Transformer Installation, Assembly & Testing

1 Transformer installation , Assembly & (Bill) Bergman, , , LSMIEEEP owerNexAssociates Provide explanations as to why certain process are important and should be followed Describe some examples of what to do and what not to do Comments on my personal experiences? Provide references that you can study at your leisure Answer questions2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton2 Format of Presentation Ask questions Encourage discussion and understanding (especially on topics where there may be more than one way or procedure to install a Transformer ). Please add your experiences. Please turn your cell phones OFFso we are not distracted by texting, email, / (Bill) Bergman, IEEE -Calgary / Edmonton32019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton4 Basis of Presentation Industry Accepted Practices; Based on IEEE and other consensus Guides Practical processes that are based on physics, chemistry and logic Based on others many years experience Personal Experience Have personally done this work on transformers from 10 to 750 MVA, 72 to 550 kV for 50 years (proving [to me] processes are possible & practical)2019-02-11 / (Bill) Bergman, IEEE -Calgary / Transformer after transport to a substation PROCESSINGof a Transformer at Transformer to verify its suitability for of integrating the Transformer into the power system2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton6 Importance of Transformer Processes The way a Transformer is handled and the procedures that are used to receive, assemble, process and test the Transformer are of fundamental importance to the long life of the Transformer .

2 The installation and Testing of the Transformer verifies its condition at the time it is ready for service as well as forming the baseline or signature tests for all future maintenance and later condition assessment or / (Bill) Bergman, IEEE -Calgary / Edmonton72019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton82019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton92019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton102019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton11 Transformer Condition Tests2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton12 Possible ProblemMagnetic Circuit IntegrityMagnetic Circuit InsulationWinding GeometryWinding/Bushing/LTC ContinuityWinding/Bushing InsulationWinding Turn-to-Turn RatioDiagnostic TestElectrical TestWinding RatioXWinding ResistanceXMagnetizing CurrentXXCapacitance and DF/PFXI nsulation ResistanceXXCore Ground TestXFrequency Response AnalysisXXXXL eakage ReactanceXDissolved Gas AnalysisXXXXXI ndustry Standards & Guides Presented in the order of when they are used in the Transformer Assembly and installation process Recognize that the Transformer Assembly and installation process starts much before the Transformer ever arrives on site2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton13 Reference Standards and GuidesFactory CAN/CSA-C88-M90 (Reaffirmed 2009)

3 Power transformers and Reactors IEEE -2015 IEEE Standard for General Requirements for Liquid-Immersed Distribution, Power, and Regulating transformers IEEE Std -2010 Standard Requirements for Liquid-Immersed Power transformers IEEE Std -2011 IEEE Standard Terminal Markings and Connections for Distribution and Power transformers IEEE Std -2010 IEEE Standard Test Code for Liquid-Immersed Distribution, Power, and Regulating transformers 2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton14 Reference Standards and GuidesTransportation Cargo Securement Rules Federal Motor Carrier Safety Administration (North American) Cargo Securement Driver s Handbook on Cargo Securement A Guide to the North American Cargo Securement Standard Responsibility of shipper and driver2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton15 Reference Standards and Guides Transportationand Site CIGRE 673 (WG ) Guide on Transformer Transportation IEEE -2012 IEEE Guide for the Transportation of transformers and Reactors Rated 10 000 kVA or Higher 2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton16 Reference Standards and Guides Site IEEE -2007 IEEE Guide for installation and Maintenance of Liquid-Immersed Power transformers CAN/CSA-C50-08 (R2013) Mineral insulating oil, electrical, for transformers and switches IEEE Std -2015 IEEE Guide for Acceptance and Maintenance of Insulating Oil in Equipment IEEE Std -2013 IEEE Guide for Diagnostic Field Testing of Fluid-Filled Power transformers , Regulators, and Reactors IEEE Std -2012 IEEEG uidefor the Application and Interpretation of Frequency Response analysis for Oil-Immersed transformers 2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton17 Other Standards & Guides of Interest Accessories CAN/CSA (Reaffirmed 2011)

