Power Transformers and Reactors 1656967301

A2 TECHNICAL BROCHURE
Power transformers
and reactors
On-Site Assembly, On-Site

Rebuild, and On-Site High Voltage
Testing of Power Transformers
Reference: 857
December 2021
TECHNICAL BROCHURE
On-Site Assembly, On-Site

Rebuild, and On-Site High
Voltage Testing of Power
Transformers
WG A2.59
Members
Y. SHIRASAKA, Convenor JP T. HASEGAWA, Secretary JP

K. AOKI JP R. FRITSCHE DE
T. GONÇALVES PT T. NOONAN IE
R. PETIT FR M. RAMKVIST SE
J. SZCZECHOWSKI DE T. TANAKA US
E. TENYENHUIS CA P. WERLE DE
S. YAMADA JP Z. ZHAO CN
Corresponding Members
S. NOGUCHI JP K. YAMAGUCHI JP
Copyright © 2021
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ISBN : 978-2-85873-562-4
Disclaimer notice
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TB 857 - On-Site Assembly, On-Site Rebuild, and On-Site High Voltage Testing of Power Transformers
Executive summary
The aim of the working group was to address the new challenges presented by on-site assembly, on-
site rebuild, and on-site high voltage testing.
The scope of the working group was:
1. Survey of international experience and best practice with on-site assembly, on-site rebuild, and
on-site high voltage testing.
2. Applications and case studies for on-site assembly including alternatives such as 2x3-phase
transformers in parallel or 3x1-ph transformers to reduce mass and dimensions.
3. Design and construction issues, mainly for on-site assembly.
4. Dis-assembly and re-assembly issues, mainly for on-site assembly but also on-site rebuild.
5. Scope of works test etc., mainly for site-assembly.
6. Applications and case studies for on-site high voltage testing including limits of what is possible
with currently available technology.
7. Any additional requirements for pre-commissioning and trial operation.
Site Assembly of large transformers was shown to be a viable solution for severe transport limitations.
Some countries (Japan in particular) have severe weight or size limitations for transport that make it
near impossible to ship a transformer with desired high MVA rating. Solutions have been developed
that allow the transformer to be manufactured and then the windings and core dismantled to be shipped
to site in several transportable segments for full assembly on site. A temporary building on site with a
controlled environment is required for the assembly since windings and cellulose are exposed. Fixed
cranes in site buildings or mobile cranes are used for the lifting. On-site testing may be done after the
site assembly.
A survey of site assemblies performed by several manufacturers in Japan, Europe and China showed
the below solutions:
 A 3 phase 5 limb core design was shown to be typically utilized. The core is manufactured in 4
separate “U” cores that can be easily combined at site. The windings are nested together as a
single phase for transport to site. At site the “U” cores are assembled on to a bell type tank
base and the winding phases are landed onto the core main limbs. The transformer is fully
assembled and tested in the factory before being dismantled and shipped to site.
 A 3 phase 5 limb core design was shown also where the core legs and yokes are shipped
individually to site. A core stacking table is required at site where the bottom yokes are inserted.
The core is up-righted and then the winding phases are installed. The top yokes are inserted,
and the active part is installed.
 Solutions with shell form type transformers were shown
 A variant of the site assembly was shown to be the split tank type transformer. The transformer
is divided into several tank components that are connected on site such that it will be an
equivalent three phase or single phase required rating. For this type, the windings and cores
are not assembled on site.
 These solutions have been done on hundreds of transformers globally and ratings above 1
500 MVA have been achieved. The field failure rate was shown to be very low.
A survey was similarly done for on-site rebuild of existing transformers requiring new windings. In the
event of failure, it may not be possible or practical to transport a transformer to a factory for repair. This
may occur if railway lines or bridges have been decommissioned and the existing transformer can no
longer be shipped out of the site in the same way it arrived. It is possible to disassemble the transformer
and active part on site, and repair or replace damaged windings. This is termed “site repair” and involves
many similar challenges and solutions as the above discussed on-site assembly. The survey included
site repairs done in Canada, China, Japan and Europe.
The solutions for the site building / clean house were shown which are special purpose buildings that
are reused and contain the necessary lifting systems or have removable roof panels for mobile cranes.
It may be possible to use an existing building at site (i.e. generator hall with high bay ceiling and
overhead crane) or a local company can prepare a tent type building on site. The site building must
have a controlled atmosphere for low humidity and minimization of dust.
A survey was done for the dryout of the core & windings. The windings are manufactured in a
transformer factory and dried out by vapor phase method prior to shipment. The various methods to
limit moisture ingression during the site assembly process were shown. The final dryout was shown to
3
be done by either hot oil / vacuum cycles, Low Frequency Heating (LFH) method or by site vapor phase.
The final testing of the assembled transformer at site varied in the survey. Some manufacturers test
the assembled transformer in the factory (and some only as design tests on the first transformer) and
then only perform low voltage tests at site. Other manufacturers only do full testing at site on the
assembled transformer (no factory testing). All situations were proven to be successful with low field
failure rates.
Technology developed for mobile test equipment was shown that allows all parameter and dielectric
verification tests to be performed at site. Loss measurement, impedance measurement, temperature
rise, applied voltage and induced voltage are performed using AC HV test equipment. Lightning impulse
voltage and switching surge voltage tests are performed with a mobile HV impulse test set. DC tests
such as DC applied voltage or DC induced voltage tests are performed with mobile DC test equipment.
Modern mobile AC HV test systems utilize an Electronic Power System (EPS) which can widely vary
the output voltage and output frequency. The system includes inductive and capacitive compensation
and a step-up-transformer that can be switched manually into many different configurations. By using
external capacitor banks, a temperature-rise test can be also performed at site with this system.
Transformers up to 800 kV have been tested with this type of mobile AC HV test system for induced
voltage, applied voltage and loss measurement. Temperature-rise testing is limited by available
capacitors and power supply (typically a very large 2 MW diesel generator).
The HV mobile impulse test set is a modified version of factory impulse test equipment where the test
circuit lays down flat into a 40 ft. ISO container or road trailer for shipment. Mobile impulse sets that
can perform testing up to 1800 kV BIL are in use and higher voltages are technically possible.
The methods and quality controls were surveyed by several manufacturers. Detailed quality checks,
testing, clean house requirements, processing / dryout and inspections are shown.
It was overall demonstrated that varying solutions have been developed and successfully executed for
site assembly and site repair for more than 20 years. The increased risks of performing tasks at site
such as installing windings, core assembly, active part dryout and dielectric testing have all been
managed. The site assembly and site repair are shown to be a viable and fully possible solution and are
done in accordance with a local regulations, practices, and specifications.
This technical survey of on-site assembly and on-site rebuild is new for power transformers. This
technical brochure shows a collection of many different procedures and experiences of the on-site
assembly and the on-site rebuild. Many experiences of the on-site assembly show reliability with only
FAT (Factory Acceptance Tests) and on-site acceptance tests without on-site high voltage testing
(Japan in particular). This technical brochure summarizes the quality assurance aspects to ensure high
reliability under on-site work..
4
Contents
Executive summary ............................................................................................................. 3
Figures and Illustrations ..................................................................................................... 7
1. Introduction.............................................................................................................. 10
1.1 Background.............................................................................................................................................. 10
1.2 Aim and Scope ......................................................................................................................................... 10
1.3 Definitions ................................................................................................................................................ 11
1.3.1 On-site assembly ............................................................................................................................... 11
1.3.2 On-site rebuild ................................................................................................................................... 11
1.3.3 On-site high voltage testing ............................................................................................................... 11
1.3.4 Split-tank type transformer ................................................................................................................. 11
2. Survey of On-Site Assembly ................................................................................... 12

2.1 Experiences in Japan .............................................................................................................................. 12
2.1.1 Introduction ........................................................................................................................................ 12
2.1.2 Experience A with Core Type ............................................................................................................ 13
2.1.3 Experience B with Shell Type ............................................................................................................ 20
2.1.4 Experience C with Core Type ............................................................................................................ 28
2.1.5 Summary ........................................................................................................................................... 37
2.2 Experiences in Europe ............................................................................................................................ 45
2.2.1 Experience D - Mountain Transport for Hydro-electric Generator Transformer ................................. 45
2.2.2 Experience E - Replacement with Larger/ Heavier Transformers ...................................................... 48
2.3 Experience in China (1 000 kV AC Power Transformers) ..................................................................... 52
2.3.1 Introduction ........................................................................................................................................ 52
2.3.2 Key Technology Research ................................................................................................................. 53
2.3.3 Engineering Practice of Field Assembly............................................................................................. 58
2.3.4 System Commissioning and Trial Operation ...................................................................................... 62
2.3.5 Conclusions ....................................................................................................................................... 63
2.4 Split-tank type transformer ..................................................................................................................... 64
3. Survey On-Site Rebuild ........................................................................................... 66

3.1 Experience in North America and Europe ............................................................................................. 66
3.1.1 Experience A ..................................................................................................................................... 66
3.1.2 Experience B ..................................................................................................................................... 70
3.1.3 Experience C ..................................................................................................................................... 73
3.1.4 Experience D ..................................................................................................................................... 75
3.2 Experience in China ................................................................................................................................ 77
3.3 Experience in Japan ................................................................................................................................ 80
3.3.1 Introduction ........................................................................................................................................ 80
3.3.2 On-site refurbishment overview ......................................................................................................... 80
3.3.3 Challenges for on-site refurbishment and study on countermeasures ............................................... 81
3.3.4 Verification by pilot unit ...................................................................................................................... 83
3.3.5 Advantages of on-site refurbishment ................................................................................................. 87
3.3.6 Conclusion ......................................................................................................................................... 87
4. On-Site High Voltage Testing.................................................................................. 88

4.1 Mobile Test Systems ............................................................................................................................... 88
4.1.1 Mobile High Voltage AC Test Systems .............................................................................................. 88
4.1.2 Mobile Impulse Test Systems ............................................................................................................ 94
5
4.2 Experience ............................................................................................................................................... 96

4.2.1 Experience A ..................................................................................................................................... 96
4.2.2 Experience B ................................................................................................................................... 101
4.2.3 Experience C ................................................................................................................................... 104
5. Quality Assurance ..................................................................................................108

5.1 Introduction ............................................................................................................................................ 108
5.2 Disassemble after FAT and Delivery from Factory ............................................................................. 109
5.3 Transportation ....................................................................................................................................... 111
5.4 On-Site Works ........................................................................................................................................ 112
5.5 On-Site Tests ......................................................................................................................................... 117
5.5.1 Introduction ...................................................................................................................................... 117
5.5.2 On-site test items ............................................................................................................................. 117
5.6 On-Site High Voltage Testing ............................................................................................................... 119
5.6.1 Standards pertaining to on-site tests including on-site high voltage testing ..................................... 119
5.6.2 Test items and its voltage levels ...................................................................................................... 121
5.6.3 Example of on-site high voltage testing reasons.............................................................................. 121
5.6.4 Applying on-site high voltage testing ............................................................................................... 121
6. Summary .................................................................................................................123
References ........................................................................................................................129
6
Figures and Illustrations

Figure 1.1 - Severe transportation condition (see CIGRE TB 673 page 4) [1] ....................................... 10
Figure 2.1 - Development of On-Site Assembly Transformers in Japan ............................................... 12
Figure 2.2 - Production record of on-site assembly transformer (in China and Japan) ........................ 13
Figure 2.3 - Number and Capacity of on-site assembly transformers ................................................... 13
Figure 2.4 - Core unit and Winding configuration .................................................................................. 14
Figure 2.5 - Dismantle and re-assembly process (Phase 1) ................................................................. 17
Figure 2.6 - Core segmented state and core erected state ................................................................... 18
Figure 2.7 - Re-assembly process (Phase 2) ........................................................................................ 19
Figure 2.8 - Production experience of on-site assembly transformer (Shell Form)............................... 20
Figure 2.9 - Number and Capacity of On-site Assembly Transformers (Shell Form) ........................... 20
Figure 2.10 - Basic structure of Shell type on-site assembly transformer ............................................. 22
Figure 2.11 - Coil group film packing ..................................................................................................... 22
Figure 2.12 - Block insertion method of core leg ................................................................................... 23
Figure 2.13 - Panel type clean house .................................................................................................... 23
Figure 2.14 - Tent type clean house ...................................................................................................... 23
Figure 2.15 - Longitudinal division of upper and middle tank for transportation ................................... 24
Figure 2.16 - Divided coil groups for transportation .............................................................................. 24
Figure 2.17 - On-site assembly transformer after completing its installation (500 kV - 1 000 MVA) .... 27
Figure 2.18 - Needs of On-site assembly transformer .......................................................................... 28
Figure 2.19 - Development of a new type On-site assembly transformer ............................................. 29
Figure 2.20 - Disassembled Components for transportation ................................................................. 30
Figure 2.21 - Divided core components ................................................................................................ 30
Figure 2.22 - Winding and its film packing ............................................................................................ 31
Figure 2.23 - Divided tank components ................................................................................................. 31
Figure 2.24 - Overview of Clean House ................................................................................................ 32
Figure 2.25 - On-site Assembly Work Flow ........................................................................................... 32
Figure 2.26 - Kaprun Water Storage Power Plant Limberg ................................................................... 45
Figure 2.27 - left: Road transportation of core with special low road vehicle; right: Loading of core on
elevator at mountain valley station ........................................................................................................ 46
Figure 2.28 - left: Mountain elevator to lift devices, core and tank including winding blocks to the
middle station Lärchenwald of Kaprun mountain; right: transportation from elevator to power station via
road transport vehicle, here: tank transportation including winding blocks ........................................... 46
Figure 2.29 - left: Core after upper yoke and clamping removal inside the tent; middle: Winding block
fitting to the core; right: Upper yoke stacking ........................................................................................ 47
Figure 2.30 - left: Internal active part tanking; right: Transformer during impulse testing ..................... 47
Figure 2.31 – PEI Comparison of the 2015 and 2021 EU regulation .................................................... 48
Figure 2.32 - Impacts to loss, weight and cost between 2007 (Step 1) and 2011 (Step 3) .................. 48
Figure 2.33 - Railway limits and over-sizing by new regulation ............................................................ 49
Figure 2.34 - Complexities of the transportation ................................................................................... 49
Figure 2.35 - On-site of the transformer ................................................................................................ 50
Figure 2.36 – Working flow in accordance with the unit (User Specification) ....................................... 51
Figure 2.37 - Disassembly process flow of on-site assembly transformer after factory tests ............... 55
Figure 2.38 - Single transportation unit for U-shaped core frame ......................................................... 56
Figure 2.39 - Single transportation unit for winding column .................................................................. 56
Figure 2.40 - Transportation unit for main tank ..................................................................................... 57
Figure 2.41 - Field assembly building external and internal view.......................................................... 57
Figure 2.42 - Assembly process flow inside field assembly building..................................................... 58
Figure 2.43 - Installation platform position and assembly of first U-shaped core frame ....................... 59
Figure 2.44 - Assembly of U-shaped core frames and its end product ................................................. 59
Figure 2.45 - Assembly of winding columns and its end product .......................................................... 60
Figure 2.46 - End products of upper yoke and upper clamp ................................................................. 60
Figure 2.47 - Assembly of leads and semi-finished product test........................................................... 61
Figure 2.48 - Assembly of final production ............................................................................................ 61
Figure 2.49 - Kerosene vapour phase drying treatment for transformers ............................................. 62
Figure 2.50 - Transportation and installation in substation of on-site assembly transformer ................ 62
Figure 2.51 - Acceptance test of on-site assembly transformer ............................................................ 62
Figure 2.52 - UHV AC on-site assembly transformer in service ............................................................ 63
Figure 2.53 - 6 split-tank type transformer for pumped-storage hydraulic power plant ........................ 64
Figure 2.54 - 6 split-tank type transformer for other cases ................................................................... 64
7
Figure 2.55 - 9 split-tank type transformer for pumped-storage hydraulic power plant ........................ 65
Figure 3.1 - Transformer Being Moved from Pad to Turbine Hall ......................................................... 67
Figure 3.2 - Transformer Being Moved into Turbine Hall Pit with Overhead Crane .............................. 67
Figure 3.3 - Core/Windings Being Removed from the Tank ................................................................. 67
Figure 3.4 - Removal of the Top Yoke of the Core ............................................................................... 68
Figure 3.5 - Removal of Windings ......................................................................................................... 68
Figure 3.6 - New Winding Shipping Containers and Installation of New Windings ............................... 68
Figure 3.7 - Re-installation of Top Yoke of Core and Finished Core/Windings .................................... 69
Figure 3.8 - Cleaned Tank, Core/Windings Back in Tank and Sealed Tank ......................................... 69
Figure 3.9 - Assembled Transformer Undergoing Final HV Field Induced Voltage Test ...................... 69
Figure 3.10 - Original transformer in service prior to the failure ............................................................ 70
Figure 3.11 - Temporary Building Next to the Transformer Pad with Air Control .................................. 71
Figure 3.12 - Removal of the Cover and Removal of the Core/Windings from the Tank ...................... 71
Figure 3.13 - Windings Being Removed from the Core/Windings and New Windings ......................... 71
Figure 3.14 - Installation of New Windings and Core/Windings being worked on ................................ 72
Figure 3.15 - Painted Tank (done on pad) and Completed Core/Windings .......................................... 72
Figure 3.16 - Heavy Crane Lift of Repaired Core/Windings ................................................................. 72
Figure 3.17 - Installation of Bushings, LFH Dryout (hoarding required due to cold weather) ............... 73
Figure 3.18 - Impulse Testing ................................................................................................................ 73
Figure 3.19 - Transformer...................................................................................................................... 74
Figure 3.20 - Temporary Building .......................................................................................................... 74
Figure 3.21 - Shell Type Core Stacking ................................................................................................ 74
Figure 3.22 - Field Testing..................................................................................................................... 75
Figure 3.23 - Transformer Un-tanking ................................................................................................... 75
Figure 3.24 - Transformer New Winding Installation and Cleats & Leads Work ................................... 76
Figure 3.25 - DC HV Testing ................................................................................................................. 76
Figure 3.26 - left: Repair facility outside view with open roof top; right: Repair facility inside view with
air conditioning device and heater ......................................................................................................... 77
Figure 3.27 - left: Sketch of main component disassembly; right: Photo taken during disassembly of
main components .................................................................................................................................. 77
Figure 3.28 - left: Sketch of disassembly; right: Photo taken during upper clamping arrangement
disassembly ........................................................................................................................................... 78
Figure 3.29 - left: Drawing of winding block shipment tank; middle: Lifting of winding block tank into
repair facility; right: Removal of damaged limb while new winding block stand beside for replacement
............................................................................................................................................................... 78
Figure 3.30 - Refurbishment process at factory .................................................................................... 80
Figure 3.31 - Refurbishment process at site ......................................................................................... 81
Figure 3.32 - Additional separation parts for transformer main unit tank .............................................. 81
Figure 3.33 - Conventional laying down and erecting work .................................................................. 82
Figure 3.34 - Core rotation machine overview (Core disassembly work) ............................................. 82
Figure 3.35 - Clean house outline view (Opened condition) ................................................................. 82
Figure 3.36 - Preventive measure for moisture and dust ingression for winding .................................. 83
Figure 3.37 - Single-phase pilot unit schematic construction ................................................................ 84
Figure 3.38 - Lifting upper and middle tanks ......................................................................................... 84
Figure 3.39 - Core rotation machine ...................................................................................................... 85
Figure 3.40 - Clean house installation states ........................................................................................ 85
Figure 3.41 - Equipment layout for on-site work.................................................................................... 85
Figure 3.42 - Winding refurbishment work in clean house .................................................................... 86
Figure 4.1 – Example of HV-AC mobile test system installed in 40 ft container ................................... 88
Figure 4.2 - Static Frequency Converter (SFC)..................................................................................... 89
Figure 4.3 - Voltage signals measured before (above) and after (below) the filter ............................... 89
Figure 4.4 - Applied voltage test using resonant circuit ........................................................................ 90
Figure 4.5 - Control panel ...................................................................................................................... 91
Figure 4.6 - Examples of AC tests on-site ............................................................................................. 91
Figure 4.7 - Noise level using conventional technique .......................................................................... 92
Figure 4.8 - Noise level using spectrum analyser technique ................................................................. 92
Figure 4.9 - Additional external capacitive compensation for temperature-rise tests ........................... 93
Figure 4.10 - AC test with 2 mobile test systems in parallel .................................................................. 93
Figure 4.11 - Set-up of system .............................................................................................................. 94
Figure 4.12 - Mobile Impulse System .................................................................................................... 94
Figure 4.13 - Test of an 850 MVA GSU ................................................................................................ 95
Figure 4.14 - The schemes shown general test set-up of winding connections in HV winding ............ 96
8
Figure 4.15 - Applied voltage test setup ................................................................................................ 97

