer, use a plum
bob.
 1.2 INSPECTION AND Ref.No. : IE-11101
INSTRUCTIONS
Rev. : D
DAIHEN ELECTRIC Date : 23-Jan-07
CO., LTD. ON ARRIVAL AT SITE Page : 1 / 2

The transformer is transported in some sections, the main tank, bushings,

conservator, radiators, and other accessories. the dismantled accessories are
packaged in crates or boxes.

Immediately on arriving at site, the following examination should be made for any
damage sustained in transport, and a check for lost parts.

If injury or rough handling is evident, a damage claim should be filled.

(1) Check for gas pressure :

In order to prevent moisture impregnation, the main tank is filled with dry nitrogen gas.
(Approx. 0.2 kg./sq. cm. At 30 degree Celsius)

Remove the protective cover for the compound gauge mounted on the tank, and
open the connecting valve, and check the gas pressure. (After checking the
pressure, close the valve tightly.) Positive indication shows that air and / or water has
not entered into the tank.

If the point read zero, air ingress might happen. At this occasion, measure the
insulation resistance of windings to know the degree of moisture impregnation refer
to the "INSTRUCTIONS FOR INSPECTION AND MAINTENANCE" for the criterion
of moisture impregnation.
Measurement in low humidity atmosphere is preferable to prevent the live parts
from moisture impregnation. If the measured value is lower than the criterion, a
drying treatment will be required.

(2) Inspections for exterior :

(2.1) Check for damage
Check if the transformer was dropped accidentally, or reinforcements and
piping were distorted.

When a shock recorder is provided, check the records carefully after arrival at
site. If the recorded figures at all axis exceed 3 G, please contact DAIHEN
ELECTRIC CO.,LTD.

(2.2) Rust
When the painting is damaged or the metal parts are rusted, remove the rust
with a sandpaper, and coat with touch-up paint.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 1.2 INSPECTION AND Ref.No. : IE-11101
INSTRUCTIONS
Rev. : D
DAIHEN ELECTRIC Date : 23-Jan-07
CO., LTD. ON ARRIVAL AT SITE Page : 2 / 2

(2.3) Bolts and nuts

Check if the bolts and nuts are loosed. When the bolts fastening the covers or
valves are loosed, make measurement for insulation resistance mentioned above
(1).

(2.4) Inspection of impact recorder chart

Check the impact recorder chart before transferring the transformer and after the
arrival to the destination. If the recorded figure exceeds the following value,
please ask manufacture for further information.

- Vertically : 3 G
- Length-wise : 3 G
- Short-wise : 3 G
(3) Transport at site and unpacking
Refer to IE-12101 and IE-14101 in this instruction manual.

CAUTION :

Before removing a manhole cover, shipping plate, or other device, vent the
transformer to atmospheric pressure. Do not enter the transformer until the gas
space has been flushed with dry air, or a suitable oxygen (not less than 18% of
oxygen in the tank) supply is available for safety working.
 SECTION 2
BEFORE INSTALLATION
 Ref.No. : IE-21102
Rev. : A
2.1 STORAGE 18-Dec-09
DAIHEN ELECTRIC Date :
CO., LTD. Page : 1 / 1

It is recommended that the transformer will be put into service immediately in its
permanent location. If this is not possible, the following precautions must be taken
to insure the proper storage of the transformer.

(1) The transformer tank has been filled with dry nitrogen gas totally . When
stored for more than 4 months from the date of shipment, the transformer tank
should be filled with insulating oil up to the level lower than the tank cover by
about 25 cm. The gas space between the cover and the oil should be filled with
dry nitrogen gas.

As to the oil filling method , refer to clause IE - 41201 in this instruction . The
gas pressure must be checked periodically .
After fill with insulation oil up to the level lower than the tank cover by about
25 cm,the nitrogen gas will dessolve into insulation oil .
When nitrogen gas pressure deteriorated less than 0.1 kg/cm², the nitrogen
gas shall be supplemented.
The gas filling pressure ,refer as following.

(2) It is recommended that the transformer tank and accessories will be stored
indoor. The accessories would be stored in the boxes to avoid the loss of them.
When the accessories are taken out from the boxes, vinyl sheets covering the
accessories should not be removed.
When stored outdoor, cover totally the tank and accessories with strong water
proof sheets to prevent the water ingress. And lay wooden beams under the
tank and boxes. The tank and accessories should be stored in a dry and clean
location, free form corrosive gases or fumes.

(3) When painted surface is damaged, retouch with attached paint.

Designed by : S.Winyou Checked by : TEERAWAT Approved by : M.OCHI

 Ref.No. : IE-14101
2.2 INSPECTION OF Rev. : -
DAIHEN ELECTRIC PACKAGES AND UNPACKING Date : 20-Jan-04
CO., LTD. : 1 / 4
Page

It is necessary to inspect the number of packages and unpack these in the presence
of a representative of your company and our technical staff in the
following manner.

(1) Checking of the number of packages

When the packages etc. are brought into the installation site it is necessary to
inspect the number of packages and the appearance of each, before unpacking
them. Check the number of packages against the packing list prepared by our
company or our agent.
If any package is missing; take steps to have it found or replaced.
(2) Inspection of the appearance of package
At the time of inspection of the number of packages, also inspect their
appearance. Check the damage to packing, exposure of contents etc. visually.

Especially to the packages opened at the time of custom clearance, this should
be carried out most carefully, As to the packages damaged or packages whose
contents are missing, take the necessary action regarding an insurance claim and
take pictures to cover a future claim for insurance money.
(3) Unpacking

When the checking of the number of packages and inspection of the appearance
is over, open the packages. Unpack the wooden boxes carefully by using pincers
so that the contents are not damaged. As far as possible avoid the use of a crow
bar. After unpacking a wooden box, or cardboard box etc. inspect the number
and appearances of the parts according to (1) and (2).

Crow bar
Pincer

Fig. 1
Unpack the package holding bushing carefully according to the following
method, and using care not to damage the contents.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-14101
2.2 INSPECTION OF Rev. : -
PACKAGES AND UNPACKING 20-Jan-04
DAIHEN ELECTRIC Date :
CO., LTD. Page : 2 / 4

Ceiling
When the package is longer in
Cover the upright position as shown by
the figure at left, do not lay it down
Inner partition in a horizontal position but open it
board in upright position according to the
following.

Use pincers but not crow bars.

- Remove the ceiling.
Fig. 2 - Remove the cover.
- Draw out the inner partition board.

As for the handling of bushing

after unpacking refer to the
" instructions for bushing"

Cover

inner partition boad

inner partition boad

Support
- Do not cut
Fig. 3

When the packing is an inclined package as shown above, do not cut off the
supports but draw out the nails by pincer and remove the cover and inner
partition board while keeping it in the inclined position. Do not use a crow bar.
As for the handling of bushing after unpacking, refer to the instructions for
bushing.
 Ref.No. : IE-14101
2.2 INSPECTION OF Rev. : -
DAIHEN ELECTRIC PACKAGES AND UNPACKING Date : 20-Jan-04
CO., LTD. Page : 3 / 4

Cover

Inner partition board

Fig.4

When the package is a horizontal type as shown above, draw out nails by pincers
and remove the cover and inner partition board. Do not use a crow bar.

(4) Rearrangement and accommodation

When the parts are taken out of the packages, rearrange them and
accommodate them in a safe place to prevent damage. Radiator, pipes, etc.

May be stored out-doors with sufficient protection to preclude the possibility of

damage but small parts such as a thermometer should be stored inside a building .
The drums of insulating oil for the transformer should be stored out -doors in a
horizontal position with their filling holes aligned horizontally . (to see Fig.5)

No good No good

Fig.5 Fitting holes should

be aligned horizontally

Good
 Ref.No. : IE-14101
2.2 INSPECTION OF Rev. : -
DAIHEN ELECTRIC PACKAGES AND UNPACKING Date : 20-Jan-04
CO., LTD. Page : 4 / 4

In storing the radiators vertically, do not arrange them in more than 3 levels.
Prevent damage by inserting wood blocks in between the radiators. (Fig.6)

Wood

Aligned vertically
Fig.6
 SECTION 3
INSTALLATION
 Ref.No. : IE-13404
3.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSFORMER INSTALLATION Date : 20-Jan-04
CO., LTD. Page : 1 / 4

1) Work in the tank

When opening the transformer tank, precaution must be taken to prevent the moisture.
If wet air enters the transformer, it may be cooled by the tank wall below its dew point
and condensed, so it will lower the dielectric strength of the transformer.
Do not enter the transformer tank until the nitrogen gas has been entirely dissipated.
When working in the tank, take care especially not to drop tools or foreign substances.
It is recommended that tools used in the tank are tied to worker with a cord. Worker
should not carry anything unnecessary in the tank.
Care should be taken to see that all nuts, bolts, and lead connections are tight and all
parts in their right places.
Check the internal terminal connections.
When the work in the tank is completed, the inside of the tank should be inspected.
Check that it is clean and no foreign substances are left behind. For inside cleaning,
the dry, clean, and lint-free clothes should be used.

2) Lifting and transportation of the main tank

The main tank must be lifted by the same manner as IE-12101. When the transformer
is skidded, moved on rollers or jacked up, take care not to injure the base and not to tip
over the transformer. The transformer is also equipped with jacking bosses . Jacks
should be placed under the jacking bosses . The transformer should never be lifted or
moved with jacking up the radiators or other accessories . When rollers are used , skids
must be placed between the base and the rollers to distribute the stress .

3) Lifting of accessories
Position and direction of the accessories and other parts should be according to the
transformer drawing exactly. Before fitting them, read the instructions completely.
Mishandling will result in damage to the accessories.

Treatment of gasket joints at site

In order to perfect the seal effect of gasket joints, following treatments should be
done at site.

3.1) Gasket of Cork - Nitrile - Rubber (CN-PG)

a) Clean the flange surface with thinner and clothes and remove the moisture, oils
and fats, stains and others.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-13404
3.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSFORMER INSTALLATION Date : 20-Jan-04
CO., LTD. Page : 2 / 4

b) Apply the liquid gasket (Super Three Bond 1215) to both sides of CN-PG,
smoothly and uniformly.
c) Then, attach the separated parts to their positions with gasket.
d) Start of oil filling should be more than 24 hours after applying the liquid gasket .
e) If temporary fixing of gaskets are needed for vertical or inclined joints , apply the
adhesive ( Cemedine 501 ) around the gasket (refer to Fig.1) Cemedine 501 is
included in our packing .

Super Three Bond 1215

( x maker )
CN - PG 5 5 5 5
xxxx
CN - PG
xxxxxxxxx

xxxx
xxxxxxxxx

Flange (mm.) 5 5
5 5
(mm.)
Cemedine 501
( o maker ) Fig. 1

3.2) Gasket of Nitrile - Butadiene - Rubber (NBR-PG)

a) The liquid gasket ( Super Three Bond 1215 ) should not be applied to NBR -PG.
b) Clean the flange surface with thinner and clothes and remove the moisture, oils
and fats, stains and others.
c) Then, attach the separated parts to their positions with gasket.
d) If temporary fixings of gasket are needed for vertical of inclined joints , apply the
adhesive ( Cemedine 501 ) around the gasket by spot-applying and after 2 or 3
minutes drying, attach them to the flanges. (refer to Fig.2)

NBR - PG

Flange Fig. 2

Cemedine 501
( o maker )
 Ref.No. : IE-13404
3.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSFORMER INSTALLATION Date : 20-Jan-04
CO., LTD. Page : 3 / 4

4) Fastening with bolts and nuts

Each bolt and nut should be screwed rigidly. But in order to avoid the bolts and
nuts broken, pay attention not to over tighten.
Fasten the bolts and nuts under suitable torque as follows by measuring torque
wrench or torque meter.

Size of Bolt Suitable Torque for Fastening

M10 249 ~ 303 (kg.cm)
M12 434 ~ 529 (kg.cm)
M16 1080 ~ 1310 (kg.cm)
M20 2100 ~ 2560 (kg.cm)
M22 2860 ~ 3490 (kg.cm)
M24 3620 ~ 4420 (kg.cm)

5) Fastening of stud-bolts
Each stud-bolt should be screwed rigidly. But in order to avoid the stud-bolt broken,
fasten the stud-bolt under suitable torque as follows by measuring torque wrench or
torque meter.

Size of Stud-Bolt Suitable Torque for Fastening

M12 500 ~ 600 (kg.cm)
M16 1100 ~ 1300 (kg.cm)
M20 2100 ~ 2500 (kg.cm)
 Ref.No. : IE-13404
3.1 CAUTIONS FOR Rev. : C
DAIHEN ELECTRIC TRANSFORMER INSTALLATION Date : 20-Jan-04
CO., LTD. Page : 4 / 4

6) Water protection by the silicone

6.1) Radiator valve position

Upper side Silicone

Tank side Radiator side

Lower side

6.2) Thermometer position

Thermometer

Silicone

Terminal box

Silicone
 Ref.No. : IE-15101
3.2 SUPERVISION FOR WORK Rev. : -
DAIHEN ELECTRIC AND SAFETY MEASURES Date : 23-Dec-03
CO., LTD. Page : 1 / 6

(1) Supervision of work

To execute assembly work of transformer at site smoothly and accurately
the supervision of work must be clearly established.
For reference purpose, we illustrate below the supervision of work we have
been adopting.

Customer like
Our company
your company
Supervisor Engineer, Person-in-charge

Leader of working party

Work chief

Workmen

As illustrated above, our supervisor makes arrangements with your engineer,

person-in-charge, on details of field assembly of transformer and determines
how to proceed with field work. Then the supervisor explains to the leader of
working party details on how to proceed with work, method, cautions, etc.

The leader in turn assigns a specific part of the work to each workman, and
then the working party executes.

It is not desirable that an instruction is given to a workman directly from the

supervisor, without informing the leader.
In the case of large work, when several leaders are to be arranged,
supervision of work should follow the illustrated pattern.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-15101
3.2 SUPERVISION FOR WORK Rev. : -
DAIHEN ELECTRIC AND SAFETY MEASURES Date : 23-Dec-03
CO., LTD. Page : 2 / 6

(2) Safety measures for working

It is necessary to take safety measures in order to secure personal safety
during field work and to prevent machine parts from being damaged. We
shall deal with matters that demand special attention, mentioning some major
items.

a) Work at an elevated place

In the case of assembling the transformer much work is done at elevated

places.
Therefore, it is necessary to take the following measures in order to prevent
an accident such as a fall by a workman, or an accident caused by a falling
object or collapsing scaffold.

For work to be done at an elevated place, build up a strong scaffold with

metallic pipe or timber, and be sure to provide it with a means of safe ascent
and descent.
For such work in which a scaffold can not be used, it is necessary for the
workman to use a safety belt.
When the transformer tank cover gets covered with oil, rainwater, etc., it is
necessary to clean it, otherwise a workman might lose his footing and fall.
Because work at elevated places is always dangerous because of the
possibility of falling, this has the danger of causing more serious accidents.
Therefore, it is necessary to take a forward-looking attitude of taking positive
safety measures even if these measures may be troublesome when work is
going smoothly.

b) Work inside the transformer tank

Lack of oxygen
Shortage or lack of oxygen may take place inside the transformer tank
because nitrogen gas which is sealed into it for the purpose of transportation
still remains there or ventilation inside the tank is insufficient.
 Ref.No. : IE-15101
3.2 SUPERVISION FOR WORK Rev. : -
DAIHEN ELECTRIC
AND SAFETY MEASURES Date : 23-Dec-03
CO., LTD. Page : 3 / 6

Therefore, when connection work or inspection work is to be done inside the

tank, it is necessary to takes measures against accidents caused by lack of
oxygen.

