Vendor Print For Generator Step-Up Transformer

DOCU. NO.
:
3x15MW WAMPU HEPP PROJECT 1009-4261-PE-352-001
Rev. No. : 0
GENERATOR STEP UP TRANSFORMER
TITLE
SPECIFICATION & DATA SHEET Page. No : Cover

SPECIFICATION & DATA SHEET
DISCIPLINE : Electrical
PROJECT NAME : 3×15MW WAMPU HEPP PROJECT
DOCU. NO. :
Rev. No. : 0
TITLE
SPECIFICATION & DATA SHEET Page. No : 1 / 15

SPECIFICATION & DATA SHEET
For Construction
0 27/11/13 FOR CONSTRUCTION H.G.RYU K.D.KANG. T.H.YOON W.C.JEONG
REV.
DATE DESCRIPTION PREP'N CHECK REVIEW APPROVAL
NO.
REV.
HYOSUNG PREPARATION CHECK REVIEW APPROVAL
NO.
H.G.RYU K.D.KANG T.H.YOON W.C.JEONG

FOR
0
CONSTRUCTION
27/11/13 27/11/13 27/11/13 27/11/13
12-HSM-03621 For Construction
For Construction HYOSUNG Spec. No. : 12-HSM -03621
SPECIFICATION FOR
POWER TRANSFORMER
Item Description Q’ty
3Ph 50Hz 15/20MVA 150/11kV YNd1

1 3 set
w/OLTC on HV ONAN/ONAF
□ Project Name : POSCO Engineering / WAMPU HWPP PJT
Specification
□ : 12-HSM-03621-01
Number
Head Office : 450 Gongduk-Dong, Mapo-Ku, Seoul, Korea 121-020/Tel.+82-2-707-6927/Fax.+82-2-707-6449

Changwon Plant : 454-2 Nae-Dong, Changwon, Korea 641-712/Tel.+82-55-268-8188/Fax.+82-55-268-9839
1 Printed in KOREA Nov, 2013

Contents
Section I. General
1. General scope
2. Applicable standard
3. Service ambient conditions
4. Construction
5. Conservators
6. Painting
7. Packing and shipment
8. Tests
Section II. Technical Information
1. Technical Data Sheets for Generator Step up Transformer

Section I. General
1. General scope
3. Service ambient conditions
4. Construction
5. Painting
7. Tests

1. General Scope
This specification describes three phases, oil immersed, On-load tap changing transformers
suitable for outdoor installation under the service conditions mentioned herein and the
information about the following power transformer which will be supplied by HYOSUNG.
Item Description Q’ty
3Ph 50Hz 15/20MVA 150/11kV YNd1

1 3 set
w/OLTC on HV ONAN/ONAF
Electrical equipment covered by this specification will be complied with the following standards.
2.1. IEC (International Electro-technical Commission)
2.2. NEMA (National Electrical Manufacturers Association)
3. Service conditions
These transformers are suitable for operation under the following service conditions
3.1 Ambient temperature

▪ Maximum 38.0℃
▪ Minimum 17.6℃
3.2 Annual Mean Relative humidity Up to 100%
3.3 Altitude of site Up to 1000m

4. Construction
4.1 Core
The core consists of three column, parallel, laminated cold-rolled and non-aging silicon-steel
having high permeability and low hysteresis loss.
The steel sheet is thoroughly coated on both sides of each sheet with insulation to reduce eddy
current losses to minimum levels.
Structural rigidity is given to the core by the use of steel plates at the top and the bottom of the
core. So that distortion due to short circuit stresses or transport handling is prevented.
4.2 Windings
Coils are designed and manufactured to withstand impulse voltage and prevent it from distortion
when a short circuit occurs.
Permanent current carrying joints or splices will be welded or clamped, formed, finished and
insulated to avoid concentration of dielectric stresses.
The conductors will be transposed at sufficient intervals to minimize currents and equalize the
current and temperature distribution along the winding.
The conductor material is copper.
4.3 Tank
The transformer is provided with a suitable steel tank of substantial construction which is
oil-tight and gas-tight. All gaskets are made of materials which do not deteriorate under service
conditions.
The tank has sufficient strength to withstand an internal pressure of full vacuum and vacuum
drying without damage or permanent deformation. The transformer tank is provided with
manholes and hand holes of suitable size to afford easy access to the lower ends of bushing
terminals, upper portions of the coils and side position of tap changer.
In the case of core-form transformer the joint between the tank and cover is provided with
suitable flange and gaskets at top of the tank so that the assembly service is oil-tight and
gas-tight. The transformer is provided with lugs for lifting the essential parts also for lifting the
completely assembled transformer filled with oil.