Figure 4.16 - Induced voltage test with PD measurement .................................................................... 97
Figure 4.17 - PD measurement - calibration ......................................................................................... 98
Figure 4.18 - Test sequence (Time and voltage at LV side) ................................................................. 98
Figure 4.19 - PD Pattern recorded during test (Example) ..................................................................... 99
Figure 4.20 - LI impulse generator ........................................................................................................ 99
Figure 4.21 - Mobile test system used for applied and induced voltage test ...................................... 101
Figure 4.22 - The schemes shown general test set-up of winding connections ................................. 102
Figure 4.23 - PD Pattern recorded during test .................................................................................... 103
Figure 4.24 - AC mobile test system used for applied and induced voltage test ................................ 104
Figure 4.25 - The schemes for general test set-up of winding connections ........................................ 105
Figure 4.26 - AC mobile test system used for temperature-rise test shown in front of the compensation
unit ....................................................................................................................................................... 105
Figure 4.27 - Two AC mobile test systems used for temperature-rise test shown in front of the
compensation unit ............................................................................................................................... 106
Figure 4.28 - Temporary housing for the test system - protection from the weather condition ........... 106
Figure 5.1 - Criteria of insulation resistance [6] ................................................................................... 116
Figure 5.2 - Reasons for on-site high voltage testing on power transformers in Europe .................... 121
Tables
Table 2.1 - On-site assembly transformer comparison (500 kV – 1 500 MVA) ..................................... 15
Table 2.2 - Basic assembly process of on-site assembly transformer .................................................. 16
Table 2.3 - Quality control items for on-site assembly transformer ....................................................... 16
Table 2.4 - Dust-proof on-site assembly house..................................................................................... 19
Table 2.5 - Technology transition of on-site assembly transformer ...................................................... 21
Table 2.6 - Procedure of on-site assembly and items of quality management ..................................... 24
Table 2.7 - Disassembly Work in Factory to Shipping .......................................................................... 33
Table 2.8 - On-Site Assembly ............................................................................................................... 34
Table 2.9 - Experiences of the on-site assembly transformers in Japan .............................................. 37
Table 2.10 - Principal quality control items for on-site assembly transformer....................................... 37
Table 2.11 - Process and quality management of 500 kV on-site assembly transformer under the
factory desassembly work ..................................................................................................................... 38
Table 2.12 - Process and quality management of 500 kV on-site assembly transformer during
transportation ......................................................................................................................................... 40
Table 2.13 - Process and quality management of 500 kV on-site assembly transformer at on-site work
............................................................................................................................................................... 40
Table 2.14 - Test items for on-site assembly transformer at on-site ..................................................... 44
Table 2.15 - Statistics of China's UHV AC transmission projects in operation ..................................... 52
Table 2.16 - Main parameters of main transformer for UHV AC on-site assembly transformer ........... 54
Table 2.17 - Transportation parameters of different parts for UHV AC on-site assembly transformer . 55
Table 3.1 - Main shop test items with air-core....................................................................................... 83
Table 3.2 - Comparison between calculation value and measurement value air-core leakage
inductance ............................................................................................................................................. 86
Table 3.3 - On-site completion test items .............................................................................................. 86
Table 3.4 - Period and cost comparison required for refurbishment ..................................................... 87
Table 4.1 - Test sequences levels according to 420 kV tap-changer position 1 ................................... 98
Table 4.2 - PD level during test sequence 3 ......................................................................................... 99
Table 4.3 - Equipment of the High Voltage Mobile Test System used during testing ......................... 100
Table 4.4 - Test sequences levels ....................................................................................................... 103
Table 5.1 - Major quality assurance items for on-site assembly transformers .................................... 108
Table 5.2 - Quality assurance details (Disassemble and delivery after FAT) ..................................... 109
Table 5.3 - Quality assurance details (Transportation) ....................................................................... 111
Table 5.4 - Quality assurance details (On-site works) ........................................................................ 112
Table 5.5 - On-site test items .............................................................................................................. 117
Table 5.6 - Comparison of on-site test items on existing standards ................................................... 119
9
1. Introduction
1.1 Background
Most large power transformers are transported to site with the active part fully assembled inside the
tank. Installation work at site is limited to assembly of external parts and filling with oil or other dielectric
fluid. The mass of the main tank including the active part may be very high for large power transformers
(more than 200 t).
Figure 1.1 - Severe transportation condition (see CIGRE TB 673 page 4) [1]
To transport the main tank with active part using existing infrastructure may not be possible for all sites.
For such sites, a new technology has been developed to allow installation of large power transformers
without the need to develop new infrastructure. The active part of the transformer is prefabricated in
large sections for assembly at site. This greatly reduces the maximum transport mass but introduces
new challenges during the assembly process at site. It is applicable mainly to transformers rated at 150
MVA and larger and 145 kV class and higher.
A similar situation may arise for existing transformers at some sites. In the event of failure, it may not
be possible or practical to return the transformer to a factory for repair. However, it may be possible to
disassemble the transformer on site, including the active part, and repair or replace damaged
components. This involves many similar challenges as with on-site assembly.
Following on-site assembly or on-site rebuild, and sometimes also in other circumstances, there is a
need to prove that the transformer is in good condition and ready for service. For transformers which
are not assembled or rebuilt on site, this is normally done by high voltage testing in a factory test
laboratory. For transformers which have been assembled or rebuilt at site, there may be still a need to
make high voltage tests, usually using mobile equipment. This introduces additional new challenges.
On-site assembly and on-site rebuild cases are surveyed in this document. This technical brochure
shows a collection of many different procedures and experiences of the on-site assembly and the on-
site rebuild. Many experiences of the on-site assembly show excellent reliability with only FAT and
without on-site high voltage testing (Japan in particular). This technical brochure summarizes the
sequences of quality assurance to ensure high reliability under on-site work.
1.2 Aim and Scope

The aim of the working group was to address the new challenges presented by on-site assembly, on-
site rebuild, and on-site high voltage testing. This brochure presents many cases from around the world
to introduce state-of-the-art techniques and demonstrate what possibilities exist today. The described
cases demonstrate differences in procedures somewhat due to varying local rules and regulations.
Scope
1. Survey of international experience and best practice with on-site assembly, on-site rebuild, and
10
on-site high voltage testing.

2. Applications and case studies for on-site assembly including alternatives such as 2x3-phase
transformers in parallel or 3x1-ph transformers to reduce mass and dimensions.
3. Design and construction issues, mainly for on-site assembly.
4. Dis-assembly and re-assembly issues, mainly for on-site assembly but also on-site rebuild.
5. Scope of works test etc., mainly for site-assembly.
6. Applications and case studies for on-site high voltage testing including limits of what is possible
with currently available technology
7. Any additional requirements for pre-commissioning and trial operation.
1.3 Definitions
1.3.1 On-site assembly
To assemble a transformer at the installation site including assembly of the windings, and complete or
partial assembly of core.
1.3.2 On-site rebuild
To rebuild, repair or refurbish of a transformer at the installation site including complete or partial
replacement of windings.
1.3.3 On-site high voltage testing
To test of a transformer at site with high voltages for dielectric tests at specified or reduced voltages.
1.3.4 Split-tank type transformer
To construct a transformer where the main components are split between several different tanks, so
that when installed it will have equivalent performance to a conventional transformer with the same rated
power and voltage.
11
2. Survey of On-Site Assembly

2.1 Experiences in Japan
2.1.1 Introduction
This chapter gives an overview of the historical background and developments of the on-site assembly
transformer technology in Japan following changes to transport infrastructure and increases in
transformer ratings, size and mass. This is illustrated in Figure 2.1.
Figure 2.1 - Development of On-Site Assembly Transformers in Japan
In the post Second World War revival, high-voltage large-capacity power plants and substations were
built. The transportation of large-capacity power transformer became a critical issue due to insufficient
transportation infrastructure and remote mountainous locations of hydroelectric power plants.
The application of special three phase transformers in the 1950’s was developed to reduce
transportation size. At this time, the on-site assembly of transformers was also developed. After passing
factory acceptance tests, the transformers were disassembled to be suitable for the transportation
limitations and re-assembled on-site.
There was a brief decline in the application of on-site assembly due to improved road infrastructure and
the development of large-scale special trailers for transportation such as the Schnabel type trailer.
In the 1980’s, changing environmental conditions and changing regulations on road/railway
transportation led to very severe transport restrictions. As a result, transportation costs increased
significantly. New types of on-site assembly transformers were developed and applied from the
viewpoint of minimum total cost and reduced transformer size and installation footprint [2] .
Presently in Japan, the on-site assembly transformer has become standard for large-capacity 500 kV
transformers. Three Japanese experiences are surveyed.
12
2.1.2 Experience A with Core Type

2.1.2.1 Application trend of on-site assembling of transformers
In the last 20 years, the application of on-site assembly of transformers has increased dramatically.
Figures 2.2 and 2.3 show the production record of on-site assembly of transformers by one company
(within Japan and China) since 1992. There are several reasons for the increase in application: on-site
assembly of transformers can provide the same quality as factory assembled transformers, integral 3-
phase construction is now possible for 500 kV transformers, cost reductions in on-site assembly of
transformers, and lastly transportation restrictions have become harsher. Furthermore, there are
advantages from the energy management perspective by reducing the environmental impact, de-
bottlenecking the transportation constraint, responding to accident and replacement requirements,
reducing system losses and improving life cycle cost (LCC).
Total number of units
Figure 2.2 - Production record of on-site assembly transformer (in China and Japan)
Figure 2.3 - Number and Capacity of on-site assembly transformers
13
2.1.2.2 Construction and effect of application

(1) Concerned items for construction
Disassembly in the factory is minimized as much as possible and on site quality control is kept simple
but yet duplicates the verification done at the time of factory assembly.
(2) Construction features
a) Core Construction - 3-phase 5-leg core is applied to on-site assembly transformers. By configuring
it to disassemble only the upper yoke, the time for the on-site assembly is substantially reduced.
The lower yoke is configured to be segmented into 4 pieces of U shape taking advantage of the
standard core structure of a 3-phase 5-leg main core which allows it to be separated at the centre
part (Figure 2.4 (a)). By using this construction, it is possible to assemble the core on-site in 4 days
(erection of U shape unit x 2 days, upper yoke assembly x 2 days).
b) Winding Construction - The winding is assembled as a unit (nested per phase) and clamped with
the upper and lower press rings. The nested winding phase can be handled as a single unit,
minimizing the time for assembly of the winding on-site. To prevent moisture absorption and dust-
proof during the transportation and on-site assembly, the winding unit is packed with the polymer
film (Figure 2.4 (b)).
c) Tank Construction - The tanks are horizontally split. The core & coils are assembled on to the
lower tank. The number of segments used for the upper tank construction is decided in accordance
with the transportation condition and the transport trailer to be used. After the assembly is
completed, the outer circumference flange part is welded to be integral construction.
(a) Core unit (U shape core) (b) Winding configuration (film pack)
Figure 2.4 - Core unit and Winding configuration
d) Transportation Construction - The core U shape unit and winding unit are mounted and fixed on a
dedicated transport tank for transportation by a low platform trailer. The standard transportation
control criterion (maximum acceleration < 3G) was developed by performing an actual transport
test up to 5G using a vibration generator (since the transportation mode is different from
conventional transformers).
(3) Effect of application - By applying on-site assembly transformers, other advantages were realized:
a) Reduction of Transportation Cost and Lead Time - Transport costs such as reinforcing roads and
bridges for heavy loads are no longer required. Vehicle costs are reduced as no special freight
cars or trailers are used.
b) By changing from the configuration from 3 units of single-phase to a normal 3-phase unit, the
volume of materials required for the transformer production is reduced and additionally, the site
layout footprint is decreased (Table 2.1).
c) Realizing a Lower Life Cycle Cost Transformer due to Increased Design Flexibility - By reducing
the volume of required materials, the equipment is optimized by means of life cycle cost
assessment and impact on the environment.
It is expected that transportation constraints will become more severe. On-site assembly will be the
14
principle technology to support the current and future electrical power infrastructure system for failures
of existing equipment and replacements of deteriorated equipment.
2.1.2.3 On-site assembly procedure

(1) Quality Assurance
The quality goal of on-site assembly is to reproduce the transformer at site after factory disassembly of
the active part. The process of the re-assembly is shown in Table 2.2.
Quality control standards for the on-site assembly are:
1. Apply the same control standard as that of the factory assembly.
2. Perform quality checks with intermediate electrical tests.
3. The on-site assembly environment should be similar to the factory with dust-proof management
(dust-proof volume 20 cpm or less) and moisture-proof management (relative humidity 50 % or
less).
Items of the quality control standards for each process are shown in Table 2.3.
Table 2.1 - On-site assembly transformer comparison (500 kV – 1 500 MVA)

type Single phase transformer On-Site assembly transformer
Drawing
(1) 1phase-500 MVA transformer X 3 (1) 3phase-1 500 MVA transformer X 1

Configuration
(2) Two winding-groups / 1 phase (2) One winding group / 1 phase
Mass Total mass:100 % Total mass: 75 %
Area Installation area: 100 % Installation area: less than 50 %
15
Table 2.2 - Basic assembly process of on-site assembly transformer

2. Coil insert and upper 3. Tank and internal lead
1. Core setting
yoke assembly assembly
Following can be eliminated: Following can be eliminated: Lead connection and tank
>Leg stacking >Drying process at site assembly
>Lower yoke assembly
>Core erection Dust /moisture will be
controlled.
Table 2.3 - Quality control items for on-site assembly transformer

Items Workflow Inspection items
1. Oil drain --
2. Replacement with dry air --
3. External parts disassembly 3. Packing, inspection before shipment
4. Tank decomposition 4. Packing, inspection after shipment
5. Internal activity lifting --
6. Internal lead disassembly 6. Packing, inspection before shipment
Disassembly at factory
7. Upper parts, upper yoke 7. Packing, inspection before shipment
disassembly
8. Windings lifting --
9. Film packing of windings 9. Packing, inspection before shipment
10. Lower parts of core disassembly 10. Packing, inspection before shipment
11. Core disassembly (U-shape 11. Packing, inspection before shipment
core)
Transportation Transport from factory to site --
1. Clean house assembly --
2. Bottom tank on-base 2. Site acceptance inspection
3. Core re-assembly 3. Site acceptance inspection
(U-shape core)
4. Suspended the windings and 4. Site acceptance inspection
Work in the insert
clean
5. Core re-assembly 5. Site acceptance inspection
house
(upper yoke)
6. Internal leads re-assembly 6. Site acceptance inspection
Assembly
at site 7. Tank re-assembly 7. Site acceptance inspection
8. Tests of active part --
9. Clean house disassembly --
10. External parts assembly 10. Site acceptance inspection
External 11. Bushing lead connection 11. Site acceptance inspection
assembly &
oil filling 12. Vacuum, oil filling and circulation --
13. Repair painting --
14. Test of finish product --
16
(2) On-site assembly work procedure (Phase1) (1992~2007)

(i) Transportation Unit - For transformers completed with tests at the factory, its internal assembly is
de-oiled and dried to be disassembled into transportation units such as a core or windings. For
transportation mass (including a trailer), the largest item is the U shape core of approximately 60 t.
In the case of the trailer transportation, transportation permits must be prepared in advance.
(ii) On-site assembly Conditions and Layout - The dust-proof house erected at the site has an open
ceiling so that mobile cranes are used to assemble a transformer. Therefore, it is necessary to
suspend the work during rain or depending on the weather. Figure 2.5 shows the erection work of
a core. Two large size heavy machines are required necessitating the space of at least 800 m2
adjacent to the dust-proof room. Thus, Phase1 work method has risk for weather delay and
requires a large space at the site. A series of the process of the on-site transformer assembly from
the shop disassembly, transportation and on-site assembly is shown in Figure 2.5.
(a) Factory test (b) Core dis-assembly (c) Transport (core)

(U-shape core)
(d) Transport (windings) (e) Installation of bottom tank (f) Lifting of core by 2 cranes
(400 t and 100 t)
(g) Installation of core by crane (h) Insertion of windings by crane (i) Inserting top yoke laminations
(j) Insertion of middle tank k) On-site assembly completed

Figure 2.5 - Dismantle and re-assembly process (Phase 1)
17
(3) On-site assembly work procedure (Phase2) (2007~)

(i) Transport mass segmentation
Transport permits are required for heavy weight materials by road trailer. In the case of the on-site
assembly transformer Phase 1, permits were necessary since the transportation weight of the cores
was 60 t.. In 2007, the transport of 50 t or less was simplified in Japan and this led to the
development of reducing the transport masses in on-site assembly to 50 t or less. .
a) Core construction - The core was transported in a dedicated tank by further dividing the
conventional U shape core into the leg core and the lower yoke. This simplified core binding method
minimized core displacement during transport and the transportation weight of the core was able
to be reduced. In addition, the transport tank of the core leg also serves as the lifting tank at site
which enables the U shape core to be restored. Figure 2.6 (a) shows a segmented state of core
and Figure 2.6 (b) shows the erected state at the site.
b) Winding construction - Reduction of the transportation weight was realized by simplifying the
transportation configuration within the tank and reducing the tank weight by using aluminium for
the tank material.
(a) Core segmented state (Phase2) (b) Core erected state (Phase2)
Figure 2.6 - Core segmented state and core erected state
(ii) Development and application of all-weather type internal assembling work process
Dust-proof houses used for on-site assembly were initially open ceiling type but had the
disadvantage of being weather dependent. Based on this, in the Phase2 on-site transformer
assembly, the all-weather dust-proof house was developed and the indoor assembly process not
requiring the heavy machine crane was developed. Comparison of dust-proof houses is shown in
Table 2.4.
a) Core erection - After connecting the leg core, the lower yoke is assembled to complete the U shape
core. Then, the core is erected by using the gantry lifter placed in the dust-proof room. It can be
erected by using only the gantry crane so that it can be done within the dust-proof house realizing
better space efficiency. The erection process of the core inside the dust-proof house is shown in
Figure 2.7 (b).
b) Assembly of internals - This time, the dust-proof house has the assembly room and the second
house holds the 450 t heavy lift machine and gantry lifter capable of lifting heavy weight materials
of 60 t for the indoor assembly work. The lid where the equipment can be brought in by the heavy
machine was provided on the ceiling part of the second house. For this work procedure, the
equipment is carried into the second house to be disassembled in such a way that it can be lifted.
Then the assembly of the transformer is performed by using the gantry lifter. The equipment is
placed in the transport tank when it is delivered. There are no weather interruptions for disassembly
and assembly work as the second house top part is closed. Due to this, the work becomes possible
during rainy weather without exposure to wind and rain except for the time when materials are
carried in. Figure 2.7 shows the assembly process of internals.
18
Table 2.4 - Dust-proof on-site assembly house
Type With open / close roof top type All weather type
House appearance
photo
Structure Open and close the bellows ceiling of No ceiling opening. Brought in
Characteristics the upper part, carry in parts parts with slide device
Transformer Parts carry-in and unpacking are Parts carry in and carry out
assembly carried out in outdoor environments, assembly without exposure to
quality assurance, processes are outside air
affected
(a) Installation of bottom tank (b) Erecting of core tank by lifter (c) Insertion of windings by lifter
(d) Insertion of windings by lifter (e) Inserting top yoke laminations (f) Insertion of middle tank
Figure 2.7 - Re-assembly process (Phase 2)
19
2.1.3 Experience B with Shell Type

2.1.3.1 Application trend of on-site assembly transformer
In recent years, the application of on-site assembly transformers is increasing. Figures 2.8 and 2.9
shows production results of company B from 1978 to 2017.
As a background, the disassembly for transport application is increasing as transport constraints
become more severe each year. In recent years, the capacity (MVA) of transformers for 500 kV
substations and transformers for hydroelectric power plants has been able to increase due to compact
and lightweight transportation.
Applying disassembly for transport not only solves transport constraints but also reduces installation
footprint and losses.
Figure 2.8 - Production experience of on-site assembly transformer (Shell Form)
More than 1000 MVA

less than 1500 MVA
Capacity (MVA)
More than 500 MVA

less than 1000 MVA
Less than 500 MVA
Number of unit (unit)
Figure 2.9 - Number and Capacity of On-site Assembly Transformers (Shell Form)
2.1.3.2 Technology transition

Table 2.5 shows the technology transition of Company B's disassembly for transport transformer.
Because the on-site assembly of a transformer involves work that exposes solid insulation to the air at
site, it is necessary to prevent moisture absorption of insulation and strengthen dust control from the
viewpoint of securing quality. For this reason, coil film pack technology and clean house technology was
established. Also, when working inside the transformer tank and clean house, dry air with low dew point
is applied to prevent moisture absorption of insulation.
20
Table 2.5 - Technology transition of on-site assembly transformer
Element technology development stage (1978-1980) Real system demonstration stage 1980-1981)
① Selection of insulation moisture absorption {Single phase 500 kV，Transformer 100 MVA}
prevention material (film packing material)
② Film pack method, confirmation of moisture ① Demonstration of reassembly method at site
prevention effect (method, moisture preventing effect)
③ Transport structure verification of coil group
1980 ④ Verification of reassembly method ② Real system long term charge test
③ Take away test at factory/ detailed inspection
Adoption of new technology Purpose/ Effect

Practical use of 275 kV (1984) ① Coil group products Minimization of demonstration range
Storage transport of lower (reduction of construction period)
Tank
1985
② Structure of three phase With above ①, use part of transport
divided transport of lower tank tank for coil group
③ Lower tank interphase arm With above ②, suppression of

type automatic welding dimensional increase of transformer
equipment on site
① On site assembly house A factory–like work environment was

（bellows type） realized on outdoors assembly
②Block insertion method of leg Reduction of assembly period
1990 core
③Lower tank interphase leak Confirmation of oil-tight performance
test equipment for welded at the preprocess of core assembly
parts only (conventionally visually and
confirmation of oil pressure after
Practical use of 500 kV (1992)
installation)
Practical use of large capacity 500 kV

(1993) ① Lower tank interphase Improve correspondence of large
gate type automatic capacity (long length)
welding equipment at site
1995 ② Coil group fixing device in Improve correspondence of large
the process of assembly at capacity (weight increase)
site
Improvement of practical use of large ① Storage sideways Simplified transport (Eliminate the
capacity 500 kV (1997) transport of lower tank of height limit of transportation)
coil group
② On site assembly house Reduction of house assembly and
（Panel assembly type） demolition period
③ Longitudinal Simplified transport (Resolution of
2000 disassembled transport of transport length and width limitation)
upper and middle tank
④ Low dew point dry air Reduction of thermal oil circulation
generator -40℃⇒-50℃
2005
① Divided transport of coil Simplified transport (Reduction of

Practical use of ultra large capacitors 500 kV transport weight of ultra large
capacitors)
(2007-2013) ② All weather clean house Reduction of construction period at
site
③ Tent type assembly house Reduction of construction period at
site
2010
21
2.1.3.3 Technology of on-site assembly transformer

(1) Basic structure of shell type on-site assembly transformer
Figure 2.10 shows the basic structure of Company B’s shell type on-site assembly transformer. The
coil group is covered with moisture absorption prevention pack film, placed in the transport tank and
transported by trailer. The core is film packed in blocks and transported by truck.
Figure 2.10 - Basic structure of Shell type on-site assembly transformer
(2) Film packing method for moisture absorption prevention of coil group
In the element technology development started in 1978, ETFE (Ethylene Tetra Fluoro Ethylene type
film) was selected for excellent in moisture permeability, mechanical strength, sealing processability, oil
resistance and electrical characteristics. (Figure 2.11)
Figure 2.11 - Coil group film packing
(3) Block insertion method for leg core

When transporting the shell type transformer core to site, the yokes and legs are disassembled into
separate block units for transportation. To minimize field assembly time, each core leg block is re-
inserted using a winch (see Figure 2.12).
22
Figure 2.12 - Block insertion method of core leg
(4) On-site assembly house (clean house)

Initially a bellows type house was used but now either panel type clean house (Figure 2.13) or a tent
type clean house (Figure 2.14) is selected according to local conditions and the size of the transformer.
Partition sheet between

Ceiling protection sheet assembly room and front room
Gateway partition sheet
Small crane
beam for core
loading
Partition sheet for

Wall protection sliding door of core
sheet loading
Floor surface
water proof sheet Changing room
Figure 2.13 - Panel type clean house
Dew condensation prevention

double structure sheet Partition sheet between
assembly room and front
room
Changing room
Floor surface water

proof sheet
Figure 2.14 - Tent type clean house
23
(5) Longitudinal division of upper and middle tank for transport

Reduction of transport length and width dimension was done by dividing the upper tank and middle tank
vertically for each phase (Figure 2.15).
(a) Divided three phase tank for transportation (b) Welded three phase tank at site
Figure 2.15 - Longitudinal division of upper and middle tank for transportation
(6) Divided coil groups for transport

Transportation mass of the large transformer is further reduced by dividing the coil group of each phase
into two groups. (Figure 2.16)
Core
Divided the
group into two
at this place
Group 1
HV
MV
LV
Group 2
Coil group arrangement at assembly
Coil group at transportation
Figure 2.16 - Divided coil groups for transportation
2.1.3.4 On-site assembly method and quality management

