Document 2.4.

06, Revision 4
Medium Power Substation Transformers June 2013
Document 2.4.06, Revision 4
June 2013

Instructions
Installation, Operation, and Maintenance
of Medium Power Substation Transformers

Howard Industries
Substation Transformer Division
Document 2.4.06, Revision 4
June 2013 Medium Power Substation Transformers

IMPORTANT SAFETY INFORMATION

Read these instructions carefully before proceeding with installation, operation, or maintenance of this equipment.

Medium power transformers contain extremely hazardous voltages. To prevent death, serious personal injury, or property
damage, all information in these instructions should be read and observed. Safe use of this equipment is dependent
on proper installation, operation, and maintenance procedures.

Certain information in this manual is marked with the words DANGER, WARNING, or CAUTION. DANGER indicates an
imminently hazardous situation which, if not avoided, will result in death, serious personal injury, and property damage.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death, serious personal
injury, and property damage. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate personal injury, and property damage.

Personnel should not attempt to service this equipment until it has been completely de-energized and all high-voltage
and low-voltage bushing terminals have been properly grounded.

Only qualified personnel should install, maintain, and operate this equipment. Qualified personnel are those who are
trained in the installation, maintenance, and operation of high-voltage equipment; trained in the proper use of protective
equipment (such as rubber gloves, safety glasses, protective clothing, hard hats, etc.); and trained in appropriate first
aid procedures.

IMPORTANT INFORMATION ABOUT THESE INSTRUCTIONS

The instructions contained herein are intended to be a general guide for the installation, operation, and of Howard
Industries medium power transformers, when they are used in typical applications and are operated in normal
environments. Although efforts have been made to ensure accuracy and completeness, these instructions do not
address every conceivable application or circumstance that might be encountered. Features presented herein may
not be present in all transformer designs. Standard and optional features are subject to change without notice.

Howard Industries makes no representation or warranty with respect to and assumes no responsibility for the
completeness, accuracy, sufficiency, or usefulness of these instructions. Questions regarding installation, operation,
and maintenance (particularly when encountering unusual or special circumstances not sufficiently covered by
these instructions) should be directed to the Howard Industries Substation Transformer Division.

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 Document 2.4.06, Revision 4
Medium Power Substation Transformers June 2013

Table of contents
IMPORTANT SAFETY INFORMATION................................................................................................................................................................... 2
IMPORTANT INFORMATION ABOUT THESE INSTRUCTIONS.............................................................................................................................. 2
Receiving Inspection..................................................................................................................................................................................... 4
Impact Recorder........................................................................................................................................................................................... 4
Drawings and Documents............................................................................................................................................................................ 4
External Inspection....................................................................................................................................................................................... 4
Tank Pressure............................................................................................................................................................................................... 5
Moisture Test (for units shipped dry).......................................................................................................................................................... 5
Internal Inspection....................................................................................................................................................................................... 5
Table A: Conversion of dew point in degrees centigrade to vapor pressure in micrometers of mercury.............................................. 6
Table B: Moisture equilibrium chart showing acceptable and unacceptable moisture limits............................................................... 6
Handling........................................................................................................................................................................................................... 7
Lifting............................................................................................................................................................................................................ 7
Jacking, Skidding, and Rolling..................................................................................................................................................................... 7
Storage.............................................................................................................................................................................................................. 8
Transformer Storage.................................................................................................................................................................................... 8
Extended Storage......................................................................................................................................................................................... 8
Quarterly Inspection..................................................................................................................................................................................... 8
Annual Inspection......................................................................................................................................................................................... 9
installation.................................................................................................................................................................................................... 10
Location and Mountingw........................................................................................................................................................................... 10
Opening Transformer Tank......................................................................................................................................................................... 10
Installation of Detachable Radiators........................................................................................................................................................11
Filling Installed Radiators with Fluid.........................................................................................................................................................12
Installation of High-Voltage Bushings.......................................................................................................................................................12
Installation of Draw-Lead Bushings..........................................................................................................................................................12
Installation of Condenser Bushings..........................................................................................................................................................13
Vacuum Oil Fill Process..............................................................................................................................................................................13
Installation of Surge Arresters.......................................................................................................................................................................... 14
Installation of Air Terminal Chamber and 15kV or 5kV Switchgear Adapters........................................................................................ 14
Pre-energization Tests and Checklist........................................................................................................................................................ 14
COMPONENTS AND ACCessories.................................................................................................................................................................. 16
Transformer Nameplate............................................................................................................................................................................. 16
Control Cabinet........................................................................................................................................................................................... 16
Alarm Switch Ratings................................................................................................................................................................................. 16
Current Transformers................................................................................................................................................................................. 16
Pressure/Vacuum Gauge........................................................................................................................................................................... 16
Automatic Pressure Relief Device............................................................................................................................................................. 16
Fluid Level Gauge....................................................................................................................................................................................... 17
Fluid Temperature Gauge.......................................................................................................................................................................... 17
Winding Temperature Gauge..................................................................................................................................................................... 17
Thermal Overload Relay............................................................................................................................................................................. 17
Rapid Pressure Rise Relay......................................................................................................................................................................... 17
Transformer Cooling Fans..........................................................................................................................................................................18
De-Energized Tap Changer........................................................................................................................................................................18
Dual-Voltage or Delta/Wye Switch............................................................................................................................................................18
On-Load Tap Changer.................................................................................................................................................................................19
High-Voltage Bushings...............................................................................................................................................................................19
Low-Voltage Bushings................................................................................................................................................................................19
Surge Arresters...........................................................................................................................................................................................19
Radiators.....................................................................................................................................................................................................19
MAINTENANCE..................................................................................................................................................................................................20
Periodic Tests and Inspections..................................................................................................................................................................20
Sampling of Insulation Fluid .....................................................................................................................................................................20
Gaskets....................................................................................................................................................................................................... 21
Additional Maintenance Instructions........................................................................................................................................................ 21
Repair Parts................................................................................................................................................................................................ 21
Warranty Claims......................................................................................................................................................................................... 21