4 Power Transformer and Reactor Bushings IEEE Std -2000 IEEE Standard Performance Characteristics and Dimensions for Outdoor Apparatus Bushings IEEE Std -2012 IEEE Standard Requirements for Load Tap Changers CAN/CSA-C60044-1-07 (R2011) -Instrument transformers -Part 1: Current transformers (Includes CSA C13) IEEE Std -2006 IEEE Guide for Field Testing of Relaying Current transformers IEEE Std -2014 IEEE Guide for Grounding of Instrument Transformer Secondary Circuits and Cases 2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton18 Other Standards & Guides of Interest 2/4 Operating Condition IEEE Std -2008 IEEE Guide for the Interpretation of Gases Generated in Oil-Immersed transformers IEEE Std -[2018 November] Unapproved Draft Guide for the Interpretation of Gases in Oil Immersed transformers IEEE -2011 IEEE Guide for Loading Mineral-Oil-Immersed Power transformers and Step Voltage Regulators 2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton19 Other Standards & Guides of Interest 3/4 Specialized transformers IEEE std -2014-"IEEE Guide for transformers Directly Connected to Generators IEEE Std -2008 IEEE Standard Requirements, Terminology, and Test Code for Shunt Reactors Rated Over 500 kVA IEC 62032 / IEEE -2005 Guide for the application, specification, and Testing of phase-shifting transformers 2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton20 Other Standards & Guides of Interest 4/4 IEC IEC 60076 (Power transformers Parts 1 through 21) EC 60076-1 IEC 60076-8 guide IEC 60214-1 Tap-changers -Part 1.

5 Performance requirements and test methods IEC 60137 Insulated bushings for alternating voltages above 1 000 V2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton21 Information Required for installation Presented generally in the order that the information is / (Bill) Bergman, IEEE -Calgary / Edmonton22 Customer InformationSpecificationand Change Orders Purchaser s Transformer specification(s) (general and rating/data specifications) Purchase order and change orders that may influence technical considerations when installing the Transformer (unpriced).2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton23 Customer & Factory InformationDesign Review Explanations, commitments, clarifications and notes from the design review meeting Recommended to be conducted -by a Transformer expert at the factory -in accordance with CIGRE-Publication 529 Guidelines for Conducting Design Reviews for Power transformers , and -Publication 673 Guide on Transformer transportation 2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton24 Factory Information DocumentationRelated to Receiving Transport and handling drawing Receiving instructions (in instruction manual?)

6 Assembly instructions (in instruction manual?) Pre-Transport test results Photographs of Transformer loaded on carrier Detailed packing lists should indicate individual parts in each package/crate Final drawings2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton25 Factory Information Testing (Related to Transport & Receiving) Core and clamp insulation Megger tests (with correct Megger voltage at core ground test terminal) Leak test results Transport gas pressure and dew point tests Shock recorder settings and information and accessories required to interpret results FRA tests in Fully assembled and oil filled condition, and/or Transport condition with test bushings2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton26 Factory Information Testing (Related to site Testing )Factory test report Winding & bushing insulation resistance, PF (power factor) & capacitance Winding ratios Polarity Winding resistance (demagnetize after) Low voltage excitation current Single-phase excitation test Other2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton27 Factory Information (Required for installation ) Factory drawings Factory test report(s) Instruction manual(s) Photographs of assembled or partially assembled Transformer (at factory) Substation foundation, bus, station service, grounding, protection & control , and SCADA drawings2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton28 Transformer Warranty Considerations 1 of 2 Inspections and receiving Proper (and sometimes supervised) Assembly , processing, & Testing of Transformer Adherence to manufacturer s or industry protocols for Assembly , processing, & Testing Acceptable test methods and results Adequate records2019-02-11 / (Bill)