The procedure for on-site assembly and the quality management items are shown in Table 2.6.
Particularly, core reassembly on site is an important point of construction of on-site assembly
transformer. The quality is maintained while shortening the site process. Figure 2.17 shows shell-type
application of on-site assembly transformers.
Table 2.6 - Procedure of on-site assembly and items of quality management

Major Item Figure Work Item Management Item
(1) ① Set of clean ・ Humidity inside the clean
house house
Set of clean
house and Clean
組立ハウスhouse ・ Humidity inside the dust
bottom tank cover (less than 50 %)
Bottom Tank
下部タンク・ Foreign particle
・ Dry air dew point (less
than -50℃)
② Receipt of ・ Visual inspection

bottom tank
・ Internal pressure
・ Impact level
[less than 29.4 m/s2(3G)]
24

③ Set of Bottom ・ Foreign particle
tank
than -50℃)
・ Weather (not rainy
condition)
・ Flatness
・ Centering
(2) ① Receipt of coil ・ Visual inspection
group
Set of coil ・ Internal pressure
group ・ Impact level
コイルグループ
Coil Group
[less than 29.4 m/s2(3G)]
② Set of coil ・ Dimension check
group
・ Visual inspection
・ Foreign particle
than -50℃)
・ Number of all tools
・ Direction and position
check
③ Low Voltage ・ Winding resistance
Test measurement
・ Insulation resistance
measurement
・ Water content in insulation
materials (0.5 %･wt.)
(3) ① Receipt of core ・ Visual inspection

Core ・ Impact level
Winch for
ブロック牽引用
stacking Core block
[less than 29.4 m/s2 (3G)]
ウインチ
② Insert of Leg ・ No abnormality
block
・ Core stack height
measurement
Core
鉄心・ Foreign particle
鉄心ブロック用
Pallet of core block
パレット than -50℃)
③ Low Voltage ・ Voltage ratio
Test measurement
・ Short-circuit impedance
measurement
・ No-load current
measurement
measurement between
core blocks
25

(4) ① Receipt of tank ・ Visual inspection
Middle tank Middle
中部タンク Tank ・ Internal pressure
assembly ・ Impact level
[less than 29.4 m/s2 (3G)]
② Middle tank ・ Foreign particle

assembly
than -50℃)
・ Weather (not rainy
condition)
・ Weather (humidity less
than 80 %)
③ Welding of ・ Weld leg length check

Tank Flange
(5) ① Upper tank ・ Foreign particle

Assembly
Upper tank ・ Dry air dew point (less
Upper ・
Assembly Tap changer tank than -50℃)
上部・M R タンク
Disassembly
Disassembly of ・ Weather (not rainy
of clean clean house condition)
組立ハウス撤去コイル
house
・ Humidity (less than 80 %)
② Vacuuming of ・ Degree of vacuum
tank ,
・ Internal N2 pressure check
N2 filling and ・ Weld leg length check
welding of tank
flange
③ Repair paint ・ Visual check
(6) ① External ・ Weather (not rainy

HV Oil - Gas assembly condition)
External spacer LV Oil – Oil bushing
高圧油 - ガススペーサ低圧油中貫通ブッシング
Assembly ・ Weather (humidity less
than 80 %)
・ Tightening torque
・ Visual inspection of
cooling equipment
than -50℃)
② Repair paint ・ Visual check
26

(7) ① Internal ・ Weather (not rainy
Internal Lead
リード Connection condition)
Connection ・ Humidity (less than 80 %)
・ Tightening torque check
・ Foreign particle
・ Check of connection and
insulation work
than -50℃)
(8) ① Oil filling under ・ Check of insulation oil
Sound insulation
Final filling tank vacuum ・ Check of degree of
the oil and vacuum (67 Pa) and
site holding time
acceptance ・ Check of oil-treatment
tests
・ Check of dielectric
characteristic of oil (60
kV/2.5 mm)
・ Check of water contents in
oil (less than10 ppm･wt.)
・ Check of quantity of gas in
oil (less than 0.5 %・vol)
② On-site ・ Voltage ratio

acceptance test measurement
(low voltage ・ Short-circuit impedance
test) measurement
・ Capacitance, and
dissipation factor (tanδ)
measurement
measurement
・ Oil tightness check
・ No-load current
measurement
Figure 2.17 - On-site assembly transformer after completing its installation (500 kV - 1 000 MVA)
27
2.1.4 Experience C with Core Type

2.1.4.1 Needs and History
Company C began on site assembly with 230 kV, 135 MVA transformers delivered to mountainous
areas in the 1950’s. They were assembled and tested at the factory, disassembled for transportation,
and re-assembled at site. In the 1980’s, development of on-site assembly technology for new demand
was carried out and the application was expanded [3] .
Needs
Figure 2.18 - Needs of On-site assembly transformer
Figure 2.18 shows the needs of on-site assembly technology. For company C, the application for on-
site assembly of transformers started as a solution to achieve Total Cost Minimum as demanded in the
transformer market. The idea of on-site assembly is to cut down the overall cost by reduction of
transportation costs and minimizing the capacity requirement during site assembling.
An extensive study of on-site assembly of transformers related research such as core
splitting/assembling methods, evaluation of film pack material developments etc. was carried out in the
late 1980’s. The results of these studies were implemented in 220 kV, 250 MVA transformers that were
delivered in 1989.
These applications were continuously adopted up to 500 kV class with new materials for film packing
and revised site assembling methods to improve the on-site assembly technology. Pilot tests were
successfully performed in 1999 to 2000 using a 1 Phase 1000 MVA 500 kV prototype model. The first
transformers to apply this technology were 400 MVA 275 kV class which were delivered in 1999 to a
Japanese local utility. Figure 2.19 shows the history of on-site assembly of transformers for Company
C.
28
‘85 ‘90 ‘95 2000 ‘05 ‘10
Figure 2.19 - Development of a new type On-site assembly transformer
2.1.4.2 Outline of On-site assembly Transformer

For on-site assembly, the transformer is disassembled into core, winding coil and tank components after
successfully passing the factory testing. These components are re-assembled at site through strict
quality control workflow. Each package of these components is designed to fit a readily available low
load truck. Special design structure and manufacturing processes are applied.
The design concept is:
1） Minimize transport handling costs such as eliminating requirements of bridge reinforcement,

utilizing low-loader trucks and keeping transport package weights below 40 t.
2） Maximize site work efficiency by minimizing number of transport package.
On-site assembling work requires a controlled house (Clean House), where winding and lead wire
connections and tank cover installation are performed. Upon installing the tank cover, assembly work
shall be performed as per a normal transformer installation (i.e. accessories, oil impregnation, final site
tests etc).
Figure 2.20 shows the transporting structure of a disassembled transformer. The transformer is
generally divided into three main components for transport, - core, winding and tank structure.
29
Figure 2.20 - Disassembled Components for transportation
(1) Core Structure

The core structure is divided into 13 parts (wound leg: 3 pieces, non-wound leg: 2 pieces, upper and
bottom yoke: 8 pieces).
Figure 2.21 - Divided core components
30
(2) Winding Structure

The windings are transported in separate tanks. Each of the winding units is wrapped by special film to
avoid absorbing moisture during transportation. The film is designed so that any fragments shall not
remain after removing the film and degradation of insulating performance shall not occur.
Moisture in paper insulating material is securely controlled by monitoring a specimen.
Figure 2.22 - Winding and its film packing
(3) Tank Structure

The tank is divided horizontally into 3 parts considering its transportation limit and workability at site.
The tank is welded after being assembled at site.
Figure 2.23 - Divided tank components
31
(4) Clean House
The Clean House atmosphere is controlled for humidity (less than 50%) and temperature (between 5℃
and 30℃).
(a) Outside view of Clean House (b) Inside view of Clean House
Figure 2.24 - Overview of Clean House
2.1.4.3 On-Site Work

To secure active part quality during site assembly, special quality control is considered. This especially
includes prevention of moisture absorption in the insulation material and strengthening of dust proofing
control. Film packing technology and clean house technology is applied. In addition, during assembly
work in the transformer tank and clean house, humidity controlled dry air is blown continuously,
minimizing moisture absorption in the insulation material. Figure 2.25 shows the on-site assembly work
flow [4] .
Figure 2.25 - On-site Assembly Work Flow
32
2.1.4.4 Quality Control for Factory to On-Site

Tables 2.7 and 2.8 show the actual quality control work flow of the on-site assembly transformers.
Table 2.7 - Disassembly Work in Factory to Shipping

Work step Figure Work detail
1. Factory Test Tests will be performed according to the
Inspection and Test Item (ITP)
2. Disassembly Transformer body and accessories shall be free

from damage
3. Outer Body (1) Dry air shall be continuously blown into the
Disassembly tank during work to prevent moisture
absorption.
(2) Dry air dew point: Below -40℃
4. Upper Yoke (1) Work shall be performed in an air conditioned,

Removal dustproof room
(2) Cover the coil with dustproof, moisture proof
film pack
(3) Dry air shall be continuously blown into film
pack during work
5. Coil Removal (1) Work shall be performed in air conditioned,

dustproof room
(2) Lifting slings shall be used
(3) Load parts into special transport truck
6. Core Setting (1) Work shall be performed using the Iron Core
Stand
(2) Oil shall be removed from the disassembled
yoke plates
(3) Load parts into special transport truck
33

7. Lower Yoke
Removal
8. Packing (1) Coil, Core, Upper Yoke, and Lead Conductors

shall be packed into special transport tank
 Enclosed dry air dew point: Below -40℃
 Enclosed pressure: 0.015 MPa
(2) Install accelerometer on the coil, core tank
and check for device operation
(3) Check moisture content of insulating paper
9. Transport and (1) Control criteria during transportation:

shipping  Speed Limit: Below 40 km/H
 Sudden acceleration & braking is prohibited
(Running condition will be monitored using
tachometer)
(2) Acceleration: Below 29.4 m/s2
Table 2.8 - On-Site Assembly

1. Clean House (1) Humidity: Below 50 % RH
Setup (2) Floating dust: Below 20 cpm
(4) House Temperature: 15℃ - 30℃
2. Core Leg (1) Accelerometer: 29.4 m/s2

Check (2) Transport tank internal pressure: Positive
pressure
(3) Visual check: No visible damage during
transportation
3. Stacking・ (1) No overlapping between core sheets

(2) Check for insulation between core and metal
Tightening of
fittings
Lower Yokes
 Insulation resistance: Below 50 MΩ
4. Core Setting (1) Leg dimension tolerance: 0 - +5 mm
34

5. Coil Check (1) Accelerometer: 29.4 m/s2
(2) Transport tank internal pressure: Positive
pressure
(3) Visual check:
 No visible damage on coil film pack
 No visible damage, deformation on coil
(4) Check for moisture content of insulating paper
6. Coil Assembly (1) Coil must be level

(inserting coil) (2) Dry air shall be continuously blown into film
pack during work
7. Internal (1) Stacking / Tightening of upper yoke

Assembly  No overlapping between core sheets
 Core insulation resistance: 50 MΩ or more
(between core and fittings)
 Core sheets resistance: > 0.4 Ω, less than 1
MΩ
(2) Connect lead conductor
 Prevent moisture absorption by film pack
 Torque control of tightening parts
8. Install Upper, (1) Film pack shall be removed before tank

Middle Tank installation
(2) Confirm the distance between internal body
and tank
(3) Check the moisture content of insulating
paper
9. Tank Flange (1) Tank internal pressure: Positive pressure

Welding (2) Monitor surface temperature of tank flange
(using thermo-level)
(3) Check welded area using partial pressure
method
 Gas pressure: 0.1 MPa
10. Internal (1) Acceptance check of external accessories

Connection,  Visual check: No visible damage
External (2) Internal connection and check
Assembly  Tighten all fitting with suitable torque
 Visual check: No visible damage
 Check for insulation distance
 Tank internal humidity: Below 50 %RH
 Check for moisture content of insulating
paper
35

11. Preliminary Test shall be performed according to ITP
Test Preliminary Test Item:
1) Voltage Ratio Test
2) Core Resistance Test
3) Core Insulation Resistance Test
4) Low Voltage Excitation Current Test
5) Low Voltage Impedance Test
6) Insulation Distance Check
7) Internal Connection Check
12. Insulation (1) Vacuuming

Treatment  Vacuum pulling time: According to
manufacturer's standard
 Pressure: Below 67 Pa
 Vacuum leakage: Below 800 Pa·ℓ /s
(6 000 μHg·ℓ /s)
(2) Oil Acceptance Check
 Water content in oil: Below 30 ppm
 BDV: 40 kV/2.5 mm or more
(3) Oil Injection Characteristics
(4) Oil Final Characteristics
 Degassing cycle: 3 cycle or more for all oil
volume (2 cycle or more is required as per
"Electric Technology Research Association
(ETRA)"[2]
 Water content in oil: Below 10 ppm
 Gas content in oil: Below 0.5 %
 Moisture content of insulating paper: Below
0.5 %
(5) Oil Tightness Test
 0.03 MPa or more
(0.02 MPaG or more x 24 h Pressurized
(6) Oil Level Adjustment
 Oil level adjustment according to oil
temperature and oil level curve.
13. Tests after Test shall be performed according to ITP
Assembled After Oil Filling:
1) Winding Resistance Test
2) Polarity and Phase Test
3) Insulation Resistance Test
4) Tank Pressure Test
5) Oil Water Content Analysis
6) Operational Check (OLTC)
Final Assembly Test Item:

1) Dimension Check
2) Oil Tightness Test
3) Oil Water Content Analysis
4) Tan δ Test
5) Flow Electrification Test
6) Fan Control Input Test
7) Test on Control Cubicle, Accessories
(Bushing, BCT, etc.)
8) Sequence Check
36
2.1.5 Summary
Although each manufacturer has different quality control details, the minimum quality management
items and quality control standards from factory to on-site assembly are summarized in Technical Guide
No.69-2 ETRA (Electric Technology Research Association) in Japan titled “Survey of applied experience
for quality control of disassembly, transportation and site assembling of power transformer” published
in Aug. 2013 [2] . This is referred to below. In the past 30 years, Japan has experienced a large number
of on-site assembly transformers as shown table 2.9. These transformers are all in service without any
major accident or failure. Presently it is very common to apply the 500 kV class to the on-site assembly
transformer in Japan [5] .
Table 2.9 - Experiences of the on-site assembly transformers in Japan

Experiences of the on-site assembly transformers in Japan between 1980 and 2020
No. Voltage Units Remarks
1 500 kV 54
2 220 – 275 kV 31
3 110 – 154 kV 5
4 Total 90 All transformers in service
As shown in Table 2.10, on-site-assembly transformers are controlled so that factory assembly quality
is maintained from factory disassembly to on-site assembly including moisture absorption in each
process. To prevent moisture absorption affecting insulation performance, a film pack is attached from
the factory to the site assembling, and a clean house is installed to realize a working environment such
as humidity and particle control equivalent to that of the factory. Furthermore, to confirm the moisture
absorption of the solid insulation in the process of transportation and site work, a moisture absorption
monitoring material is attached at the factory, and the amount of absorbed moisture in each process is
managed. This is detailed in Table 2.11, 2.12, 2.13, and 2.14. Details of tests at each step are shown
in Appendix A “Detail of the factory and on-site tests methods for the on-site assembly transformers in
Japan”.
Quality control, especially in the field assembly work, is very important. At each point, such as at the
time of core, coil assembly, etc., a unique test as shown in Table 2.14 is conducted. It is effective in
ensuring the quality of these products and minimizing the process loss due to reversion work.
To further study the on-site assembly transformer, Japanese power utilities, including hydro utilities,
investigated the number of incidents involving on-site assembled transformers between 1980 and 2020.
No incidents were observed and only faults due to either machine aging or lack of maintenance
occurred. In addition, separate three phase bank transformers, which are largely supplied, showed
records of fault due to natural phenomenon or lack of maintenance to cooling units, which is not related
to fault causes.
Thus, the quality control standard for work performed for on-site assembly transformer and separate
three phase transformer is ensuring transformer reliability. Moreover, no faults / incidents accidents
were observed from overhaul projects.
Table 2.10 - Principal quality control items for on-site assembly transformer
No Quality control item Contents
1 Disassembly work at the factory - Visual inspection of coil, core, lead and internal
activity
- Number of parts check
2 Transportation (Record and check) - Internal pressure of transportation tank
- Impact level
3 Assembly condition at the site - Keep the level of humidity and foreign particle in
(Equivalent condition with the factory) the clean house
4 Prevention from moisture absorption in the - Windings film packing
37
No Quality control item Contents

insulation materials - Dry air blowing
- Moisture content measuring by monitoring
insulation materials
5 Prevention from foreign particle and damage - Protective covering
- Visual inspection
6 No abnormality check of assembly parts - On-site inspection and test
Table 2.11 - Process and quality management of 500 kV on-site assembly transformer under the factory
desassembly work
Process Management item Criteria Remarks
1. Oil drain  Residual oil check  No residual oil
2. Dry air substitution  Dry air dew point  Below criteria Depend on
manufacture’s criteria
3. Disassembly of  Visual inspection  No abnormality
external parts
 Number of external parts  No missing
check
 Foreign particle check  No abnormality
 Packing condition check  No abnormality
 Dry air dew point  Below criteria Depend on
(Lead compartment)
 Internal pressure  Positive pressure (Lead compartment)

4. Tank disassembly  Visual inspection  No abnormality
 Transportation cover  No abnormality
clamping
 Internal pressure  Positive pressure
5. Internal activity  Visual inspection  No abnormality
lifting
 Dry process condition check  Dry condition of Not applicable
insulation materials depend on
surface manufacturer
6. Internal lead  Visual inspection  No abnormality
disassembly
 Packing condition check  No abnormality
 Number of leads check  No missing
manufacture criteria
 Internal pressure  Positive pressure
7. Core disassembly  Visual inspection  No abnormality
 Number of disassembly core  No missing
and insulation parts check
 Layer and insulation  More than 10 MΩ Not applicable
resistance measurement depend on
manufacturer
38

 Dry process condition check  Dry condition of Not applicable
materials surface depend on
manufacturer
 Packing condition check  No abnormality Not applicable in
case of using the
sealed transportation
tank
 Transportation tank and  No abnormality
fittings clamping
 Dry air dew point in  Below criteria Depend on
transportation tank manufacture’s criteria
 Internal pressure in  Positive pressure Not applicable in
transportation tank case of using the
sealed transportation
tank
8. Winding  Visual inspection  No abnormality
disassembly
 Attachment of moisture  Done
monitoring insulation
materials
 Windings drying  Done Not applicable for
some manufacturers
 Film packing of windings  Done

 Visual inspection after film  No abnormality
packing
 Insulation resistance  As per Fig 9 in Oil-
measurement immersed transformer
test guideline,
Technical Report of
IEEJ, Part II, No. 119,
page 7 [6]
 Transportation cover  No abnormality
clamping
 Internal pressure in  Positive pressure
transportation tank
Note: It is carried out when moisture absorbed by the dismantling work is removed. Depending on the
manufacturer, it may be unnecessary to check the moisture content on the moisture absorption monitor
material or to dry the coil before the factory test.
39
Table 2.12 - Process and quality management of 500 kV on-site assembly transformer during
transportation
1. Transportation  Installation of impact  Done
recorder
transportation tank
 External condition at loading  No abnormality
and un-loading
 Transportation Normal  Below 40 km/h Reference
speed road
Highway  Below 70 km/h Reference
 Impact record  Below 29.4 m/s2
Table 2.13 - Process and quality management of 500 kV on-site assembly transformer at on-site work
Work item Management item Criteria Remarks
1. Clean house  Humidity in the house  Below 50 %
installation
(Below 80 % when
ceiling is open)
 Floating particle  Below 20 cpm
 Dry air dew point by generator  Satisfy the criteria Depend on
2. On base  flatness  Satisfy the criteria Depend on
 Centering  Satisfy the criteria Depend on
3. Coil assembly  Internal pressure in  Positive pressure
transportation tank
(inserting coil)
 Visual inspection  No abnormality
 Moisture content in insulation  Below 0.5 %･wt.

material measurement
(acceptance test)
 Winding resistance  Within +/- 5 % of FAT measure on later
measurement value stage in some cases
Timing depends on
manufacturer’s
process
 Insulation resistance  As per Fig 9 in Oil- measure on later

measurement immersed transformer stage in some cases
test guideline,
Technical Report of
IEEJ, Part II, No. 119,
page 7 [6]
 Horizontal dimension check  Satisfy the criteria Depend on
(assembling)
40

 Dry air dew point  Satisfy the criteria Depend on
4. Core assembly  Visual inspection  No abnormality

 Internal pressure in  Positive pressure (In case of using
transportation tank transportation tank)
 Protective covering condition  No abnormality
 Humidity inside of dustproof  Satisfy the criteria Depend on
cover manufacture’s criteria
 Dew point of blowing dry air  Satisfy the criteria Depend on
 Stacked core dimension  Satisfy the criteria Depend on
measurement manufacture’s criteria
(assembly inspection)
 Layer resistance measurement  Satisfy the criteria Depend on
 Insulation resistance
measurement
 Satisfy the criteria
5. Internal lead  Internal pressure in  Positive pressure
assembly transportation tank
 Tightening torque  Tightened by
manufacturer criteria
 Insulation condition check  According to the
drawing requirement
 Dimension check  According to the
drawing requirement
(Compare with drawing) on lead
 Connecting condition  No abnormality
 Lead position check  According to the
drawing requirement
6. Tank assembly  Visual inspection  No abnormality

transportation tank
 Impact record  Below 29.4 m/s2 In case of
transportation with
windings and/or leads
41

 Weather condition  Not rainy condition In case of work
outside the clean
house
 Weld leg length  Satisfy the criteria Depend on
 Degree of vacuum  Satisfy the criteria Not applicable for
some manufacturers
 N2 density  Satisfy the criteria
 Damage check of internal  No abnormality on

activity internal activity
 Weld leg length after assembly  Satisfy the criteria Depend on
 Leakage check by gas  No leakage
pressurization
7. Internal parts test  Low voltage test  Satisfy the criteria Depend on
8. Clean house  Visual inspection of  No abnormality
disassembly transformer
9. External parts  Check external condition  No abnormality
assembly
(acceptance test)
 Clamping  No abnormality
 Visual inspection of  No abnormality
transformer
 Weather condition  No rainy day
 Humidity of outside air  Below 80 %
manufacturer control
value
 Insulation resistance  Satisfy the criteria Depend on
measurement manufacture’s criteria
10. Connecting of  Visual inspection  No abnormality
bushing lead

transportation tank
 Protective covering condition  No abnormality
manufacturer control
value
 Insulation condition check  According to the
drawing requirement

 Dimension check  According to the
drawing requirement
(Compare with drawing) on lead position
 Worker clothes check  No abnormality
 Check number of parts and  No missing
42

tools bringing in the tank
 Humidity of inside air  Satisfy the criteria Depend on
 Weather condition  Not rainy condition
 Humidity of outside air  Below 80 %
 Connecting condition  No abnormality
 Lead position check  According to the
drawing requirement
11. Vacuum, Acceptance  Breakdown  Over 40 kV/2.5 mm
degassing and oil voltage
filling and oil
circulation  Water contents  Below 30 ppm･wt.
Vacuum,  Water content  Below 0.5 %･wt.