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Document 2.4.06, Revision 4
June 2013 Medium Power Substation Transformers

receiving inspection

These instructions apply to medium power transformers caused damage to the equipment. If rough handling
manufactured by Howard Industries. It is important to is indicated, this fact should be noted on the shipping
read the safety information on Page 2 before attempting documents and brought to the attention of the shipper
any installation, operation, or maintenance activities. representative and the Howard Industries Substation
Transformer Division before proceeding with inspection
Although all transformers, components, and accessories of the transformer.
are carefully inspected and tested prior to shipment,
a thorough receiving inspection should be conducted Drawings and Documents
to detect any damage or loss that might have occurred Locate all shipping papers, packing lists, outline
during shipment. The receiving inspection should be drawings, and other pertinent information. Use these
done upon receipt and before unloading from the truck documents and this instruction manual during the
or rail car. Note any damage or discrepancies on the inspection.
bill of lading and file a claim with the carrier, and notify
the Howard Substation Transformer Division prior to The transformer outline drawing indicates the locations
unloading the transformer. of nameplates and warning labels, and provides physical
dimensions and weights. The nameplate provides
Impact Recorder electrical characteristics, winding connections, and
Impact recorders are provided on all rail shipments weights. The wiring diagram provides details of control,
and on some truck shipments. An impact recorder is fan and alarm wiring.
a mechanical recording accelerometer that can record
shock and impact from all directions. The impact DO NOT REMOVE OR OBSCURE ANY WARNING LABELS
recorder records on pressure sensitive chart paper each OR NAMEPLATES.
impact that has occurred, its magnitude, direction, and
time of occurrence. These impacts are recorded through External Inspection
three independently operating styli in each of three The following external inspections should be made at a
separate axes: longitudinal, lateral, and vertical. minimum.
1. Ensure that all equipment, accessories, and
The impact recorder should be checked for evidence components listed on the bill of lading are
of possible damage to the transformer due to impacts present.
during shipment. This check should be performed prior
to unloading the transformer. A representative of the 2. Ensure that there are no signs of external
shipper should be present when the recorder is checked. damage.
Any evidence of damage should be noted on the bill of 3. Ensure that the paint finish has not been
lading and signed by the shipper’s representative before damaged.
the transformer is accepted. Consult with the Howard 4. Ensure that fittings, conduit, wiring, and other
Substation Transformer Division if shipping damage is attachments are tight and undamaged.
found or suspected. 5. Check for evidence of fluid leakage on the tank,
valves, or cooling assemblies.
Refer to the operating manual accompanying the impact
recorder for instructions explaining how to turn off the 6. Check for damage to bushings.
recorder and to interpret the chart. If it appears the 7. Check for damage to shipping crates, packages,
chart recorder stopped running before arrival at the final or other materials shipped separately from the
destination, the shutdown time should be noted and this transformer.
fact should be brought to the attention of the shipper
representative and to the Howard Industries Substation
Transformer Division.

Impacts in any axis of less than 4 G’s are considered

acceptable. Impacts in any axis of 4 G’s or greater
indicate rough handling that could potentially have

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 Document 2.4.06, Revision 4
Medium Power Substation Transformers June 2013

Tank Pressure Internal Inspection

The tank vacuum/pressure gauge may indicate positive An internal inspection of the transformer tank is
or negative when the transformer is received, depending rarely necessary and is required only when there are
on the relative fluid and ambient temperatures. This indications that the transformer has received severe
indicates that the transformer is sealed effectively. If the impact damage during transit. If an internal inspection
vacuum/pressure gauge reads zero, this may indicate is necessary, follow the instructions on Page 10 for
the possibility of a tank leak, although a zero reading can opening the transformer tank. Contact the Howard
occur occasionally with changing internal and external Substation Transformer Division before proceeding with
temperatures. In the case of a zero reading the tank any internal inspection.
should be pressure tested according to the instructions
on Page 14 (Pre-energization Tests and Checklist). It is important to follow a careful receiving inspection
Report any suspected tank leaks to the Howard program to record the condition of the transformer when
Substation Transformer Division. received and to identify the source of any damage that
may have occurred during shipping and handling. A
Moisture Test (for units shipped dry) complete inspection of the transformer and detached
The transformer core and coil assembly was thoroughly parts should be made as soon as possible to identify any
dried before shipping from the factory. Precautions such damage.
were taken to ensure that dryness is maintained during
shipment. Since it is possible that moisture could
enter the transformer tank due to mishandling or other
causes, perform a dew point test as described below to
ensure the core and coils are sufficiently dry.

A dew point measurement of the gas inside the

transformer tank can be used to estimate dryness of the
insulation system. Using this technique, it is assumed
that moisture content of the gas is in equilibrium with
the moisture content at the surface of the insulation
material.

The dew point test should be performed as described

below. The easiest way to ensure reasonable accuracy
is to take the dew point and temperature measurements
during the early morning hours, when the ambient
temperature and the insulation temperature are in
equilibrium. The gas in the transformer tank should be
at a slight positive pressure (5 PSI max.) when the dew
point measurement is made.
1. Use a dew point tester to measure the dew point
of the gas inside the transformer tank.
2. Using Chart A (Page 6), convert the dew point
measurement to vapor pressure.
3. Measure the temperature of the insulating
material.
4. Using Chart B (Page 6), estimate the moisture
content of the insulating material.
5. Moisture content above the curve is in the
acceptable range. Moisture content below the
curve is excessive and should be brought to the
attention of the Howard Industries Substation
Transformer Division before proceeding.

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Document 2.4.06, Revision 4
June 2013 Medium Power Substation Transformers

+20

+10

0
Dew Point Temperature (°C)

-10

-20

-30

-40

-50

-60

-70
10 100 1,000 10,000
Vapor Pressure (Micrometers of Mercury)

Table A: Conversion of dew point in degrees centigrade to vapor pressure in micrometers of mercury

+80

+70

+60
Insulation Temperature (°C)

+50

+40
Acceptable range is above the curve
`

+30

Unacceptable range is below the curve

`

+20

+10

0
10 100 1,000 10,000
Vapor Pressure (Micrometers of Mercury)

TABLE B: Moisture equilibrium chart showing acceptable and unacceptable moisture limits.

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 Document 2.4.06, Revision 4
Medium Power Substation Transformers June 2013

handling

Lifting
Lifting hooks are provided near the top of the
transformer tank for lifting. All four lifting hooks must be
used simultaneously. The transformer must not be lifted
from any points other than the provided lifting hooks. It
is recommended that spreader bars be used to keep
the lifting cables nearly vertical, reducing the likelihood
of tank deformation or damage to painted surfaces.
Transformers should be lifted in an upright position,
allowing no more than 15 degrees of tilt from vertical.

Jacking, Skidding, and Rolling

Jacking pads are provided at all four corners of the
transformer base for use in jacking. Do not use cooling
fins or pipes, valves, or sheet metal surfaces for jacking.
Jacking must be done from two adjacent corners
simultaneously to prevent warping of the tank bottom.
When rolling, use an adequate number of rollers to
distribute the transformer’s weight evenly. Refer to the
transformer outline drawing for the location of jacking
pads on the transformer tank.