First of all, measure the concentration of oxygen inside the tank by means of
the oxygen densitometer, confirm that the oxygen concentration is more than
18% and record the concentration value.
Working lamp
Next, it is necessary to use working lamp having a sufficient intensity of
illumination for safety and to facilitate work inside the tank.
A working lamp with guard is recommended in order to prevent a workman
from receiving an electric shock as well as to protect the bulb from damage
due to unintentional knocks. Oil proof lead wire is recommended.
The lower the voltage of working lamp the better it is, for safety.
Pay attention to the above-mentioned points, and carry out work inside the
transformer tank.
Moreover, prohibit one man work inside the tank, and station a watch at a
place from where he can see workmen.
Finally, consider the fastening of a rope to each workman who enters the
transformer tank.
This can be used in an emergency. The rope would be the means of
rescuing a workman and would be pulled form the outside.

c) Lifting and lowering of heavy parts

Usually a crane car is used to raise and lower the parts at the time of
assembling the transformer.
Our company adopts a practice of requiring the operator of crane car to
submit to us the operator's license and maintenance check list of his crane
car.
The sling work, we likewise require this work to be executed under the
command of a qualified sling workman who has a license to this effect.
We think that the control corresponding to our practice stated above is
necessary in your country, too.
Prior to the work being done with the crane car, be sure to try a trial
suspension.
 Ref.No. : IE-15101
3.2 SUPERVISION FOR WORK Rev. : -
AND SAFETY MEASURES
DAIHEN ELECTRIC Date : 23-Dec-03
CO., LTD. Page : 4 / 6

In the case of a large article to be suspended or in the case of suspension in

a narrow place, it is recommended to attach a long rope to the suspended
article so it does not spin in suspension and so as to guide it into the desired
place.

In the case of lifting an article under the horizontal condition or in the case of
fine adjustment in lowering, it is recommended to use a chain block together
with crane car.

Chain
block

d) Clothes for workmen

d.1) Clothes for workmen
- The head : Put on The prescribed helmet marked with The name of
Our company and name of workman, and be sure to fasten The chin
strap.

- Eyes : When work is to be done with a grinder or when a chemical is

to be used, put on the prescribed protective glasses made of acrylic
resin.
- The upper half of the body : Wear the long-sleeve jacket prescribed
by our company, and put the workman's name card on the left breast.
- The lower half of the body : wear the trousers prescribed by our
company.
- Hands : It is in order to put on a pair of working gloves; however,
when touching the transformer interior, tap-change, etc., do so with
naked hands.
- Feet : Wear the leather laced boots prescribed by our company, and
put the cuffs of trousers into the boots.
 Ref.No. : IE-15101
3.2 SUPERVISION FOR WORK Rev. : -
DAIHEN ELECTRIC AND SAFETY MEASURES Date : 23-Dec-03
CO., LTD. Page : 5 / 6

d.2) Clothes for welding work

In the case of welding work, a welder should wear a protector in
addition to the above-mentioned clothes for field workmen.

d.3) Clothes for special works

In the case of work to be done inside the transformer and work on the
indoor panel, it such work is difficult to do wearing the above-
mentioned clothes, it is in order to put on the cloth working cap and
canvas shoes instead of the helmet and leather laced boots with
permission of customer's person in charge and field work responsible
person of our company.

It is also recommended to wear in addition a dry vinyl waterproof

when working inside the transformer tank.

d.4) Clothes for painting work

When engaging in painting work, it is in order to put on a cloth

working hood an rubber boots instead of the helmet and leather laced
boots after obtaining permission from the customer's person in charge
and field work responsible person of our company to carry out painting
work with painter's mask.

e) Electric shock preventive measures

Field work responsible person is required to call workmen's attention to
the following :

e.1) Not to handle anything long in the neighborhood of the high-tension

charging part. However, in case such handling is unavoidable, carry
anything long by two or more persons with the permission of the field
work responsible person.

e.2) A workman should not come within a less distance than show in the
following table from any high-tension part:
 Ref.No. : IE-15101
3.2 SUPERVISION FOR WORK
Rev. : -
AND SAFETY MEASURES
DAIHEN ELECTRIC Date : 23-Dec-03
CO., LTD. Page : 6 / 6

In cases where approach as to the high tension part is unavoidable, he

should take the necessary measures to be safeguarded against an
electric shock following instructions from a field work responsible
person prior to working near a high-tension area.

Nominal Voltage (kV) Off-limits Distance (cm)*

3-6 80
11-22 100
33-44 120
60-70 140
154 250
257 400

* Distance from the high-tension part for workmen to whom a warning

should be given by field work responsible person.
 Ref.No. : IE-81101
3.3 PREPARATION OF TOOLS, Rev. : A
DAIHEN ELECTRIC INSTRUMENTS AND MATERIALS Date : 21-Dec-03
CO., LTD. Page : 1 / 6

The items, specifications and requirements for all tools and materials
required for assembling, inspection and testing of transformer are listed below.

(1) Tools required for assembling

(a) Crane car

It is convenient to use crane car to fix
radiator, conservator, etc. Crane car having
hoisting capacity of 10 ton and beam length
of about 10 m is suitable. Skilled operator
must operate the crane car.
Before hoisting the parts, suspend a cargo
having similar weight as the part to be
suspended to check if it operates correctly.

(b) Oil bath made of steel sheet

Before oil filling of the transformer, transfer
the oil in a drum into the oil bath. The proper
capacity of the oil bath is about 20 % of the
total quantity of oil for the transformer when
the rated voltage of the transformer to be
assembled is less than 100 kV.
When the rated voltage of the transformer is
100 kV and above, it is better to use an oil
bath having a capacity equivalent to the total
oil quantity, because it is preferable to drain
the entire quantity of oil from the transformer
following a total filling.
When the capacity of one oil bath is
insufficient, use several of them.
The internal surface of the oil bath should
be clean being free from moisture and dirt. It
should be a sealed bath which prevents
infiltration of rain or outside air even when it
is installed outdoors.
Transparent pipe If the oil bath allows entry of air, attach a
container holding silica-gel at the air passage
to prevent entry of moisture air. It is
convenient if an oil level indicator or a
transparent pipe is attached.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-81101
3.3 PREPARATION OF TOOLS, Rev. : A
DAIHEN ELECTRIC INSTRUMENTS AND MATERIALS Date : 21-Dec-03
CO., LTD. Page : 2 / 6

(c) Oil filter press

Use oil filter press to transfer oil from the
drum to oil bath. Use a thoroughly dried
fresh filter paper for the oil filter press as the
duty of the press is to remove fine dirties or
moisture contained in the oil.
Usually a capacity of 5-10 kl/h is
appropriate for such an oil filter press.

(d) Oil purifier

Use oil purifier to transfer oil from oil bath to
VC the transformer.
The main duty of the oil purifier is to

VP SP eliminate gas contained in the oil.

It also eliminates moisture and dirt.
F
Therefore the oil purifier must comprise
vacuum pump, heater, filter, injection pump,
etc.
H
Usually the purifier having a capacity of
2000 - 5000 Lt./h is used.
EP FP
Carry out test run before oil filling into the
Oil bath transformer to drain residual oil in the oil
Trans. purifier and clean up the inside.
VP : Vacuum pump
VC : Vacuum chamber
SP : Spray pump
EP : Extraction pump
F : Filter tank
H : Heater
FP : Filter pump
 Ref.No. : IE-81101
3.3 PREPARATION OF TOOLS, Rev. : A
DAIHEN ELECTRIC INSTRUMENTS AND MATERIALS Date : 21-Dec-03
CO., LTD. Page : 3 / 6

(e) Vacuum pump

Usually the vacuum pump with
displacement of about 3000 l/min is used.

Transformer (f) Nitrogen gas cylinder

Nitrogen gas cylinder should be equipped
with reducing valve, meter and rubber hose.

(2) Instruments for inspection and testing

Conduct inspection and testing during and
after assembling work of the transformer by
using the following apparatus.

(a) Oil tester

Test all item are as appendix 1

The measurement should be roughly as

follows :
* Select several drums out of drum pool and
test them.
* After filling oil bath with oil and
immediately before it is pumped into the
transformer.
* After transformer is filled with oil. Take
sample from the bottom of the drum. Judge
the test results against ASTM, BS or other
equivalent standard.
Appendix 1 Page 1/2

1. Transformer oil test : Dielectric breakdown, Neutralization

number, Interfacial tension. Moisture content, Power factor
and Colour check
- After electrical test
1.1 Dielectric breakdown
Objective Before and after oil filling, and intermediately before the induced overvoltage and
separate source voltage withstand tests

Acceptance criteria
More than 30kV for average value

Standard reference
IEC 60156 (1995)

1.2 Neutralization number ( Sampling by Ekarat and submit to EGAT Lavatories)

Standard reference ASTM D 664-95

Acceptance criteria
Limit (Max) 0.20 mg KOH/g

1.3 Interfacial tension ( Sampling by Ekarat and submit to EGAT Lavatories)

Standard reference ASTM D 971

Acceptance criteria
Limit (Min) 25.0 mN/m

1.4 Moisture content

Objective For checking water mixed in transformer oil

Procedure 1 Sampling oil from main tank into water content tester
2 Set timer 10 – 15 Sec for testing
3 Test result will be record by tester ( PPM)

Acceptance criteria
< 35 PMM

Standard reference
ASTM D 1533

1.5 Power factor

Standard reference ASTM D 924

Acceptance criteria
< 0.5% @ 25 ºC

1.6 Colour test ( Sampling by Ekarat and submit to EGAT Lavatories) Standard
reference ASTM D 1500

Acceptance criteria
Limit (Max) 2.50
Appendix 1 Page 2/2

2. Transformer oil test : Dissolved gas analysis (DGA) test

- After electrical test
- After energized 1 month and 6 month

Objective Dissolved gas in oil shall be analyzed by automatic dissolved gas in oil analyzer. Oil
shall be collected from filter valve at time of before any tests and after dielectric
tests and temperature rise tests.

Standard reference
ASTM D3612-02 (2009)

Acceptance criteria
No C2H2
 Ref.No. : IE-81101
3.3 PREPARATION OF TOOLS, Rev. : A
DAIHEN ELECTRIC INSTRUMENTS AND MATERIALS Date : 21-Dec-03
CO., LTD. Page : 4 / 6

(b) Volt meter

An A.C. Voltmeter is required for the
following test.
* Ratio test
* Polarity test
* Sequence test of control circuit
One set of each of the following double
range precision meters for AC are required.
AC 150/300 V ......................... 1 set
AC 30/75 V ......................... 1 set

(c) Ammeter
One set each of the following precision
double range ammeter are required for
measurement of exciting current when low
voltage is impressed on the transformer and
for measurement of current of auxiliary
apparatus of the transformer such as cooling
fan, oil pump, etc. If they are equipped on
the transformer.
AC 20/100 mA ...................... 1 set
AC 10/50 A ...................... 1 set

(d) Double bridge

This is required to test the winding
resistance etc. of the transformer.
Measuring range of 0.001Ω - 10 Ω is required.
Kelvin double bridge as appropriate.
Batteries should also be made ready.
 Ref.No. : IE-81101
3.3 PREPARATION OF TOOLS, Rev. : A
DAIHEN ELECTRIC INSTRUMENTS AND MATERIALS Date : 21-Dec-03
CO., LTD. Page : 5 / 6

(e) Megger
Megger is used for measurement of
insulation resistance.
Manually operated megger having rating of
about 2000V and 2000MW as appropriate.

(f) Universal tester

This is the portable tester which can
measure AC voltage, resistance and DC
current by changing the range.

It is used for the checking of control wiring

or electric items.

(g) Testing transformer

It is used for dielectric test of the
transformer. The capacity of testing
transformer is determined by a calculation
based on the ground static capacity
described in the table of test results supplied
It is better to use one having ample
allowance.
Impressed voltage and impressing time
shall be determined by ANSI standards, BS
standards, etc. Which apply to the
transformer.

(h) Phase rotation meter

This is the meter to check the direction of
phase rotation of three-phase electric motor,
etc.

(i) Vacuum gauge

It is necessary to have a vacuum gauge for
the measurement of the degree of vacuum
raised during the operation of the vacuum
pump.
Macleod or Pirani gauge should be used.
-2
It should be able to measure up to 10 mmHg.
 Ref.No. : IE-81101
3.3 PREPARATION OF TOOLS, Rev. : A
DAIHEN ELECTRIC INSTRUMENTS AND MATERIALS Date : 21-Dec-03
CO., LTD. Page : 6 / 6

(j) Pressure gauge

To inspect the leakage of pressurized oil

after assembling of transformer, a pressure
gauge is required. Borden tube type gauge
(compound gauge) having a measuring
range of 0-1.0 kg/cm2 is required.

(k) Others
Instruments necessary of executing a
temperature rise test, measurement of
dielectric loss tangent (d), noise test
and High voltage test should be
obtained.

(3) Tools
(a) Drum opener
(b) Screw driver for cross recessed head screws
(c) Screw driver for slotted head screws
(d) Scissors
2
(e) Compression pliers (for 2.0, 3.5, 5.5, 8.0mm )
(f) Pliers
2
(g) Wire stripper (for 2.0, 3.5, 5.5, 8.0mm )
(h) Jack with capacity of 10 t
(i) Monkey wrench 6", 8", 10", 12"
(j) Spanner
(k) Pincer.
 Ref.No. : IN-10013
3.4 FLOW CHART Rev. : C
DAIHEN ELECTRIC
FOR INSTALLATION Date : 19-Jan-09
CO., LTD. Page : 1 / 1

Order of installation for transformer is shown bellows.

SET TRANSFORMER ON BASE

Yes
Note
No
FIT COMMON PIPES OF RADIATOR Note :
In case of oil filling
VACUUM TREATMENT under vacuum up to level
above coil from factory.
(#1) OIL FILLING UP TO LEVEL ABOVE COIL

FIT MOUNTING BRACKETS

FOR ACCESSORIES
Caution :
FIT RADIATOR On process (#1) to (#2).
Every day before finish the
FIT MOUNTING FOR ALL BUSHINGS
day work, the transformer
FIT CONSERVATOR tank shall be filled with dry
nitrogen gas to prevent
ASSEMBLY PIPES OF OIL CIRCUIT moisture inside.

FIT ALL BUSHINGS

VACUUM TREATMENT FIT OTHER ACCESSORIES

OIL FILLING UP TO ASSEMBLY WIRING PIPES

OIL LEVEL-OIL TEMP CURVE

CHECK OIL TIGHTNESS FIT COOLING FANS

DRAIN OIL AND FILL NITROGEN GAS CONTROL WIRING

VACUUM TREATMENT TOUCH UP PAINT

(#2) FINAL OIL FILLING

CHECK FOR INSTALLATION

ELECTRIC FIELD TEST

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : ED-IM 17111
3.5 SETTING OF THE Rev. : -
DAIHEN ELECTRIC TRANSFORMER TANK ON A BED Date : 17-Dec-03
CO., LTD. Page : 1 / 1

(1) On bed

Install the transformer at the specified location at a substation or power station.

Take care not to incline the transformer too sharply, and prevent it from shocking
during installation work. The foundation should be able to bare the load and the
vibration of an earthquake. Since the center of the transformer is marked ( ↓ ) at the
bottom side, line it up to the center of the specified installation site. To adjust the
perpendicular alignment of transformer, use the markings at the top and bottom of the
transformer and check with a plumb bob, etc. If it is not perpendicular, insert thin iron
plates at an approprite point to adjust it perpendicularly.

(2) Fixing of transformer (when anchor bolts are attached)

Install the transformer with attached anchor bolts at the correct position in the way
previously stated and then fix the anchor bolts with cement. After a few days, when
the cement is sufficiently dry, again clamp the anchor bolts and secure them.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref. No. IE-41201
3.6 DE-AERATED OIL FILLING Rev. A
DAIHEN ELECTRIC
UP TO THE LEVEL ABOVE Date : 15-Jan-09
CO., LTD. THE COIL Page 1 / 2

To prevent direct contact of coil and insulator with atmosphere during

assembling of transformer, it is desirable to fill with the insulating oil first up to
the level about 25 cm below the tank cover.

It is necessary to carry out dielectric strength test of insulating oil stored in the
drums before oil filling.

Take samples from each drum and check whether they have specified
dielectric strength. If the oil does not have specified dielectric strength, filter the
entire oil content. Oil filling should be carried out only after its dielectric strength
reaches the specified value.