degassing measurement
and oil filling in insulation
before vacuum
 Degree of  Satisfy the criteria Depend on
vacuum and manufacture’s criteria
duration
 Moisture  Below 0.5 %･wt.
content in
insulation
material
measurement
after vacuum
 Number of oil  More than 2
circulation for circulation
degassing
 Settling time  More than 72 h
After oil  Breakdown  Over 60 kV/2.5 mm
filling voltage
 Moisture  Below 10 ppm･wt.
contents in oil
 Gas contents  Below 0.5 %･vol
in oil
 Oil tightness  Satisfy the criteria Depend on
pressure and manufacture’s criteria
duration
 Moisture  Below 0.5 %･wt.
content in
insulation
material
measurement
after degassed
oil filling
 Oil leakage  No leakage
check
 Oil level check  Based on oil curve Depend on
12. Touch-up paint  Check Touch-up paint  Done Depend on
condition manufacture’s criteria
43

13. Finished product  Electrical test  Satisfy the criteria Per manufacturer’s
testing criteria
Table 2.14 - Test items for on-site assembly transformer at on-site

Test item Purpose of test
1. Winding insulation resistance No abnormality check of windings after transportation and
on-site assembly.
2. Ratio Lead connecting work check
3. Polarity check
4. Short-circuit impedance measurement in low No abnormality check of windings after transportation and
voltage on-site assembly.
5. Excitation test in low voltage No abnormality check of core assembly
6. Capacitance measurement No abnormality check of coil after transportation and on-
site assembly
7. Dissipation factor measurement Insulation materials condition check, especially moisture
absorption
8. Core layer resistance/insulation resistance No abnormality check of core assembly
measurement
44
2.2 Experiences in Europe

2.2.1 Experience D - Mountain Transport for Hydro-electric Generator Transformer
The first example for on-site assembly transformer in Europe is from the 1990’s. A transformer for the
pumped storage power plant in the Alps at Kaprun Limberg (Austria) was to be delivered and installed.
The transformer was 116 kV star to 10.25 kV delta connection with a 56 MVA rating and forced oil water
cooling plant. The transformer was assembled and tested on-site to enable transportation to the power
plant in the mountains. Figure 2.26 illustrates the power plant in Kaprun Limberg.
Figure 2.26 - Kaprun Water Storage Power Plant Limberg

(Source: German newspaper Augsburger Allgemeine)
The transformer main components were manufactured in the factory before shipment on site. The
transformer was not assembled and tested in the factory before shipment on site. The core and winding
blocks were assembled in the factory before shipment on site.
The winding blocks were dried and impregnated via oil spray. A temporary clamping device was used
to clamp and fix the winding block during shipment. The winding blocks including a temporary clamping
system were assembled and shipped inside the transformer tank.
The core was assembled completely in the factory and fixed with special supports to enable the
shipment of the core. The core was wrapped with plastic foil to protect it from dust during shipment.
All auxiliary equipment such as turrets, bushings, coolers, etc. were packed in crates. All necessary
tools, assembly facilities and testing facilities were packed in containers and shipped to site.
The transportation was done mainly by flat-bed vehicle. A special elevator was used for lifting of the
components and materials to the Kaprun mountain middle station Lärchenwald. Figure 2.27 and Figure
2.28 shows pictures of the transportation.
45
Figure 2.27 - left: Road transportation of core with special low road vehicle; right: Loading of core on
elevator at mountain valley station
Figure 2.28 - left: Mountain elevator to lift devices, core and tank including winding blocks to the middle
station Lärchenwald of Kaprun mountain; right: transportation from elevator to power station via road
transport vehicle, here: tank transportation including winding blocks
The final assembly of the transformer was performed in the power station of the water power plant. A
kind of tent was installed inside the power plant housing to provide an enclosed area, encapsulated from
the environment. The roof top of the tent was movable to lift components and devices inside the tent.
The power station facility had sufficient crane capacity to lift all necessary devices and components
including the fully assembled transformer. Further mobile air conditioning devices were installed inside
the power station facility to control the ambient air for transformer final assembly. A slight overpressure
was applied inside the tent to prevent contamination with dust and particles inside the tent.
First the core was put into the assembly area. Next the upper clamping arrangement and the upper yoke
were removed in order to assemble the winding blocks. The winding blocks were removed from the
transformer tank and assembled to the prepared core. Afterwards, the winding blocks were covered with
plastic foil to prevent any contamination during yoke stacking. The lead assembly was done after
finalization of yoke stacking. The active part was lifted out of the tent for tanking. Afterwards, final
assembly of all external components was done. Vacuum and oil filling process was performed according
to the factory processes and parameters. Figure 2.29 and Figure 2.30 shows the on-site manufacturing
process.
The transformer was tested in a specially prepared area inside the power station. The area was cleaned
in order to achieve required clearances and cleanliness. The test equipment was shipped to site
beforehand. The following routine tests were performed to certify the transformer function and to
46
guarantee lifetime expectation.

 Temperature rise test (note: was performed before tanking)
 Vector Group and ratio measurement
 Winding resistance in all tap positions
 Lightning impulse testing at 440 kV on HV side (Note: corresponds to 80 % of nominal levels)
 Applied voltage testing
 No load losses testing (with temporary generator)
 Impedance measurement (with temporary generator)
 Capacitance and tan δ measurement
 Insulation resistance measurement
 Testing of protection and control equipment
 Testing of Oil samples
The tests were performed successfully, and the transformer was put into operation.
Figure 2.29 - left: Core after upper yoke and clamping removal inside the tent; middle: Winding block
fitting to the core; right: Upper yoke stacking
Figure 2.30 - left: Internal active part tanking; right: Transformer during impulse testing
47
2.2.2 Experience E - Replacement with Larger/ Heavier Transformers

This experience is described for the example of transformer replacement done in a mountainous area.
2.2.2.1 Background
The replacement transformer followed a new transformer efficiency regulation (reduced loss
requirement). The replacement transformer has the same rated voltage and power, but increased weight
and size. As a result, these replacement transformers need on-site assembly technology due to the
severe transportation situation and limitations.
The transformer efficiency regulation in EU is shown below,
(1) Peak Efficiency Index (PEI)
Key issues are as follows:
 Relevant for transformers above 3150 kVA
 Apply new thresholds for the efficiency
The 548/2015 regulation of the EU directive targets to lower CO 2 emissions:
PEI regulation for transformer capacity > 100 MVA shown in Figure 2.31
PEI > 0.99737 PEI > 0.99770

1st July 2015 1st July 2021
Figure 2.31 – PEI Comparison of the 2015 and 2021 EU regulation
(2) Impact to new transformers

The new transformer efficiency regulation causes loss reduction leading to an increase of transformer
weight and cost as shown in Figure 2.32. The transport weight increased 30% between 2007 (step 1)
and 2011 (step 3).
Impact of the capitalization evolution on the losses level

Ratio losses
Figure 2.32 - Impacts to loss, weight and cost between 2007 (Step 1) and 2011 (Step 3)
48
(3) Transportation
Transportation dimensions exceed the rail limits as shown in Figure 2.33. On-site assembly transformers
were then applied to the replaced transformers.
Impacts for the transportation are described as follows:
 Removal of the French railway sizing from specification
 More complex routes & logistics
- Specific trailers / load breaks
- Bridges, tunnels,
 Higher transport costs
 Modification of substation designs (civil work, heavy roads, access)
 Most substations no longer accessible
↓
“On-site assembly (OSA) of Transformers” should be applied.
Figure 2.33 - Railway limits and over-sizing by new regulation
Figure 2.34 shows the severe situation of the transformer transportation examples.
(a) Pass under bridge (b) Severe corner on the load

Figure 2.34 - Complexities of the transportation
2.2.2.2 Project example and User specification example

(1) RTE Example Project
Details of the example project for the transformer replacement is shown below. Figure 2.35 shows the
site of this project.
 RTE « Haute Durance » Project
 First On-Site Assembly for RTE
 3 *170 MVA - 220/66 kV YD TFO project in French Alps
 45 t transport limitation
 Design TFO 161 t
 Project starts in June 2017
 Type tests done on 1st unit only
49
(a) On-site for the transformer installation (in the French Alps)
(b) Foundation of the transformer

Figure 2.35 - On-site of the transformer
(2) RTE Specification

RTE specified the following key items for applying the first on-site assembly transformers:
 Definition of OSA (On-Site Assembly)
 OSA unit must be same design as 1st unit
 Minor design adaptations can be authorized due to on site process constraints
 Considered OSA if one of the following steps is done near/in the substation rather than in factory
 Construction of core
 Assembly of windings on core
 Connections to bushings and tap changer
 Vacuum and oil process
 Routine tests
 Routine and type test of 1st unit in factory (mandatory)
 Routine tests only for OSA TFO
 Same quality as factory units must be guaranteed
 If unit was previously tested in factory than RTE can authorize
 New construction of magnetic circuit
 New connections
50
Figure 2.36 shows flow for the first unit or repeated unit.
Figure 2.36 – Working flow in accordance with the unit (User Specification)
(3) On-site tests

On-site routine tests consider the site situation and condition as follows:
(i) Tests - Alternatives
 Equipment restrictions and/or environment conditions could limit
 Impedance
 Load Losses
𝐼𝑟
 current limitations ( < ) (Ir: rated current)
2
 IVPD
 Modification of PD thresholds (external PD impact)
 Subtract background noise during the measurement
(ii) Adapted test in order to:

 Correlate results to FAT tests
 Compare to guaranty values
 Validate tests
51
2.3 Experience in China (1 000 kV AC Power Transformers)

2.3.1 Introduction
As a large energy consuming country, the energy distribution of power generation and economic
development in China is very uneven. Water, energy, and coal are mainly distributed in the western and
northern regions, and the demand for energy and electricity is mainly concentrated in the economically
developed eastern and central regions. The distance between the energy source and the energy
consumption area is very long. At the same time, the demand for energy is also increasing with the rapid
development of the economy. The imbalance between the energy distribution and consumption defines
that the energy resource distribution should be optimized throughout the country. Through the
construction of a strong national grid based on the UHV power grid, coal to electricity in situ
transformation and large-scale development of hydropower had been promoted vigorously to realize
coordinated development between hydropower and coal power across regions and basins. As a result,
clean electricity has been transmitted from the western and the northern regions to the northern and
eastern regions to meet the growing demand of electricity brought about by China's rapid economic
development. Since the first UHV AC demonstration project of Jindongnan via Nanyang to Jingmen was
approved to start construction in August 2006, there have been 11 UHV AC power transmission projects
put into commercial operation successfully as of the end of 2017. The backbone of UHV AC power grid
has been built in the vast area of Sanhua (North, Central and East China), which plays a major role in
ensuring China's energy security, promoting green development and haze governance. The UHV AC
transmission projects in operation increased a total power transformation capacity of 135 000 MVA and
a total line length of 20 170 km including 27 UHV AC substations, one UHV AC switching station and
three UHV AC fixed series capacitor (FSC) stations (see Table 2.15).
Table 2.15 - Statistics of China's UHV AC transmission projects in operation

No. of Line
Capacity Time of Time in
No. Project name UHV AC Length
MVA approval operation
stations km
Jindongnan via Nanyang
1 6 000 3 Note 1 August 2006 January 2009
to Jingmen project
Extension of Jindongnan 640 Note 2
2 via Nanyang to Jingmen 12 000 3 Note 3 December 2010 December 2011
project
Huainan via Zhebei to 2×648
3 21 000 4 Note 4 Note 5 September 2011 September 2013
Shanghai project
4 Zhebei to Fuzhou project 18 000 4 2×596 March 2013 December 2014
Huainan via Nanjing to September 2016
5 12 000 5 Note 6 2×738 April 2014 Note 7
Shanghai project
Ximeng to Shandong
6 15 000 4 Note 8 2×730 July 2014 July 2016
project
Mengxi to Tianjinnan
7 24 000 4 2×630 January 2015 November 2016
project
Yuheng to Weifang
8 15 000 4 Note 9 2×1,050 May 2015 August 2017
project
9 Ximeng to Shengli project 6 000 2 Note 10 2×240 December 2016 June 2017
10 Linyi substation project 6 000 1 2×58 September 2016 December 2017
Extension project of
11 3 000 1 Note 11 2×75 October 2016 September 2017
Weifang substation
Note 1: Including two substations and one switching station.
Note 2: Single transmitting line only used in those two projects.
Note 3: Including 3 extension substations and two new FSC stations, FSC stations constructed
inside substations.
Note 4: Including three new substations and one extension substation.
Note 5: Double transmitting lines used from the project and follow-up projects.
Note 6: Including three new substations and two extension substations.
Note 7: Sutong GIL utility tunnel project supporting construction planned to be put into service in
52
October 2019.
Note 8: Including 3 substations and one new FSC station.
Note 9: Including three substations and one switching station.
Note 10: Including one new substation and one extension substation.
Note 11: Including one extension substation.
As the key equipment in UHV AC grid, a great number of success experiences have been accumulated
over ten years’ of UHV AC engineering practice in design, process, manufacturing, testing,
transportation and installation, acceptance test, system commissioning and operation maintenance of
UHV AC transformers in China. More than 150 transformers have been put into service successfully to
ensure safe and reliable operation of the UHV AC grid. However, because of the limitations with
transportation dimension, weight, and geographical environment, it has always been difficult for the
integral transportation of UHV AC transformers filled with dry air or nitrogen. Therefore, it was necessary
to carry out the R&D of UHV AC site assembled transformers for use in areas where transport conditions
are particularly difficult and UHV AC transformers could not be transported as a whole or in several parts
by conventional dismantling [7] [8] .
After in-depth scientific analysis, it was decided to use UHV AC site assembled transformers as a
demonstration application in the Jin-Zhong UHV AC substation of a UHV AC project from Shaanxi to
Shandong in China, same as Item 8 of Yuheng to Weifang project in Table 1 mentioned above. Based
on the prototype R&D results of UHV AC site assembled transformer with rated capacity of single phase
1 500 MVA, and a great deal of engineering application achievements accumulated in 500 kV & 750 kV
site assembled transformers of Chinese transformer factories, a general technical route for UHV AC site
assembled transformers has been defined. This includes factory disassembly, split transportation, field
assembly and final installation on concrete foundation with the improvement of key technologies in
design scheme, disassembly and transportation technology in split parts, field assembly plant design,
quality control measures of assembly process, transportation in substation after assembly is finished,
installation on concrete foundation and special acceptance test items etc. Finally, the engineering
demonstration application of UHV AC site assembled transformer has been realized which could be
used as a feasible technical solution for transformer transportation of follow-up projects.
2.3.2 Key Technology Research

Based on technical achievements of UHV AC transformers from many successful applications in UHV
AC transmission projects, R&D was carried out for UHV AC site assembled transformers. Key
technology research was completed on structural type and technical parameters, modular design and
production process, quality control measures of split parts transportation, field assembly plant design,
assembly flow and process quality control measures and special acceptance testing methods etc.
2.3.2.1 Structural Type and Technical Parameters

The structural type of on-site assembly transformer would be the same as that of UHV AC transformers
for a large number of engineering applications, i.e. a UHV AC transformer consists of a main transformer
and a regulation-compensation transformer inside with different oil tanks connected by outside pipe type
bus in air between two transformers. The main transformer is designed to be an assembled type
including the split frame type iron core structure, complete assembly winding structure, detachable lead
structure and upper and lower two sections of oil tank structure etc. The voltage regulation method at
the neutral point of off-circuit tap-changer is adopted by the site assembled transformer, and the cooling
method is OFAF. The on-site assembly transformer has excellent performance such as low losses, low
noise and PD free etc. The parameters of the main transformer are listed in Table 2.16.
53
Table 2.16 - Main parameters of main transformer for UHV AC on-site assembly transformer
Items Parameters
Rated capacity (HV/MV/LV) / MVA 1 000 / 1 000 / 334
Rated voltage (HV/MV/LV) / kV (1 050/√3) / (525/√3) / 110
Voltage regulating mode De-energized tap-changing ±4×1.25 % (9 taps)
LIFW / LICW / SI 2 250 / 2 400 / 1 800
HV
AC (5 min) 1 100
LIFW / LICW / SI 1 550 / 1 675 / 1 175
MV
Insulation levels AC (1 min) 630
kV LIFW / LICW 650 / 750
LV
AC (1 min) 275
LIFW 325
Neutral-point
AC (1 min) 140
No-load loss, P0 / kW (75℃) ≤180
Load loss, Pk / kW (75℃) ≤1 500
Short-circuit impedance, Uk (H-M / M-L / H-L）/ % 18 / 40 / 62
Cooling type OFAF

Noise / dB (A) ≤75
Note: LIFW-Lightning Impulse of Full Wave, LICW-Lightning Impulse of Chopped Wave, SI-Switching
Impulse, AC-Alternating current with power frequency.
2.3.2.2 Modular Design and Production Process

The modular design of electrical and structural aspects has been completed which could meet the
requirement of factory manufacturing, split transportation and field assembly. An independent design
has been used for the core, active part, lead and oil tank. The core is designed to be three U-shaped
core frames, the oil tank is divided into an upper & lower section and the main body of transformer is
decomposed into different parts but excluding external components such as coolers, bushings, leads
exit with ascending flanged base turrets etc. The maximum transportation weight of a single part could
be about 70 - 80 t.
The disassembly process flow after factory tests is shown in Figure 2.37:
Finish all factory test items → Transformer oil discharge → Dismantling external components → Hoisting
out active part and drying in furnace → Surface de-oiling treatment of active part → Fastening main
body in position → Releasing pressure of main body → Dismantling leads (among HV, LV sides and
columns) and wiring clamps → Dismantling upper clamp and upper yoke → Hoisting out complete
assembly windings → Dismantling barrier pressboards of core limbs → Hoisting out core and
transferring to core assembly area → Laying down core limbs on a roll platform → Dismantling clamps
and core laminations → Refolding core into U shaped core frames → Assembling core → Transporting
split parts.
54
Upper Yoke Lamination
Bushing & Other

Components
U Shaped Core
Frame
Complete Assembly
Winding
Lead, Clamp,
etc.
Main Tank
(a) Assembled transformer after factory tests (b) Diagram of disassembly of each component
Figure 2.37 - Disassembly process flow of on-site assembly transformer after factory tests
2.3.2.3 Quality Control Measures of Split Parts Transportation

The transformer core could be disassembled into three U-shaped core frame transportation units, upper
yoke lamination and integral upper clamp transportation units. The internal active part could be
disassembled for transport into several units, comprising two complete winding assemblies, their
separate lead and cleat bar components, yoke shields and other insulation parts units. The frame lead
could be transported inside the oil tank and be disassembled into several frame units. The oil tank could
be disassembled into upper and lower oil tank transportation units. A simulated test of the whole set of
procedures has been carried out in the transformer factory for split transportation, field assembly and
acceptance test. The feasibility and reliability of quality control measures has been fully verified for
different transportation units. Finally, the safe and reliable transportation of different parts is realized
such as oil tank, core and winding etc. The maximum transportation weight of a single part is about 70
- 80 t. Different parts could be put into special transport boxes respectively and transported filled with
high purity nitrogen or dry air. Transportation parameters of different parts for UHV AC on-site assembly
transformer are listed in Tab.2.17.
Table 2.17 - Transportation parameters of different parts for UHV AC on-site assembly transformer
Transportation
Transportation Transportation
dimension (length, Note
unit weight / t
width and height) / m
Upper 11.6×5.1×4.5 75 Oil tank consisted upper and lower

Oil
sections, clamp and lead transported
tank
Lower 11.6×4.3×0.6 35 inside oil tank
U-shaped frame and transportation

U-shaped core 5.1×4.1×3.5 80
box
complete Φ4.3×4.2 (diameter complete assembly winding and

55
assembly winding and height) transportation box
Yoke 7×0.8×2.6 16 Yoke and transportation box
Yoke shield & other insulation parts

Insulation part 5.5×3.2×1.5 12
and transportation box
55
(1) Core Frame Transportation Unit

The special transportation box can be used to transport each U-shaped core frame which would be
transported after turnover to limit the transportation height. The U-shaped core frame has related
fastening devices such as pulling plates, clamping pieces etc and could be transported in the vertical or
horizontal position (see Figure 2.38).
Figure 2.38 - Single transportation unit for U-shaped core frame
(2) Transportation Unit of Complete Assembly Windings

The special transportation box can be used to transport each complete assembly winding which could
be transported as a unit for each column fastened by upper and lower press plates and support plates.
Each complete assembled winding is transported in its own container and has an upper steel press
plate installed that ensures winding pressure to guarantee transportation reliability (see Figure 2.39).
Figure 2.39 - Single transportation unit for winding column
(3) Transportation Unit of Main Tank

Temporary tank covers will be used to realize the transportation for upper and lower oil tanks
respectively, including components such as insulation, leads and integral upper clamp etc. (see Figure
2.40)
56
(a) Transportation box for upper oil tank (b) Transportation box for lower oil tank
Figure 2.40 - Transportation unit for main tank
(4) Other Transportation Units

Coolers, bushings, oil pipes, oil storage tanks are transported as normal.
2.3.2.4 Field Assembly Building Design

The field assembly building can also be later used as the substation spare parts storehouse, which is
shown in Figure 2.41. The field assembly building is arranged so that it has sufficient capacity to
assemble one transformer at a time. To ensure a clean environment during the assembly process, an
internal and external dustproof chamber is specially set up inside the assembly building. The inner
dustproof chamber protects the active part during assembly by creating an environment of constant
temperature, humidity and air cleanliness similar to a traditional factory environment. This can also
include a mobile vacuum treatment unit, kerosene vapour phase drying equipment and other process
treatment equipment. The external dustproof chamber facilitates the receiving of materials.
Figure 2.41 - Field assembly building external and internal view
2.3.2.5 Process Quality Control Measures of Field Assembly

Process quality control measures for field assembly mainly consist of assembly deviation control (U-
shaped core frames, complete assembled windings, lead dimensions between coil limbs and core
insulation resistance) and drying process. Because of variations of field environment conditions and
moisture-proof measures, it is inevitable that the active part and insulation parts would gather moisture
during the assembly process. Therefore, mobile kerosene vapour phase drying equipment similar to the
factory has been utilized to carry out the entire drying for transformers after field assembly.
2.3.2.6 Special Acceptance Testing Methods
To meet the requirements of overall inspection and assessment of site assembled transformer
performance, a special no-load and load testing system with high voltage and high current has been
developed which could be used to carry out the no-load loss measurement under 100% rated voltage
57
and load loss measurement under 50% rated current on site. This confirms there are no defects in the
core, windings and insulating materials after the process of factory disintegration, split transportation
and field assembly. At the same time, combined with the induced voltage test with partial discharge
measurement (IVPD), the overall inspection and assessment of transformer quality after field assembly
has been successfully realized. Finally, the safety and reliability of UHV AC site assembled transformer
can be guaranteed.
2.3.3 Engineering Practice of Field Assembly