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Document 2.4.06, Revision 4
June 2013 Medium Power Substation Transformers

storage
Transformer Storage Sidewall-mounted bushings, if exposed and not
Transformers can be stored if properly prepared. It is contained in a terminal chamber or switch enclosure,
recommended that stored transformers be completely should be protected from moisture and ultraviolet
assembled. Prior to storage, transformers should be damage with an appropriate covering. This covering
pressure tested according to the instructions on Page should be checked periodically to ensure it is intact.
14 (Pre-energization Tests and Checklist). The gas Cover-mounted bushings which are shipped separately
space above insulating fluid should be pressurized with from the transformer should be stored in a clean,
dry nitrogen to a pressure of between two to three PSIG. dry location in their original shipping cartons. These
This will prevent a negative internal pressure which bushings should be carefully inspected for damage prior
might draw moisture into the tank. Transformers not to installation on the transformer.
designed for outdoor use must be stored indoors. If
the transformer is not completely assembled, separate All space heaters (if supplied) in terminal chambers,
components and accessories should be stored in a switch cabinets, control cabinets or other enclosures,
clean dry area in their original shipping containers. must be connected and energized at all times to control
Transformer fluid containers or totes should be covered moisture. Desiccant packets may be used to control
or stored in a protected area to prevent exposure to moisture in control cabinets only, if it is not practical to
rain water or other contaminants. Condenser bushings energize the control cabinet space heater. Desiccant
should be stored in an upright position. packets must be replaced periodically to maintain
effectiveness.
Extended Storage
If the transformer is to be stored for an extended period It is recommended that the transformer be inspected
of time before being placed into service, it should periodically as described below while it is in extended
be placed on a firm level surface. The following test storage. Results should be recorded and compared with
procedure should be used prior to storage (in addition previous results to ensure that no damage or change in
to following the Receiving Inspection instructions condition has occurred.
on Pages 4 and 5 and Transformer Storage
recommendations on this page). Quarterly Inspection
1. Measure and record ambient temperature and The quarterly inspection described below should be
barometric pressure (for correction of test data). performed after the first month of storage and then
2. Pressure test the tank using the procedure on quarterly thereafter.
Page 14 (Pre-energization Tests and Checklist) 1. Inspect protective covering on sidewall-mounted
and check for fluid leaks. Following pressure bushings. Replace covering if damaged.
test, reduce tank pressure to two (2) PSIG. 2. Inspect space heaters to ensure they are
3. Test insulating fluid for dielectric strength and working properly. Inspect desiccant packets (if
moisture content. any) in control cabinets; replace if necessary.
4. Test insulation with a 1000-Volt or 2500-Volt 3. Record fluid-level and pressure/vacuum
Megger test set. (Omit if bushings have not been gauge readings. Ensure that tank pressure is
installed.) maintained at approximately 2 PSIG.
5. Measure insulation power factor using Doble or 4. Measure and record ambient temperature and
similar test set. (Omit if bushings have not been barometric pressure.
installed.) 5. If vacuum/pressure gauge or fluid level gauge
6. Measure coil ratios in each tap position to readings indicate a possible tank leak, perform
ensure proper operation of the de-energized a tank pressure test according to instructions
tap changer. (Omit if bushings have not been found on Page 14 (Pre-energization Tests and
installed.) Checklist). Any leaks found should be repaired
immediately and then rechecked during
7. Observe fluid level gauge to verify proper fluid
subsequent inspections.
level.
6. Transformer fluid containers or totes should be
visually inspected for damage and any indication
of water intrusion or other contamination.

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 Document 2.4.06, Revision 4
Medium Power Substation Transformers June 2013

Annual Inspection
The annual inspection should include the following
checks in addition to the quarterly inspection checks
listed above.

1. Check paint finish and repair any damage.

2. Test insulating fluid for dielectric strength and
moisture content.
3. Test insulation with a Megger test set. (Omit if
bushings have not been installed.)
4. Check insulation power factor with a Doble or
similar test set. (Omit if bushings have not been
installed.)
5. Transformer fluid containers or totes should be
visually inspected for damage and any indication
of water intrusion or other contamination.

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Document 2.4.06, Revision 4
June 2013 Medium Power Substation Transformers

installation

Location and Mounting If it is necessary to remove some fluid from the tank to
The transformer should be mounted on a level concrete allow for inspection or other work, the transformer must
foundation of sufficient strength to support the weight be refilled with fluid after work is completed.
of the completely assembled transformer. If the
transformer is not level, insulating fluid may not circulate Personnel should not be permitted on top or inside the
properly through the cooling assembly, possibly causing transformer while it is open unless they have emptied
overheating and reduced transformer life. The mounting all pockets and checked for loose objects that might fall
location should provide for adequate ventilation and into the tank. All tools should be accounted for after
easy access for inspection. The transformer should be work is completed. It is recommended that any tools
located at least 24 inches from any obstruction. When used on top of the transformer or inside the tank be
installing transformers designed for indoor operation, attached with safety cords to prevent them from being
adequate air inlets and outlets must be provided for lost inside the transformer.
proper cooling. Avoid locating transformers in corrosive
areas. Personnel must not stand directly on any electrical
insulation. Clean drop cloths should be used under
Opening Transformer Tank working areas in the transformer to prevent objects from
Transformers are usually shipped sealed and should not dropping into the core/coil assembly.
be opened unless necessary. Opening the transformer
will be necessary when transformers are shipped without The following procedure should be used to remove the
bushings, when internal field connections are required, manhole cover.
or when core ground tests are required.
1. Thoroughly clean the manhole cover.
DANGER: SLOWLY RELEASE INTERNAL Remove all moisture, dirt, and grease to
PRESSURE PRIOR TO REMOVING TANK avoid contaminating the transformer’s fluid
ACCESSORIES. FAILURE TO DO SO COULD RESULT compartment.
IN SEVERE PERSONAL INJURY, DEATH, OR PROPERTY 2. Relieve internal tank pressure by manually
DAMAGE. operating the pressure relief valve.
3. Remove cover fasteners.
4. Gently pry the cover upward, making sure that
DANGER: TO AVOID DEATH FROM
the cover gasket does not fall into the tank. Lift
SUFFOCATION NEVER ALLOW ANYONE TO
the cover vertically to prevent damage to cover,
ENTER THE TRANSFORMER TANK UNLESS AN
bolts, and gasket.
ANALYSIS OF THE AIR IN THE TANK SHOWS AT LEAST
19.5% OXYGEN. THE GAS SPACE IN AN OPERATING 5. Remove the gasket sections from the manhole
TRANSFORMER USUALLY CONSISTS OF NITROGEN flange. Record the location and orientation of
GAS. WHENEVER ANYONE IS IN THE TANK, A each gasket piece, so they can be reinstalled
PERSON SHOULD BE STATIONED AT THE MANHOLE correctly.
OUTSIDE THE TANK TO ENSURE SAFETY OF THE
PERSON INSIDE. The following procedure should be used to reinstall the
manhole cover.
Transformer should not remain open for more than 1. Place gasket sections in their original positions
24 hours at a time. If work is interrupted, the tank and orientations.
should be resealed, evacuated, and filled with dry air or 2. Reinstall manhole cover. Reinstall fasteners
nitrogen. and torque to 25 ft-lbs. After tightening all
fasteners, re-torque each one to ensure proper
To prevent contamination of the transformer tank, do torque.
not open the transformer in an unprotected area during
3. Remove the pressure relief valve and pressurize
inclement weather or where the air may contain dirt
the headspace and check for fluid leaks. Do not
or other particles. Either of the above could cause
exceed 7 PSIG during this test. This pressure
a transformer failure. The tank opening should be
should be maintained for at least four hours.
protected against entry of foreign matter.