There are two methods to carry out oil filling. The first method is to fill with oil
through the drain valve while discharging gradually the nitrogen gas filled in the
tank. (see Fig. 2) The nitrogen gas pressure in the transformer tank should be
kept the value of from 0.05 to 0.2 kg/cm2 during oil filling.

The second one is to do oil filling after vacuuming the transformer. (See Fig. 3)
This method is superior to the first one.

approx. 25 cm
Insulating oil

Tank
Coil

Fig. 1

Designed by : S.Winyou Checked by : I.TEERAWAT Approved by : I.TEERAWAT

 Ref. No. IE-41201
3.6 DE-AERATED OIL FILLING Rev. A
UP TO THE LEVEL ABOVE
DAIHEN ELECTRIC Date : 15-Jan-09
CO., LTD. THE COIL Page 2 / 2

Discharging N2 gas
Compound gauge

Oil purifier with

de-aerator Oil filter press
Transformer

Oil tank Drum

Drain valve

Fig. 2

Compound gauge

Transformer

Connect to oil line

Vacuum (same as above)
pump
Fig. 3
 Ref.No. : IE-61202
Rev. : A
3.7 FITTING OF RADIATORS
DAIHEN ELECTRIC Date : 24-Dec-03
CO., LTD. Page : 1 / 4

1. Fitting of radiators :

Radiators are shipped separately. Blank covers are attached to the openings
of radiators and radiator valves to prevent moisture. Radiator valve is located on
each radiator connection so that any individual radiator may be removed in time
of necessity without lowering the oil level of the transformer tank.

As each radiator has an oil drain plug and an air relief plug, it is easy to drain
the oil individually.
The radiator withstands the same vacuum (full vacuum) and pressure condition
as the main tank.
Radiators should be handles carefully to prevent bending or puncturing the
panels.

Position number is stamped on the upper header of each radiator and this
should be matched with the position number stamped on the flange on the main
tank side. Fit the radiator according to the following procedures.

(1) Hoist the radiator from the stored position, and pay attention not to
damage other radiators with the hoisting tools.
(2) Remove the blank cover and gasket on the radiator.

(3) Inspect the inside of the radiator visually.

(4) Clean the fitting flange surface of the radiator.

(5) Remove the blank cover and gasket on the radiator valve of the
transformer.
(6) Clean and paint the flange surface of the radiator valve (See Fig. 1)
(7) Clean the gasket groove of the valve. Apply a small amount of adhesive
to the groove and fit the specified new gasket.
(8) Hoist the radiator by crane car with the side of the flange on which the
number is stamped showing upward.
(9) Pull the radiator by hand, incline it and drain the residual oil inside the
radiator. (See Fig. 3)
(10) Fit the radiator to the radiator valve.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-61202
Rev. : A
3.7 FITTING OF RADIATORS
DAIHEN ELECTRIC Date : 24-Dec-03
CO., LTD. Page : 2 / 4

(11) Match the radiator valve and the flange surface of the radiator and
clamp them by nuts. (See Fig.2)
(12) Clamp the pair of nuts located diagonally one after another in order to
clamp evenly. (See Fig. 4)
(13) Clamp them tightly until the radiator valve and radiator flange closely
match with each other.

2. fitting of the radiator supports :

When radiator fitting is over, attach the supports and the fasteners of the
radiator symmetrically as shown in fig. 5 and 6

(1) Fit the supports (E) at the transformer tank wall. (since the radiator in
outer and obstacle for fitting the supports (E) , it is preferable of fitting the
radiator) before.

(2) Put the fasteners (A) and (B) on the upper side of the radiators and put
(C) under the lower side (see Fig.7)
(3) Set jacks under the support (C) and jack up until the radiator may be
vertical (see Fig.6)
(4) Keeping the radiators vertical, joint the supports (E) to the support (C)
and fix with nut.

(5) Tank off the jacks.

Clean and repair with rust-

proof paint if the paint is
defoliated

Clean surface

Fig. 1
 Ref.No. : IE-61202
Rev. : A
3.7 FITTING OF RADIATORS
DAIHEN ELECTRIC Date : 24-Dec-03
CO., LTD. Page : 3 / 4

Match this surface

Transformer side Radiator side

Radiator valve
Fig. 2 Clamp it until there is
no clearance

Stemp of number
Radiator

Fig. 3

Incline and
drain residual
oil.

Clamp the pair of nuts located diagonally

one after another as shown left.
So that they should be clamped uniformly.

Fig. 4
 Ref.No. : IE-61202
Rev. : A
3.7 FITTING OF RADIATORS
DAIHEN ELECTRIC Date : 24-Dec-03
CO., LTD. Page : 4 / 4

(B)
(A)

Radiator
(C)
(E)

Transformer Wooden block

Jack
(C)

Fig. 6

Fig. 5 (A),(C)

(B)

Fig. 7

3. Operation of radiator valve :

Remove the protective cap located on the side of the valve. Turn the valve
stem with a spanner to desired position. Then attach the cap and bolt it. It is
desirable to change gasket with new one every time the cap is removed.

O S O S

Shut (Close) Open

Fig. 8
 Ref.No. : IE-62701
3.8 FITTING OF MOUNTS Rev. : -
DAIHEN ELECTRIC FOR BUSHINGS (GENERAL) Date : 20-Jan-04
CO., LTD. Page : 1 / 2

The mechanism of the transformer which may be equipped with the mount is
showing Fig. 1.
Do not give severe shock to the mount since the current transformer is often
located in it.

(1) Check the stamp indicate which phase the mount is fitted to . (See Fig. 2)
(2) Open the CT terminal box attached to the mount and measure the insulation
resistance of CT. It should be 200 MΩ and above.
(3) Remove the top and bottom blank cover of the mount, pass the insulated
wire into CT and check the polarity of CT for all taps . (See Fig. 3) The
polarity is shown in the nameplate .

(4) Carefully remove the blank cover on the mount fitting flange, and also
remove gasket. (On the transformer side).
At this time, pay attention not to let bolts, nuts, tools and dirt fall into the
transformer.
(5) Clean the flange part by sand paper, and apply a small amount of adhesive
to the surface, and fix the new gasket.
(6) Hoist the mount by crane car and pass the lead wire through the central
hole of it. (See Fig. 6)
The lead wire is fixed in the transformer by tape during transport. When
drawing up it, remove the tape and pay attention not to damage the lead
wire and not to apply external force to the transformer coil.

(7) Clamp the bolts and nuts uniformly until the stopper on the flange matches
to the mount flange. (See Fig. 4).
(8) when fitting is over, tie the lead wire at the nut which welded below the
blank cover. (See Fig. 5)

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-62701
3.8 FITTING OF MOUNTS Rev. : -
DAIHEN ELECTRIC FOR BUSHINGS (GENERAL) Date : 20-Jan-04
CO., LTD. Page : 2 / 2

Bushing Stamping
Insulated wire
Mount CT terminal
box terminals

Trans-
former CT
CT G
Fitting flange
Fig. 1 Fig. 2 Fig. 3

Nut Wind the lead

wire and tie it by
Match this Bolt Mount string
surface
Gasket
Stopper
Tank cover
Spring washer side

Nut

Fig. 4 Fig. 5

Mount
Lead wire
Tank cover

Core

Transformer coil

Fig. 6
 Ref.No. : IE-63401
3.9 FITTING OF CONSERVATOR Rev. : C
DAIHEN ELECTRIC Date : 20-Jan-04
CO., LTD. Page : 1 / 3

(1) The rubber cell type conservator is shipped separately and filled with
nitrogen gas to prevent from moisture.
When mounting the conservator on the transformer, it is necessary to take
care of the followings.
Don't heat the conservator by welding or grinding, as the rubber
diaphragm is installed in.
Please refer to the instruction of rubber cell type conservator in detail.

(2) Fitting the protective relay

If the transformer is provided with a buchholz relay or other protective
relay, install them to the conservator before mounting it on the transformer.
The relay is connected to the conservator through a connecting valve.
Remove a blank cover of the flange surface, change the gasket to new one.
Install the relay to the conservator and clamp bolts tightly and uniformly,
Be sure to sets the relay in the direction indicated on the nameplate fitted
to it
Fitting of the protective relay should be referred to the instruction
manual in detail.

(3) Setting an oil level indicator on the conservator for OLTC

The conservator for OLTC with a dial oil level indicator is equipped on that
for the main tank.
The indicator is packaged separately from the conservator during transport.
Attach it to the conservator according to the following procedure.
(3)-1. Manually shift the float up and down , and check the operation of
alarm contact. Make sure of the arm length. (See Fig. 3).
(3)-2. Remove a blank cover and a gasket on the indicator fitting flange
of the conservator.
Attach the indicator to it carefully using a new gasket. Screw
bolts tightly and uniformly.

(4) Mounting the conservator on the transformer.

When the above fitting is over , hoist the conservator using lifting lugs and
mount firmly at the specified location . Pay attention not to incline in the
when hoisting. (to see fig. 4).

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-63401
Rev. : C
3.9 FITTING OF CONSERVATOR
DAIHEN ELECTRIC Date : 20-Jan-04
CO., LTD. Page : 2 / 3

Handhold
Oil level gauge Conservator

Rubber cell

Protective relay

Elbow Connecting valve

Drain valve

Fig. 1

Oil filling hole

Oil level gauge

Arm

Float

Fig. 2 Conservator for OLTC.

 Ref.No. : IE-63401
Rev. : C
3.9 FITTING OF CONSERVATOR
DAIHEN ELECTRIC Date : 20-Jan-04
CO., LTD. Page : 3 / 3

Conservator Float

Arm To check that the float does not

stop between upper and lower part.
If the float stops in its half way,
adjust the arm length again.

Indicator

Fig. 3 Check for float (operation) & contact.

Lifting lug

Conservator

Mounting bracket

Fig. 4 Hoist conservator horizontally

 Ref. No. : IN-05001
3.10 FITTING OF Rev. : A
DAIHEN ELECTRIC COOLING FAN Date : 14-Aug-08
CO., LTD. Page : 1 / 2

(1) Fitting
The cooling fans attached to the radiator panel The radiators, which provided
with fan fitting supports, are located at the end of each cooling bank.

The fans will be installed to the supports by nuts fastened surely. The fan
motors should be placed so that their cable outlets will be at the bottom of a fan
motor.

(2) Cabling

The terminal boxes, to which fan motor cables are to be connected , are
attached to the fitting supports on the radiator panel . After terminating the
cables as shown in Fig.1, connect them with the terminal blocks with confirming
to match the wire color to the block mark, i.e. The black covered wire is
connected to the blue mark U, the grey to V, the red to W and the black to E .

(3) Checking
After wirings are completed, supply the proper power to the fan motors, and
make sure that the fans rotate in the normal direction and without abnormal
sound.

(4) Moisture protection in the motor.

If a fan is stationary for long periods in a humid atmosphere, it should be
switched ON for minimum of 2 (two) hours every month to remove any
moisture that may have condensed within the motor.

U V W E Terminal block

Blue Black
Red
Reinforced with vinyle tape
Grey

Bush Bottom of terminal box

Cable

Fig.1 Cable connection for terminal box

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref. No. : IN-05001
3.10 FITTING OF Rev. : A
DAIHEN ELECTRIC COOLING FAN Date : 14-Aug-08
CO., LTD. Page : 2 / 2

Radiator Cooling fan

Fig.2 Cooling bank

Rotation
Fan fitting Fan motor
supports Junction box

Radiator panel
Cable

Terminal box

Fig.3 Fitting of cooling fans

 Ref.No. : IE-66201
Rev. : -
3.11 OIL PIPING 20-Jan-04
DAIHEN ELECTRIC Date :
CO., LTD. Page : 1 / 2

The oil piping should be in accordance with the diagram of PIPING ROUTE and
PIPING SYSTEM shown in the instruction manual, and based on the number tag
attached to the each pipe.

(1) Remove the blank covers from the separated oil pipes
Oil piping is provided for connecting the oil circuit of various accessories, and
some oil piping is transported separately.
Prior to fitting the oil pipes, remove the blank cover from them. Then remove
old gaskets which used for the blank covers, and clean sufficiently the gasket
groove and the gasket face by means of sandpaper.

After cleaning, be sure to wipe off foreign matter with a dry waste. If the
painted face is found to be spoiled, repaint with rust-proof paint.

(2) Check the ventilation of oil pipes

When cleaning of oil pipes is finished, pass either dry air or nitrogen gas
through the oil pipe and make sure that removal of foreign matter is complete.

(3) Remove the blank cover from the oil pipes on the transformer side.
Remove the blank covers and clean the piping faces. Check that no foreign
matter is allowed to enter inside the transformer tank.

(4) Assembling
Apply a small amount of adhesive to the gasket groove and fit the new gasket.
Tighten the clamp bolts in diagonal order and evenly until the flange faces
match.

(5) The connecting valves are also joined to oil pipes by means of above
procedure.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-66201
Rev. : -
3.11 OIL PIPING 20-Jan-04
DAIHEN ELECTRIC Date :
CO., LTD. Page : 2 / 2

Flange without a
gasket groove

Flange with a gasket groove

Fig. 1

Match surface

Fig. 2
 Ref.No. : IE-66301
3.12 PIPING AND WIRING Rev. : -
DAIHEN ELECTRIC OF ELECTRIC SYSTEM Date : 25-Dec-03
CO., LTD. Page : 1 / 3

(1) Pipe matching

In accordance with piping system diagram shown in the instruction
manual and based on the number tag attached to each pipe, arrange
a number of pipes to various accessories over the ground.

(2) Temporary assembly

Remove the blank covers from each conduit pipe and terminal box .
Temporarily set the conduit pipes from the terminal box to accessories
in numerical order as shown on the number tag attached to each conduit
pipe, and check piping direction , keeping the pipe connecting bolts
under the temporary screwed condition. (See Fig. 1)

(3) Determination of length of wires to be put in the conduit pipes

Based on wiring diagram, check the required number of wires to
be put in the conduit pipes leading to various accessories.
Measure the length along the temporarily assembled piping from
the terminal boxes to accessories, and cut out the required
number of insulated wires accordingly.

(4) Installing wires into the conduit pipes

Install the insulated wires into the conduit pipes from the
terminal box side to accessories side . (See Fig.2) However
before putting the insulated wires into the conduit pipes , check to
see if the end of each conduit pipe is smooth . If not, smooth in
inner end of pipes with a file in order not to damage the insulation
of the wires. Replace all gaskets for pipe connections with new
ones. Apply a small amount of adhesive to the gaskets groove
before putting the gaskets.

(5) Tightening of conduit pipes

When connecting the conduit pipes in which the insulated wires
are installed, check if any wires are caught in between the
connecting faces (See fig. 4), then tighten until the face match .

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-66301
3.12 PIPING AND WIRING Rev. : -
DAIHEN ELECTRIC OF ELECTRIC SYSTEM Date : 25-Dec-03
CO., LTD. Page : 2 / 3

(6) Another method of installing the wires into a conduit

As shown in Fig. 5, pass a cotton tube through the conduit pipe
by nitrogen gas or dry air pressure . Tie a bundle of insulated
wires to one end of the cotton tube.

The cotton tube enables smooth pulling of wires into and

through a conduit pipe. Instead of cotton tube, a fish wire
(steel wire) is also useful.

Fig. 1 Arrangement of pipes (over the ground)

Fig. 2 Temporary assembling and installing the wires

(over the ground)
 Ref.No. : IE-66301
3.12 PIPING AND WIRING
Rev. : -
OF ELECTRIC SYSTEM
DAIHEN ELECTRIC Date : 25-Dec-03
CO., LTD. Page : 3 / 3

Protective relay

Transformer Terminal box

Thermometer

Fig. 3 Fitting of pipes on the transformer

wiring

WRONG GOOD
Fig. 4

Conduit pipe

Insulated wires

Fig. 5
Cotton tube
 Ref.No. : IE-62101
3.13 FITTING OF Rev. : -
DAIHEN ELECTRIC BUSHING (GENERAL) Date : 25-Dec-03
CO., LTD. Page : 1 / 1

Bushings should be installed lastly to minimize the possibility of their being

damaged while installing other parts.
Care should be taken in unpacking the bushing package to avoid damage of the
porcelain. Before fitting the bushings clean the porcelain and the live part
thoroughly.
Bushings should be mounted on their locations as shown in outline drawing.