The assembly process flow inside the field assembly building is presented as follows (see Figure 2.42):
Start the assembly work → Lower section tank put in position on the platform → U-shaped core frames
assembly → Winding columns assembly → Upper yoke assembly → Upper clamp assembly → Leads
assembly and bandaging insulation → Adjustment and press-fitting → Semi-finished product test →
Finished assembly → Transportation in the substation → Installation on the foundation → Installation of
external components → Vacuum pumping and oil injection → Hot oil circulating → Standing for suitable
time → Acceptance test.
Figure 2.42 - Assembly process flow inside field assembly building
(1) Installation Platform Position and Assembly of Core Frames

The lower section oil tank put in position and assembly of U-shaped core frames inside the field
assembly building are shown in Figure 2.43.
58
(a) Lower oil tank into position (b) Assembly of No.2 U-shaped core frame
(c) Assembly sequence as No.2, No.3 & No.1 frame

Figure 2.43 - Installation platform position and assembly of first U-shaped core frame
(2) Assembly of Core Frames and Its End Product

The assembly of core frames inside the field assembly building is shown in Figure 2.44.
Figure 2.44 - Assembly of U-shaped core frames and its end product
(3) Assembly of Winding Columns
59
The assembly of winding columns inside field assembly building and its end product are shown in Figure
2.45.
Figure 2.45 - Assembly of winding columns and its end product
(4) Assembly of Upper Yoke and Upper Clamp

The assembly of upper yoke and upper clamp inside field assembly building as well as their end products
are shown in Figure 2.46.
(a) End product of upper yoke (b) End product of upper clamp
Figure 2.46 - End products of upper yoke and upper clamp
(5) Assembly of Leads and Semi-product Test

The assembly of leads and semi-finished product test inside field assembly building are shown in Figure
2.47.
60
(a) Assembly of Leads (b) Semi-finished product test

Figure 2.47 - Assembly of leads and semi-finished product test
(6) Assembly of Final Production

The assembly of final production inside field assembly building is shown in Figure 2.48.
Figure 2.48 - Assembly of final production
(7) Drying of Production

The kerosene vapour phase drying of transformer inside field assembly building is shown in Figure 2.49.
61
Figure 2.49 - Kerosene vapour phase drying treatment for transformers
(8) Transportation and Installation of Transformer in Substation

The transportation in substation and installation on the concrete base of an on-site assembly transformer
is shown in Figure 2.50.
Figure 2.50 - Transportation and installation in substation of on-site assembly transformer
(9) Acceptance Test

Four on-site assembly transformers have successfully passed all acceptance tests with excellent
performance of various parameters. Finally, a strict review of the whole process quality has been
completed for site assembled transformers after factory test, split transportation and field assembly.
Figure 2.51 - Acceptance test of on-site assembly transformer
2.3.4 System Commissioning and Trial Operation

Transformer condition is maintained by On-site inspection, protection & control, and real-time monitoring
of noise, vibration, heating, dissolved gas-in-oil analysis (DGA) and ground lead current coming from
the core and clamp respectively. As a result, transformers have been stable and reliable during the
62
system commissioning and trial operation. Finally, the first global engineering demonstration application
of UHV AC site assembled transformers has succeeded.
Figure 2.52 - UHV AC on-site assembly transformer in service

(spare phase on the right side)
2.3.5 Conclusions
(1) Based on key technology research and engineering, a large number of successful experiences of
UHV AC site assembled transformers have been accumulated in design scheme, factory
manufacturing, split transportation, field assembly, acceptance test, system commissioning and
trial operation. It could be used to significantly reduce the transformer transportation weight by
which the maximum transportation weight of single part is limited to about 80 t and would be a
useful solution to the transportation problem of UHV AC transformers.
(2) A series of quality control measures have been implemented to guarantee the performance of UHV
AC site assembled transformers, including production quality control in the factory, transportation
quality control of disassembly parts, manufacturing environment and process quality control of field
assembly building etc. In particular, the application of kerosene vapour phase drying technology
would be an effective solution to the assembly quality control under complicated field conditions.
(3) Test equipment selection and development has been implemented for the requirement of site no-
load and load test of transformers. Many problems have been solved such as the waveform
distortion of the no-load test, the large capacity demand of the load test power and the precise
control of the reactive power compensation etc. For the first time, the no-load test under high
voltage and load test under large current have been carried out in the field environment same as
that in the factory test to ensure the quality of UHV AC site assembled transformers after building
disintegration, split transportation, field assembly and final installation on concrete foundation.
(4) Equipment transportation is no longer an impediment and a wider geographical spread of UHV AC
application is now possible. Finally, a feasible solution to UHV AC transformers transportation could
be utilized in regions where transportation condition is particularly difficult or the whole
transportation is rather difficult to carry out.
63
2.4 Split-tank type transformer

To cope with changes to the transportation conditions, the form of transformer transportation has been
developed from a normal three-phase transformer to a special three-phase transformer and to a site-
assembly transformer. The special three-phase transformer is a transformer in which the core and
windings are divided into three for each phase and housed in a tank, and the three phase connection is
made by a three phase connection upper tank or three phase connection duct. The special three phase
transformer is divided into each phase tank at the time of transportation. A transportation cover (tank)
is attached so that it is sealed for transportation.
In the case of transporting a special three-phase transformer to places where transportation conditions
are severe such as underground substations and hydropower plants in mountainous areas, the
necessity to increase the number of transformer divisions has come up. For this reason, a 6-split special
three-phase transformer and a multi-split special three-phase transformer with one phase divided into
two, three or greater have been produced. Examples of a 6-split special three-phase transformer are
shown in Fig. 2.53 (a) (Core-form), Fig. 2.53 (b) (Shell-form), Fig. 2.54 (a) (core-form, DC 250 kV
Converter station) and Fig. 2.54 (b) (Core-form, Factory substation). An example of a special nine-split
special three-phase transformer is shown in Fig. 2.55 (Core-form).
(a) Case 1 - 584 MVA, Core-form (b) Case 2 - 390 MVA, Shell-form
Figure 2.53 - 6 split-tank type transformer for pumped-storage hydraulic power plant
(a) Case 1 - 872 MVA, Core-form converter transformer (b) Case 2 - 150 MVA, Core-form
Figure 2.54 - 6 split-tank type transformer for other cases
64
Figure 2.55 - 9 split-tank type transformer for pumped-storage hydraulic power plant
(680 MVA, core-form)
65
3. Survey On-Site Rebuild

3.1 Experience in North America and Europe
Below are described four on-site rebuilds performed in Canada and Spain.
3.1.1 Experience A
The transformer was a 138 kV star to 13.8 kV delta transformer with a rating of 91.2/114/127.7 MVA
ONAN/ONAF/ONAF and located at a hydroelectric station. This transformer failed in service due to an
internal fault on the HV winding. It was decided to replace all windings and perform an on-site rebuild
in the turbine hall which was in fact originally designed for un-tanking the core and windings. The turbine
hall crane had the lift capacity to hoist the transformer into a pit and had the required overhead height
to lift the core/windings out of the tank onto the turbine hall floor. A factory rewind was not practical due
to transportation issues [9] .
All new modern windings were designed and manufactured at a transformer plant. The windings were
oven dried, sized, vapour phased oven dried, oil impregnated and clamped in the factory and then
shipped to site in steel containers under dry air.
Prior to the on-site rebuild, the repair area in the turbine hall was thoroughly cleaned and made a limited
access area to ensure cleanliness and protection of the transformer during the repair. The actual on-
site rebuild work was performed by 2 factory experienced transformer technicians and supported by
other workers from the hydroelectric plant. All work was inspected by a transformer design engineer at
critical hold points similar to factory inspection hold points. While the windings were being replaced on
the core/windings, the tank was taken to a nearby paint shop for cleaning & repainting.
After all work on the core/windings was completed, it was installed back into the transformer tank. The
transformer then underwent a special drying process called Low Frequency Heating [10] . This process
applies current to the HV terminals with the LV terminals shorted (similar to a factory temperature-rise
test). However, the voltage is applied at a very low frequency (few mHz) so that there is negligible
leakage flux (it is proportional to frequency) and also the applied voltage is very low (impedance voltage
is also proportional to frequency). In this manner, the current can be applied with no oil in the tank (safe
due to the low voltage) and the temperature across the winding is constant (since there is no hot spot
gradient and no oil gradient). The winding temperature can then be raised to 110℃ for an effective
dryout. This special LFH dryout process is required for the site repair due to the long exposure of the
windings during the on-site rebuild. After this LFH process was completed, a dryness of 0.3 % moisture
in cellulose was achieved.
The below tests were successfully done on the transformer:
 Ratio, Resistance, SFRA, Insulation Resistance, Power Factor, Auxiliaries
 No-load Loss, Load Loss, impedance
 Applied voltage and induced voltage dielectric tests
The losses and dielectric tests were completed using a mobile test trailer.
Below are pictures that show the site repair from start to finish.
66
Figure 3.1 - Transformer Being Moved from Pad to Turbine Hall
Figure 3.2 - Transformer Being Moved into Turbine Hall Pit with Overhead Crane
Figure 3.3 - Core/Windings Being Removed from the Tank
67
Figure 3.4 - Removal of the Top Yoke of the Core
Figure 3.5 - Removal of Windings
Figure 3.6 - New Winding Shipping Containers and Installation of New Windings
68
Figure 3.7 - Re-installation of Top Yoke of Core and Finished Core/Windings
Figure 3.8 - Cleaned Tank, Core/Windings Back in Tank and Sealed Tank
Figure 3.9 - Assembled Transformer Undergoing Final HV Field Induced Voltage Test
69
3.1.2 Experience B
This transformer was a 345 kV/138 kV auto transformer with a 12.47 KV tertiary rated for 78 Mvar and
a main rating of 207/272/340 MVA ONAN/ONAF/ONAF. It was removed from service due to high
gassing which was later found to be due to a flashover from the tertiary winding to the core (because of
earlier winding buckling). It was decided to replace all windings in an on-site rebuild due to
transportation issues and better schedule.
This transformer was located in a switchyard with no available local building – thus a temporary building
was constructed adjacent to the transformer. In this manner, the tank with accessories could be left on
the pad and the core / windings could be lifted out of the tank into the temporary building for repair. The
temporary building was constructed using large wood timbers for the flooring with a rubber floor overlay.
The temporary building had a steel frame with removal roof sections to allow crane lifts. The building
was sealed and had an atmospheric control to ensure clean and dry air quality in the building for the
transformer. The building was cleaned (vacuumed & mopped) each night to ensure a high level of
cleanliness was maintained.
New windings were designed, manufactured, vapour phased and shipped to site from a transformer
factory similar to the other on site rebuild.
The core and windings were removed from the tank using a large 450 T mobile crane and placed into
the temporary building for repair. The core top yoke was taken out and the old windings were removed
using a boom truck crane. The new windings were installed, and the top yoke was put back in. When
completed, the core/windings were placed back into the tank (which was newly painted on the pad)
using the 450 T mobile crane. A Low Frequency Heating (LFH) dryout (as described up above) was
also performed on this large transformer and a dryness of 0.4 % moisture in cellulose was achieved [11]
.
Full dielectric testing was done on the transformer including impulse tests. A special mobile test set
was brought to site for the impulse tests. Another mobile test set was provided for the other tests. All
testing was performed successfully.
Pictures of the on - site rebuild can be seen below.
Figure 3.10 - Original transformer in service prior to the failure
70
Figure 3.11 - Temporary Building Next to the Transformer Pad with Air Control
Figure 3.12 - Removal of the Cover and Removal of the Core/Windings from the Tank
Figure 3.13 - Windings Being Removed from the Core/Windings and New Windings
71
Figure 3.14 - Installation of New Windings and Core/Windings being worked on
Figure 3.15 - Painted Tank (done on pad) and Completed Core/Windings
Figure 3.16 - Heavy Crane Lift of Repaired Core/Windings
72
Figure 3.17 - Installation of Bushings, LFH Dryout (hoarding required due to cold weather)
Figure 3.18 - Impulse Testing
3.1.3 Experience C
The two transformers were 400 kV/230 kV with 500 MVA ODAF rating. The transformers received new
windings, bushings, OLTC, tank and cooling. The rating was increased to 600 MVA. These were shell
type transformers. The on-site rebuilds were performed in a temporary tent with removal wall panels
similar to the above example of on-site rebuild.
The first transformer was dried with traditional vacuum / hot oil spray and the second unit was dried with
the LFH technology, which reduced the drying time by 1 week.
The following tests were performed:
 Insulation resistance.
 Capacitance and Power Factor in windings.
 Capacitance and Power Factor in bushings.
 Ratio and vector group.
 Winding resistance.
 Excitation current at reduced voltage.
 Leakage reactance.
 Cooling equipment.
 FRA.
 DFR
 Induced overvoltage with Partial Discharge measurement.
 Applied overvoltage.
 Lightning impulse test
 No Load losses and current measurement.
Pictures of the on - site rebuild can be seen below.
73
Figure 3.19 - Transformer
Figure 3.20 - Temporary Building
Figure 3.21 - Shell Type Core Stacking
74
Figure 3.22 - Field Testing
3.1.4 Experience D
The transformer was 132 MVA, 345/55-55 kV, HVDC application and originally manufactured in 1983.
The transformer failed in service requiring a full rewind.
A site building was used for the site repair. Due to height limitations, the core and windings were left on
a heavy haul trailer which was moved outside as required for with mobile crane lifting. There was a
heightened level of cleanliness required for the HVDC application. The windings were manufactured in
a transformer factory and shipped to site in special steel containers. The transformer dryout was
performed using LFH technology.
The transformer underwent AC and DC high voltage testing which required 3 separate sets of large
mobile test equipment:
 Impulse Test
 Switching Surge Test
 DC Tests including Polarity Reversal Test and DC High Potential Test
 Excitation Current & No Load Loss Tests
 Impedance and Load Losses Tests
 Applied Potential (Hi-Pot) Test
 Single Phase Induced Test with PD measurement
 15 minute over excitation Test
Several pictures are shown below of the HVDC site repair [12] .
Figure 3.23 - Transformer Un-tanking
75
Figure 3.24 - Transformer New Winding Installation and Cleats & Leads Work
Figure 3.25 - DC HV Testing
76
3.2 Experience in China

The on-site rebuild transformer was a single phase HVDC transformer that failed after a short time in
operation. The failure was due to a short inside the converter winding caused by a manufacturing
deviation during winding copper soldering to the winding exit lead. The transformer was a three winding
type transformer 230 kV star to 208 kV star (connected to 500 kV DC converter bridge) to 208 kV delta
(connected to 250 kV DC converter bridge) with a rating of 345 MVA. It was decided to perform an on-
site rebuild or repair of the transformer due to transportations challenges and to accelerate the repair
time of the transformer.
A hard case repair facility at site was prepared to provide a proper environment for the transformer repair
including active part disassembly, re-assembly and processing. The repair facility was designed
enabling the transformer to enter via railway and enabling heavy lifting inside the tent via mobile crane.
The roof of the tent was especially prepared to enable opening without losing mechanical stability of the
overall structure. Further the floor of the repair facility was designed according to requirements for
transformer factory facility. The facility was equipped with air conditioning system to control
environmental conditions during repair work and to apply a slight overpressure to avoid contamination
with dust and particles from outside. Strong focus was put on environmental conditions during repair
work to avoid any influence by particles and dust. Figure 3.26 shows pictures of the repair facility.
Figure 3.26 - left: Repair facility outside view with open roof top; right: Repair facility inside view with air
conditioning device and heater
Before the transformer disassembly, an in-tank inspection was performed to determine the affected limb/
winding of the parallel connected limbs. The main components were disassembled before transformer
movement into the repair facility. The conservator, cooling plant, AC terminal bushings and turrets, the
DC terminal delta bushings and turrets were all removed after draining the oil. Figure 3.27 shows the
dismantling of the main components.
Figure 3.27 - left: Sketch of main component disassembly; right: Photo taken during disassembly of main
components
77
The further transformer disassembly was performed inside the repair facility. The facility roof top was
removed to enable lifting of heavy components such as the tank cover, clamping frame and finally the
winding block. The upper yoke was removed and the leads were disconnected while the roof top was
closed. The damaged winding block was removed via mobile crane and open roof top. A special lifting
device was designed to lift the winding block from the core. Further special designed beams stabilized
the transformer tank during disassembly at the tank opening. Figure 3.28 shows the disassembly of the
transformer.
Figure 3.28 - left: Sketch of disassembly; right: Photo taken during upper clamping arrangement
disassembly
A new winding block was manufactured in the transformer factory. The windings and winding block were
treated in the same manner as normal factory manufactured windings (dried and oil impregnated via oil
spraying immediately after the drying process was finished). The winding block had clamping forces
applied to prevent height increase. A special winding block tank for shipment was designed and
manufactured enabling constant clamping force to the winding block.
The winding block was replaced in one sequence. First the new winding block tank was lifted into the
repair facility and the new winding block was un-tanked. Next the damaged winding block was lifted
from the core and the new winding block was assembled to the core. This was all performed on a day
with good weather to avoid contamination to the new winding block and the active part. Figure 3.29
shows the winding block exchange.
Figure 3.29 - left: Drawing of winding block shipment tank; middle: Lifting of winding block tank into
repair facility; right: Removal of damaged limb while new winding block stand beside for replacement
The re-assembly was done in reversed direction:

 Yoke stacking
 Assembly of the clamping frame and retightening of the core
 Lead re-connection
 Winding block pressing
 Check of winding resistance and voltage ratio
Next the modified tank cover was assembled. The tank cover was modified with special pipes and spray
nozzles on the inner side of the tank cover. These nozzles were used to clean, dry and impregnate the
78
active part under vacuum condition via oil spraying. The oil spraying was performed under vacuum and
with an oil temperature of approximately 80 ℃ . The moisture was extracted from oil drainage to
determine the drying status. The drying process was completed after reaching a sufficient level of
remaining moisture in the oil drainage. The nozzles were removed from the tank after drying finalization
without lifting of tank cover. The performance of the drying process was approved via dew point
measurement.
The final assembly of the transformer was done outside of the facility and the components were
assembled to the transformer. Vacuum oil filling, oil filtration and vacuum were done using mobile
treatment devices and per transformer factory parameters.
Acceptance testing was performed to verify the repair:
 Insulation resistance
 Capacitance and Power Factor in windings
 Capacitance and Power Factor in bushings
 Ratio and vector group
 Winding resistance
 Induced AC test of valve windings (long duration)
 Applied DC test of valve windings
 Second induced AC test of valve windings (long duration, to verify DC test results)
All tests were completed successfully.
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3.3 Experience in Japan

3.3.1 Introduction
Originally, power transformers were transported as a single item (non-segmented). However, in the
recent years, transportation conditions have become very severe due to the size reduction of train cars
& loads and the loss of local spur rail lines. This occurred due to urbanization of the areas where
substations are located in Japan. In addition, it is anticipated there will be higher demand for transformer
replacement as the number of aged equipment grows. Therefore, it is expected that on-site assembly
transformers will be adopted.
On the other hand, when transformer internal failures occur such as in the core or winding, it is
necessary to transport them to the factory as there are limitations in dismantling or repairing locally.
However, in recent years, formal railway transportation permitting has become more difficult in Japan
and it is concerning that the repair time for transformers becomes too long. In addition, failure
investigation and repair at the factory increases repair cost as round-trip transportation between the
factory and the site is required.
As an effective measure to cope with the above challenges, on-site repair or replacement is considered
to be a viable option [13] [14] . On-site refurbishments are reported to have been carried out for high
voltage, large capacity transformers [15] [16] and large capacity shunt reactors [17] . In the case of
those examples, large-scale clean rooms were set up at locations different from where transformers are
installed. However, there are substations which do not have this kind of facility. Therefore, it is desirable
to establish measures to carry out refurbishment at the location where the transformer is installed.
A single-phase pilot unit of 154/77 kV and 200/3 MVA was produced to cover the 154 kV class for which
the on-site assembly transformer experience is small.
3.3.2 On-site refurbishment overview
Based on the examples of winding refurbishment, Figure 3.30 shows the conventional refurbishment
process by transporting it to the factory and Figure 3.31 shows the refurbishment process utilizing the
on-site assembly technology.
Site
Railway
transportation
Transformer Exterior parts removal
for refurbishment
Factory
Internal assembly Disassembling Winding Internal assembly

removal internal assembly replacement
Exterior
Assembling tank Exterior parts Test parts
installation
removal
Site
Railway
transportation
Main unit Exterior parts Test

installation installation
Figure 3.30 - Refurbishment process at factory
80
Factory
Truck
Winding transportation
production Test
Site
Transformer for Disassembling Disassembling Winding

refurbishment tank internal replacement
assembly
Internal Exterior parts

assembly Assembling tank installation Test
Figure 3.31 - Refurbishment process at site
3.3.3 Challenges for on-site refurbishment and study on countermeasures

(1) Transformer structure compatible with refurbishment work
When the transformer is to be refurbished at site, it is necessary to lift the internal assembly out of the
transformer if the tank can only be separated at the cover. The internal assembly of 154 kV class
transformers has a weight of 100 t or above requiring it to be lifted by a 200 t class crane. There are
some substations where there is insufficient space to set up a crane. For these cases, the heavy lifting
can only be done with 65 t cranes or less. Facing this, tank separating points are added for the lower
part of the main unit tank as shown in Figure 3.32 so that it will be possible to work on the internal
assembly of the transformer by lifting the tank only - which is much lighter than the internal assembly of
the transformer. In addition, an inspection window for a fibre scope is provided to identify failed internal
parts at the site.
Fiber scope inspection window
Upper tank Manhole
Upper separation part
Middle tank
Lower separation part
Lower tank
Figure 3.32 - Additional separation parts for transformer main unit tank
(2) Refurbishment procedure in view of limitation on on-site work

In the disassembly and assembly processes of transformers for the refurbishment of cores, there are
operations to lay down and up right a core with dedicated equipment called the core erector as shown
in Figure 3.33. Normally a 200 t class crane is required and again there are substations that cannot
facilitate such a large crane. For this reason, the core rotation machine as shown in Figure 3.34 was
adopted which enables core laying down and erecting operations without using a crane. This core
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rotation machine facilitates core assembly work of on-site assembly transformers. The tank or structure
to hold the core of the core rotation machine is designed so that it does not have to be lifted in and out.
In addition, consideration is given so that it can be installed at the transformer lower tank with the
anticipation that the refurbishment work is carried out at the installation location of a transformer.
Crane (200 ton or

Core
Core erection machine
Figure 3.33 - Conventional laying down and erecting work
Transport tank
Lower yoke
Rotat
e
Lower yoke Core rotation machine
Figure 3.34 - Core rotation machine overview (Core disassembly work)
(3) Quality control

Disassembly and assembly work will be performed in the clean house where dust volume and humidity
are controlled as the internal assembly of the transformer is exposed to the atmosphere at the site.
However, it is anticipated that it may be necessary to refurbish at the transformer pad due to the space
limitation of a substation. For this reason, the clean house is designed in such a way that it can be
assembled at the transformer pad as shown in Figure 3.35.
Bellows structure
Anchor steel structure
Dust-proof net
Fixed end Operation scaffold
Rail for opening and closing
Rail fixing steel member