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 Document 2.4.06, Revision 4
Medium Power Substation Transformers June 2013

When internal work is being done on the transformer, Installation of Detachable Radiators
dry air should be used to ventilate the inside of the tank. When radiators are shipped detached, they should be
Dry air can be obtained in high-pressure cylinders or installed according to the instructions below.
from desiccant-type air-drying equipment. When using 1. Verify that all valves on the tank are in the
dry air, the following precautions should be observed. closed position.
2. Remove shipping plates from the valves on the
1. The temperature of dry air entering the tank and from the radiator flanges. Take care
transformer should equal to or greater than the not to damage gaskets.
temperature of the transformer fluid and at least
10°F higher than the dew point of the ambient 3. Inspect for moisture and contamination
air. inside the radiator headers. Contact the
Howard Substation Transformer Division if any
2. The dry air flow should be directed so as to contamination is found.
continuously purge the transformer gas space.
4. Clean all mating surfaces on the tank valves
3. The dew point in the tank gas space should and radiator flanges and apply a small amount
never exceed 20°F. of petroleum jelly to the gaskets on the tank
valve flanges to hold them in place during
While the tank is open, the following tests should be installation of the radiators.
conducted. 5. Lift the radiators into position using the lifting
1. A ratio test should be made on all windings eyes on top of the radiators and align holes
and on each tap position. Contact the Howard in the radiator flanges with holes in the valve
Industries Substation Transformer Division if any flanges. If fans are provided, attach the
measurement is off-ratio by more than 0.5%. radiators having fans first, then attach the other
2. Insulation resistance of each winding to all radiators.
other windings and from each winding to ground 6. Insert bolts in the top and bottom flanges, with
should be measured. (Coil windings must be bolt heads adjacent to the transformer tank.
completely covered with fluid.) Record the
temperature of the fluid. These readings should 7. Tighten bolts evenly, alternating across corners,
be comparable with factory measurements. until metal-to-metal tightness is achieved at all
four corners of each flange.
3. Disconnect the core ground connection, when
accessible, on core-form transformers and
measure the resistance from the core to the
tank or end frames, using a 1000-Volt Megger
test set. The resistance should exceed 100
megohms if the core is not covered with fluid or
200 megohms if the core is covered with fluid.

When the internal inspection is complete, reseal the

tank and refill with fluid (if any was removed prior to
inspection). The gas space should be filled with dry
air or dry nitrogen. Contact the Howard Substation
Transformer Division if any internal damage is found
during the internal inspection.

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Document 2.4.06, Revision 4
June 2013 Medium Power Substation Transformers

Filling Installed Radiators with Fluid 6. Observe the fluid level gauge and ensure that
Follow the steps below to fill installed radiators with the fluid level is correct. If the level is low, add
insulating fluid. fluid to the tank.
Installation of High-Voltage Bushings
DANGER: TRANSFORMER OIL SHOULD Transformers are usually furnished with draw-lead or
ALWAYS BE HANDLED AS A FLAMMABLE FLUID. condenser type high-voltage bushings. If bushings
SEALED TRANSFORMER TANKS MAY UNDER SOME were removed prior to shipment and shipped separately
CONDITIONS ACCUMULATE EXPLOSIVE GASES, AND from the transformer, install them according to the
HANDING OF TRANSFORMERS MAY GENERATE instructions below.
STATIC ELECTRICITY. SAFETY PRECAUTIONS BEFORE
OIL-FILLING OR FILTERING SHOULD INCLUDE WARNING: DO NOT OVERSTRESS BUSHINGS
PURGING ALL GAS SPACES WITH NITROGEN AND WHEN MAKING CONNECTIONS TO AVOID
GROUNDING THE TRANSFORMER, ALL BUSHINGS, DAMAGE. DAMAGED BUSHINGS COULD CAUSE
AND ALL OIL HANDLING EQUIPMENT. FAILURE TO DO SEVERE PERSONAL INJURY, DEATH, OR PROPERTY
SO COULD RESULT IN SEVERE PERSONAL INJURY, DAMAGE.
DEATH, OR EQUIPMENT DAMAGE.

Installation of Draw-Lead Bushings

WARNING: TRANSFORMERS SHOULD NOT BE
If draw-lead type bushings are furnished, install each
LEFT UNDER VACUUM EXCEPT DURING THE
bushing as follows.
VACUUM FILLING OPERATION. THE TANK SHOULD
1. Remove the blind flange covering the bottom
BE UNDER POSITIVE PRESSURE DURING PERIODS
end of the bushing.
OF RAIN OR HIGH HUMIDITY IN ORDER TO PREVENT
MOISTURE FROM BEING DRAWN INTO THE TANK. 2. Locate and uncoil the draw lead.
FAILURE TO FOLLOW THESE PRECAUTIONS COULD 3. Install the gasket supplied with the bushing to
RESULT IN SEVERE PERSONAL INJURY, DEATH, OR the bushing boss. For cork-neoprene gaskets,
EQUIPMENT DAMAGE. apply a uniform coating of gasket cement to
the gasket area of the bushing boss and to the
Every container or tote of transformer fluid used in the bottom of the gasket. Allow cement to become
filling process should be visually inspected and tested tacky and then position gasket on the bushing
for water and other possible contaminants before boss. Then apply a thin coating of petrolatum
proceeding with the filling process. to the top surface of the cork-neoprene gasket.
For nitrile or viton gaskets, apply a thin coating
During the process do not allow the fluid level to drop of petroleum jelly to the bottom surface of the
below the top of the core and coil assembly. If the gasket and place the gasket in the center of the
fluid level in the transformer becomes too low, stop the gasket area on the bushing boss.
radiator filling procedure and add fluid to the tank before
completing the filling process.
WARNING: When applying gasket
1. Loosen the top header plugs and slowly open
cement, keep all sparks and flames
the bottom radiator valves one at a time to start
away from work area. Avoid breathing large
the flow of fluid.
quantities of vapor and avoid continuous or
2. Add fluid to the tank if necessary during the excessive contact with skin. Failure to do so
process to maintain fluid level in the tank at its could result in severe personal injury or
proper level. death.
3. After the radiators are filled, open the top
radiator valves.
4. Insert a fish wire through the bushing porcelain
4. Remove the top header plugs and reinstall them and attach the bottom end of it to the top of the
using Teflon pipe thread tape. terminal on the end of the draw lead.
5. Ensure that top and bottom radiator valves on 5. Straighten the draw lead, so that it is free of
each radiator are in the full “OPEN” position. twists and kinks.