Make connections to both ends of the bushings in such a manner that strain is
avoided. When heavy busbars are connected to bushings, flexible connections
should be used to prevent damage that might possibly result from expansion and
contraction due to temperature changes. Be sure that all connections are tight to
prevent local heat of the terminal.

When the bushings are installed on the transformer , change a gasket to new one
for the fitting seat. The flange should be fixed uniformly by nuts in such manner
as shown in Fig. 1.

Throughout the work, worker should not use the gloves and tools-monkey
wrench, spanner, etc., unless they are tied to the worker with hempen strings to
prevent them being dropped into the transformer tank.

3' 2
Each pair of stud bolt 1-1', 2-2' and 3-3'
should be tighten with nuts at same time
2' 3 in order to fix the flange uniformly .

1'
Bushing fitting flange
Fig.1

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IN-01001
3.14 FITTING OF Rev. : A
CONDENSER TYPE BUSHING
DAIHEN ELECTRIC Date : 22-Aug-11
CO., LTD. Page : 1 / 2

Before fitting the bushing, read the attached instruction manual in which
described bushing handling manner such as unpacking, lifting.

Connection of lead wire and installation of bushing.

1. Draw the lead wire from the transformer tank.

2. Insert a hamper or cotton string into the hollow conductor of bushing as

shown in Fig.1 .

3. Lift the bushing over the transformer.

4. Attach a ring screw (M12) to the top of the inner terminal stud, and then
tie the lower end of string to the ring screw as shown in Fig.2 .

5. Pass the lead wire through the bushing while pulling up the string and
bringing down the bushing gradually.

Do not pull the string too strong not to damage the transformer winding
and the lead wire.

6. Match the flange surface of bushing to the fixing part by tightened with
nuts. (See Fig.3)

7. Draw the inner terminal stud from the bushing head, and insert refraining
pin into bushing tube through inner terminal stud as shown in Fig.4 .

8. Fix the inner terminal stud to the outer terminal stud. It is unnecessary to
change the flat gasket to new one (See Fig.4)

9. Fix the top terminal to the outer terminal stud head with bolts as shown in
Fig.5 .

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

3.14 FITTING OF CONDENSER
TYPE BUSHING
 Ref.No. : IE-62303
3.15 FITTING OF SOLID TYPE Rev. : -
DAIHEN ELECTRIC BUSHING ( Plate type ) Date : 20-Jan-04
CO., LTD. Page : 1 / 1

(1) Tighten the nut (A) and (B) to porcelain slightly.

(2) Clean the gasket groove of bushing fitting seat, and apply a small amount of
adhesive in the groove in order to fix a new gasket.

(3) Put the bushing on the seat, and tighten nuts until the flange surface matches to
the seat.

Do not over-tighten.
(4) Connect the copper plate brought out from the transformer winding to the
bushing terminal tightly by using bolts, nuts and washers.

Gasket

Washer
Nut (A) Spring washer
Nut (B) Bolte
Lead terminal
Terminal Plate

Bolte
X X'

Lead
Nut

X - X'

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref. No. IN-09141
3.16 Oil filling and Rev. -
DAIHEN ELECTRIC draining process Date : 18/05/2015
CO., LTD. Page 1 / 4

1. Draini ng the ins ulati ng oil while filli ng w ith nitroge n ga s.

Supply nitrogen gas into the transformer to displace the insulating oil, then to drain off the
insulating oil. Do not allow the internal pressure inside transformer to become negative. Sealing
pressure of nitrogen gas should be from 0.05 to 0.2 kg/sq.cm. (Refer to item 3 "In case of oil
draining")
2. Filli ng of tota l qua ntity of ins ulati ng oil unde r vac uum.
After draining the total quantity of insulating oil from the transformer, arrange the machine parts as
illustrated in the last page of this cause (OPERATION OF VALVES), and carry out filling.
2.1 Cautions for va cuum ing a nd oil filli ng.
1) When opening drums of oil, care should be exercised to prevent moisture from condensing
within them. It is preferable that filling is done when humidity is low. Drums should be opened
only at the time when the oil is needed. Before filling the oil, take sample from oil tank/drums
as the following table A and test the dielectric strength as the following table B.
Table A
Number of Number of
Number of samples Number of samples
drums drums
2 - 5 2 101 - 200 10
6 - 20 3 201 - 400 15
21 - 50 4 more tha n 400 20
51 - 100 7 - -

Table B
IEEE C57.106 IEC60422
Voltage class Minimum voltage (kV) Voltage class Minimum voltage (kV)
(kV) at 1 mm gap at 2 mm gap (kV) at 2.5 mm gap
≤ 69 ≥ 25 ≥ 45 < 72.5 > 55
> 69 - < 230 ≥ 30 ≥ 52 72.5 - 170 > 60
> 230 - < 345 ≥ 32 ≥ 55 > 170 - 400 > 60
> 345 ≥ 35 ≥ 60 Note : Test metho d accor ding t o IEC60156
Note : Test metho d accor ding t o ASTM D1816

2) The oil filling apparatus should be clean and free from moisture, care should be taken to
prevent moisture from being introduced into oil though oil line.
3) Do not energize the transformer when vacuuming and filling oil.
4) In the case of transformer with resistor type on-load tap-changer the partition wall of diverter
switch compartment can not withstand full vacuum. Before exhausting air from the transformer,
open the equalizing valve located between the switch compartment and the transformer tank in
order to maintain same pressure as the transformer interior.
5) In the case of transformer with diaphragm type conservator. Before exhausting air from the
transformer, open the equalizing valve located with the conservator in order not to damage the
diaphragm.
6) In the case of transformer with nitrogen seal equipment. Before exhausting air from the
transformer, do not vacuum the nitrogen gas expansion tank, because the tank can not
withstand full vacuum.

Designed by : M.UTEN Checked by : S.Winyou Approved by : K.Nagai

 Ref. No. IN-09141
3.16 Oil filling and Rev. -
DAIHEN ELECTRIC draining process Date : 18/05/2015
CO., LTD. Page 2 / 4

2.2 Vacuum Treat ment

1) Connect the service tool to flange (13) and (21).
2) Close (1), (2), (5), (6), (8), (9), (11), (12), (14), (17), (18), (20)
Open (3), (4), (7), (10), (13), (15), (16), (19)
and exhaust air from the inside of rubber cell until the degree of vacuum is less than 10 mm.Hg.
3) Close (15)
4) Open (20), exhaust air from the main tank until the degree of vacuum is less than 10 mm.Hg.
5) Open (15), exhaust air from both inside rubber cell and transformer tank until the degree of
vacuum is less as specified in table C. Continue vacuuming to keep degree of vacuum as
specified in table D.
Table C : Vacuum level. (mm.Hg)
Capacity
< 20 MVA < 60 MVA < 200 MVA > 200 MVA
Rated Voltage
less than or equal 36 kV 5 5 5 --
36 kV < x < 84 kV 5 5 3 --
84 kV < x < 170 kV 3 3 1 1
more than 170 kV 1 1 0.5 0.5

Table D : Vacuum keeping hour for new transformer. (hour)

Capacity
< 20 MVA < 60 MVA < 200 MVA > 200 MVA
Rated Voltage
less than or equal 36 kV 2 2 4 --
36 kV < x < 84 kV 2 4 4 --
84 kV < x < 170 kV 6 12 12 18
more than 170 kV 12 18 18 24
6) After the vacuum degree was confirmed, stop the vacuum pump temporarily, and carry out
the stop test. Criteria for stop test is by degree of vacuum, and increment of vacuum is as
specified in table E by 15 minutes after stopping. If the result of stop test is satisfactory,
proceed with oil filling.
Table E
Rated Voltage of transformer Increment of degree of vacuum
less than or equal 77 kV less than 5.0 mm.Hg
more than 77 kV less than 3.0 mm.Hg
more than 154 kV less than 1.0 mm.Hg

2.3 Oil fil li ng

1) After the transformer has carried out vacuum treatment described in item 2.2, then close (4),
open (1) and pump degassed oil into the tank. The insulating oil should be through the oil filler
press and the vacuum oil preconditioned.
2) During oil filling, continue the operation of vacuum pump. When degree of vacuum become
more than vacuum level, temporarily suspend oil filling and operate only the vacuum pump in
order to achieve required degree of vacuum.
 Ref. No. IN-09141
3.16 filling and Rev. -
DAIHEN ELECTRIC dra ining pr oce ss Date : 18/05/2015
CO., LTD. Page 3 / 4

3) Start oil filling until the indication of oil level gauge of main conservator indicates the scale 3-4.
Then temporary stop oil filling.
4) Close (15), (20) and stop vacuum pump.
5) Take off the vacuum line from (16) and replace with nitrogen gas line, open (15) and fill
nitrogen gas into the rubber cell until it comes into atmospheric pressure. Take off the nitrogen
gas line from (16).
6) Take off service tool from (13) and (21), Then close (21) by blank cover, Open (20)

7) Open (18) and start oil filling again when oil come out (18), Close (18), Then adjust oil level
until oil level of main conservator indicated follow at oil level-temperature curve, Then close (1)

8) Oil filling for OLTC conservator.

Open (4), the insulation oil from main conservator flow to OLTC conservator through (7)
and (4) until oil level reach the level indicated at oil level-temperature curve, close (7).
9) Open (14) and fill nitrogen gas to OLTC conservator until it comes into atmosphere pressure.
10) Install the dehydrating breathers. (Refer to the instruction manual of dehydrating breather)
11) Residual gas release and oil level adjustment:
Allow more than 8 hours for oil to permeate into the
immersed parts after oil filling. Then release residual gas ! WARNING :
from various parts by loosening the air relief plugs or KEEP THE EQUALIZING VALVE CLOSE
valves until oil escape. AT ALL TIME, EXCEPT WHEN VACUUMING

After residual gas is released, carry out oil level adjustment according to "Oil level-Oil
temperature curve" attached to the transformer.

3. In c ase of all oil drainin g.

1) Connect the service tool to flange (13) and (21).
2) Status of valve before oil draining. (14) (16)
Close (1), (2), (5), (6), (7), (8), (9), (11), (12), (15), (20)
Nitrogen line
Open (3), (4), (10), (13), (14), (16), (17), (19) Pressure gauge
3) Connect the nitrogen line to flange (14) and (16), connect
the insulation oil line to valve (1).
4) Open (1), (15), (20), drain insulation oil and fill nitrogen ( Keep pressure 0.05 to 0.2 kg/sq.cm
) to displace the insulating oil untill the main tank without the insulation oil. Stop operation of
draining, close (1) .
5) Take off the insulation oil line from (1) and connect to (9).
6) Open (9) , drain insulation oil and fill nitrogen to displace the insulating oil untill the OLTC
without the insulation oil. Stop operation of oil draining and nitrogen filling, close (9).
 Ref. No. IN-09141
3.16 Oil filling and Rev. -
DAIHEN ELECTRIC
CO., LTD.
draining process Date :
Page
18/05/2015
4 / 4

(18) (21) (21)

Air
detector (13)
(13 (14) (20)
Flange for Flange for OLTC (15)
Dehydrating Dehydrating breather Main Tank Conservator
Cons.
breather and Nitrogen line

(17) To Vacuum pump

(4 (6) ( ) (5 and Nitrogen line
(16)
Oil flow Relay

(7) (3)
Buchholz
(3 (2) Serv ic e too l
Relay
(19)
Q S R E2 Sudden pressure

(8) Main Tank

(11 (10

Radiator
(9) OLTC
(12) (1)
(10)
To Oil Line
No. Description Vacuuming Oil Filling In Service Oil Drianing
close- open- close- open-
1 Drain valve for main tank close close
close close
2 Filler valve for main tank close close close close
3 Connecting valve for main conservator open open open open
open -close -
4 Connecting valve for OLTC conservator open open open
open
5 Drain valve for main conservator close close close close
6 Drain valve (plug) for OLTC conser. close close close close
7 Equalizing valve for OLTC. open open -close close close
8 Connecting valve for oil filter unit close close close close
close- open-
9 Connecting valve for oil filter unit close close close
close
10 Connecting valve for radiator open open open open
11 Gas release valve close close close close
12 Oil sampling valve ( If any) close close close close
To
13 Connecting flange for Air breather open open
Air breathe r
open

Connecting flange for fill nitrogen to To

14 close close- open open
OLTC conservator Air breathe r
Temporary valve for vacuum and fill open -close - open -close - open -close -
15 N/A
nitrogen to main tank open open open
Temporary flange for vacuum and fill
16 open open N/A open
nitrogen to main tank
17 By-pass valve for Buchholz relay close close close close -op en
close- open-
18 Gas release valve for Air detector close close close
close
19 Connecting valve for Sudden pressure open open open open
open -close open -close
20 Connecting valve for Air detector close -op en open
-op en -op en
21 Connecting flange for vacuum open open -close close close -op en
3.17
 1. Recomm ended set ting temp erat ure of Therm ometer

1.1) In the case of Alarm and / or Trip

Thermometer for Oil for Windi ng

Alarm 80 ° C 100 ° C

Trip 90 ° C 110 ° C

1.2) In the case of cooling fan control.

Thermometer for Windi ng

stop -°C
2 nd Stage
of Cooli ng
start-up 90 ° C
(NOTE) In the case of over load operation,there is a possibility
of alarm and / or trip contacts operating

2. Recomm ended to m oisture protec tion in the motor of cooli ng fan.

If a fan is stationary for long periods in a humid atmosphere.

It should be switched ON for minimum of 2 (two) hours every month to
remove any moisture that may have condensed within the motor.

Process No. Title Description Date Rev.

Sett ing for Transf ormer
PP0443B Acce ssory
Date : 28/04/2015 Scale : X
DES 'D M.UTEN
CHK 'D S.Winyou Reference No.
APP 'D S.Winyou DAIHEN ELECTRIC CO., LTD. FD-PP0443B-20-01
 SECTION 4
AFTER INSTALLATION
 Ref.No. : ED-IM-17112
4.1 INSPECTION AND TEST Rev. : -
DAIHEN ELECTRIC AFTER INSTALLATION Date : 25-Dec-03
CO., LTD. Page : 1 / 1

After assembling transformer, check it in accordance with the followings:

1) Construction
Make sure that all parts are located on their proper position, and clamping of
all bolts and nuts is complete.
2) Connection
Make sure that electrical connections are complete and wiring are without
mistake.
3) Cooling equipment
Make sure that all radiator valves are opened, and cooling control device,
cooling fans operates is normal condition.
4) Tap changer
Make sure that the tap-changer operates smoothly, and the tap position is
corresponding to the specified voltage. Control device for OLTC is in normal
condition.

5) Protective relays
Check the contact operation.
6) Indicators
Check the oil level gauges or thermometers indicate the proper position of the
scale.
7) Dehydrating breathers
Check the breathers operation.
8) Check air-release is complete.
9) Check the valves are in the proper position.
10) Grounding system
Make sure that the ground system of the transformer is perfect. Since the
surface of ground pads are painted to prevent it from rusting during transport;
remove the paint for good connection of ground cable.

11) Live parts of bushings and lighting arresters.

Make sure that phase to phase and phase to ground distance are sufficient.