11m (Width)
Figure 3.35 - Clean house outline view (Opened condition)
Specifically speaking, it is designed to deal with various foundation shapes by providing the fixing steel
member with a rail for sliding the bellows to open and close the clean house. It also has the width which
can fit when the space between anchor steel structures for the power line connections is narrow (in the
case of our company, the smallest is 11m for 154 kV class transformers.)
In addition, to prevent moisture and dust from entering the clean room building, the winding is provided
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with a film pack into which the dry air is blown as shown in Figure 3.36 at the time of the on-site
refurbishment. It is difficult to put a bag shape film onto the winding due to lead connections. Therefore,
it is designed to wrap the sheet shaped film around the winding.
Winding
Film pack
Blowing dry air
Figure 3.36 - Preventive measure for moisture and dust ingression for winding
(4) Unit test for winding performance check

In the case of repairing internal failures of transformers, the shop test for the winding needs to be
performed without a real core (hereafter referred to as “air-core”), unlike a new transformer being
manufactured. Since the new winding is the same design as the old winding, the main purpose of the
shop test is to check the manufacturing quality. Therefore, the test items related to the winding as a unit
with the air-core are in accordance with Table 3.1. Among those, it is difficult to perform the short-circuit
impedance measurement with the existing technology. For this reason, the leakage inductance
measurement was invented as an alternative measure noting that the component of the leakage
inductance is the dominant factor with respect to the short-circuit impedance measurement. It is
possible to assure the health of the winding if the calculated value of the inductance of the air-core is
confirmed to coincide with the measurement value.
Table 3.1 - Main shop test items with air-core

Test item
Winding resistance measurement
Insulation resistance measurement
Dielectric loss angle measurement
Note 1
Short-circuit impedance measurement (Leakage inductance measurement)
Voltage application test
Withstand voltage test Induced test (Substituted by switching impulse test)
Lightning impulse withstand voltage test
Note 1: Test item not possible with existing technology
3.3.4 Verification by pilot unit

To verify items studied in Paragraph 3, the single-phase pilot unit was produced. Figure 3.37 shows
the schematic construction of the pilot unit.
83
Upper tank Core yoke
Winding
Core leg LTC
Middle tank
Lower tank
Figure 3.37 - Single-phase pilot unit schematic construction
(1) Transformer construction compatible with refurbishing work

As the transformer main unit tank is divided into 3 parts, it became possible to expose the internal
assembly at the site by lifting the upper and middle tanks. This facilitates the refurbishment of the
internal assembly of the transformer at the site. Figure 3.38 shows lifting of the upper and middle tanks.
Upper and middle tanks
Clean house
Rough terrain crane
Figure 3.38 - Lifting upper and middle tanks
(2) Refurbishing procedure in view of limitation on on-site work

The core refurbishment work was verified by using the core rotation machine. It was confirmed that the
rotation work can be done without issue with a core being mounted. Assembly and removal of the core
rotation machine are confirmed to be possible by a 65 t class crane. Further, it is confirmed that the core
rotation machine can be installed on the lower tank and that the work to rotate the core in the clean
house without interfering with other items is possible. Figure 3.39 shows the state of the core rotation
operation.
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Core transport tank

Drive part
Follower part Lower tank
(a) After installation (b) Rotation operation

Figure 3.39 - Core rotation machine
(3) Quality control

Space where the installation was done was graded by 1 % towards the direction of the rail for opening
and closing. It is confirmed that the clean house can be set up level by providing the rail fixing steel
member. This indicates that it will work when the foundation shape changes depending on substations.
Figure 3.40 shows the installation state of the clean house and Figure 3.41 shows the equipment layout
for the on-site work.
Rail for opening and

closing
Opening
Sliding direction
Rail fixing steel member
Figure 3.40 - Clean house installation states
Crane
Working radius of 22 ton
Clean house
Pilot unit
Dehumidifier in house
Steel structure post
Generator
Dry air generator
Figure 3.41 - Equipment layout for on-site work
It is confirmed that the inside of the clean house can be kept at the equivalent factory environment
(humidity is 50 % or less and suspended dust volume is 20 cpm or less). In addition, it is confirmed that
85
the water content in the insulation material can be controlled as 2.0 % • wt. or less by providing the
winding with the film pack and by blowing dry air. Figure 3.42 shows the winding refurbishment work in
the clean house.
Figure 3.42 - Winding refurbishment work in clean house
(4) Unit test for winding performance check

Inductance of the winding as a unit was measured (inductance observed from the primary winding was
measured by short-circuiting the secondary winding) and their comparison with the calculation values
are shown in Table 3.2. Errors between the calculated values and measurement values are less than
2%. Thus, it is confirmed that there is no fabrication quality problem as verified by the inductance
measurement.
Table 3.2 - Comparison between calculation value and measurement value air-core leakage inductance
Calculation value Measurement value Error
tap No.
/ mH / mH /%
1 (Lowest) 39.1 39.5 1.02
7 (Rated) 31.6 31.8 0.632
13 (Highest) 25.3 25.7 1.58
(5) On-site test

Completion test items to be carried out at the site after the winding refurbishment are shown in Table
3.3. Withstand voltage test at site is not performed based on the facts of the quality control in each
process. This is similar to on-site assembly transformer technology.
Table 3.3 - On-site completion test items

No Test item
1 Transformer ratio measurement
2 Polarity test
3 Phase displacement test
4 Insulation resistance measurement
5 Electric capacitance measurement
6 Dielectric loss angle measurement
86
No Test item
7 Winding resistance
8 In-oil dissolved gas analysis
9 Electric insulation oil test
3.3.5 Advantages of on-site refurbishment

Based on the example of 154 kV voltage and 200 MVA capacity, a comparison of the costs and the
timeline between the factory refurbishment and on-site refurbishment is shown in Table 3.4. In both
cases of the winding and the core refurbishment, the on-site refurbishment has advantage in terms of
cost and schedule.
Table 3.4 - Period and cost comparison required for refurbishment

Cost Note 1 Work period
Refurbishment location Refurbishment component
/% / month
Winding 100 15.5
Factory
Core 90 19.0
Winding 70 11.5
Site
Core 60 12.0
Note 1: 100% cost is based on the winding refurbishment of an integral three-phase type.
3.3.6 Conclusion
We have studied the requirements for refurbishment of transformers at their installation locations, the
procedure, the quality control and the performance check tests and verified by using a pilot unit. By
applying the achievements of this study, it will be possible to perform the refurbishment with less cost
and shorter work period compared with the conventional method. Further, this technology will contribute
to the reduction of transformer life cycle cost as this can be applied to partial renewal projects.
87
4. On-Site High Voltage Testing

4.1 Mobile Test Systems
4.1.1 Mobile High Voltage AC Test Systems
Past high-voltage AC tests performed on site often used motor-generator-sets, which are usually quite
heavy and therefore difficult to transport [18] .
New technology was developed for a mobile AC test system, which can be integrated into a 40 ft
container and uses a static frequency converter as voltage source, as shown in Figure 4.1.
SFC Adaption
transformer
Reactor
Figure 4.1 – Example of HV-AC mobile test system installed in 40 ft container
The main part of this system is the static frequency converter shown in Figure 4.2, in which the functional
principle is explained. The three-phase line voltage is first rectified, thus the direct voltage is buffered
by a capacitor bank. The DC voltage feeds then the inverter module, which consists of power transistors
(IGBT’s) and is driven by a micro-controller, thus sinusoidal modulated voltage pulses of adjustable
frequency and amplitude could be generated. A controlled power sine wave filter connected to the
converter output is used to filter the fundamental wave, which finally feeds a step-up transformer, which
is connected to the device under test.
88
Figure 4.2 - Static Frequency Converter (SFC)
The voltages that can be measured before and after the filter are shown in Figure 4.3, thus the
generation of the sine wave curves becomes clearer.
Figure 4.3 - Voltage signals measured before (above) and after (below) the filter
The applied high voltage test can be done in a resonant circuit consisting of the internal reactor as
inductance and the transformer to be tested as capacitance as shown in Figure 4.4. These two
components define a certain resonant frequency, which is usually automatically detected and chosen
by the control of the static frequency converter. A high voltage divider in parallel to the transformer under
test directly connected to the reactor is used to measure the applied test voltage.
89
Figure 4.4 - Applied voltage test using resonant circuit
For the induced voltage test, a frequency in accordance with IEC 60076-3 is used which is adjusted to
the self-compensation frequency of the transformer to be tested.
Self-compensation appears at the change-over of the test object from an inductive characteristic at lower
frequencies to a capacitive characteristic at higher frequencies. At the self-compensation point, only
active losses have to be fed to the test circuit and the power of the frequency converter can be kept as
low as necessary. The free adjustable frequency of the system in a range from 15 to 200 Hz in 0.1 Hz
steps is an important advantage in this case.
Additional inductive (for higher frequencies) or capacitive (for nominal frequency) compensation before
the step-up transformer is possible. An HV T-filter at the output of the adaptation transformer serves as
a partial discharge (PD) filter as well as a capacitive HV divider and an optic current measurement
system to measure the voltage and current at the transformer under test precisely.
The electrical PD measurement has to be performed at the secondary site of the transformer under test
using the measuring taps at the HV-bushings or separate capacitive coupling capacitors.
To perform HV tests on transformers up to a few 100 MVA, the system needs to have at least a converter
power of 1350 kW in single and three phase mode and an adaption transformer of up to 2 MVA with 90
kV output - thus induced tests can be done up to 90 kV with a total harmonic distortion typically below
2 %. Applied voltage test are possible up to 500 kV using a reactor for the resonance test. For more
power demand, a system can be connected in parallel increasing the total output power.
A typical control of the mobile HV-AC test system is shown in Figure 4.5, in which the touch screen
panel of the control PC could be seen in the middle, whereas the PD recording system is running on the
PC below the control panel.
90
Figure 4.5 - Control panel
All types and brands of transformers, from small grid transformers up to the largest step-up generator
transformers can be tested on-site using this mobile technology. Some examples are shown in Figure
4.6.
Figure 4.6 - Examples of AC tests on-site
The partial discharge measurement during the induced voltage test is usually performed using
equipment with an integrated spectrum analyser to increase the sensitivity, thus often a noise level
below 50 pC can be reached. A typical PD-measurement during an induced voltage test on a three
phase 420 kV transformer can be seen in Figure 4.7. It becomes obvious that in this case on all high
voltage phases, only noise signals in a range of approximately 100 pC could be determined using
conventional technique, which can be reduced to less than a third if additional spectrum analyser
techniques are used. The sine wave acquired via the HV-bushing taps shows a low THD (Total
Harmonic Distortion) at a line to line test voltage close to 600 kV.
91
Figure 4.7 - Noise level using conventional technique
The calibration using a spectrum analyser technique is shown in Figure 4.8, in which 200 pC is used as
the calibration charge, thus centre frequencies below 1 MHz according to IEC standards can be found,
with a noise level in a range of 20 to 30 pC. Depending on the test environment, the impact of the
external noises can vary between 10 to 500 pC (in some extreme conditions – industrial external noises
can rise up to nC).
Calibration impulses (200 pC)
Noise
level
Figure 4.8 - Noise level using spectrum analyser technique
If load losses or temperature-rise tests need to be performed, additional containers with capacitive
compensation up to 200 Mvar are available today as shown in Figure 4.9. Thus today there is almost
no restrictions concerning AC tests.
92
Figure 4.9 - Additional external capacitive compensation for temperature-rise tests
However, if more active power is needed, mobile AC tests systems can be operated in parallel. Up to
8 modules have been used parallel to achieve 8 X 1 350 kW, which is equal to approximately 10 MW.
Figure 4.10 shows an example of a test with 2 mobile test systems running in parallel.
Figure 4.10 - AC test with 2 mobile test systems in parallel
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4.1.2 Mobile Impulse Test Systems

Impulse voltage tests should also be performed after a repair on-site, thus mobile lightning impulse
generator systems are available up to a charging voltage of 2 MV and an energy of 300 kJ. Using such
systems, lightning impulse tests up to 1 800 kV and switching impulse tests up to 1 300 kV can be
performed by this technique. They are installed in a 40 ft container, in which the Marx-Impulse
Generator is transported horizontally. Therefore, the roof of the container must be opened before the
impulse generator can be raised using a hydraulic system. This procedure can be done automatically in
less than 1 hour with almost no physical labour required.
Figure 4.11 is visualizing the set-up, whereas in Figure 4.12 the system ready to use is shown.
Figure 4.11 - Set-up of system
Figure 4.12 - Mobile Impulse System
The voltage divider needed for the test is stored together with the generator. To provide a proper
distance to the divider, a telescopic system is used. Thus neither a crane nor special tools are needed
for the erection of such a system. This can also be used to test HV-cables, which represent a much
higher capacitive load than transformers.
94
Below a test is demonstrated for an 850 MVA 400 kV GSU in a power plant.
Figure 4.13 - Test of an 850 MVA GSU
95
4.2 Experience
4.2.1 Experience A
(1) Project Outline
The transformer was manufactured in 1974. In 2016 an on-site rebuild with new windings was done for
an MVA upgrade
(2) Transformer Rating
 Transformer type: Three Phase Autotransformer
 Rated Power: 600 MVA
 Rated Voltage HV: 400 kV
 Rated Voltage LV: 100 kV
 Cooling system: ONAF
 Vector group: YNa0d11
 Frequency: 50 Hz
 Year of manufacturing: 1974
 Year of re-manufacturing: 2016
(3) Purpose of the on-site high-voltage testing
On-site testing was performed for verification of the conducted work. High voltage testing equivalent to
the FAT was performed for quality assurance.
(4) High Voltage Tests Performed
Each winding was impulse tested three times at 100 %. The impulse waveform was characterized by a
front time T1 = 1,2 µs and tail time T2 = 50 µs.
Figure 4.14 - The schemes shown general test set-up of winding connections in HV winding
An applied voltage test with a test level of 100 % of the original values (70 kV) was done on all winding
successfully. The test duration was 1 minute.
96
Figure 4.15 - Applied voltage test setup
The transformer passed an induced voltage test with 1.3 x Un (nominal voltage) and with PD
measurement. For the 3 phases induced voltage test, the low voltage winding of the transformer under
test was directly connected to the adaption transformer via the HV-divider, whereas the high voltage
terminals were open and the neutral grounded. The three-phase test setup is shown in the scheme
below in Figure 4.16.
The scheme also shows the functional principle of the performed PD-measurement, for which the
measurement taps of the bushing (U, V, W, u, v, w) was used for the decoupling of the PD-signals
simultaneously. Testing was performed continuously. No PD abnormalities in the transformer were
detected by means of PD-pattern and frequency spectrum during the test time and no voltage
breakdown was detected.
Figure 4.16 - Induced voltage test with PD measurement
The spectrum analyser method was used for the PD-measurement as a narrowband filter to optimize
the signal to noise ratio. The calibration is shown in the figure below, in which a calibration impulse of
500pC was injected on the high voltage side. The background noise was the averaged measured pC
on the high voltage side.
97
Figure 4.17 - PD measurement - calibration
Table 4.1 - Test sequences levels according to 420 kV tap-changer position 1
Test Test Voltage at HV Voltage at LV

Duration
sequence voltage side [kV] side [kV]
1 5 min 1.1 Ur 462 29.5
2 36 min 1.3 Ur 546 34.8
3 5 min 1.1 Ur 462 29.5
Figure 4.18 - Test sequence (Time and voltage at LV side)
During the induced voltage test, the PD-measurement was performed continuously to control any
tendencies, but according to the standards, the values of the measured PD-signals were evaluated after
defined durations.
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Table 4.2 - PD level during test sequence 3
Average partial discharges [pC]

Voltage level
U V W
1.1 x Ur 75 75 75
Figure 4.19 - PD Pattern recorded during test (Example)
Due to inductive power consumption of the tested object, which influences the THD of the applied sin
wave voltage, the No-Load measurement was performed also at a frequency different than 50 Hz. This
gives a possibility to correct this value to the 50 Hz.
(5) Specification of the facilities for the on-site high-voltage testing for this transformer.
The High Voltage Mobile Impulse Test System is installed in one 40ft. container. The functional principle
of the HV Mobile Impulse Test System is based on a Marx-Generator, which is transported horizontally
and can be raised by a hydraulic jacking system (see Section 4.1.2).
Figure 4.20 - LI impulse generator
The High Voltage Mobile Test System is installed in one 40 ft. Container, which is schematically shown
in the Figure below and ensures an efficient transportation either by truck or by ship. The functional
principle of the HV Mobile Test System is based on a static frequency converter, which converts a 400
V input voltage at 50 or 60 Hz to an output voltage with a frequency between 15 and 200 Hz. By applying
99
the test voltage to the secondary side of the test object, the transformer to be tested is a simple
capacitive load. Therefore, an oscillating circuit can form between the test object as a capacitive load
and a reactor with fixed inductance of approximately 400 H. By tuning the frequency of the converter's
output voltage, the transformer to be tested and the reactor are operated in resonance, thus the
converter only must cover the losses of this resonant circuit.
Table 4.3 - Equipment of the High Voltage Mobile Test System used during testing
Type
Static Frequency Converter (SFC) with integrated PD filters:
Power = 1 350 kW
Input Voltage = 400 VAC (diesel generator or line connection),
Input Frequency 50-60 Hz,
Output Voltage = 360 VAC,
Output Frequency = 15 Hz – 200 Hz
Equipment for Voltage Compensation System:

Generation Capacitive = 1 MVA,
Inductive = 450 kVA
Step-Up Transformer:
Connection group = IIIiii0,
Output Voltage = 90.1 kV
Total Power = 2 MVA
HV Reactor (Applied Voltage Test):
Inductance = 400 H,
Output Voltage = 500 kV,
Output Current = 4 – 6 A
HV- Filters with Type Calibration
integrated Voltage and HV-Filter, current and voltage measuring system
Current Dividers YES
3 x 100 KV, Full power range
External Voltage Type Calibration
Divider 500 KV HV Divider 500 kV operate with HV Reactor YES
Type Calibration
Power Analyzer, Minimum - 4 Channels YES
Partial Discharge Measurement System:
- Calibration Generator
Measuring Equipment - Quadrupole (Signal decoupling with separate
YES (Calibration
channels Pre-Amplifier for PD and Synchronization
Generator)
for Voltage measurement)
- Evaluation, Storage and Visualization (phase
resolved partial discharge - PRPD)
The induced voltage test can be performed up to a voltage of 90 kV either in a one, two or three phase
connection with a nominal power of the adaption transformer of 2 MVA, which can be overload for a
short time duration.
For the connection between the HV Mobile Test System and the transformer under test, special
polyethylene cables are used which are partial discharge free up to a voltage of 100 kV phase to phase
or 60 kV phase to ground.
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Figure 4.21 - Mobile test system used for applied and induced voltage test
(6) Transportation of the on-site high-voltage testing facilities to the site

The test equipment is stored in 40 feet container and transported by road. The container remains on the
trailer during the tests.
(7) Monitoring performed
DGA sampling before and after test was performed. During AC test, PD measurement was performed.
(8) Other comments
The transformer was located on the concrete platform in the substation and was used before as a
foundation for a temporary workshop..
4.2.2 Experience B
(1) Project Outline
The transformer was manufactured in 1999. A repair of the transformer was performed in 2016. Some
components of the active part were replaced.
(2) Transformer Rating
 Transformer type: Three Phase Transformer
 Rated Power: 190 MVA
 Rated Voltage HV: 230 kV
 Rated Voltage LV: 15.75 kV
 Cooling system: ONAF
 Vector group: YNd1
 Frequency: 50 Hz
 Year of manufacturing: 1999
 Year of remanufacturing: 2016
(3) Purpose of the on-site high-voltage testing
After the repair, an induced voltage test with PD measurement (quality check) and short-circuit-
impedance measurement were performed. The partial discharges signals were decoupled on the
measuring taps of the high voltage bushings (U, V, W). The HV tests were performed in the power plant.
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(4) High voltage testing performed

An Induced voltage test was performed for 60 minutes and ad 1.1 x Un (nominal voltage). The maximum
induced voltage on the high voltage bushing during a 40 second increase on tap changer position 1 was
299 kV. During the whole test, the voltage and current remained stable. The test was performed as
agreed upon with the customer.
PD measurement was performed continuously on the high voltage side. No PD abnormalities in the
transformer were detected by means of PD-pattern and frequency spectrum during the test time.
Due to the sharp edges and the short distance to the installed oil expansion vessel, external discharges
(corona) occurred by 1.2 x Un on phase W. The influence of corona can be seen at the pattern on phase
W.
Figure 4.22 - The schemes shown general test set-up of winding connections
During the induced voltage test, the PD-measurement was performed continuously to control any
tendencies, but according to standards, the values of the measured PD-signals were evaluated after
defined durations.
Ur = rated voltage at maximal tap position (position 1) = 241,5 kV
Un = nominal voltage at nominal tap changer position (position 3) 230 kV
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Table 4.4 - Test sequences levels

Test Test Voltage at HV Voltage at LV
Duration
sequence voltage side [kV] side [kV]
1 5 min 0.2 Ur 48.3 3.15
2 5 min 0.5 Ur 120.75 7.785
3 5 min 0.8 Ur 193.2 12.6
4 5 min 1.0 Ur 241.5 15.75
5 5 min 1.1 Ur 253 16.5
6 5 min 1.2 Ur 276 18
7 40 sec 1.3 Ur 299 19.5
8 5 min 1.2 Ur 276 18
9 60 min 1.1 Ur 253 16.5
10 5 min 1.0 Ur 241.5 15.75
The spectrum analyser method was used for the PD-measurement as a narrowband filter to optimize
the signal to noise ratio, however it was not possible to reduce the noise level below 220 pC at rated
voltage. During the induced voltage test, the PD-measurement was performed continuously to control
any tendencies. Corona discharges were observed and detected on the phase W (sharp edges of the
installed oil expansion vessel).
Figure 4.23 - PD Pattern recorded during test
103
The High Voltage Mobile Test System is installed in one 40 ft. Container
Figure 4.24 - AC mobile test system used for applied and induced voltage test

The test equipment is stored in a 40 feet container transportation and had sea / road transportation. The
container was positioned on the ground due to the close proximity of an overhead line. A special loader
lift truck was used to avoid crane operation.
(7) Monitoring during testing
DGA sampling before and after test was performed.
During the AC test, PD measurement was performed.
(8) Other comments
The transformer was located on the spare transformer platform in the power plant.
4.2.3 Experience C
(1) Project Outline
The transformer was manufactured in 2015. An additional temperature-rise test was performed by
mobile test units as the factory test laboratory was occupied. The power demand necessary for the test
was larger than a single test system. The flexible configuration allows to increase the power by parallel
connection of two mobile test systems.
(2) Purpose of the on-site high-voltage testing applying
Congestion in the factory test room
(3) High voltage tests performed
A temperature rise test was performed with the below mobile test set configuration.
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Figure 4.25 - The schemes for general test set-up of winding connections
Two High Voltage Mobile Test Systems with each installed in one 40 ft. container.
Figure 4.26 - AC mobile test system used for temperature-rise test shown in front of the compensation
unit
105
Figure 4.27 - Two AC mobile test systems used for temperature-rise test shown in front of the
compensation unit
Figure 4.28 - Temporary housing for the test system - protection from the weather condition
106