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Medium Power Substation Transformers June 2013

6. Using the fish wire, carefully pull the draw-lead Every container or tote of transformer fluid used in the
through the bushing, taking care not to damage filling process should be visually inspected and tested
the insulation on the lead. for water and other possible contaminants before
7. Install the bushing mounting hardware and proceeding with the filling process.
fully tighten by alternately tightening opposite
corners. For bushings with porcelain flange and 1. Check all radiators to be sure the radiator valves
clamping flange, torque hardware to 8 ft-lbs. are in the open positions and to verify that all
For bushings with metal flange, tighten until the the radiator flanges are tightened.
bushing flange has contacted the bushing boss 2. Check all high voltage bushing bolt flanges and
and lock washers are flattened. all low voltage bushing bolt flanges and be sure
8. Rotate the terminal until the steel pin pressed all are properly tightened.
in the draw lead seats in the slot inside the 3. If the manhole access cover has been removed
porcelain top end. With the pin seated in the for any reason verify that the bolts securing the
groove, approximately 1/2 inch of thread should manhole cover(s) are properly tightened.
protrude above the porcelain top. If the lead 4. Connect the vacuum pump suction line to the
appears to be too short, a problem may exist tank cover fitting. If the transformer has an OLTC
that should be corrected before proceeding. then vacuum must be applied to the OLTC tank
9. Apply a thin coating of petroleum jelly to the top at the same time as the main tank is vacuumed.
surface of the terminal cap sealing gasket and Connect vacuum lines and pull a vacuum on the
press the coated surface into the gasket recess OLTC tank.
in the terminal cap. 5. Connect the oil fill line to the tank at the bottom
10. Remove the fish wire taking care to prevent drain valve connection.
the draw lead from slipping back inside the 6. Start the vacuum pump.
porcelain bushing.
7. When the vacuum level inside the tank reaches
11. Install the terminal cap on the draw lead 500 microns (500 milliTorr) start timing and
terminal and hand tighten, being careful to when this vacuum level has been maintained for
keep the steel pin seated in the slot inside the 12 hours the oilfilling may be started. Fill rate to
porcelain top. be 30 – 40 gpm.
12. Verify that the gasket is properly seated and the 8. Continue to fill until the oil fill gauge registers
terminal cap is centered on the porcelain. slightly above the 25 C oil level.
13. Torque the terminal cap to 35 ft-lbs. 9. After the oil filling has been completed continue
14. Test for gasket leaks by pressurizing the to hold the vacuum level for 1 additional hour.
transformer with dry air or nitrogen to a 10. The vacuum pump may now be stopped. Use
pressure of approximately 2-3 PSIG and dry nitrogen to vent the transformer tank.
applying a soap bubble solution.
11. After the transformer has been filled with oil
it should be allowed to sit for 24 hours before
Installation of Condenser Bushings energizing in order to allow bubbles of gas
If condenser type bushings are furnished, install them (which have been pulled out of solution by the
according to the instruction literature shipped with the vacuum filling process) to be reabsorbed by the
bushings. These instructions will cover installation oil.
maintenance, and use of the power factor test terminal. 12. At any time during the installation of the
transformer if the oil level in the transformer
Vacuum Oil Fill Process has been lowered to a level that exposes part or
This procedure is for the vacuum oil filling of a all of the coils to air, the oil must be completely
transformer. This procedure applies for transformers removed and the above procedure followed.
which have been shipped dry air filled. It also applies
if the oil level in the transformer has been lowered to
a level that exposes part or all of the coils to air at any
time during the installation of the transformer.

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June 2013 Medium Power Substation Transformers

Installation of Surge Arresters reinstalling the adapter housing, check for adequate
Surge arresters should be installed according to the electrical clearances as indicated on the outline drawing
following instructions and the outline drawing. and check tightness of connections and supports.
Complete the installation by assembling the housing.
WARNING: FAILURE TO FOLLOW THESE Install the adjustable plate and ensure proper gasket
INSTRUCTIONS COULD RESULT IN SEVERE sealing of the switchgear throat.
PERSONAL INJURY, DEATH, OR EQUIPMENT DAMAGE.
Pre-energization Tests and Checklist
1. Carefully unpack and inspect surge arresters for The following tests and checks should be performed at
damage. a minimum to ensure that the transformer is ready to
2. When installing arresters, all mounting feet be energized. Do not energize the transformer without
must be flush with the mounting surface before performing these tests and checks.
tightening bolts. Use shims if necessary.
1. Insulating Fluid Test. Draw a fluid sample and
3. Do not climb or stand on arrester. Do not place test its dielectric strength. Dielectric strength
undue mechanical stress on arrester. of new fluid should be 30 kV or greater when
4. Use only the lifting devices provided on the tested in accordance with ASTM D877.
arrester for lifting. 2. Pressure Test. Check the transformer tank for
5. Arrester exhaust ports (if supplied) must be leaks by pressurizing the tank with dry air or
oriented so that exhaust will be directed away dry nitrogen through the pressure test fitting to
from other arresters and other equipment. a pressure of 3 to 4 PSIG. Let the tank stand
under pressure for one to two hours, then
Installation of Air Terminal Chamber and examine the tank and fittings for leaks. Leaks
above the fluid level can be detected by applying
15 KV and 5 KV Switchgear Adapters soap solution to all welds, joints, pipe fittings,
Air terminal chambers are designed to protect
and cable connections. Upon completion of this
personnel from high voltages and to provide a clean, dry
test, reduce the internal pressure to 1 or 2 PSIG.
environment for bushings. Air terminal chambers must
be installed according to instructions on the drawing. 3. Insulation Megger Test. Perform a 1000-Volt
Refer to transformer outline drawing, detail drawing, and Megger test and a power factor test to ensure
station plan drawing. that none of the windings is grounded.
4. Ratio Test. Perform a ratio test at each tap
WARNING: IMPROPER INSTALLATION OF position to ensure that transformer coil ratios
CONNECTING CHAMBERS AND ADAPTERS and tap changer connections are correct.
MAY ALLOW WATER OR OTHER CONTAMINANTS 5. Continuity Test and Resistance Test. Perform
TO CONTACT LIVE PARTS, POSSIBLY RESULTING IN a continuity check on each winding. Measure
SEVERE PERSONAL INJURY, DEATH, OR PROPERTY the winding resistance of each winding and
DAMAGE. compare results to factory test values. An
increase of more than 10% could indicate a
loose internal connection.
Securely attach the flexible connectors to the switchgear
6. Line Connections. In preparation for making
bus bars (The number of flexible connectors supplied
line connections, check to make sure that
is determined by the transformer current and not
all mating connector surfaces are clean and
by the current rating of the bus bar.). Check the
smooth. Connections must be tightened
length of flexible connectors and ensure that there is
appropriately to prevent overheating and
approximately 0.375 inch (10 mm) of slack. This will
possible subsequent failure of the connection.
permit some movement of the bus bars to allow for
Connections to should be made with care to
expansion and contraction and possible settling of the
avoid placing undue stress on the bushings.
transformer. Securely attach the ground bus connection
Refer to bushing connection information on
between the transformer and switchgear. Before
Pages 12 and 13.
7. Tap Changer Setting. Check the tap changer
setting to ensure it is set to the proper position
for the required voltage.