When above inspections are complete, carry out the field test such as insulation
resistance measuring, ratio test angular displacement measuring. Execution of
applied potential test and temperature rise test is preferable.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-54201
4.2 FIELD TEST AFTER Rev. : A
DAIHEN ELECTRIC INSTALLATION Date : 22-Oct-10
CO., LTD. Page : 1 / 3

In the field test to be conducted during and after field assembly, there are the
following.
a) Insulation resistance measurement
b) Polarity, phase rotation & transformation ratio tests
c) Test of alarm devices and control units
d) High voltage test

a) Insulation resistance measurement

(i) Transformer body
Measure insulation resistances between two windings and between
each winding and earth by means of a megger of more than 1000 V,
and record the measured values. Because insulation resistance
values change according to temperature, be sure to record the
temperature of transformer.
According to the document no. NE-TC6-061, Fig 1. "Tolerance for
insulation resistance of transformer"

(ii) Accessories & wiring

Measure insulation resistances between two terminals of terminal box
and between each terminal and earth from terminal to terminal, and
record insulation resistance value and temperature. In the case of
bushing CT, be sure to measure insulation resistance between two
CTs in addition to insulation resistance between each CT and earth.
According to the document no. ED-IM-17154, Table 3. "Insulation
resistance values of the low-tension electrical works"

b) Polarity, phase rotation & transformation ratio tests

(i) Polarity & phase rotation tests
Perform the polarity and phase rotation test at the rated tap.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-54201
4.2 FIELD TEST AFTER Rev. : A
DAIHEN ELECTRIC INSTALLATION Date : 22-Oct-10
CO., LTD. Page : 2 / 3

Criterion Polarity
H V1 > V2 Subtractive
X1
V1 < V2 Additive

V1

X2
H
V2
H

X2
H X3 H
X1 H3-X3=H2-X2 < H3-X2=H2-X3
H2

X2
H1 H3
X1 X3

H2

X2
H1 H3
X1 X3 H3-X3=H3-X2=H2-X2 < H2-X3
H2

X2
H1 H3
X1 X3

(ii) Transformation ratio test

In the case of a three-phase transformer, measuring it with a single-
phase power source will give better precision. Measure transformation
ratio at all taps with regards to each phase.
 Ref.No. : IE-54201
4.2 FIELD TEST AFTER Rev. : A
DAIHEN ELECTRIC INSTALLATION Date : 22-Oct-10
CO., LTD. Page : 3 / 3

In the case of a delta-delta connection

V V

Primary Secondary

In the case of a star-delta connection

V
V

Primary Secondary

In the case of a delta-star connection

V
V

Primary Secondary

c) Test of alarm devices and control units

Actuate each accessory such as the temperature relay, Buchholz relay,
etc. or short-circuit the terminal of such an accessory and check its
performance from terminals in terminal box and alarm panel.

d) Others
Continuously pressurize the transformer with pressure of 0.3 kg/cm2
(preferably delivered by nitrogen gas) for more than 24 hours, and visually
inspect to see if there are any oil leaks. With reference to drawings, carry
out appearance, dimensional and other checks on the transformer,
Measure insulation oil for its measurable properties such as withstand
voltage, acid value, volume, specific resistance, water content, etc.
It is also recommended to measure the winding resistance.
 Ref.No. : IE-72101
Rev. : -
4.3 PAINTING Date : 25-Dec-03
DAIHEN ELECTRIC
CO., LTD. Page : 1 / 4

Painting procedures are as follows:

(I) Clean the whole transformer with use of thinner and rag.

(II) Polish with emerypaper any parts that have been scratched or marked, and
further clean each area lightly with emerypaper so that paint will adhere to
surface.

(III) By a brush, apply under coat (red primer) to the parts where flaws were found.

(IV) Cover up the following parts with paper or vinyl sheet so as to prevent them
from being fooled by paint. (See 2-3)

(V) By means of the spray gun, apply paint to the whole transformer.

(VI) After painting is over, remove the paper of vinyl sheet which is set out in the
above procedure (IV).

Further details of painting, including those parts that should not be painted, and
items that demand special attention when under coating and/or finish coating are
to be done after assembly of transformer is completed at site.

(1) Materials to be used

They are as follows; air compressor, spray gun, air reservoir, air hose, lead
wires, power source, switch, emerypaper, rag, painting brush, paint, thinner
and washing agent.

(2) Under coating

Under coating is anticorrosive painting to be executed prior to finish coating,
and using anticorrosive paint, apply it with brush.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : IE-72101
Rev. : -
4.3 PAINTING Date : 25-Dec-03
DAIHEN ELECTRIC
CO., LTD. Page : 2 / 4

(2-1) Parts to be subject to under coating and finish coating

the following parts are to be subjected to an under coating and then a
finish coating:
a) Those parts where the painted face was flawed during transportation.
b) The parts separately shipped and assembled at site, where the
painted face was flawed during transportation.
c) Parts to which blank covers are attached for transportation purpose.

(2-2) Parts to be subjected to under coating only

The following parts are to be subjected to an under coating only as the
finishing coat is omitted when the transformer is to be assembled at site:
a) From the gasket face of radiator fitted flange to the flange face of
outer side.
b) From the gasket face of radiator valve to the flange face of outer side.
c) From the gasket face of oil piping flange to the flange face of outer side.
d) From the gasket faces of fitted flanges of other accessories to the
flange faces of outer side.
e) From the gasket effective face of opening flange of a handhold or
manhole to the flange face of outer side. (However, when the flange
face is made of brass or non-metal, under coating can be also omitted
there.)

Examples
Part to be
subjected to
foundation coating

Part not to be
subjected to
coating

Radiator fitting flange Opening angle of Handhold

Fig. 1 Examples of Parts to be Subjected to Foundation Coating Only

 Ref.No. : IE-72101
Rev. : -
4.3 PAINTING Date : 25-Dec-03
DAIHEN ELECTRIC
CO., LTD. Page : 3 / 4

(2-3) Parts not to be subjected to under coating

The following parts are not to be subjected to under coating.
a) Gasket face of radiator fitted flange and part of inner side from this
gasket face.
b) Gasket face of radiator valve and part of inner side from this gasket face
c) Gasket face of oil piping flange and part of inner side from this gasket
face.
d) Gasket faces of fitted flanges of other accessories and parts of inner
side from these gasket faces.
e) Gasket effective face of opening angle of a handhold or manhole.
f) Parts of ground terminal block where the ground conductor makes
contact. However, in the case of flange of a conduit pipe, it is in order
to apply under coat to the gasket face.

(3) Finish coating

Finish coating is a coating of final paint of designated color and is to be
applied by spraying by means of a spray gun. The following parts are not to
be subjected to finish coating.
a) Porcelain tube, terminals, oil level indicator and nameplate of bushing.
b) Glass part of oil level indicator of conservator and plated part of frame of
instruments.
c) The whole lightning arrester (except the lightning arrester fitted part.)
d) Dial type thermometer
e) Inspection window and needle valve of gas release plug of gas detector
and Buchholz relay.
f) All nameplates on the transformer.
g) Exposed charging part.
h) Ground conductor and ground terminal (However, the cleat for fixing
ground conductor is to be coated.)
 Ref.No. : IE-72101
Rev. : -
4.3 PAINTING Date : 25-Dec-03
DAIHEN ELECTRIC
CO., LTD. Page : 4 / 4

(4) Mixing of paint

In the case of under coating of finish coating, depending upon method of

paint application, that is bushing or spraying, and the kind of paint to be used,
mix the thinner with the paint by the appropriate ratio listed in the following
table, and then apply the resulted mixture.

Ratio of thinner relative to paint

Brushing Spraying
Paint
(%) (%)
Foundation
Daigo (#200) 5 20-30
coating
Finish Graston 10 15-25
coating Phtharon 10-20 30

(5) Cautions for coating

a) In the case a vinyl resin paint is used for finish coating, use a vinyl resin
paint for under coating. The finish coating is to be applied after 24 hours
from applying the under coating.

b) Whenever under or finish coating is to be applied, completely remove oil

and grease from the surface on which paint is to be applied.
c) Whenever under coating is to be applied, polish thoroughly the rusted
part of surface to be painted, and then apply under coating. Do not apply
under coating directly to a rusted surface.

d) When dirt, dust, etc. are found on the surface to be painted, apply coating
only after removing.
 Ref.No. : X-80-02
4.4 RE-DRYING OF Rev. : -
DAIHEN ELECTRIC THE TRANSFORMER AT JOB SITE Date : 21-Jan-04
CO., LTD. Page : 1 / 7

Re-drying
Drying the transformer at job site is necessary in the following cases :
- When air-tightness is broken during transport or during storage (if nitrogen
gas leakage is found after checking it's pressure, see IE-11101)

- When the transformer core-coil has exposed to air as follows :

Maximum operating Exposed time
voltage (kV) (hour)
to 72.5 30
from 73 to 170 16
from 171 to 300 12

Page 7/7 might be helpful to understand following explanations.

1) Principle
Hot oil and vacuum treatment method
- Heating Preliminary vacuum treatment to judge the degree of humidity.
Oil filling under vacuum.
Oil circulation during heating.

- Drying Oil draining, filling the tank with nitrogen gas.

Vacuum treatment of the transformer tank.

- Judgment Judgment of the drying degree from dew point, vapor pressure
and temperature.

2) Heating
2-1 Preparation
- Mount the bushings on the transformer to measure the winding temperature
by resistance method.
- Drain off the residual oil completely by pumping out from the drain valve.
- Open the upper filter valve so as to make the air in tank for draining the
residual oil.

Designed by : I.TEERAWAT Checked by : M.OCHI Approved by : M.OCHI

 Ref.No. : X-80-02
4.4 RE-DRYING OF Rev. : -
DAIHEN ELECTRIC THE TRANSFORMER AT JOB SITE Date : 21-Jan-04
CO., LTD. Page : 2 / 7

- Fit the transparent tube, as the oil level indicator, between the drain valve
and the flange located on the cover (or the flange on the conservator
connecting pipe). This tube must endure a vacuum and withstand hot oil.
Clamp the flange sufficiently.

- Connect the vacuum pump equipped with a vacuum gauge and a condenser
to the upper part of the transformer (to a flange on the cover, for example).
- After lead wire connections of all bushing are finished, take preliminary
measurements of winding resistance and temperature so as to get a basis of
comparison for the subsequent operations.

- Put the vacuum pump into operation until a vacuum of at least 3 torrs is
obtained in the tank.
- Every hour, measure the volume of water taken from the condenser of the
vacuum pump until not more than 500g of water per hour is drained off.
- Once this value is reached, connect the oil purifier through two pipes
(suction on the lower filter value and delivery on the upper filter valve). Close
the under filter valve, and open the upper filter valve, and start the oil filling
(treated, dried and deserted oil) through the upper filter valve to the
transformer under vacuum.
The oil is then raised to the temperature of 50~60°C approximately. When
the oil level is 15 cm. Below the tank cover stop the oil filling and close upper
and lower filter valves. Continue the operation of the vacuum pump.

2-2 Heating operation

- Take the temperature measurements (by resistance variation or by
interpolation) twice a day.

Note ;
For measuring temperatures, two alternatives are possible.
- by measuring the resistance variation of one of the windings (by using a
measuring bridge and a D.C. battery)
- by interpolation; the temperature of the core-coil assembly lies between
the oil temperature at suction and delivery.
These temperature measurements should be made as near as possible to
the transformer so as to prevent any error due to heat, losses in the piping.
The oil temperature difference between suction and delivery must not
exceed 5 to 10°C.
 Ref.No. : X-80-02
4.4 RE-DRYING OF Rev. : -
DAIHEN ELECTRIC THE TRANSFORMER AT JOB SITE Date : 21-Jan-04
CO., LTD. Page : 3 / 7

- Flit the temperature curve of the core-coil assembly as a function of time.

- Open the lower and upper filter valves.
Start up the oil circulating by oil purifier.
This apparatus must comprise vacuum pump , heater, filter, injection
pump, etc. This apparatus should produce oil which is perfectly clean,
dried, deserted and treated. Allow the oil temperature rise until 90-95°C

The oil temperature should not exceed at 100°C . During the whole
heating process, record the temperature indicated by the thermometer at
every hour.

3) Drying
3-1 Preparation
- Stop the vacuum pump and break the vacuum in the tank
- Close the upper and lower filter valves and remove the oil circulating apparatu
- Completely drain the total quantity of insulating oil through the lower filter
valves, filling the tank with nitrogen gas (Blow the nitrogen gas through the
orifice of the cover) .

3-2 Drying operation

- Close the orifice, upper and lower filter valves.
- Put the vacuum pump into operation.
- Plot the curve, as a function of time, of the volume of water taken from the
condenser of the vacuum pump at every hour.
- Also, take the hourly reading of the residual pressure of vacuum.
- Continue the operation until the vacuum is obtained at least 3 torrs in the
tank. Maintain this vacuum value throughout the drying operation (at least
for 48 hours) .

4) Judgment
- When the water volume curve reaches below 50g per hour ,stop the vacuum
pump operation.
- Measure the pressure in the tank at every minute and plot the pressure
curve as a function of time. Fig. 1 shows the typical pressure curve.
- Decide the end point of vapor generation from this curve.
 Ref.No. : X-80-02
4.4 RE-DRYING OF Rev. : -
DAIHEN ELECTRIC THE TRANSFORMER AT JOB SITE Date : 21-Jan-04
CO., LTD. Page : 4 / 7

- Decide the temperature of core-coil assembly from the measurement of the

winding resistance.
- Decide the water concentration in insulation materials from Fig. 2 .
- If the water concentration is under 0.5%, finish the drying work.

5) Oil filling
- Start the vacuum pump operation again, and continue the vacuum pump
operation until the vacuum degree is obtained at least 3 torrs in the tank
(Maintain this vacuum value at least for 1 hour.) .

- Start the oil filling to the transformer through the lower filter valve.
- Bring the oil level as up as possible to the cover. Close the lower filter valve.
- Maintain the vacuum operation for 4 hours.
Installation, Operation and maintenance

Service : Unit Auxiliary Transformer

Tag no. : 20BBT10/ 21BBT10

11/6.9 kV, ONAN 8 MVA, Oil Immersed, Conservator tank with rubber bag

Ekarat Engineering Public Company Limited

9/291 U.M Tower, 29 Fl., Ramkamheang Road.,Suanluang Dis., Bangkok 10250
Tel : (+662) 719-8777 Fax : (+662) 719-8760
Website : http://www.ekarat.co.th
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 1/1
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 03 / 04 0 1

CONTENT
PAGE
1 Introduction 1/1
2 Handling and Installation 1/2-2/2
3 Commissioning and Testing 1/1
4 Inspection after Energizing 1/1
5 Operating Instruction 1/1
6 Inspection and Maintenance 1/1
7 Safety and Environment 1/1
8 Information on Nameplate 1/1
9 Inspection and Maintenance of Warranty 1/2-2/2
10 Services Centers 1/1
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 1/1
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 10 / 03 1 0

1. INTRODUCTION
1.1 General
This instruction manual covers oil – immersed transformers (hereinafter called the transformer) suitable
for outdoor and/or indoor installation. The transformers are gas cushions sealed tank type } hermetically
completely filled with oil type or conservator type. The transformers shall be operated and serviced only
by competent personnel , having experienced good safety practices. This instruction manual is
prepared for such personnel and is not intended as a substitute for adequate training and experience in
the use of transformers. The transformer outline drawing shows details and location of nameplate ,
equipment and accessories.

1.2 Caution
Please read this instruction manual carefully before attempting to handle , install , use or make services
to the transformers. In case that assistance required or having any questions , please contacts your local
Ekarat Sales and Services Officers , which are located throughout Thailand.
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 1/2
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 10 / 03 2 0

2. HANDLING AND INSTALLATION

2.1 Tilting
The transformer must not be tilted for more than 15 degree.

2.2 Lifting
Lifting lugs or eyes are on the transformer tank cover and attached to the tank wall for the small and
big transformer respectively.

In case of large transformers , the lifting eyes on tank cover are used for lifting the internal parts
during untanking or tanking only , untanking weight for selection of proper hoist or chain hoist can be
obtained from lifting weight as stated in nameplate. The lifting lugs and lifting eyes are shown on
transformer outline drawing for proper lifting position.

2.3 Jacking
Refer to the transformer outline drawing for jacking area on the transformer tank. Only this area can
be used for this purpose only.

2.4 Storage
Transformers , parts and accessories should be kept indoor in clean and dry area.
2.5 Installation
The correct and appropriate installation is one of the safety factor of the operators , asset and lifetime
of transformers.