4.4 Radiator
The HYOSUNG radiator is an efficient cooling unit designed for use on large transformers
requiring a self cooling rating. The radiator is detachable and is removed from the transformer
for shipment. The radiator is mounted to the tank directly or separately.
The radiator is all welded sheet metal construction with vertical cooling sections through which
the oil circulates and cools. A formed metal header is welded to each end of the vertical fin
sections. Plugs are fitted at the top and at the bottom of each radiator for filling, draining and air
releasing.
4.5 Forced air fan

The fan assembly is designed specially for use with HYOSUNG radiators. Groups of fan are
mounted on the side of a radiator bank and provide forced air circulation through the continuous
ducts formed by the parallel mounting arrangement of the radiators.
The fan assembly consists of a fractional horsepower motor and specially designed Stainless fan
blade and guard.
The motor is mounted on a steel wire form bracket which also service as a guard for the fan
blade.
4.6 Conservator
In air seal cell type conservator, the oil surface is completely isolated from the atmosphere by
installing an oil-resistant rubber cell in the interior of the conservator, so that atmospheric
pressure is always maintained without the necessity of employing intervening mediums.
The outside of the rubber cell attached on the inside of the conservator is filled with insulating
oil. The inside is open to the atmosphere through the silica gel breather.
(Refer to the Figure 1.)
Namely, during the operation the insulating oil is always isolated from the air by the oil-resistant
rubber and there is no oxidation or moisture contamination of the oil at all.
And this type conservator allows also the main tank to remain full oil level despite of oil
expansion and contraction with temperature changes.
A pipe connection between the lowest part of the conservator and the cover of main tank permits
the gas from main tank to pass into the conservator through Buchholz relay, so that the
transformer tank will be completely filled with oil.

Figure 1. Structural diagram of Air Seal Cell Conservator
This type oil preservation system is an ideal device for maintaining the optimum dielectric strength
of insulating oil.
High tension, large capacity transformer in which this system is adopted are highly reliable
and ideal units.

5. Painting
All surfaces are thoroughly cleaned by shot blasting before painting.
Rough surfaces are filed and all surfaces liable to rust are painted with a priming coat immediately
after cleaning followed by two further coats oil resisting and weather resisting paint of good quality.
5.1 Paint
- Main tank, Conservator
Description Inside Outside

Type of paint Poly Urethane
Primer coat Dry film thickness 40 ㎛ ↑ 40 ㎛↑
Color Red Brown Red Brown
Type of paint Acrylic Urethane
Intermediate coat Dry film thickness N/A 80 ㎛↑

Color Yellowish grey
Type of paint Acrylic Urethane
Top coat Dry film thickness 40 ㎛↑ 40 ㎛↑

Color White Pebble Gray(N 6.5)
Total film thickness 80 ㎛↑ 160 ㎛↑

The transformers are shipped without oil. Instead of oil, the tank is filled with N2 gas or dry air.
A pressure gauge and stop valve are provided, so as to enable the pressure of the inert gas within the
tank to be read before installation at the site.
All openings for transformer components, (e.g. bushings which have been removed from the
transformer during transport) are covered by means of blanking off plates. All parts are carefully
packed for transport in such a manner that they are protected against mechanical injury and
injurious effects of climatic conditions encountered during transit to their destination, as well as
during long storage before erection.

7. Tests
The following test items will be performed according to the latest IEC standard 60076
after completion of assembling.
1. Dimension & Construction Check

2. Winding Resistance Measurement
3. Winding Insulation Resistance Measurement
4. Winding Turn Ratio Check
5. Phase Relationship Check
6. No-Load Loss & Exciting Current Measurement
7. %Impedance Voltage & Load Loss Measurement
8. Sound Level Measurement
9. Temperature Rise Test
10. Lightning Impulse Test
11. Applied Potential Test
12. Induced Potential & PD Measurement
13. Insulation Power Factor (DOBLE) Test
14. Leakage Test
15. Control Panel, Auxiliary Equipment & Wiring, CT Tests
16. Auxiliary Losses Measurement
17. Dissolved Gas-in-Oil Analysis Test
18. Zero Sequence Impedance Test
19. Curve of insulation resistance vs. top oil temperature on all windings
20. Sweep frequency response analysis
21. Painting inspection
22. Shipping preparation Inspection
23. Bushing & Accessories Test*(See Note below)
--------------------------------------------------------------------------------------------------------
Note : The test marked *, are not tested separately during the transformer factory test.
Instead of HYOSUNG’s factory test, the test report will be submitted by its maker.
But The functional tests will be done at factory.