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 Document 2.4.06, Revision 4
Medium Power Substation Transformers June 2013

8. Delta/Wye and Series/Multiple Switch Settings.

Check delta/wye and series/multiple switch
settings to make sure they are set correctly. If
these connections are made using an internal
terminal board, check to ensure that these
connections are made properly according to
the chart on the transformer nameplate. If
the transformer is equipped with an internal
terminal board, refer to Page 10 for instructions
and warnings prior to opening tank.
9. Grounding. Check to ensure that the
transformer tank is permanently and effectively
grounded. The transformer tank ground pad is
located near the bottom of the tank.
10. Wiring. Check wiring of control and alarm
circuits (if provided) to make sure there are no
loose connections and no damage to insulation.
11. Fluid Level. Check to make sure the fluid
level as indicated by the fluid level gauge is as
indicated on Page 17.
12. Tank Finish. Check all painted surfaces to
make sure that there is no damage or corrosion.
13. Bolted Connections. Check all bolted
connections for tightness.
14. Tools. Check to make sure that all tools and
equipment are accounted for and have been
removed from the transformer.
15. Fluid Temperature. Read the fluid temperature
gauge and make sure the temperature is no
lower than minus 20°C before the unit is
energized.

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Document 2.4.06, Revision 4
June 2013 Medium Power Substation Transformers

Components and accessories

Refer to the outline drawing for a list of accessories Pressure/Vacuum Gauge

furnished with the transformer. The pressure/vacuum gauge indicates the pressure in
the tank gas space relative to atmospheric pressure.
Transformer Nameplate The pressure will normally vary as a function of
A nameplate is supplied on each transformer according transformer temperature. If the transformer is lightly
to ANSI standard C57.12.00. The nameplate provides loaded or de-energized during times of low ambient
certain physical and electrical information about the temperature, the gauge may indicate a negative
transformer. pressure.

Control Cabinet Pressure/Vacuum gauges can be supplied with an

Refer to the wiring diagram for a description of electrical optional alarm/signal switch. Refer to the schematic
circuits inside the control cabinet. Use caution when wiring diagram furnished with the transformer.
testing alarm switches to prevent damage to the switch.
WARNING: IF THE PRESSURE/VACUUM
GAUGE CONSTANTLY READS ZERO UNDER
DANGER: THE CONTROL CABINET VARYING LOAD AND AMBIENT CONDITIONS,
CONTAINS DANGEROUS VOLTAGES. DE- THE TRANSFORMER SHOULD BE CHECKED FOR
ENERIGZE THE CONTROL CABINET VOLTAGE A POSSIBLE TANK LEAK. A LEAK WILL ALLOW
SUPPLY PRIOR TO PERFORMING WORK INSIDE THE MOISTURE AND AIR TO ENTER THE TRANSFORMER,
CONTROL CABINET OR ON EXTERNAL ACCESSORIES WHICH COULD DEGRADE THE INSULATION AND
CONNECTED TO EQUIPMENT WITHIN THE CONTROL FLUID. LEFT UNREPAIRED, LEAKS COULD LIMIT
CABINET. FAILURE TO DO SO COULD RESULT IN TRANSFORMER LIFE OR CAUSE A VIOLENT FAILURE
SEVERE PERSONAL INJURY, DEATH, OR PROPERTY THAT COULD RESULT IN SEVERE PERSONAL INJURY,
DAMAGE. DEATH, OR EQUIPMENT DAMAGE.

Alarm Switch Ratings Automatic Pressure Relief Device

When control wiring or alarm contacts are provided, refer Medium power transformers are usually furnished with
to the control wiring diagram, or the outline drawing for a weatherproof, cover-mounted automatic pressure
contact type, contact ratings, and terminal locations. relief device (PRD) to relieve excessive tank pressures
that might occur during operation of the transformer.
Current Transformers The device consists of a self-resetting, spring-loaded
Current transformers (if provided) are mounted inside diaphragm and a visual indicating flag. When gas
the transformer tank around the transformer line leads. pressure in the tank exceeds the PRD’s specified limit,
For cover-mounted bushings, current transformers are the gas pressure will open the diaphragm, vent the
located underneath the transformer cover. For tank-wall excess pressure, and trip the visual indicating flag.
mounted bushings, current transformers are usually
located on top of the core and coil assembly. Current After the internal pressure decreases below the PRD
transformer leads are always terminated inside a reseal rating, the valve will automatically close and
junction box. Refer to the transformer wiring diagram to reseal the transformer. The visual indicating flag must
identify the wire markings. Current transformer leads be manually reset. The cause of PRD activation should
are always shorted and grounded to the tank at the always be investigated, since pressure venting indicates
factory before shipment. a potential problem inside the transformer.
WARNING: CURRENT TRANSFORMER
SECONDARIES MUST BE CONNECTED TO A
LOAD OR SHORT CIRCUITED TO AVOID DAMAGING
VOLTAGES AT THE TERMINALS. FAILURE TO MAKE
THESE CONNECTIONS COULD RESULT IN SEVERE
PERSONAL INJURY, DEATH, OR PROPERTY DAMAGE.

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 Document 2.4.06, Revision 4
Medium Power Substation Transformers June 2013