7 Bergman, IEEE -Calgary / Edmonton29 Transformer Warranty Considerations 2 of2 Manufacturer, as a condition of warranty, almost always want their representative on site when the Transformer arrives. (Megger and impact recorder reading), and during some portions of installation ( installing bushings, internal inspection, etc). Owners should always give a manufacturer the option to come to site (even if the manufacturer doesn't require it).2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton30 TransformerInstallation Records Assembly log indicating dates/times and weather conditions, people during entire process Records of all inspections and Testing (ratio including phase angle and current, Megger , excitation current and voltage, insulation power factor and capacitance of windings and bushings, FRA, other dielectric tests, oil physical and DGA tests including sampled location(s), functional tests (and methods) on all accessories, etc.)2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton31 Transformer Receiving2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton32 Transformer Receiving Safety Be aware of Terms of Transport INCO terms Understand point of transfer of ownership as well as warranty obligations Understand point of transfer of responsibility Assess Condition of Transformer2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton33 INCO terms2010 RULES FOR ANY MODE OR MODES OF TRANSPORT EXW EX WORKS DAT Delivered At Terminal DAP Delivered At Place DDP Delivered Duty Paid RULES FOR SEA AND INLAND WATERWAY TRANSPORT FAS Free Alongside Ship FOB Free On Board CFR Cost and Freight CIF Cost Insurance and Freight2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton34 Transformer Receiving -Acceptance Assess Condition of Transformer Importance of knowing condition when Transformer left the factory to allow comparison.

8 Compare ex-factory condition to as-received conditions to determine change that could be caused by transport or storage. Testing and inspection2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton35 Transformer Receiving Safety Transport gas could be N2or air test for life compatibility (O2), absence of combustible gas, absence of CO or CO2 Working at height (especially when receiving Transformer on transporter). Appropriate fall arrest, falling objects prevention, ladder and electrical safe work practices. Confined space entry and extraction. Be aware of loose or broken parts, crates, / (Bill) Bergman, IEEE -Calgary / Edmonton362019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton37 Transformer -Unloading Is foundation in condition to receive Transformer ? [Size, shape, capacity, flat, level, cured, condition, etc.] Use of crane and slings [transport condition vs. fully assembled condition] Use of jack and slide [jacking, blocking, slide areas] Transport drawing, markings on tank and parts Concentrated loading on tank bottom?

9 2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton38 Transformer Receiving Visual Inspection Visual inspection for security/tightnessof attachments to transporter, movementon transporter, damage caused by securement, collisions with other objects or vibration or impact(s) Positive pressureon transport gas gauge Absence of shock or vibration recording on shock recorder andconfirmation that shock recorder is still functioning Visual inspection of accessories to verify arrival in undamaged condition and shipment is complete2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton39 Transformer Receiving Testing Visual Inspection Transformer transport gas pressure (positive pressure or sustained negative pressure) and dew point (correct for temperature and pressure) Core and clamp insulation (with correct voltage of Megger (also correct for temperature) Shock (electronic) recorder assessment (Use CIGRE 673) FRA test if other indications of possible damage2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton40 Transformer Assembly2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton41 Transformer Safety People Working at height (especially when receiving Transformer on transporter).)

10 Appropriate fall arrest, falling objects prevention, ladder and electrical safe work practices. Confined entry plan and process, extraction? Transport gas could be N2or air test for pressure, (before opening manhole), lifecompatibility O2, absence of combustible gas and absence of CO or / (Bill) Bergman, IEEE -Calgary / Edmonton42 Transformer Safety Transformer Minimize people entry into Transformer Minimize entry of moisture into Transformer Maintain dry air environment Bond and ground the Transformer , all bushings, oil hoses, oil filtering and vacuum equipment. Vacuum and oil processing only above +10 C Perform leak-down vacuum test prior to vacuum and oil processing No electrical Testing during vacuum stages2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton43 PaschenCurve:Voltage Breakdown vs Pressure2019-02-11 / (Bill) Bergman, IEEE -Calgary / Edmonton44 Transformer Assembly Cleanliness is very important! Ensure parts are naturally aligned rather than force fit.