2.5.1 Transformers should be located at the appropriate location , comfortably moving in and out ,
inspecting and maintaining both outdoor yard/pole mounted and indoor room.
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 2/2
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 10 / 03 2 0

2.5.2 Provision of good ventilation of transformers should be made to ensure that the transformers is
sufficient ventilated during operating.

2.5.3 In case of indoor installation , these should be at least 100 cm and 60 cm space between
transformer and wall , and transformer and ceiling respectively. Also at least 30 cm from
inflammable material , clearance shall be provided.

2.5.4 Outdoor installation of transformers should be fenced at least 100 cm space between wall or
fence and live part of high voltage , at least 180 cm .

2.5.5 Transformers should be mounted or stood firmly in the station.

2.5.6 Level of floor or platform must be even and strong enough for each transformers.
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 1/1
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 10 / 03 3 0

3. COMMISSIONING AND TESTING

3.1 Check installation arrangement
3.2 Connect and check connection to earth
3.3 Check all external bolt (if necessary , retighten)
3.4 Check al accessories are in place and setting (usually all protective devices are set by
manufacturer) or according to requirement (if any suggestion is needed please contact Ekarat Sale
and Service)
3.5 If fan is installed , it is necessary to check the fan control system and correct direction of rotation of
the fan.
3.6 Tap position must be selected and locked in place.
3.7 For conservator type , the mylar sheet between the siliga gel cylinder and the pipe from conservator
tank must be removed (see work instruction attached to cylinder)
3.8 All tools , equipments and any objects used in installation shall be removed from the transformers ,
and cleaned.
3.9 Any scratches of paint must be touched up with the paint attached. (Contact Ekarat’s representative
for more information)
3.10 Make sure that phasing is correct according to nameplate attached.
3.11 If requird , insulating resistance test is carried out with insulation tester.
3.12 Check all valves if they are properly closed and no sign of leaking including the transformer tank
and gaskets.
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 1/1
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 10 / 03 4 0

4. INSPECTION AFTER ENERGIZING

After the transformers are energized , do the following inspection to ensure proper function of the
transformers.
4.1 Any vibration during operating
4.2 Measuring the output voltage whether it is correct according to selected tap position
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 1/1
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 10 / 03 5 0

5. OPERATING INSTRUCTION

The general operating conditions are applicable according to IEC 354/1991 or equivalent standards
unless deviating customer specifications have been agreed upon. The following are general operating
guideline.
5.1 Ambient temperature should not exceed 40° c
5.2 When electrical connections are made , all mounting or connecting must be done according to the
correct procedure.
5.3 Electrical protection equipment must be properly selected to match the transformers.
5.4 Operating voltage should not exceed ±5 % at on load and should not exceed ±10% at no load.
5.5 Normally Ekarat transformers are designed for oprating at maximum 3300 feet above sea level ,
any installation above 3300 feet will affect to the capabilityof transformer and oil temperature.
5.6 Frequency range of source voltage should be as that of stated on the nameplate.
Please contact Ekarat’s representative if more explanation is needed.
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 1/1
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 10 / 03 6 0

6. INSPECTION AND MAINTENANCE

Oil-immersed type transformers are recommended for periodic inspection and maintenance to verify that
the transformers are in normal operation, and extends the life time of transformers
General Inspection
6.1 Inspect indicating accessories such as thermometer, oil level, and pressure gauge to ensure their
proper functioning. If any signs of malfunction is noticed, please contact Ekarat’s representative.
6.2 Inspect tank and all joints of gaskets to ensure that there is no liquid leakage.
6.3 Inspect conditions of external compartments such as bushings, color of silica gel, contacts or
termination of cable lugs or cable, bolts and nuts whether they are still tight, paint etc. The above
general inspections are recommended to be carried out as your periodic routine inspection.
For further inspections which require internal parts checking,please contact Ekarat Sales and Services
Centers.
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 1/1
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 10 / 03 7 0

7. SAFETY AND ENVIRONMENT

All the transformers are designed and produced according to the customers’ requirement. Quality
control system is implemented in each stage of production to ensure effectiveness and long life time of
transformer. The followings are instructions that must be followed strictly:
7.1 Transformers must be switched off, isolated and grounded if maintenance, internal inspection,
connection or changing tap position are necessary as to ensure that no residual or feedback
voltage remains in transformers.
7.2 The transformer oil is mineral oil produced from crude oil, and does not contain any PCBs
(Polychlorinated Biphenyl’s) which is banned in many countries. However it is necessary to handle
and dispose of with care and in proper manner, please contact Ekarat’s representative.
7.3 Transformers should be operated strictly under the conditions or specified environment.
7.4 In case of fire, the appropriate extinguisher is co2 or other which is suitable for each purpose.
7.5 Signboard should be put at the position which can be seen clearly during operation or for alert. To
avoid unexpected incident, please read and follow the instruction and suggestion for safety and
correct operation. More information and services can be obtained through Ekarat Sales and
Services Centers.
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 1/1
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 03 / 04 8 1

8. INFORMATION ON NAMEPLATE
Nameplate which gives the basic information for reference is supplied and attached on one side of every
transformer.
Information shown on Nameplate :
8.1 kVA : Power output in kilovolt – ampere of transformers under the specified
condition of operating.
8.2 Phase : The number of phase
8.3 Frequency : Frequency of the system on which transformer is connected
8.4 Type : Type of cooling system.
8.5 Class : Class of insulation, which used for production.
8.6 Pri. Volt and Amp./ : Rated line voltage and rated line current of primary and secondary of
transformers.
Sec. Volt and Amp.
8.7 Percent Imp : Impedance voltage in percentage.
8.8 Oil Temp. Rise : AN Top oil temperature rise above ambient temperature at rated kVA
8.9 Oil Qty (L) : The estimated oil volume in liter.
8.10 Drain Oil Qty (L) : This information is for “hermetically sealed” (completely oil filled)
transformer, and used by manufacturer only.
8.11 Total Wt. (Kg) : Total weight of whole transformer.
8.12 Lifting Wt. (Kg) : The weight of total internal parts for untanking.
8.13 Voltage and Tap : The relevant primary voltage at any Tap position with the condition of
position constant secondary voltage.
8.14 Connection : Position of terminal of primary and secondary side.
Diagrams
8.15 Vector Diagram : The phase rotation and phase angle shift between the high voltage and low
voltage
8.16 Item Code : Manufacturer’s particular design reference.
8.17 Serial Number : Identification number of each specific transformer. Please refer to this
serial number.
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 1/2
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 03 / 04 9 0

9. INSPECTION AND MAINTENANCE OF WARRANTY

TABLE OF INSPECTION AND MAINTENANCE FOR OIL IMMERSED TRANSFORMER
IN 10 YEARS WARRANTY
TYPE OF TRANSFORMER
YEAR TYPE OF FREQUENCY
INSPECTION ITEM Conservator Nitrogen Hermetically COST
CHECK (PER YEAR)
gas sealed sealed
1 NO SHUT DOWN 1.OUTSIDE APPEARANCE INSPECTION ONCE 9 9 9 NO
2 NO SHUT DOWN 1.OUTSIDE APPEARANCE INSPECTION ONCE 9 9 9 NO
3 SHUT DOWN 1.OUTSIDE APPEARANCE INSPECTION & TWICE YES
MAINTENANCE 9 9 9
2.OIL SAMPLING FOR BREAK DOWN ONCE NO
9 - -
VOLTAGE TEST
4 SHUT DOWN 1.OUTSIDE APPEARANCE INSPECTION & TWICE YES
MAINTENANCE 9 9 9
2.OIL SAMPLING FOR BREAK DOWN ONCE NO
9 - -
VOLTAGE TEST
5 SHUT DOWN 1.OUTSIDE APPEARANCE INSPECTION & TWICE YES
MAINTENANCE 9 9 9
2.OIL SAMPLING FOR BREAK DOWN ONCE YES
VOLTAGE TEST POWER FACTOR,
MOISTURE CONTENT, ACID NUMBER, 9 9 9
DGA (FOR TRANSFORMER MORE THAN
1000 KVA)
6 SHUT DOWN 1.OUTSIDE APPEARANCE INSPECTION & TWICE YES
MAINTENANCE 9 9 9
2.OIL SAMPLING FOR BREAK DOWN ONCE NO
9 - -
VOLTAGE TEST
7 SHUT DOWN 1.OUTSIDE APPEARANCE INSPECTION & TWICE YES
MAINTENANCE 9 9 9
2.OIL SAMPLING FOR BREAK DOWN ONCE NO
VOLTAGE TEST 9 9 9
8 SHUT DOWN 1.OUTSIDE APPEARANCE INSPECTION & TWICE YES
MAINTENANCE 9 9 9
2.OIL SAMPLING FOR BREAK DOWN ONCE YES
VOLTAGE TEST POWER FACTOR,
MOISTURE CONTENT, ACID NUMBER, 9 9 9
DGA (FOR TRANSFORMER MORE THAN
1000 KVA)
9 SHUT DOWN 1.OUTSIDE APPEARANCE INSPECTION & TWICE YES
MAINTENANCE 9 9 9
2.OIL SAMPLING FOR BREAK DOWN ONCE NO
9 - -
VOLTAGE TEST
10 SHUT DOWN 1.OUTSIDE APPEARANCE INSPECTION & TWICE YES
MAINTENANCE 9 9 9
2.OIL SAMPLING FOR BREAK DOWN ONCE NO
VOLTAGE TEST 9 9 9
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 2/2
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 03 / 04 9 0

ADDITIONAL INSPECTION ITEM TO ANALYZE TRANSFORMER

FOR TRANSFORMER PUT IN SERVICE 3 YEARS AND MORE

TYPE OF TRANSFORMER
INSPECTION ITEM Nitrogen Hermetically
Conservator
gas scaled sealed
1.Test of Moisture Content, Acid Number, Power Factor 9 9 9
2.DGA Test 9 9 9
3.Insulation test by Polarize index 9 9 9

REMARK : - If the oil test results are not according to standard, filtering or changing the oil is a MUST
- Our sales person and service can provide the cost of inspection & maintenance for
transformer put in service 3 years and more.
 EKARAT ENGINEERING PUBLIC COMPANY LIMITED SET PAGE
Operating and Maintenance Instruction Manual for Oil-immersed A 1/1
Transformer
DOCUMENT NO. EFFECTIVE DATE CHAPTER REV.
EN-S-004 01 / 03 / 04 10 0

10. SERVICES CENTERS

1. Bangkok Branch :1068/2 Sukumvit 101/1 (Soi Wachiratumsatit),Pakanong Bangkok 10260
Tel (02) 3930437 , 393-0875-6 , 398-6992 , 393-0642 Fax (02) 3982903
2. Chachoengsao Branch : 190/1 Moo 6 Tasa-An, Bangpakong, Chachoengsao 24130
Tel (038) 531818 , 532306-8 Fax (038) 531505
3. Nakorn Patom Branch : 900/5 Phretkasem Road ,Huaijorake , Muang , Nakorn Patom 73120
Tel (034) 244045-6 Fax (034)244047
4. Ayuttaya Branch : 26/7 Moo2, Asia Highway (Bangkok-Nakornsawon), Tanoo, Uthai,
Ayuttaya 13210 Tel (035) 345078 Fax (035) 345020
5. Chiangmai Branch : 399/7 Mahidol Road, Nonghoi, Muang, Chiangmai 50000
Tel (053) 271631 Fax (053)271427
6. Surattani Branch : 218/21 Pedkasam Road, Makamtai, Muang, Surattani 84000
Tel (077) 219140 Fax (077) 219141
7. Hadyai Branch : 486/10 Phretkasem Road, Duanlang, Hadyai, Songkla 90110
Tel (074) 257622 Fax (074) 917046
8. Nakronrachasima Branch : 2175/2, Seubsiri Road, Naimuang, Muang, Nakronrachsima
30000 Tel (044) 277279,277050 Fax (044) 277050
9. Khonkaen Branch : 324/80 Moo 3, Mitraphap Road, Sila, Muang, Khankaen 40000
Tel (043) 364276-7 Fax (043) 364277
10. Phuket Branch : 75/40, Moo 6, Rusada, Muang, Phuket 83000
Tel (076) 254297 Fax (076) 254297
Head office 9/291 U.M. Tower Bldg. 28th foor, Ramkhamhaeng Road, Suanluang, Bangkok 10250
Tel (02) 7198777 Fax (02) 7198760-2
http ://www.ekarat-transformer.com
email : [email protected]

Factory 190/1 Moo 6 Tasa-An, Bangpakong, Chachoengsao 24130

Tel (038) 531818 , 532306-8 Fax (038) 531505
Installation, Operation and maintenance

Service : Auxiliary Transformer

Tag no. : 20BFT10/ 20BFT20
6.9/0.4 kV, AN 4000 kVA, Dry type Cast Resin

Ekarat Engineering Public Company Limited

9/291 U.M Tower, 29 Fl., Ramkamheang Road.,Suanluang Dis., Bangkok 10250
Tel : (+662) 719-8777 Fax : (+662) 719-8760
Website : http://www.ekarat.co.th
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/1
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/09/63 0 1

สารบัญ
หน้ า

1. บทนํา 1/1
2. การบรรจุหบี ห่ อและการจัดเก็บ 1/1
3. การเคลื่อนย้ ายและการขนส่ ง 1/1
4. การติดตัง้ 1/1
5. การจ่ ายไฟ 1/1
6. ข้ อแนะนําในการใช้ งานและการบํารุ งรั กษา 1/1
7. การเกิดความเสียหาย การรื อ้ และการซ่ อมแซม 1/1
8. วงจรควบคุมอุณหภูมแิ ละอุปกรณ์ ตรวจจับอุณหภูมิ 1/1
9. ระยะปลอดภัยสําหรั บ ROUND BUSBARS ด้ านแรงสูง 1/1
10. ตารางข้ อมูลต่ างๆ 1/1
11. ข้ อควรระวังในการต่ อสายแรงสูง 1/1
12. การตรวจสอบหม้ อแปลงไฟฟ้ าในระยะประกัน 1/3-3/3
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/1
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/08/57 1 0

1.บทนํา
หม้ อแปลง CAST RESIN ของบริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) เป็ นหม้ อแปลงไฟฟ้าชนิดแห้ ง(DRY TYPE) ผลิต
โดยสอดคล้ องกับมาตรฐาน IEC 60076-11 เมื่อเปรี ยบเทียบกับหม้ อแปลงไฟฟ้าชนิดแห้ งโดยทัว่ ไป หม้ อแปลง CAST
RESIN จะมีความแตกต่างที่ขดลวดอลูมิเนียมด้ านแรงสูง จะถูกห่อหุ้มด้ วย RESIN โดยผ่านกระบวนการหล่อในสภาพ
สูญญากาศที่ไม่มีฟองอากาศหลงเหลืออยู่ ทําให้ มนั่ ใจได้ วา่ มีโอกาสเกิด PARTIAL DISCHARGE ได้ น้อยมาก(สามารถ
ทนแรงดันฟ้าผ่าและแรงดันจากการปลด / สับสวิทซ์ได้ ดี) ในขณะเดียวกันทางด้ านขดลวดแรงตํ่าจะใช้ แผ่นอลูมิเนียม
(ALUMINIUM FOIL) พันทับไปกับฉนวน และเคลือบผิวโดยการจุ่ม RESIN (EPOXY RESIN-IMPREGNATED
INSULATION) ลักษณะการออกแบบเช่นนี ้ ทําให้ ทนต่อการลัดวงจรได้ ดีและมีความแข็งแรงทางฉนวนสูงสุด นอกจากนี ้
หม้ อแปลง CAST RESIN ไม่มีตวั ถังเหมือนหม้ อแปลงชนิดนํ ้ามัน จึงสามารถตรวจสอบรายละเอียดต่างๆ ของตัวหม้ อ
แปลงได้ อย่างสะดวกในแง่ของการบํารุงรักษา นอกจากนี ้ข้ อมูลทางเทคนิคอื่นๆ ได้ ถกู จัดเตรี ยมไว้ ให้ แล้ ว ได้ แก่
- วงจรการต่อสายแรงสูง และเนมเพลท (ติดที่ตวั หม้ อแปลง)
- แบบขนาดมิตขิ องตัวหม้ อแปลง
- แบบวงจรคอนโทรล
- ผลการทดสอบ (ถ้ าต้ องการ)
เพื่อให้ เกิดความปลอดภัยทังทรั้ พย์สนิ และตัวบุคคล ดังนัน้ ผู้ปฏิบตั งิ านควรอ่านคูม่ ือเล่มนี ้อย่างละเอียดก่อนที่จะ
ปฏิบตั จิ ริ ง หากมีข้อสงสัยหรื อต้ องการรายละเอียดเพิ่มเติม สามารถติดต่อได้ ที่ศนู ย์บริการของ บริษัท เอกรัฐวิศวกรรม
จํากัด (มหาชน) ที่มีอยูท่ วั่ ประเทศ
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/1
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/08/57 2 0