The test equipment was stored in 40 feet containers with sea / road transportation. The containers were
positioned on the trailer close to the temporary compensation unit.
(6) Monitoring during testing
DGA sampling before and after test was performed.
(7) Other comments
The transformer was located on the transformer platform at the manufacturing site.
107
5. Quality Assurance
5.1 Introduction
As shown in Table 5.1, on-site-assembled transformers are controlled so that factory assembly quality
is maintained from factory disassembly to site assembly. To prevent moisture absorption of the
insulation, a film pack is attached from the factory to the on-site assembling, and a clean house is
installed to ensure a working environment equivalent to that of the factory for humidity and particle
control. To verify insulation moisture absorption during transportation and site work, a moisture
absorption monitoring material is attached at the factory so that the absorbed moisture can be checked
at each process step. Detailed quality assurance at each process is described below.
Table 5.1 - Major quality assurance items for on-site assembly transformers
No Major Item Contents (Recommended)
1 Disassembling at factory • Visual inspection of windings, core, lead connector and parts of
internal activity
• Number of parts checked
2 Transportation • Tank internal pressure check
• Impact and acceleration
3 Environment at site • Humidity and dust in the clean house
4 Moisture absorption in Insulation • Prevention from moisture absorption using coil film packing
materials • Prevention from moisture absorption by dry air flowing
• Moisture content measuring by monitoring insulation materials
5 Foreign particle and damage • Dust proof protective covering and visual inspection
6 Check of assembly transformer • Internal activity inspection and on-site acceptance tests
These recommended control criteria are practiced by most manufacturers with some minor differences.
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5.2 Disassemble after FAT and Delivery from Factory

After the factory acceptance test (FAT), dissembling of the parts into the transportation units is carried
out. This includes internal disconnections inside the tank, disassembling of the internal leads, the core
and the windings. Internal lifting activities from the main tank are carried out in an air-conditioned room
to prevent moisture absorption.
Items are packaged and secured within the transportation tank with a sealed positive dry air pressure
to minimize deterioration in quality due to damage or moisture absorption during transportation. The
windings are fitted with test insulation blocks to monitor moisture absorption between factory
disassembly to transportation and site assembly. The windings are sealed in dry air and covered with
a film pack.
Detailed control criteria are shown below in Table 5.2 for factory dismantling.
Table 5.2 - Quality assurance details (Disassemble and delivery after FAT)
Major item Work item Management item Example of criteria
1 Oil drain 1-1 Oil drain • Residual oil check (visual check) No residual oil
2 Dry air filling 2-1 Dry air filling • Dry air dew point - 30℃ or less
3 External parts 3-1 External parts disassembly • Visual inspection No abnormality
disassembly
• Foreign particle check No abnormality
3-2 Bushing lead disconnection • Visual inspection No abnormality
3-3 Packing • Visual inspection No abnormality
• Number of external parts and No missing
bushing leads
3-4 Dry air substitution • Dry air dew point - 30℃ or less
• Internal pressure Positive pressure
3-5 Inspection before shipment • Visual inspection No abnormality
• Number of external parts and No missing
bushing leads
4 Tank 4-1 Tank disassembly • Visual inspection No abnormality
disassembly
4-2 Transportation cover • Fastening error check No abnormality
installation
4-3 Dry air substitution • Dry air dew point -30℃ or less
4-4 Pre-shipment inspection • Visual inspection No abnormality
5 Preparation of 5-1 Lifting • Visual inspection No abnormality
internal activity
5-2 Oil de-treatment • Visual inspection No abnormality
6 Internal lead 6-1 Disassembly • Visual inspection No abnormality
disassembly
6-2 packing • Packaging abnormality check No abnormality
(visual inspection)
• Number of internal leads No missing
6-3 Dry air substitution • Dry air dew point - 30℃ or less
6-4 Pre-shipment inspection • Visual inspection No abnormality
109

7 Core 7-1 Disassembly • Visual inspection No abnormality
Disassembly
• Number of core and insulation No missing
parts
• Number of iron core No missing
7-3 Packing • Visual inspection No abnormality
• Tightening check No tightening abnormality
• Number of disassembly core No missing
7-4 Dry air filling of the • Dry air dew point - 30℃ or less
transportation tank
8 Winding 8-1 Lifting • Visual inspection No abnormality

disassembly
8-2 Installation of monitoring • Moisture content measuring No abnormality
insulation materials
8-4 Film packing • Visual inspection No abnormality
8-5 Winding check • Insulation resistance No abnormality
8-6 Fixing • Fastening check No abnormality
8-7 Dry air filling • Dry air dew point - 30℃ or less
Note: It is carried out when moisture absorbed by the dismantling work is removed. Depending on the
manufacturer, it may be unnecessary to check the moisture content on the moisture absorption monitor
material or to dry the coil before the factory test.
110
5.3 Transportation
Disassembled parts in the transportation unit are managed for impact during transport and the pressure
sealed in the transport tank. Detailed management items are shown in Table 5.3.
Table 5.3 - Quality assurance details (Transportation)

1 Transportation 1-1 Installation of impact recorder • Visual inspection No abnormality
1-2 Pressure check in • Internal pressure Positive pressure

transportation tank
1-3 Loading • Visual inspection No abnormality
1-4 Transportation • Transportation speed:
Normal Road 40 km/h or less
Highway 70 km/h or less
• Impact level 29.4 m/s2 or less
1-5 Unloading • Visual inspection No abnormality
111
5.4 On-Site Works

The on-site assembly works of on-site assembly transformers is conducted by installing a clean house
to ensure the same working environment as the factory. A dry air machine is installed to supply dry air
to the house during assembly work to prevent moisture absorption of the insulation or rust of the iron
core due to humidity rise. The clean house also manages dust and workers must wear clothing
dedicated to internal work.
During core assembly, the core laminations are inspected visually for abnormalities in appearance such
as dimensional measurement, position deviation, deformation, and damage. Furthermore, after the core
assembly is completed, the core layer resistance and core insulation resistance is measured to confirm
no abnormality.
When inserting the coil into the core, the horizontal dimension of the coil and the moisture of the test
insulation block is checked.
Detailed management items are shown in Table 5.4.
Table 5.4 - Quality assurance details (On-site works)

1 Clean house 1-1 Clean house installation • Humidity less than 50 %
installation 80 % or less when the clean
house ceiling is open
• Floating dust amount 20 cpm or less
1-2 Dry air generator installation • Dry air dew point - 40℃ or less
2 On base of 2-1 Foundation Inspection • Flatness Within manufacturer’s

main tank criteria
2-2 On base • Centering Within manufacturer’s
criteria
3 Core assembly 3-1 Packing removal and • Visual inspection No abnormality
Acceptance inspection • Impact level 29.4 m/s2 or less
(In case of using
transportation tank)
3-2 Winding dust-proof • Foreign particle check No abnormality
protective covering
• Protective covering of windings No abnormality
Prevention from moisture
absorption • Humidity in Dust Proof Cover 50 % or less
• Dry air dew point - 40℃ or less
3-3 assembly • Foreign particle check No abnormality
• Dimensions of stacking condition equivalent condition with the
factory
• Visual inspection
No abnormality
3-4 post assembly inspection • Interlayer resistance Within manufacturer's
• Insulation resistance criteria
4 Winding 4-1 Packing removal, • Internal pressure Positive pressure

assembly acceptance inspection
(Winding • Impact record 29.4 m/s2 or less
insertion) • Visual inspection No abnormality
• Moisture content in insulation a) 0.5 %・wt. or less (500
materials
kV class)
b) 1.0 %・wt. or less (275
kV class)
c) 2.0 %・wt. or less (154
kV class)
112

• Winding resistance Factory test value: Within ±
5%
• Insulation resistance As per Figure 5.1 - Criteria
of insulation resistance [6]
4-2 Assembly • Dimensions Horizontal (Within

manufacturer’s criteria)
(Coil insertion)
• Visual abnormality check No abnormality
4-3 Post-assembly inspection －－

Note: not applying the
inspection of winding itself
5 Internal lead 5-1 Packing removal， • Internal pressure Positive pressure
assembly
• Impact record 29.4 m/s2 or less
Acceptance inspection
• Visual inspection No abnormality
5-2 Assembly • Tightening torque Tightened within
manufacturer's criteria
• Abnormality check with drawings No abnormality
• Dimensions According to the drawing
requirement
5-3 post assembly inspection • Dimensions No abnormality
According to the drawing
requirement
6 Tank assembly 6-1 Packing removal， • Visual inspection No abnormality
• Internal pressure Positive pressure (In case
of insulation materials built-
in)
• Impact record 29.4 m/s2 or less (In case of
Coil, lead built-in)
6-2 Assembly • Foreign particle check No foreign particle, workers'
foreign particle, foreign
particle generated during
work
• weather condition Not rainy condition (In the
case of work outside the
clean house)
• Weld leg length Within manufacturer's
criteria
• Degree of vacuum, N2 Within manufacturer's
concentration criteria
• Visual inspection No abnormality
6-3 post assembly inspection • Weld leg length Within the manufacturer
specified value
• No Leakage check No leakage
7 Internal parts 7-1 post assembly inspection • According to the field test item Within manufacturer's
test Table 5.5.1 On-site test items criteria
8 Clean house 8-1 Clean house demolition • Visual inspection No abnormality
disassembly
9 Exterior parts 9-1 Packing removal， • Visual inspection No abnormality

assembly
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9-2 Assembly • Visual inspection check No abnormality such as
deformation or damage on
parts
• Weather, Outside air humidity Not rainy condition, outside
air humidity less than 80 %
• Tightening torque Tightened within
manufacturer's criteria
9-3 post assembly inspection • Tightening abnormality check No tightening abnormality
(visual inspection)
• Insulation resistance Within manufacturer's
criteria
10 Bushing lead 10-1 Packing removal， • Visual inspection check No abnormality
connection
• Impact record 29.4 m/s2 or less
10-2 Assembly • Protective covering abnormality No abnormality
(visual inspection)
• Dry air dew point，Internal - 40℃ or less (Internal

humidity humidity 50 % or less)
• Weather, Outside air humidity Not rainy condition, outside

air humidity less than 80 %
• Worker clothes check (visual No abnormality with clothes

inspection)
• Tightening torque Tightened
• Dimensions The lead position is in
accordance with the
drawing dimensions
• Number of in-tank carry-on parts No missing

and tools
10-3 post assembly inspection • Visual inspection No abnormality
• Dimensions According to the drawing
requirement
11 Degassed 11-1 Acceptance inspection • Insulation oil breakdown voltage Over 40 kV/2.5 mm
lubrication
• Moisture content in oil Less than 30 ppm・wt.（500
kV Class）
11-2 Oil vacuum pulling • Moisture content in insulation a) Less than 0.5 %・wt. or
materials
less (500 kV class)
(Before Vacuum drawing)
b) Less than 1.0 %・wt. or
less (275 kV class)
c) Less than 2.0 %・wt. or
less (154 kV class)
• Degree of vacuum
a) Less than 67 Pa（500kV

Class）
b) Less than 133 Pa （275
kV Class）
• Duration
c) Less than 667 Pa （154
kV Class）
Time depends on
manufacturer
114

• Moisture content in insulation a) 0.5 %・wt. or less (500
materials
kV class)
(Before oil impregnation)
b) 1.0 %・wt. or less (275
kV class)
c) 2.0 %・wt. or less (154
kV class)
• Circulating oil amount
Oil Circulation x 2 times or
• Settling time more（500 kV Class）
a) 72 hours or more（500
kV Class）
b) 48 hours or more（275
kV Class）
c) 36 hours or more （154
kV Class）
11-3 Inspection after oil • Insulation oil breakdown voltage a) More than 60 kV/2.5 mm
impregnation （500 kV Class）
b) More than 50 kV/2.5 mm
（275,154 kV Class）
• Moisture content in oil
a) Less than 10 ppm・wt.（
500 kV Class）
b) Less than 15 ppm・wt.（
275 kV Class）
• Gas amount in oil c) Less than 20 ppm・wt.（
154 kV Class）
a) Less than 0.5 %･vol （
500 kV Class）
b) Less than 1.0 %･vol （
• Oil-tightness pressure， 275 kV Class）
Retention time
c) Less than 2.0 %･vol （
• Oil leakage
154 kV Class Below）
• Oil level
More than 0.02 MpaG
(more than 24 hours)
No oil leakage
• Moisture content in insulation
materials All measurement should be
Within manufacturer's
criteria
a) Less than 0.5 %･vol （

500k V Class）
b) Less than 1.0 %･vol （
275 kV Class）
c) Less than 2.0 %･vol （
154 kV Class）
(If it would be confirmed
before vacuum drawing or
before oil impregnation,
cannot apply this item.)
12 Touch-up paint 12-1 Touch-up paint • Visual inspection No abnormality
13 Final on-site 13-1 Final on-site test According to the on-site test items Within manufacturer's
test by Table 5.5 - On-site test items criteria
"－" means those which do not define assurance standard values
115
Good
66 kV & above
Insuration resistance (MΩ)
22 kV & above, less than 66 kV
6.6 kV & above

less than 22 kV
Not good
Insulation DC resistance
measured by 1 000 V or 2 000 V
Temperature (℃)
Figure 5.1 - Criteria of insulation resistance [6]
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5.5 On-Site Tests

5.5.1 Introduction
Tests and inspections are performed at each stage. The tests performed are summarized the below
table. The lead connections are confirmed by performing voltage ratio test and phase displacement test.
The core and windings are confirmed by performing impedance, core visual check and core excitation
test.
5.5.2 On-site test items

The on-site assembly transformer work should have the same quality control as in the factory. At each
stage , a unique test shown in Table 5.5 is conducted. It is effective in ensuring quality and minimizing
rework.
All the above-mentioned low voltage tests should be performed after the complete assembly.
Table 5.5 - On-site test items

Application
Test item During on-site Finished Remarks
assembly assembly
1 Core layer insulation, insulation X - No abnormality check of core
resistance (between core layers assembly condition
and between blocks)
2 Short-circuit impedance with low X - No abnormality check of core and
voltage measurement coil assembly condition
3 No-load current with low voltage X - Core assembly condition check by
measurement low voltage excitation test (In order to
avoid reworking, check core
assembly condition)
or measurement of excitation
characteristics (AC･DC
Superposition test)
4 Winding resistance measurement X X a) During assembly
No abnormality check during

transportation, measure winding
resistance as acceptance test of coil
condition
b) Finished assembly
No abnormality check of coil

assembly condition
5 Voltage ratio measurement X X Lead connection check
6 D.C. insulation resistance X X Insulation resistance check between
windings and between winding and
ground
7 Capacitance measurement - X No abnormality check of core and
coil assembly condition
8 Dissipation factor measurement - X No abnormality check of core and
(tan δ) coil assembly condition
No abnormality check of moisture
absorption surface of insulation
materials
9 Polarity test - X Lead connection check
10 Phase displacement check X X Lead connection check
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Application
Test item During on-site Finished Remarks
assembly assembly
11 On-load tap-changers - Operation - X
test
12 Insulation oil test (including DGA) - X
13 Cooling equipment test - X
(Including cooler control cubicle,
oil pump, cooling fan, etc.)
14 General structural check - X
15 Oil tightness test - X
16 Vacuum tightness test - X
17 Auxiliary equipment test - X
118
5.6 On-Site High Voltage Testing

Depending on the specification of the work, on-site high voltage tests can be carried.
5.6.1 Standards pertaining to on-site tests including on-site high voltage testing
The existing standards for on-site tests of power transformers are listed below:
 IEEE Std C57.93™-2019: IEEE Guide for Installation and Maintenance of Liquid-Immersed Power
Transformers [19]
 IEEE Std 1861™-2014: IEEE Guide for On-Site Acceptance Tests of Electrical Equipment and
System Commissioning of 1000 kV AC and Above [20]
 IEC TS 63042-301 Edition 1.0 2018-12 UHV AC transmission systems - Part 301: On-site
acceptance tests [21]
All on-site test items are based on low voltage testing. Optionally, on-site high-voltage testing is
described in the standards for UHV transformers.
Table 5.6 compares on-site test items foreach standard. On-site high voltage testing is listed as an
optional test by the existing standards on item 15.
Table 5.6 - Comparison of on-site test items on existing standards

IEEE Std 1861™-2014 IEC TS 63042-301 -
Test item IEEE C57.93-2019 [19]
[20] 2018 [21]
1 Insulation Insulation resistance test on Insulation resistance test on Insulation resistance test
resistance test each winding to ground and each winding to ground and on each winding to earth
between windings. between windings including and between windings
bushings including bushings
Core and frame insulation Core and frame insulation
check check
2 Dissipation factor Insulation power factor or Dissipation factor (tan δ) and Dissipation factor (tan δ)
(tan δ) and dissipation factor test on capacitance measurement and capacitance
capacitance each winding to ground and on each winding to ground measurement on each
measurement between windings. and between windings winding to earth and
Capacitance should also be between windings
measured on each including bushings
connection. In addition, core
insulation should also be
tested.
3 Tests on bushings Power factor or dissipation Tests on bushings Tests on bushings
factor test on all bushings
equipped with a power factor
tap or capacitance tap. Both
C1 and C2 insulation should
be measured.
4 Ratio tests Winding ratio test on each Ratio tests Ratio test
tap. If LTC transformer,
check winding ratio on all
LTC positions.
5 Winding resistance Check winding resistance of Winding resistance Winding resistance
measurement all windings with a Kelvin measurement measurement
bridge or another suitable
test device and compare
with factory test results.
6 Liquid-level and Check operation of liquid-
hot-spot level and hot-spot
- -
temperature temperature indicating and
control devices.
119
IEEE Std 1861™-2014 IEC TS 63042-301 -

[20] 2018 [21]
7 Insulating oil tests Check dissolved gas, Insulating oil tests Insulating oil test
dielectric strength, power
Dissolved gas factor, interfacial tension, Dissolved gas analysis Dissolved gas analysis
analysis (DGA) neutralization (DGA) test (DGA) test
test
number, and water content
of the dielectric liquid.
8 Oxygen content Check oxygen content and
and total total combustible gas
combustible gas content of nitrogen gas
content cushion in sealed tank
transformers. A total
combustible gas test, where
applicable, and a dissolved
gas-in-oil test of the - -
dielectric fluid should also be
made soon after the
transformer is in service at
operating temperature to
provide a suitable post-
energization reference
“bench mark.”
9 Auxiliary Check operation of auxiliary
equipment equipment, such as LTCs,
liquid-circulating pumps,
- -
fans, or liquid or water flow
meters in accordance with
manufacturer’s instructions.
10 Polarity check and Check polarity and excitation Polarity check Polarity check
excitation current current at reduced test
measurements voltages. Excitation current Excitation current
measurements at reduced measurement at low
voltage voltage
11 Resistance, ratio, Check resistance, ratio, and
and polarity of polarity of instrument
instrument transformers when provided.
- -
transformers These tests should be made
at the terminal blocks in the
control cabinet.
12 FRA Frequency response Frequency response Frequency-response
measurement compared to analysis (FRA) analysis (FRA)
factory results, if applicable.
NOTE—If final bushings are
not used in the factory, test
results may differ.
13 Leak testing Leak testing with pressure Leak testing with pressure
-
(tightness test) (tightness test)
14 Short-circuit Short-circuit impedance Short-circuit impedance
impedance - measurement at reduced measurement
measurement current
120
IEEE Std 1861™-2014 IEC TS 63042-301 -

[20] 2018 [21]
15 On-site high- Optional tests based on the Following items are
voltage testing requirements of the user optional:
include the following:
(as option item) Induced voltage test with
Applied voltage tests partial discharge
measurement
- Induced voltage test with
partial discharge Applied voltage test
measurement (IVPD)
NOTE Above optional test
items are based on
agreement between
purchaser and supplier.
Note: “-“ means “no mentioned in the standards”.
5.6.2 Test items and its voltage levels

(1) On-site high voltage tests and their corresponding test levels should be agreed upon between
purchaser and supplier and documented.
(2) The main test items should be induced voltage test including partial discharge measurement,
applied voltage test, and in some cases impulse test.
5.6.3 Example of on-site high voltage testing reasons

Reasons for performing on-site high voltage testing are shown in Figure 5.2. One of the most important
reasons is quality control after a repair or rebuild on-site.
Figure 5.2 - Reasons for on-site high voltage testing on power transformers in Europe
5.6.4 Applying on-site high voltage testing