WARNING: DO NOT ATTEMPT TO Winding temperature gauges can be supplied with an

DISASSEMBLE A PRESSURE RELIEF DEVICE. alarm/signal switch. Refer to the schematic wiring
TO DO SO COULD RESULT IN EQUIPMENT DAMAGE diagram furnished with the transformer.
AND SEVERE PERSONAL INJURY.
Thermal Overload Relay
PRD’s can be supplied with an optional alarm/signal Transformers may be supplied with a thermal overload
switch. Refer to the schematic wiring diagram furnished relay, which is similar in operation to the winding
with the transformer. temperature gauge described above. The relay provides
alarm/signal contacts that close at approximately 100%
Fluid Level Gauge and 110% rated load.
The fluid level gauge indicates the fluid level inside the
tank. The transformer tank is filled with fluid at the Rapid Pressure Rise Relay
factory to the normal level at a reference temperature of The optional Rapid Pressure Rise Relay (RPRR) monitors
25°C. the rate of pressure rise in the transformer’s gas space
and signals when the rate exceeds a safe threshold.
Fluid Temperature Gauge This signal can trigger circuit breaker operation to de-
The fluid temperature gauge indicates the fluid energize the transformer and can send an alarm. The
temperature at the top of the fluid column. The RPRR will not be actuated by normal pressure variations
temperature gauge is mounted in a dry, leak proof during operation of the transformer. A seal-in relay
well, permitting removal of the gauge without lowering latches the output relay and illuminates an indicator
the fluid level in the tank. The gauge is furnished with lamp until the unit is manually reset. The seal-in relay
a resettable drag-hand pointer which indicates the and associated circuitry is mounted in a separate control
maximum temperature reached since it was last reset. cabinet.
The drag-hand can be reset by rotating the magnet at
the center of the dial or, on some models, by pressing a If the RPRR has activated, internal arcing has likely
reset button. occurred in the transformer tank, and the cause of such
arcing must be investigated. The following steps are
During normal operation the fluid temperature suggested to determine the extent of damage to the
gauge should read less than the sum of the ambient transformer, in any.
temperature and the rated temperature rise. For
example, a 50°C gauge reading at an ambient 1. Using a combustible gas detector, check for
temperature of 25°C yields a top oil temperature of combustible gas products of decomposition
75°C, which is below the transformer’s 85°C rated in the gas space. Refer to the operating
temperature rise. instructions that came with the gas detector.
2. Test the RPRR and seal-in relay panel to make
Winding Temperature Gauge sure they are operating properly. Refer to
Transformers may be furnished with a gauge that instructions furnished with RPRR and seal-in
displays estimated winding hot-spot temperature. The relay panel.
gauge uses a probe that measures the temperature of 3. Test for insulation power factor, insulation
the transformer fluid plus auxiliary heat from a heating resistance tests, and transformer turns ratio.
element that is energized by a current transformer 4. Remove the manhole cover and inspect the tank
mounted inside the transformer tank. interior for appearance and smell. (A burning
odor may be present.)
The gauge’s temperature probe is mounted in a dry well,
5. Make any other tests which may be appropriate
permitting removal of the gauge without lowering the
considering results of the tests listed above.
fluid level. The gauge is furnished with a resettable drag-
hand pointer that indicates the maximum temperature
reached since it was last reset. The drag-hand can be
reset by rotating the magnet at the center of the dial, or
on some models, by means of a pushbutton.

17
Document 2.4.06, Revision 4
June 2013 Medium Power Substation Transformers

Transformer Cooling Fans De-Energized Tap Changer

Optional cooling fans may be provided to increase The de-energized tap changer may be used to adjust the
the transformer load capability without overheating voltage ratio of a transformer while it is de-energized.
the transformer windings. Operation of the fans is It is intended to allow adjustment of the output
controlled by a contact in the fluid temperature gauge (secondary) voltage to the rated value. Do not use the
or winding temperature gauge (when furnished) and tap changer to raise or lower the output voltage to any
by an “auto/manual” control switch. Controls for the voltage other than that indicated on the transformer
fans are contained in a control cabinet mounted on the nameplate. If the tap changer is set to provide an output
transformer. voltage different from rated voltage, a high noise level,
high core loss, and core saturation may result.

DANGER: ALWAYS DE-ENERGIZE THE FAN DANGER: DO NOT OPERATE A DE-ENERGIZED

CIRCUIT WHEN INSTALLING OR PERFORMING TAP CHANGER UNLESS THE TRANSFORMER IS
MAINTENANCE ON FANS. IN ADDITION, DE-ENERGIZE TOTALLY DE-ENERGIZED. FAILURE TO DO SO WILL
THE TRANSFORMER WHEN IT IS POSSIBLE TO COME RESULT IN DAMAGE TO THE TRANSFORMER AND
CLOSE TO ELECTRICALLY CHARGED/LIVE PARTS. COULD RESULT IN SEVERE PERSONAL INJURY OR
FAILURE TO DO SO COULD RESULT IN SEVERE DEATH. DO NOT RE-ENERGIZE THE TRANSFORMER
PERSONAL INJURY OR DEATH. FAN GUARDS ARE UNLESS THE TAP CHANGER IS FIRMLY LOCKED INTO
FURNISHED AND INSTALLED AT THE FACTORY TO POSITION.
PREVENT ACCIDENTAL CONTACT WITH ROTATING FAN
BLADES. DO NOT REMOVE FAN GUARDS OR ALLOW The tap changer is operated by use of a rotating
PERSONNEL TO REACH INSIDE A GUARD. Doing so handle located on the outside of the transformer tank.
can result in serious personal injury and Never operate a de-energized tap changer while the
equipment damage. transformer is energized. Tap changers normally have
five or seven tap positions as indicated on the tap
The auto/manual switch determines the mode of changer dial plate and the transformer nameplate. A
operation for the fan motors. When the switch is in locking mechanism is provided to lock the tap changer
the “manual” position, fans will operate continuously. in position and prevent accidental operation. Do not
When the switch is in the “auto” position, fans will re-energize the transformer until the tap changer is firmly
be automatically controlled by contacts in the fluid locked into a tap position.
temperature gauge or winding temperature gauge.
Refer to the schematic wiring diagram provided with the The transformer is shipped from the factory with the tap
transformer. changer in the rated voltage position, unless otherwise
specified by the customer.
Fan motors are provided with thermal overload
protection. The overload protection is usually contained
within the motor. However, if the motors are located in a
Dual-Voltage or Delta/Wye Switch
Transformers designed with dual-voltage windings or
hazardous location, the overload protection device may
reconnectable delta/wye windings as indicated on the
be located in the control box. Refer to the wiring diagram
nameplate are provided with a de-energized two-position
provided with the transformer.
dual-voltage or delta/wye switch. The transformer must
Fan motors have permanently sealed ball bearings
be completely de-energized before operating the switch.
and do not normally require maintenance, except as
If the transformer is not de-energized before operating
explained on Page 20.
the switch, permanent damage will result.
When fan assemblies are installed by the user, it
WARNING: DO NOT OPERATE DUAL-VOLTAGE OR
is important to permanently remove the drain plug
DELTA/WYE SWITCH UNLESS THE
from the motor housing of each motor. This will allow
TRANSFORMER IS TOTALLY DE-ENERGIZED.
condensation to drain from the motor housing.
FAILURE TO DO SO WILL RESULT IN DAMAGE TO THE
TRANSFORMER AND COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH. DO NOT RE-ENERGIZE
THE TRANSFORMER UNLESS THE DUAL-VOLTAGE
OR DELTA/WYE SWITCH IS FIRMLY LOCKED INTO
POSITION.