2. การบรรจุหบี ห่ อและการจัดเก็บ
ดังที่ได้ กล่าวมาแล้ วว่าหม้ อแปลง CAST RESIN เป็ นหม้ อแปลงที่มีความทนทานต่อสภาพแวดล้ อมต่าง ๆ ได้ ดี ใน
การขนส่งหรื อจัดเก็บในระยะเวลาสัน้ ๆ ไม่มีความจําเป็ นต้ องป้องกันเป็ นพิเศษแต่อย่างใด เพียงแต่ใช้ ผ้าใบหรื อแผ่น
พลาสติกคลุมอย่างมิดชิดก็เป็ นการเพียงพอแล้ ว
กรณีมีการจัดเก็บหม้ อแปลงเป็ นเวลานาน ให้ ระมัดระวังเรื่ องฝุ่ น,สิ่งสกปรกและความเปี ยกชื ้น ควรจัดเก็บไว้ ใน
ที่มีอากาศถ่ายเทสะดวก
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/1
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/08/57 3 0

3. การเคลื่อนย้ ายและการขนส่ ง
3.1 การเคลื่อนย้ าย
3.1.1 การยกโดยใช้ เครน ต้ องยกที่หหู ิ ้วเท่านัน้ สําหรับวิธีการและอุปกรณ์ที่ควรใช้ ได้ ให้ คําแนะนําติดไว้ ที่หม้ อ
แปลง ผู้ใช้ ควรปฎิบตั ติ ามคําแนะนําเพื่อเป็ นการป้องกันความเสียหายต่อโครงสร้ างภายในหม้ อแปลง

3.1.2 การลาก ในกรณีจําเป็ นต้ องลากหม้ อแปลงเข้ าสถานที่ตดิ ตัง้ ให้ ใช้ รูเจาะที่จดั ทําไว้ ที่ฐานหม้ อแปลง และห้ าม
ไม่ให้ โยกหม้ อแปลงมิเช่นนันอาจจะเกิ
้ ดความเสียหายได้
3.2 การขนส่ง เพื่อหลีกเลีย่ งความเสียหายระหว่างการขนส่ง ควรมีการป้องกันหม้ อแปลงลื่นไถลหรื อล้ ม ถ้ าเป็ นไป
ได้ ควรถอดล้ อออกเสียก่อน
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/1
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/08/57 4 0

4. การติดตัง้
4.1 หลังนําวัสดุที่ห่อหุ้มออกแล้ ว ให้ ทําความสะอาดอย่างระมัดระวังโดยตรวจดูร่องระบายอากาศต่างๆ ภายในขดลวด
หรื อระหว่างขดลวด เพื่อมิให้ มีวสั ดุแปลกปลอมเข้ าไปขวางทางระบายความร้ อนได้
4.2 ตรวจสอบสถานที่ตดิ ตัง้ ต้ องมีความมัน่ คงแข็งแรง รับนํ ้าหนักหม้ อแปลงได้ มีการระบายอากาศที่ดี โดยปกติ
ขณะที่หม้ อแปลงทํางาน อุณหภูมิของหม้ อแปลงจะสูงกว่าอากาศโดยรอบประมาณ 50-80 องศาเซลเซียส ขึ ้นอยูก่ บั
การจ่ายโหลดมากหรื อน้ อย ดังนันการระบายอากาศร้
้ อนที่ตวั หม้ อแปลงให้ เร็วด้ วยการแทนที่ด้วยอากาศที่เย็นกว่า
จึงเป็ นสิง่ จําเป็ น สําหรับการติดตังหม้
้ อแปลงภายในห้ องหม้ อแปลงหากการระบายอากาศไม่ดี เพียงพอจะทําให้
อุณหภูมิของหม้ อแปลงสูงเกินไป และจะทําให้ อายุการใช้ งานของหม้ อแปลงสันลงกว่ ้ าเวลาอันควรจึงมีข้อแนะนํา
ดังนี ้
4.2.1 ในห้ องติดตังหม้ ้ อแปลง ควรจัดให้ มีช่องทางเข้ าของอากาศเย็นและช่องทางออกของอากาศร้ อนในทิศทาง
ตรงกันข้ าม โดยช่องอากาศเย็นควรจัดให้ เข้ าทางด้ านล่างของตัวหม้ อแปลง ส่วนช่องอากาศร้ อน ควรจัดให้
อยูด่ ้ านบนเหนือตัวหม้ อแปลงหรื อห้ องหม้ อแปลง
4.2.2 โดยทัว่ ไปพื ้นที่ของช่องระบายอากาศต้ องไม่น้อยกว่า 10 ตร.ซม./kVAและต้ องไม่เล็กกว่า 500 ตร.ซม.
ตําแหน่งติดตังหม้ ้ อแปลงควรให้ หา่ งจากฝาผนังหรื อหม้ อแปลงเครื่ องอื่นๆไม่ น้ อยกว่า 50 ซม.
4.2.3 กรณีที่การระบายความร้ อนไม่ดีพอ จําเป็ นต้ องติดตังพั ้ ดลมดูดอากาศเข้ า-ออกเพิ่มเติมที่ผนังห้ อง โดยมี
เงื่อนไขว่า ลมดูดอากาศเข้ าห้ องหม้ อแปลง (INLET AIR) ต้ องมีอณ ุ หภูมิไม่เกิน 40 องศาเซลเซียส โดยติดตัง้
เทอร์ โมมิเตอร์ ตรวจวัด
4.3 อุปกรณ์หรื อชิ ้นส่วนต่างๆ ของหม้ อแปลงให้ ประกอบอย่างระมัดระวัง นัต โบท์ลต่างๆ เมื่อขันแน่นแล้ ว ให้ ใช้ ปากกา
เมจิกชนิด PERMANENTทําเครื่ องหมายไว้ ให้ ชดั เจน เพื่อป้องกันการลืมขัน (ในการขัน นัต โบล์ทอย่าขันแน่น
จนเกินไป เพราะอาจจะทําให้ เนื ้อ RESIN บริเวณขัวขดลวดแรงสู
้ งแตกหักเสียหายได้ และควรขันด้ วยประแจ
ทอร์ คตามค่าที่กําหนดไว้ ในตารางด้ านหลัง
4.4 กรณีที่มีการสัง่ ซื ้อตู้ HOUSING ให้ ประกอบตู้และติดตังพั
้ ดลมระบายความร้ อนให้ ถกู ต้ องตามแบบสัง่ งานที่
กําหนด
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/2
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/08/57 5 0

5. การจ่ ายไฟ
ก่อนมีการจ่ายไฟควรมีการตรวจสอบครัง้ สุดท้ าย โดยดําเนินการตามขันตอนต่ ้ อไปนี ้
5.1 ตรวจสอบการติดตังตามรายละเอี
้ ยดในข้ อ 4
5.2 ตรวจสอบ สายต่อลงดิน ของหม้ อแปลง
5.3 ตรวจสอบวัสดุแปลกปลอม ที่อาจตกหล่นในหม้ อแปลงและทําความสะอาดถ้ าจําเป็ น
5.4 ตรวจสอบสายตรวจจับสัญญาณอุณหภูมิ อยูใ่ นตําแหน่งถูกต้ องหรื อไม่ (ฝังในขดลวดแรงตํ่าทัง้ 3 เฟส กับบาร์
อลูมิเนียม) และยึดแน่นพอดีไม่หลวมคลอน การเดินสายสัญญาณจากขดลวดแรงตํ่ามายัง TERMINAL BLOCK
ต้ องเรี ยบร้ อยและขันแน่น
5.5 ตรวจสอบการทํางานของวงจรคอนโทรลและทิศทางของพัดลม ถูกต้ องหรื อไม่
5.6 การต่อสายเคเบิลแรงสูง จุดต่อ ลําดับเฟสและการต่อแท็ปถูกต้ องหรื อไม่ ดูรายละเอียดจากเนมเพลท
5.7 นัต โบล์ท ที่ขวแท็
ั ้ ปหรื อที่ขวด้
ั ้ านขดลวดแรงสูงและแรงตํ่าทังหมดจะต้
้ องขันซํ ้า ด้ วยประแจทอร์ ค ตามค่าใน
ตาราง TORQUE VALUES ด้ านหลัง
5.8 อุปกรณ์ตา่ งๆ เช่น บาร์ แรงตํ่า กับดักฟ้าผ่า สายเคเบิล โครงเหล็กยึดอุปกรณ์ สายไฟ และชิ ้นส่วนที่เป็ นสือ่ ทาง
ไฟฟ้า ที่ไม่ใช่ชิ ้นส่วนของตัวหม้ อแปลงที่เตรี ยมมาให้ จะต้ องติดตังให้
้ มีระยะห่างดังตาราง A และ B
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 2/2
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/08/57 5 0

Full part หมายถึง ผนังที่มีลกั ษณะปิ ดทึบ

Part Griey หมายถึง ผนังที่มีลกั ษณะเป็ นรูตะแกรง

หมายเหตุ ถึงแม้ วา่ หม้ อแปลง CAST RESIN จะถูกหุ้มด้ วย RESIN อย่างมิดชิด แต่ไม่ได้ หมายความว่า
สามารถสัมผัสหรื อจับต้ องได้ นัน่ คือการปฏิบตั งิ านใดๆเกี่ยวกับ หม้ อแปลงจะต้ องดับไฟ
และลัดวงจรลงดินก่ อนเสมอ
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/1
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/08/57 6 0

6. ข้ อแนะนําในการใช้ งานและการบํารุ งรั กษา

6.1 ข้ อแนะนําในการใช้ งาน
เงื่อนไขในงานใช้ งานหม้ อแปลง CAST RESIN โดยทัว่ ๆ ไปเป็ นไปตามมาตรฐาน IEC 60076 -11 แต่ถ้า
ต้ องการใช้ งานที่มีเงื่อนไขแตกต่างออกไป ให้ ถือเป็ นข้ อตกลงพิเศษในการพิจารณาความสามารถในการจ่าย
OVERLOAD จะมีความแตกต่างออกไปจากหม้ อแปลงชนิดนํ ้ามัน และให้ ยดึ ถือมาตรฐานการจ่ายโหลดตาม
IEC 60076-12 (IEC905) แต่อย่างไรก็ตามควรปฏิบตั ติ ามข้ อสังเกตดังต่อไปนี ้
6.1.1 ความสามารถในการจ่ายโหลดเกิน (OVERLOAD)
เมื่อเปรี ยบเทียบกับหม้ อแปลงนํ ้ามันโดยทัว่ ไปแล้ ว หม้ อแปลง CAST RESIN จะมีคา่ สัมประสิทธิ์ทางด้ าน
ความร้ อนและอุณหภูมิแตกต่างกัน รวมทัง้ CLASS ของฉนวน หม้ อแปลง CAST RESIN เป็ น CLASS F คือ
อุณหภูมิระบบฉนวนเป็ น 155 องศาเซลเซียส ดังนันการป้ ้ องกันการจ่ายโหลดเกิน ซึง่ เกี่ยวข้ องโดยตรงกับอุณหภูมิ
ของหม้ อแปลง จําเป็ นต้ องได้ รับการออกแบบและเลือกอุปกรณ์การตรวจจับอุณหภูมิให้ สอดคล้ องกันเป็ นพิเศษ
เพื่อป้องกันการเสียหายหรื ออายุการใช้ งานที่สนเกิ ั ้ นไป
6.1.2 ตัวตรวจจับอุณหภูมิ
ตัวตรวจจับอุณหภูมิ ถูกติดตังอยู
้ ใ่ นขดลวดแรงตํ่าดังที่กล่าวไปแล้ ว ซึง่ ประกอบไปด้ วยการทํางาน 3 สถานะ
แต่ละสถานะมีอณ ุ หภูมิแตกต่างกัน 20 องศาเซลเซียส สถานะอุณหภูมิตํ่าสุดอันดับแรก100องศาเซลเซียส จะสัง่
ให้ วงจรพัดลมระบายความร้ อนทํางาน (FAN ON) สถานะลําดับต่อมา120องศาเซลเซียส จะสัง่ ให้ วงจรเตือน
(ALARM) ให้ ทราบว่าหม้ อแปลงมีปัญหาด้ านอุณหภูมิ และสถานะลําดับสุดท้ าย 140องศาเซลเซียส คือการสัง่
ปลดวงจร (TRIP) ให้ ตดั หม้ อแปลงออกจากระบบก่อนจะเกิดความเสียหายอย่างรุนแรง
กรณีเมื่อปรากฎเหตุการณ์ผดิ ปกติเกี่ยวกับอุณหภูมิตา่ งๆ เกิดขึ ้นมักมีสาเหตุดงั ต่อไปนี ้
- จ่ายโหลดเกินพิกดั
- อุณหภูมิลมดูดเข้ าหม้ อแปลง(Inlet Air)เกินกว่า 40 องศาเซลเซียส เมื่อจ่ายโหลดตามปกติ
- การระบายความร้ อนไม่เพียงพอ
6.2 การบํารุงรักษา
หม้ อแปลง CAST RESIN ต้ องการการบํารุ งรักษาน้ อยมาก ส่วนใหญ่การบํารุ งรักษาจะเป็ นการทําความ
สะอาดฝุ่ น สิ่งสกปรก ที่จบั หนาตามส่วนต่างๆ ของหม้ อแปลงหรื ออุปกรณ์ ซึ่งทําให้ การระบายความร้ อนไม่
สะดวก วิธีทําความสะอาดใช้ การเป่ า ดูดและเช็ดด้ วยผ้ าแห้ งที่สะอาด นอกจากนี ้ให้ ตรวจสอบ นัต โบล์ทต่างๆ
ว่ามีการหลวม คลาย หรื อไม่ ส่วนวงจรตรวจจับอุณหภูมิ ต้ องตรวจสอบว่าทํางานได้ ถกู ต้ องหรื อไม่ โดยความถี่
ในการตรวจควรทําทุกๆ 6 เดือน หรื ออาจบ่อยกว่านี ้ในกรณีที่จําเป็ น เช่น ติดตังใช้้ งานริมทะเลเป็ นต้ น
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/1
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/08/57 7 0

7. การเกิดความเสียหาย การรือ้ และการซ่ อมแซม

ปั ญหาต่างๆ ที่พบและทําให้ เกิดความเสียหายมักจะเกิดเฉพาะที่บริ เวณขัวต่
้ อต่างๆ หรื อที่ขดลวดเท่านันและ
้
สามารถตรวจพบได้ ง่ายไม่ซับซ้ อนอะไร เพราะหม้ อแปลง CAST RESIN เป็ นหม้ อแปลงชนิ ดเปิ ดโล่งสามารถ
มองเห็นหรื อตรวจสอบได้ ทุกมุม นอกจากนี ้การรื อ้ และการซ่อมแซมสามารถกระทําได้ อย่างรวดเร็ วและประหยัด
เนื่องจากสามารถถอดเปลี่ยนได้ ตรงจุดที่ชํารุ ดได้ อย่างไรก็ตามในกรณีที่มีความเสียหายเกิดขึ ้นที่แกนเหล็กหม้ อ
แปลงควรจะส่งเข้ าซ่อมที่โรงงาน
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/1
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/08/57 8 0