As seen in Figure 5.2, on-site high voltage testing can be done on new transformers and in service
transformers. The main general reasons for doing the tests are:
(1) Tests on new transformers (after a transportation event or after an assembly on-site)
(2) Tests on transformers in service (after an event or failure)
(3) Tests on a transformer on-site (before or after a repair on-site)
For all three categories, the scope of the tests as well as the test levels have to be agreed upon taking
into consideration the space on site and test equipment capability.
For category (1), the on-site high voltage testing for the new transformer is an optional item in
accordance with IEEE [20] and IEC [21] standards shown in Table 5.6. For new transformers that
121
have never been in service, it is recommended to perform at least the main HV tests at the full test levels
according to the IEC-standard. The scope of tests for a new transformer after a transportation event can
of course be reduced to induced and applied high voltage tests including PD measurements as well as
a no-load test since the purpose is to check if the active part has suffered a fault during the transportation
or not. The voltage levels applied in this case are usually below the FAT levels. This can also apply to
transformers that have been repaired in a workshop with a transportation event.
If a new transformer is assembled on-site, the site tests might replace the FAT and thus all tests
according to the standard should if possible be performed as final quality control. If the transformer was
assembled before in the factory with an FAT before it was completely disassembled for transportation,
the scope of the on-site tests might be reduced in consultation with the purchaser as shown Table 5.5.
However, if technically possible, at least the induced voltage test with partial discharge measurement,
applied test and no-load test is recommended
If on-site high voltage tests are not possible due to site limitations (not enough space, underground
installation) then it should be noted that many successful projects of on-site assembly transformers with
the quality assurance shown between clause 5.1 and 5.5 in this technical brochure were done without
any on-site high voltage tests.
For category (2), the purpose of the test is a diagnostic procedure – e.g. to localize PD in case the DGA
analysis indicates a failure. In these cases, high voltage tests are helpful to detect the failure and the
test levels are usually below the allowed test levels in standards (or the original FAT). Very often the
high voltage tests are performed in order to localize a PD defect, thus induced voltage tests with a level
in a range of 120% of nominal voltage at increased frequency (e.g. 100Hz) are performed and additional
equipment like acoustic or UHF PD sensors is used. Frequently single-phase induced tests on a three
phase transformer and applied voltage tests are performed to localize the PD source as precise as
possible.
Concerning category (3), different high voltage tests can be performed after a repair on-site, but the test
levels are reduced compared to the original FAT test levels. In any case, induced voltage tests combined
with PD measurements and applied voltage tests as well as a no load test is recommended. If the design
of the transformer was changed during the repair, temperature rise test and lightning impulse test are
recommended to verify the new design.
Sometimes a test before a repair is useful to get information on the condition of the core (no-load test)
and whether the transformer has PD (induced voltage tests with PD measurement), but this is depending
on the scope of the repair itself.
It can be concluded that today all high voltage tests on-site are possible, but the efforts increase with
scope. Usually induced, applied and no-load tests can be performed using a main mobile testing facility
(e.g. basic test container). More effort is necessary if temperature-rise tests are needed, because in
these cases capacitive compensation is often needed, which requires a second device (container). The
same applies to lightning or switching impulse tests, for which an additional device (container) is needed,
with the restriction that chopped lightning impulses would again need an additional large device
(container), thus these tests are not recommended, due to the large effort.
In cases with extremely large units in the range of 1000 MVA, it might be that basic tests can only be
done.
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6. Summary
Site Assembly of large transformers is shown to be a viable solution for severe transport limitations.
Some countries (Japan in particular) have severe weight or size limitations for transport that make it
near impossible to ship a transformer with a desired high MVA rating. Solutions have been developed
that allow the transformer to be manufactured and then the windings and core dismantled to be shipped
to site in several transportable segments for full assembly on site. A temporary building on site with a
controlled environment is required for the assembly since windings and cellulose are exposed. Fixed
cranes in site buildings or mobile cranes are used for the lifting. On site testing may be done after the
site assembly.
A survey of site assemblies performed by several manufacturers in Japan, Europe and China showed
the below solutions:
 A 3 phase 5 limb core design was shown to be typically utilized. The core is manufactured in 4
separate “U” cores that can be easily combined at site. The windings are nested together as a
single phase for transport to site. At site the “U” cores are assembled on to a bell type tank
base and the winding phases are landed onto the core main limbs. The transformer is fully
assembled and tested in the factory before being dismantled and shipped to site.
 A 3 phase 5 limb core design was shown also where the core legs and yokes are shipped
individually to site. A core stacking table is required at site where the bottom yokes are inserted.
The core is up-righted and then the winding phases are installed. The top yokes are inserted,
and the active part is installed.
 Solutions with shell form type transformers were shown
 A variant of the site assembly was shown to be the split tank type transformer. The transformer
is divided into several tank components that are connected on site such that it will be an
equivalent three phase or single phase required rating. For this type, the windings and cores
are not assembled on site.
 These solutions have been done on hundreds of transformers globally and ratings above 1
500 MVA have been achieved. The field failure rate was shown to be very low.
A survey was similarly done for on-site assembly of existing transformers requiring new windings. In
the event of failure, it may not be possible or practical to transport a transformer to a factory for repair.
This may occur if rail lines or bridges have been decommissioned and the existing transformer can no
longer be shipped out of the site in the same way it arrived. It is possible to disassemble the transformer
and active part on site, and repair or replace damaged windings. This is termed “site repair” and involves
many similar challenges and solutions as the above discussed on-site assembly. The survey included
site repairs done in Canada, Europe, China and Japan.
The solutions for the site building / clean house were shown which are special purpose buildings that
are reused and contain the necessary lifting systems or have removable roof panels for mobile cranes.
It may be possible to use an existing building at site (i.e. generator hall with high bay ceiling and
overhead crane) or a local company can prepare a tent type building on site. The site building must
have a controlled atmosphere for low humidity and minimization of dust.
A survey was done for the dryout of the core & windings. The windings are manufactured in a
transformer factory and dried out by vapor phase method prior to shipment. The various methods to
limit moisture ingression during the site assembly process were shown. The final dryout was shown to
be done by either hot oil / vacuum cycles, Low Frequency Heating (LFH) method or by site vapor phase.
The final testing of the assembled transformer at site varied in the survey. Some manufacturers test
the assembled transformer in the factory (and some only as design tests on the first transformer) and
then only perform low voltage tests at site. Other manufacturers do full testing at site on the assembled
transformer but with no factory testing. All situations were proven to be successful with low field failure
rates.
Technology was shown to have been developed for mobile test equipment to allow all parameter and
dielectric verification tests to be performed at site. Loss measurement, impedance measurement,
temperature-rise test, applied voltage and induced voltage are performed using AC HV test equipment.
Lightning impulse voltage and switching surge voltage tests are performed with a mobile HV impulse
test set. DC tests such as DC applyed or DC induced voltage tests are performed with mobile DC test
equipment.
Modern mobile AC HV test systems utilize an Electronic Power System (EPS) which can vary the output
123
voltage and output frequency across a wide range during operation. The system includes an inductive
and capacitive compensation and a step-up-transformer that can be switched manually into many
different configurations. By using external capacitor banks, a temperature-rise test can be also
performed at site with this system. Transformers up to 800 kV have been tested with this type of mobile
AC HV test system for induced, applied and loss measurement. Temperature-rise testing is limited by
available capacitors and the power supply (i.e. typically a very large 2 MW diesel generator).
The HV mobile impulse test set is a modified version of a factory impulse test set where the test circuit
lays down flat into a 40 ft. ISO container or road trailer for shipment. Mobile impulse sets that can
perform testing up to 1 800 kV BIL are in use and higher voltages are technically possible.
The methods and quality controls were surveyed by several manufacturers. Detailed quality checks,
testing, clean house requirements, processing / dryout and inspections are shown.
It was overall demonstrated that varying solutions have been developed and successfully executed for
site assembly and site repair for more than 20 years. The increased risks of performing tasks at site
such as installing windings, core assembly, active part dryout and dielectric testing have all been
managed. The site assembly and site repair are shown to be a viable and a fully possible solution when
required in accordance with local regulations, practices, and its specifications.
These on-site assembly and on-site rebuild are a new technical survey for the power transformer. This
technical brochure shows different procedures with many experiences of the on-site assembly and the
on-site rebuild. They show good reliability with FAT and on-site acceptance tests without on-site high
voltage testing (Japan in particular). This technical brochure summarizes the sequences of quality
assurance for the on-site work.
124
APPENDIX A.
Detail of the factory and on-site tests methods for the on-site assembly transformers in Japan
Disassembly and transportation of power transformers: On-site work quality management standards
Factory Test On-site Test
Test Type When to
Test
JEC−2200[22] Timing
During Assembly
Finished Product
No. Contents of the test Contents of the test
Acceptance
Original
Test Items Test Items
Special
Test Contents Test Contents
Type
Measure winding resistance Measured between

between each winding, each Winding each winding, each
Winding resistance
1 ○ －－－ phase, and each tap by Kelvin resistance ▲ ▲ phase, each and tap by
measurement
double bridge or voltage drop measurement a low resistance meter
method or voltage drop method
Measure transformer ratio between
each phase and each tap of each
Transformer ratio Transformer ratio Same as factory test
2 ○ －－－ winding question by transformer ● △
measurement measurement contents
winding ratio tester or voltmeter
method
Polarity test or
Polarity test or phase Measured by vector method or kick Same as factory test
3 ○ －－－ phase ▲ △
displacement test method contents
displacement test
Low voltage short Apply low voltage and low current
4 circuit impedance －－－ ○ at rated frequency and to measure
Low voltage short Measured by low
measurement short circuit impedance
circuit impedance ● ▲ voltage and low current
Short circuit Apply a current of 50% or more of
measurement of rated frequency
5 impedance and load ○ －－－ the rated current at the rated
loss measurement frequency and measure
Measure no load
No-load loss and no- Low voltage current with a low
Excitation measurement with rated
6 load current ○ －－－ excitation current － △ voltage of about 200 V
frequency and rated voltage
measurement measurement (do not measure no
load loss)
Conducted with
Induced Test
Apply AC voltage using generator alternating voltage

etc. (Verify the insulation strength using pressure
between winding and ground, AC withstand resistance test
Short-term between each winding, between voltage test equipment or generator
alternating
7 ○ －－－ turns, and between taps) (Equivalent to a － ▲ Test voltage, test
current withstand
on-site withstand duration, etc. are in
Apply Test
voltage test
Same as above (Verification of voltage test) accordance with the
insulation strength between winding provisions of the
and ground and, between windings) electrical equipment
technical standards
Long-term alternating
Excitation for 4 hours
current withstand Measure a partial discharge
with three-phase 100%
voltage test amount by applying a relatively low Long time
8 ○ －－－－ ▲ voltage at the rated tap,
(Including partial voltage for over a long time to a excitation test
and to performing
discharge transformer exceeding 187 kV
various measurements
measurement)
After installing the transformer, Perform tap switching
On-load tap changer perform the specified tap switching On-load tap and check that it works
9 ○ －－－－ ○
test and to confirm that it works properly changer test properly to confirm
function proper function
Conducted by the
actual load method and
Supply the total loss to the Load test
measure the oil
transformer mainly by the short (Corresponds to
temperature rise value
10 Temperature rise test － ○ －－ circuit method, and to measure the the on-site － △
measurement (Wound
oil and winding temperature rise temperature rise
temperature rise
values test)
measurement is not
performed)
Apply specified test voltage
Lightning impulse To (Verify the insulation strength of
11 － ○ －－－－－
withstand voltage test each winding against the lightning
impulse)
125

Test Type When to
Test
During Assembly
Finished Product
Acceptance
Original
Special
Type
Same as factory test
contents（It may
Measure the capacitance between become impossible to
Capacitance each winding and the ground and Capacitance measurement by
12 －－ ○ －－ ●
measurement between each winding with a measurement induction may not be
shearing Schering bridge possible due to an from
the adjacent existing
transformer）
contents（It may
Measuring the dissipation factor Dissipation factor become impossible to
dissipation factor between each winding and each Dielectric loss measurement by
13 －－ ○ －－ ●
measurement (tan δ) winding with a shearing Schering angle induction may not be
bridge measurement possible due to an from
transformer）
contents（It may
Measure the insulation resistance
become impossible to
between winding and ground and Insulation
Insulation resistance measurement by
14 －－ ○ － between each winding with an resistance ○ ○
measurement induction may not be
insulation resistance meter of 1,000 measurement
possible due to an from
V or more
transformer）
Excited at rated frequency and Perform noise level
rated voltage, and to measure with measurement in
15 Noise level test －－ ○ － Noise level test － ▲
a normal noise level meter without accordance with the
load long-time excitation test
Zero phase
Energize and measure the star
16 impedance －－ △ －－－－－
winding of three-phase transformer
measurement
Overload resistance Check the overload resistance in
17 －－ △ －－－－－
test the overload statement
Check the mechanical strength of
Short circuit strength
18 －－ △ － the coil in the short circuit strength －－－－
test
statement
Apply a low voltage waveform of
1.2 / 50μs to a high voltage or
Transition voltage
19 －－ △ － medium voltage winding and to －－－－
measurement
measure the low voltage winding
transfer voltage
Measured by the second Kyoto
University method or variable
frequency oscillator using a low
Natural frequency voltage shock voltage generator
20 －－ △ －－－－－
measurement Or open the circuit with DC current
flowing through the coil and to
measure the coil natural frequency
of the coil
Harmonic component
Measure harmonics of three-phase
21 measurement of no- －－ ○ －－－－－
no-load current
load current
Analyze the insulation oil before
Insulation oil test Insulation oil test
and after the temperature test and Same as factory test
22 (Including gas-in-oil －－ ○ － (Including gas-in- － ○
to confirm that there is no contents
analysis) oil analysis)
abnormality
Cooling equipment The Cooler control panel performs Cooling
test tests include structural inspection, equipment test
(Includes cooler insulation resistance, withstanding (Includes cooler Same as factory test
23 －－ ○ －－ ○
control panel, oil feed voltage test, and operation check control panel, oil contents
pump, and cooling For pumps and fans to check feed pump, and
fan) operation, and measure input cooling fan)
126

Test Type When to
Test
During Assembly
Finished Product
Acceptance
Original
Special
Type
current and input loss
Check whether each part is
assembled according to the
General structure General structure Same as factory test
24 －－－ ○ drawing, dimensions of each part, － ○
inspection inspection contents
attachment condition, painting
condition, etc.
Iron core
Measure the insulation resistance
Iron core interlayer interlayer
of core block between layer,
resistance/ insulation resistance/ Same as factory test
25 －－－ ○ between core and earth, between ● －
resistance insulation contents
core and clamp, between each
measurement resistance
block of core, etc.
measurement
Excitation Characteristics
Excitation Characteristics
Low voltage
Low voltage Apply a low voltage at the rated
excitation Same as factory test
excitation frequency and to measure the
characteristic contents
characteristic test excitation current of each phase
test
Core
Core excitation
26 －－－ ○ excitation ● －
characteristic Apply low voltage of AC and DC,
characteristic
measurement and to measure admittance with Same as factory test
measurement
(AC · DC magnetic flux equivalent to rated contents
(AC · DC
superposition voltage
superposition
test)
test)
Calculation of voltage Calculated based on the standard
27 regulation and －－－ ○ from the results of no load test and －－－－
efficiency short circuit impedance test
Control circuit Apply test voltage between control
28 －－－ ○ －－－－
withstand voltage test circuit and ground
Apply a rectangular wave pulse
Surge impedance with a low voltage impulse voltage
29 －－－ △ －－－－
measurement generator and measure it with the
second Kyoto University method
Pressurize the inside of the
Oil-tightness, transformer outer box, to check it Oil-tightness, Same as factory test
30 －－－ ○ － ○
airtightness test can withstand pressure, and airtightness test contents
confirm that there is no oil leakage
Check the vacuum resistance of Same as factory test
31 Vacuum test －－－ ○ Vacuum test － ○
the transformer outer box contents
Apply rated voltage at rated
Vibration Conduct vibration
frequency, and to confirm that there
measurement/ Vibration measurement in line
32 －－－ ○ are no absence of abnormal － ▲
acceleration measurement with long-term
vibration or noise on the tank
measurement excitation test
surface and accessories.
Check the potential oscillation in
Potential distribution the coil
33 －－－ △ －－－－
measurement Generally implemented at the
content stage during production
Operate the pump at rated speed
Winding leakage
Winding leakage and to check the winding leakage Same as factory test
34 －－－ ○ current － ○
current measurement current value flowing to the neutral contents
measurement
point
On-site high voltage
Confirm the power supply capacity
35 test capacity －－－ △ －－－－
of the local withstand voltage test
measurement
Long-term charge Excitation for a long time over a Conducted according to
Long-term charge
36 test (Normal ground －－－ △ long period at rated voltage and to － ▲ the long-time excitation
test
voltage) check for abnormal gas generation test
Confirmed that the accessories Conducted operation
itself has themselves the check, insulation
performance according to the resistance
Auxiliary equipment Auxiliary
37 －－－ ○ specifications － ○ measurement, polarity
test equipment test
The Bushing type current test, operation test of
transformer performs polarity test alarm circuit, etc. for
and insulation resistance each part
127

Test Type When to
Test
During Assembly
Finished Product
Acceptance
Original
Special
Type
measurement after installation
Check the mechanical strength of
the bushing and body anti-seismic
38 Seismic test －－－ △ －－－－
hardware etc. in the earthquake
proofing statement
Pipe flow rate
39 －－－ △ Measured by ultrasonic flowmeter －－－－
measurement
Variable frequency oscillator Frequency
Frequency response Same as factory test
40 －－－ △ measures frequency response response － △
analysis contents
characteristics of coil analysis
Apply a variable frequency and low Tap winding
Tap winding
voltage and to measure the Frequency Same as factory test
41 Frequency response －－－ △ △ －
frequency-response magnification response contents
measurement
characteristics of the tap winding measurement
Apply single-phase low
AC excitation
voltage and measure
42 －－－－－－ current － △
each phase current
measurement
value
○，●: Standard implementation（●: Disassembly transport transformer specific test）

△，▲: Conducted by some manufacturers or in consultation（▲；Disassembly transport transformer
specific test）
－: Not performed
Note: Fluid charge maintenance may be conducted with dielectric loss tangent and insulation oil
electrification measurement in consultation with the user
128
References
[1] Technical Brochure 673 (2016) Guide on transformer transportation, WG a2.42, www.e-cigre.org
[2] Survey of applied experience for quality control of disassembling, transportation and site
assembling of power transformer (in Japanese), Electric Technology Research Association
(ETRA) Vol.69, No.2, 2013
[3] Innovation on Energy Power Technology (11) (in Japanese), The Institute of Electrical Engineer
of Japan (IEEJ), 2008, N. Amano and M. Watanabe
[4] Experience and Countermeasures for Reliability of Site-Assembly Transformer, CIGRE SC A2
Colloquium, 2015, T. Kobayashi, K. Ogata, Y. Matsushita, M. Kadowaki, S. Yamada, Y.
Nakashima and H. Ikeda
[5] Quality Control and Site Test for Site Assemble Transformers, CIGRE SC A2 Colloquium, 2017,
T. Kobayashi, S. Ito, K. Konishi, M. Kadowaki, S. Yamada, Y. Nakashima and H. Ikeda
[6] Oil-immersed transformer test guideline (in Japanese), Technical Report of IEEJ (the Institute of
Electrical Engineers of Japan), 1981, Part II, No. 119, page 7
[7] Development of Convenient Transported UHV AC Large Capacity Transformer, CIGRE SC A2
Colloquium, 2015, L. Peng, W. Xiaoning, L. Bo, Z. Xile, L. Jinzhong and Z. Zhigang
[8] A study on key technology and demonstration application of UHV AC site assembled
transformers, CIGRE Paris Session A2-306, 2018, X. Wang, J. Wu, G. Sun, J. Chen, H. Guo, H.
Li, X. Hu, H. Yu and X. Zhang
[9] Case Studies of Recent Transformer Site Repairs, 84th International Conference of Doble Clients,
2017, C. Noël, J. Murray and Ed teNyenhuis
[10] Low Frequency Heating Field Dry-out of a 750 MVA 500 kV Autotransformer, 75th Annual
International Doble Client Conference, 2008, E. Figueroa, T. Kalicki and Ed teNyenhuis
[11] Advancements in Transformer Site Dryouts, CIGRE Paris Session A2-322, 2020, E.G.
teNyenhuis, M.M. Lahloub
[12] HVDC Transformer Site Repair & High Voltage Testing Experience, 87th International Conference
of Doble Clients, 2020, D. Garon and Ed teNyenhuis
[13] Preparation for smooth replacement of Aging Power Network System Facilities (in Japanese),
Electric Technology Research Association (ETRA) Vol.63, No.5, 2008
[14] On-site refurbishment technique of power transformer, CIGRE SC A2 Colloquium, 2015, T.
Nishioka, K. Ogata, K. Takahashi, K. Igushi, M. Takahashi and N. Miyamoto
[15] Strategies to Replace, Refurbish, Repair and Upgrade Power Transformers: The Spanish
Experience., CIGRE Paris Session A2-201, 2008 M.Oliva, M.A.Delrey, A.Marin, J.I.Anguas,
S.Quintin, M.J.Lapeira and J.Mena
[16] On Site Repair of HV Power Transformers, CIGRE Paris Session 12-114, 2002, J.C.Mendes,
R.A.Marcondes and J.Westberg
[17] Decision of on site refurbishment of large shunt reactor (in Japanese), The conference of IEEJ
(the Institute of Electrical Engineers of Japan), Paper No. 5-170, 2011, T. Nishioka, M. Kikuchi,
K. Momose, T. Higichi, K. Kajimura
[18] Benefits of High Voltage Testing at Site for Power Transformers, CIGRE Paris Session A2-301,
2018, E.G. teNyenhuis, M. L. Diaby, G. Pajaro and J. Szczechowski
[19] IEEE Std C57.93™-2019: IEEE Guide for Installation and Maintenance of Liquid-Immersed
Power Transformers
[20] IEEE Std 1861™-2014: IEEE Guide for On-Site Acceptance Tests of Electrical Equipment and
System Commissioning of 1000 kV AC and Above
[21] IEC TS 63042-301 Edition 1.0 2018-12 UHV AC transmission systems - Part 301: On-site
acceptance tests
[22] JEC-2200-1995: Standard of the Japanese Electrotechnical Committee – Power Transformers
129
ISBN : 978-2-85873-562-4
TECHNICAL BROCHURES
©2021 - CIGRE
Reference 857 - December 2021

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A2 TECHNICAL BROCHURE

On-Site Assembly, On-Site

On-Site Assembly, On-Site

Y. SHIRASAKA, Convenor JP T. HASEGAWA, Secretary JP

Figures and Illustrations ..................................................................................................... 7

2. Survey of On-Site Assembly ................................................................................... 12

3. Survey On-Site Rebuild ........................................................................................... 66

4. On-Site High Voltage Testing.................................................................................. 88

4.2 Experience ............................................................................................................................................... 96

5. Quality Assurance ..................................................................................................108

Figures and Illustrations

Figure 4.15 - Applied voltage test setup ................................................................................................ 97

1.2 Aim and Scope

on-site high voltage testing.

2. Survey of On-Site Assembly

Figure 2.1 - Development of On-Site Assembly Transformers in Japan

2.1.2 Experience A with Core Type

Figure 2.3 - Number and Capacity of on-site assembly transformers

2.1.2.2 Construction and effect of application

2.1.2.3 On-site assembly procedure

Table 2.1 - On-site assembly transformer comparison (500 kV – 1 500 MVA)

(1) 1phase-500 MVA transformer X 3 (1) 3phase-1 500 MVA transformer X 1

Table 2.2 - Basic assembly process of on-site assembly transformer

Table 2.3 - Quality control items for on-site assembly transformer

(2) On-site assembly work procedure (Phase1) (1992~2007)

(a) Factory test (b) Core dis-assembly (c) Transport (core)

(j) Insertion of middle tank k) On-site assembly completed

(3) On-site assembly work procedure (Phase2) (2007~)

Table 2.4 - Dust-proof on-site assembly house

2.1.3 Experience B with Shell Type

Figure 2.8 - Production experience of on-site assembly transformer (Shell Form)

More than 1000 MVA

More than 500 MVA

Less than 500 MVA

Number of unit (unit)

2.1.3.2 Technology transition

Table 2.5 - Technology transition of on-site assembly transformer

Adoption of new technology Purpose/ Effect

③ Lower tank interphase arm With above ②, suppression of

① On site assembly house A factory–like work environment was

Practical use of large capacity 500 kV

① Divided transport of coil Simplified transport (Reduction of

2.1.3.3 Technology of on-site assembly transformer

Figure 2.10 - Basic structure of Shell type on-site assembly transformer

Figure 2.11 - Coil group film packing

(3) Block insertion method for leg core

Figure 2.12 - Block insertion method of core leg

(4) On-site assembly house (clean house)

Partition sheet between

Gateway partition sheet

Partition sheet for

Figure 2.13 - Panel type clean house

Dew condensation prevention

Floor surface water

Figure 2.14 - Tent type clean house

(5) Longitudinal division of upper and middle tank for transport

(6) Divided coil groups for transport

2.1.3.4 On-site assembly method and quality management

Table 2.6 - Procedure of on-site assembly and items of quality management