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 Document 2.4.06, Revision 4
Medium Power Substation Transformers June 2013

On-Load Tap Changer Radiators

Some transformers are provided with an on-load tap Transformers are furnished with radiator assemblies
changer that can change taps while under load, thereby (usually panel type) to dissipate heat from the
regulating the output voltage. A user-programmable transformer. Cooling fans may also be furnished to
control unit automatically operates the on-load tap provide additional loading capability without overheating
changer to maintain the selected output voltage. Refer the transformer. Radiator assemblies may be shipped
to the manual provided with the on-load tap changer for separately from the transformer to reduce the shipping
warnings and for operating and maintenance size of the transformer and to prevent damage. When
instructions. radiators are shipped unattached, they should be
installed in the field according to the instructions on
High-Voltage Bushings Pages 11 and 12.
Transformers are normally supplied with draw-lead
or condenser type high-voltage bushings. If bushings
were removed for shipment, install draw-lead bushings
according to instructions found on Pages 12 and 13,
and install condenser-type bushings according to
instructions furnished with the transformer.

WARNING: DO NOT EXCEED THE CANTILEVER

LOAD RATING OF THE BUSHING. GREATER
LOADS MAY CAUSE BUSHING DAMAGE THAT COULD
RESULT IN SEVERE PERSONAL INJURY, DEATH, OR
PROPERTY DAMAGE.

Draw-lead bushings usually require no maintenance

except as described on Page 20. Maintenance
instructions for condenser-type bushings are furnished
with the bushings.

Low-Voltage Bushings
Transformers are normally supplied with cast resin or
porcelain draw-lead bushings. These bushings usually
require no maintenance except as recommended on
Page 20.

Surge Arresters
Transformers may be furnished with optional distribution
class, intermediate class, or station class surge
arresters. Arresters are shipped separately from the
transformer to prevent damage. Upon delivery, unpack
the arresters and carefully inspect them for damage,
especially the porcelain components. Install surge
arresters according to instruction found on Page 14.

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Document 2.4.06, Revision 4
June 2013 Medium Power Substation Transformers

MAINTENANCE

4. Paint finish (annual). Inspect the paint finish for

DANGER: THE TRANSFORMER MUST BE
damage or weathering that exposes the primer
DE-ENERGIZED BEFORE BEGINNING ANY
coat or bare metal. Repair any paint damage
MAINTENANCE WORK. FAILURE TO DO SO COULD
that might be found.
RESULT IN SEVERE PERSONAL INJURY, DEATH, OR
PROPERTY DAMAGE. 5. Fluid dielectric test (annual). Sample the
insulating fluid as described below. The
dielectric strength of the insulating fluid should
It is the responsibility of the owner to inspect, maintain, measure at least 26 kV.
and keep the transformer in proper operating condition. 6. Bushing and surge arrester insulators (annual).
Report all failures during the warranty period to the Bushing and surge arrester insulators should be
Howard Substation Transformer Division. All warranty clean. If the surfaces are excessively dirty, they
repairs must be made or approved by the Howard should be cleaned while the transformer is not
Substation Transformer Division. energized.
7. Bushing terminals (one month after initial
WARNING: TANK LEAKS MUST BE REPAIRED energization and annually thereafter). If the
IMMEDIATELY UPON DISCOVERY. FAILURE TO transformer is energized and under load,
DO SO COULD RESULT IN SEVERE PERSONAL INJURY, measure bushing terminal temperatures
DEATH, OR PROPERTY DAMAGE. using an infrared scanner. Excessive bushing
terminal temperature indicates a loose or dirty
connection. If the transformer is not energized,
Periodic Tests and Inspections use a torque measuring device to make sure
The following periodic tests and inspections are terminal connections are tight.
recommended for routine maintenance of the
transformer.
1. Gauge readings (one month after initial
Sampling of Insulating Fluid
Transformers are filled with insulating fluid, which
energization and annually thereafter). Gauge
provides electrical insulation within the transformer
readings, ambient temperature, and kVA
tank and transfers heat generated in the coils to the
load should be measured and recorded. Any
tank wall and radiators. The fluid is either conventional
abnormal reading suggests that further
transformer oil (mineral oil), Envirotemp® FR3 fluid, or
diagnostic testing or inspection should be
silicone fluid.
done. If pressure/vacuum gauge and/or
fluid level gauge readings suggest a possible
Periodically check the transformer for proper fluid level
tank leak, perform a pressure test according
by reading the fluid level gauge. Add fluid if necessary.
to instructions found on Page 14 (Pre-
When adding fluid, add only the same type fluid that is in
energization Tests and Checklist). Tank leaks
the transformer.
must be repaired immediately to prevent serious
damage to the transformer and danger to life.
It is also recommended that a fluid sample be drawn
2. Cooling fans (annual). Check the cooling fans annually and tested for dielectric strength. Samples
(if any) by setting the fan “auto/manual” control should be drawn from the bottom of the tank. Use
switch to the “manual” position. The fans proper sampling procedures to prevent erroneous test
should rotate at full speed within approximately results. Dielectric strength should measure 26 kV
five seconds. The fans should rotate smoothly minimum.
with minimal vibration.
3. Control wiring (annual). Control wiring should be
checked to insure that wire insulation is in good
condition. The control cabinet and associated
conduit should be inspected to ensure that
weather seals are intact. Control power supply
voltage should be checked and compared to the
voltage stated on the wiring diagram.

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 Document 2.4.06, Revision 4
Medium Power Substation Transformers June 2013

Gaskets
Visually check all gaskets for cracking or other signs of
deterioration. Replace as necessary. When replacing
a gasket carefully clean mating surfaces to remove any
rust, dirt, transformer fluid, old gasket material, or other
contamination that might prevent a good seal. Use an
appropriate gasket cement when installing new gaskets.
Do not reuse old gaskets. Six months after replacing a
gasket, check and retighten if necessary.

Additional Maintenance Instructions

Contact the Howard Substation Transformer Division for
additional maintenance instructions.

Repair Parts
Repair parts can be ordered from the Howard Substation
Transformer Division. A description of the part and the
transformer serial number will be required to ensure that
the correct part has been ordered.

Warranty Claims
The Howard Substation Transformer Division should
be notified immediately when problems are discovered
during the warranty period. All warranty repairs must be
made or approved by the Howard Substation Transformer
Division.

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Document 2.4.06, Revision 4
June 2013 Medium Power Substation Transformers

NOTES

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 Document 2.4.06, Revision 4
Medium Power Substation Transformers June 2013

NOTES

23
Document 2.4.06, Revision 4
June 2013 Medium Power Substation Transformers

Instructions for Installation, Operation, and Maintenance

of Medium Power Substation Transformers

Document 2.4.06, Revision 4 (June 2013)

Copyright © 2013, Howard Industries, Inc.
Laurel, Mississippi
Telephone: 601-425-3151
Fax: 601-649-8090
Web: howardtransformers.com