8. วงจรควบคุมอุณหภูมแิ ละอุปกรณ์ ตรวจจับอุณหภูมิ

8.1 ความรู้ทวั่ ไป
ปั ญหาเรื่ องหม้ อแปลงมีอณ
ุ หภูมิสงู เกินไปในขณะใช้ งาน จะทําให้ เกิดอันตรายต่อตัวหม้ อแปลง เช่นเกิดการ
แตกร้ าวของเนื ้อ RESIN หรื อค่าความแข็งแรงของฉนวนต่างๆ ลดลงทําให้ หม้ อแปลงเกิดลัดวงจรชํารุดเสียหายได้
ดังนัน้ การควบคุมอุณหภูมใิ นขณะใช้ งานจึงเป็ นสิง่ จําเป็ นอย่างยิง่ สําหรับหม้ อแปลง CAST RESIN การระบาย
ความร้ อนสามารถทําได้ 2 ลักษณะคือ การระบายความร้ อนโดยธรรมชาติ และการระบายความร้ อนโดยใช้ พดั
ลมช่วย เพื่อให้ การระบายความร้ อนโดยใช้ พดั ลมเป็ นไปอย่างถูกต้ อง รวมทังการส่
้ งสัญญาณ ALARM และ
TRIP อย่างแม่นยํา จึงเลือก RTD (RESISTANCE TEMPERATURE DETECTOR) ชนิด PT100 (PLATINUM
100) เป็ นตัวตรวจจับอุณหภูมิ
8.2 การทํางานของวงจรควบคุมอุณหภูมิ
หลักการทํางานของวงจรควบคุมอุณหภูมิ ชนิด RTD มีหลักการทํางานเช่นเดียวกันคือ ตรวจจับอุณหภูมิที่
ขดลวดหม้ อแปลง ทัง้ 3 ขดลวด การทํางานแบ่งเป็ น 3 สถานะดังที่ได้ กล่าวมาแล้ วในข้ อ (6.1.2) สําหรับ
รายละเอียดของวงจรดูได้ จากเอกสารที่แนบไว้ ในตู้คอนโทรล
กรณีพบว่าวงจรควบคุมอุณหภูมิทํางานไม่ถกู ต้ องหรื อชํารุด โปรดแจ้ งศูนย์บริการของ บริษัท เอกรัฐ
วิศวกรรม จํากัด (มหาชน) ที่มีอยูท่ วั่ ประเทศ
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/1
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/08/57 9 0

9. ระยะปลอดภัยสําหรับ Round busbars ด้ านแรงสูง

ROUND BUSBARS (DELTA CONNECTION) ด้ านแรงสูงของหม้ อแปลง CAST RESIN ถูกหุ้มด้ วยฉนวน
พิเศษ (HEAT SHRINKABLE TUBE INSULATION) โดยมีวตั ถุประสงค์เพื่อเพิ่มค่า DIELECTRIC STRENGHT
และลดระยะระหว่าง LIVE PARTS กับ GROUND แต่อย่างไรก็ตามระยะที่ลดได้ ดงั กล่าว จําเป็ นต้ องกําหนดให้
มี ค่า ที่ ชัด เจนเพื่ อ ป้อ งกัน ปั ญ หาการเกิ ด ลัด วงจร การเกิ ด ปรากฎการณ์ CORONA รวมทัง้ สามารถทนต่ อ
IMPULSE VOLTAGE ในระหว่างการใช้ งานซึง่ ค่าต่างๆ ได้ กําหนดไว้ ในตารางแล้ ว (ดูบทที่ 10 )
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/1
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/08/57 10 0

10. ตารางข้ อมูลต่ างๆ

ตาราง Torque values

ขนาด Bolt ค่า Electrical connection ค่า Mechanical connection

Torque (Nm) Torque (Nm)
M6 5 -
M8 11 -
M 10 25 -
M 12 40 85
M 14 60 135
M 16 85 210
M 18 - 290
M 20 - 410
M 22 - 560
M 24 - 710

ระยะปลอดภัยสําหรับ Round busbar แรงสูงที่มีการหุ้มด้ วยฉนวนพิเศษ

Minimum clearance (mm.)

Rated Voltage (Kv.)
Phase to Phase (mm.) Phase to bare / ground (mm.)
12 55 65
17.5 70 85
24 95 125
36 150 205
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/1
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/08/57 11 0

11. ข้ อควรระวังในการต่ อสายแรงสูง

ในขันตอนการประกอบก่
้ อนจ่ายไฟ ให้ ประกอบด้ วยความระมัดระวังโดยอาจจะต่อสายแรงสูงเข้ าด้ านบนหรื อ
ด้ านล่างของตัวหม้ อแปลงก็ได้ ตาม DIAGRAM แต่ต้องมีการสลับเฟสตาม ตัวอย่าง

PRINCIPLE SKETCH

การเข้ าสายด้ านบน

การเข้ าสายด้ านล่าง

 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 1/3
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/09/63 12 1

12. ปั ญหาและการแก้ ไขเบือ้ งต้ น

ปํ ญหาที่พบ สิ่งผิดปกติ / สาเหตุ การแก้ ไข

มีฝนุ่ ผง สิงสกปรก เกาะตามหม้ อแปลง ทําความสะอาดโดยใช้ ลมแห้ งเป่ า และ
หรื อ มีความชื ้นมากที่หม้ อแปลง การระบายอากาศช่วย
Low insulation resistance
Dielectric fault เนืองจากการใช้ งาน หรื อ ติดต่อศูนย์บริการ บริษัทเอกรัฐวิศวกรรม
จากสิง่ สกปรก
ปั ญหาของฉนวน กับคอยล์แรงสูง ติดต่อศูนย์บริ การ บริษัทเอกรัฐวิศวกรรม
มีการเปลียนแปลงแรงดัน / แรงดันปฐมภูมิ ตรวจสอบการเข้ าสายว่าถูกต้ อง ตรงกับ
Automatic cut-off activated
ไม่ตรงกับค่าที่อา่ นได้ จาก Meter Line ที่ต้องการหรื อไม่
(หม้ อแปลง Trip)
อุปกรณ์ปอ้ งกัน เช่น Protection relay ทบทวนการตังค่ ้ าเวลา และค่ากระแส
ทํางานไม่ตรงความต้ องการ ของ relay ให้ ถกู ต้ อง
Erroneous secondary แรงดันปฐมภูมิไม่เท่ากับ ค่า Nominal ติดต่อการไฟฟ้า หรื อผู้ให้ บริการจ่ายไฟ
voltage value หรื อไม่มีแรงดันปรากฏที่ด้านปฐมภูมิ
(ค่าแรงดันทุตยิ ภูมิ ไม่ถกู ต้ อง) ตําแหน่งการปรับ tap ไม่ถกู ต้ อง ปรับ tap ให้ ถกู ต้ อง
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 2/3
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/09/63 12 0

การตรวจสอบและการบํารุ งรั กษาหม้ อแปลงไฟฟ้ า

ประเภทหม้ อแปลง
วิธีการ ความถี่
ปี ที่ รายการที่ตรวจสอบ Dry Type ค่าบริ การ
ตรวจสอบ (ปี ละ)
Cast Resin
1. ดับไฟ ตรวจสภาพภายนอกและบํารุงรักษาหม้ อแปลง 1 / มี
2. ดับไฟ ตรวจสภาพภายนอกและบํารุงรักษาหม้ อแปลง 1 / มี
3. ดับไฟ ตรวจสภาพภายนอกและบํารุงรักษาหม้ อแปลง 1 / มี
4. ดับไฟ ตรวจสภาพภายนอกและบํารุงรักษาหม้ อแปลง 1 / มี
5. ดับไฟ ตรวจสภาพภายนอกและบํารุงรักษาหม้ อแปลง 1 / มี
ทดสอบ Power Factor / มีคา่ ใช้ จ่ายเพิ่ม
6. ดับไฟ ตรวจสภาพภายนอกและบํารุงรักษาหม้ อแปลง 1 / มี
ทดสอบ Power Factor / มีคา่ ใช้ จ่ายเพิ่ม
7. ดับไฟ ตรวจสภาพภายนอกและบํารุงรักษาหม้ อแปลง 1 / มี
ทดสอบ Power Factor / มีคา่ ใช้ จ่ายเพิ่ม
8. ดับไฟ ตรวจสภาพภายนอกและบํารุงรักษาหม้ อแปลง 1 / มี
ทดสอบ Power Factor / มีคา่ ใช้ จ่ายเพิ่ม
9. ดับไฟ ตรวจสภาพภายนอกและบํารุงรักษาหม้ อแปลง 1 / มี
ทดสอบ Power Factor / มีคา่ ใช้ จ่ายเพิ่ม
10. ดับไฟ ตรวจสภาพภายนอกและบํารุงรักษาหม้ อแปลง 1 / มี
ทดสอบ Power Factor / มีคา่ ใช้ จ่ายเพิ่ม
 บริษัท เอกรัฐวิศวกรรม จํากัด (มหาชน) ชุด หน้ าที่
คูม่ ือสนับสนุน C 3/3
เรื่ อง การใช้ งานและบํารุงรักษาหม้ อแปลง รหัสเอกสาร เริ่ มใช้ งาน บทที่ แก้ ไขครัง้ ที่
ไฟฟ้าชนิดแห้ งแบบ Cast Resin EN-S-003 01/09/63 12 0

ตารางการตรวจสอบและบํารุงร ักษาหม้อแปลงไฟฟ้าชนิดแห้ง ฉนวน Class F (Cast Resin)

Overhaul/Top Coating Suface Coil

Replace Bolt & Nut For Busbar

Replace Cooling Fan & Temp

Online Partial Discharge test
Insulation Resistance Test

Temperature Control Test

Power Factor Tip-Up Test

Replace Bushing Support

Winding Resistance Test

Replace Transformer
Turn Ratio Test

Polarize Index
อายุ การใชงาน

Ground Test
Tightening
้

Cleaning

Control
1     
2      
3     
4      
5     
6           
7          
8           
9          
10              
11          
12           
13          
14           
15          
16           
17          
18           
19          
20               
 ทํา ตามวาระ  ควรทํา เพิ่มเติม  ควรทํา เพิ่มเติมหากผลการทดสอบมีปัญหาหรือตามผู้ให้ บริการแนะนํา

หมายเหตุ
การเปลี่ยนยางรอง Coil ของหม ้อแปลง Cast Resin มีขีดจํากัดหลายอย่างในทางปฏิบ ัตห
ิ ลายอย่าง
1. อุป กรณประกอบของหม ้อแปลง เช ่น พัดลมระบายความร ้อน ต ้องถอดก่อนการเปลี่ยนยางรอง Coil
2. การจับ ยึด Coil ขณะที่เปลี่ยนยางรอง Coil ที่อาจทําให ้ Coil deform ไปจากเดิม และระยะทางฉนวนไฟฟ้าไม่เพียงพอ
3. เครื่องทดสอบฉนวนทางด ้านแรงสูง ทางบริษัท ไม่มี (Apply Voltage Test) ในการทดสอบที่หน ้างาน
Installation, Operation and maintenance

Service : Neutral Grounding Resistor (NGR)

Tag No. : 20BBS10/ 21BBS10
Description : Neutral Grounding Resistor (NGR)
- NGR at rated 6.9/sqrt(3) kV,100A, 10 Sec

Ekarat Engineering Public Company Limited

9/291 U.M Tower, 29 Fl., Ramkamheang Road.,Suanluang Dis., Bangkok 10250
Tel : (+662) 719-8777 Fax : (+662) 719-8760
Website : http://www.ekarat.co.th
 Sayfa / Page : 1 / 2
NEUTRAL GROUNDING RESISTOR
USER HANDBOOK
CHAPTER 1
GENERAL INTRODUCTION
Neutral Grounding Resistors are used for resistance grounding of industrial power system. They are
generally connected between ground and neutral of transformers, generators and grounding
transformers. Neutral Grounding Resistors are used in order to limit maximum fault current to a value
which will not damage the equipment in the power system, yet allow sufficient flow of fault current to
operate protective relays to clear the fault. Although it is possible to limit fault currents with high
resistance Neutral Grounding Resistors, earth short circuit currents can be extremely reduced. As a
result of this fact, protection devices may not sense the fault. Therefore, it is the most common
application to limit single phase fault currents with low resistance Neutral Grounding Resistors to
approximately rated current of transformer and / or generator.
Hilkar resistors are designed to absorb a large amount of energy without exceeding temperature
limitations defined in IEEE 32. Neutral Grounding Resistors Hilkar manufacture can be used for indoor
and outdoor and the neutral point is connected with a porcelain bushing or with a (minimum cross-
section = 70 mm2 copper or 95 mm2 aluminum) high voltage (XLPE) cable from the bottom. The most
common protection degree preferred for Neutral Grounding Resistors is IP 23 as it allows the resistor
elements to cool easier and they can be used both at sea shores and deserts because the resistor
elements are completely stainless steel and does not get affected by extreme conditions.

CHAPTER 2
TRANSPORT AND LANDING : Neutral Grounding Resistors packed for domestic shipments by carton
box, for overseas shipments by wooden materials. NTD transported by forklift or winch. On the NTD
specially manufactured inox lifting ring for safe transportation. We use these inox rings for landing and
carrying operation by winch. With the help of fork lift , fork should be locate not to damage

CHAPTER 3
INSTALLATION AND MAINTENANCE
The most reliable mounting is to connect the neutral point of desired restriction O.G. coil of phase-earth
short circuit current with the O.G. cable (min. 70mm2 cross-section copper wire) to the access of NER
(neutral grounding resistor). Installation of NER is completed by contacting of the outer casing of NER

Merkez / Head Office: 1. O.S.B. 1 .Yol. No : 16 54580 ARİFİYE / SAKARYA / TURKEY Tel: 90.264.275 55 40 Fax: 90.264.275 12 76
Şube / Branch Office: Perpa-Elektrokent K: 5 No: 444 ISTANBUL / TURKEY Tel: 90.212.210 68 54 Fax: 90.212.221 10 25
www.hilkar.com [email protected]

D203 Installation, Operation and maintenance

Page 86
 Sayfa / Page : 2 / 2
with at least 70 mm2 cross-section copper wire to the grounding grid that has maximal 1 ohm
resistance.
Today, neutral grounding resistors are generally casted of chrome alloy sheet and breakage is not
probable like casting resistors. Therefore, prevent NERs rupture by putting voltage transformer and an
over voltage relay on input of NER is needless and requires an unnecessary investment costs
approximately 1000 USD. Likewise connect separator and surge arrester to NER is a negative
situtation for business. Because by opening of the separator when transformer in service transformer
neutral is converted to the isolated system and it's necessary that protectors of transformer should be
designed according to this situation.
It's meaningless to put surge arrester on the neutral point of transformer, because atmospheric and
maneuver overvoltages are blocked by surge arresters that due to transformer phases.
It's economically to connect multiple transformers working in parallel to ground with one neutral
grounding resistor (NER), although in this case, separator solud be put on the neutral point of each
differential transformer. But the phase-neutral voltage danger at one end of the separator of the
transformer that disabled for maintenance should be kept in mind.
For maintenance, once a year by opening the labeled cover must be cleaned with compressed air.

CHAPTER 4
Spare Part: Normal operating conditions does not need any spare parts. But you can apply to our
company for any repair or spare part needs.

Safety rules in work time : All medium voltage safety rules applies as per IEC and IEEE.

Trouble Shooting : Contact factory

Stocking : No special requirements apply.

Preparation for Commissioning: Neutral Grounding Resistor must be installed on a level concrete
floor by anchorage bolts and nuts before comissioning.

Merkez / Head Office: 1. O.S.B. 1 .Yol. No : 16 54580 ARİFİYE / SAKARYA / TURKEY Tel: 90.264.275 55 40 Fax: 90.264.275 12 76
Şube / Branch Office: Perpa-Elektrokent K: 5 No: 444 ISTANBUL / TURKEY Tel: 90.212.210 68 54 Fax: 90.212.221 10 25
www.hilkar.com [email protected]

D203 Installation, Operation and maintenance

Page 87