Section II. Technical Information

Generator Step up & Unit DOC. NO. REV. NO. PAGE
Transformers 1009-4261-PE-352-001 0 1/4
1) Manufacturer HYOSUNG
2) Design standard IEC
3) Number of windings 2
4) Rated power, ONAN / ONAF, MVA 15 / 20
5) Rated frequency, Hz 50
6) Rated voltages
a) HV, kV 150
b) LV, kV 11
7) Vector group reference YNd1
8) Material of insulation (Thermal class A) Insulation paper
9) Type of cooling ONAN / ONAF
10) Winding temperature rise at average ambient 45
temperature of yearly average (20℃), ℃
11) Maximum hot spot temperature rise at average ambient

temperature of yearly average (20℃), ℃ 58
12) No load losses at rated voltage and ratio, kW 21
13) Load losses at 75 ℃ at rated voltage Ratio, kW 107
14) Total losses at 75 ℃ at rated voltage ratio, MVA 128
15) Efficiency at rated voltage ratio and unity
Power factor, % 99.36

16) Impedance voltage at 75 ℃ at rated voltage and power
(including all tolerances), % 10.67 ± 0.8
17) Impedance voltage at 75 ℃ at each end of tapping
range at rated power (including all tolerances)
a) At maximum voltage ratio, % 11.5 (reference only)
b) At minimum voltage ratio, % 10.6 (reference only)
18) Types and arrangement of windings
Transformers 1009-4261-PE-352-001 0 2/4
a) HV Shielded Continuous
b) LV Double Continuous
c) Tapping Continuous
d) Arrangement (e.g. Core/LV/HV/taps) Core/LV/HV/taps
19) Conductor material
a) HV windings copper
b) LV windings copper
c) Tapping windings copper
20) Conductor insulation
a) HV windings Insulation paper
b) LV windings Insulation paper
c) Tapping windings Insulation paper
d) Connecting leads from winding to tap changer Insulation paper
21) Basic Impulse Insulation Level (BIL) of Windings, kV
a) HV windings 650
b) LV windings 150
c) Neutral winding 95
22) Type of axial coil supports
a) HV windings R-spacer
b) LV windings R-spacer
c) Tapping windings R-spacer
23) Materials used
a) Axial supports and blocks Pressboard
b) Intermediate coil spacers Pressboard
24) Type of major insulation between windings Pressboard
25) Type of impregnate used on insulation Pressboard
26) Core construction
a) Limbs (Flux density), tesla Approx. 1.7T
Transformers 1009-4261-PE-352-001 0 3/4
b) Yokes (Flux density), tesla Approx. 1.7T

c) Number of limbs 3
d) Number of limbs wound 3
27) Tapings (OLTC)
a) Size of steps as percentage of winding
rated voltage, % 1.25
b) Number of steps 17
28) Total mass of complete transformer, tones 51.2
29) Overall dimensions, m x m x m 7555 x 4705 x 5570
30) Mass as arranged for transport, tones 33.5
31) Dimensions as arranged for transport, m x m x m 5865 x 2550 x 2760
32) Quantity of oil, Liter 14000
33) Maximum noise level, dB(A) @1m 85
BUSHING
34) Basic Impulse Insulation Level (BIL), kV
a) HV Bushing 750
b) LV Bushing 150
c) Neutral Bushing 250
CURRENT TRANSFORMER
35) Rated primary voltage, KV ; HV side 150
LV side 11
36) Rated short time withstand current (1sec), kA
37) Current ratio
a) HV side -
b) LV side -
c) HV Neutral 100/1A
38) Accuracy class
a) For instrument 5%
Transformers 1009-4261-PE-352-001 0 4/4
b) For protection 5%
39) Burden, VA
a) For instrument 30VA
b) For protection 30VA
EARTHING SWITCH
40) Nominal voltage, kV N/A
41) Rated voltage, kV
42) Rated frequency, Hz
43) Rated current , A
45) Lightning impulse withstand voltage, kV
46) Power frequency withstand voltage, kV
SURGE ARRESTER
47) Type N/A
50) Lightning impulse withstand voltage (peak), kV
DOCU. NO. :
Rev. No. : 0
TITLE SUB VENDOR LIST
Page. No : Cover
SUB VENDOR LIST
DOCU. NO. :
Rev. No. : 0
Page. No : 1 / 2
SUB VENDOR LIST
For Construction
REV.
NO.
REV.
NO.

FOR
0
CONSTRUCTION
27/11/13 27/11/13 27/11/13 27/11/13
DOCU. NO. :
Rev. No. : 0
Page. No : 2 / 2
▪ TRANSFORMER SPEC. : 3ph 50Hz 150/11kV 15/20MVA ONAN/ONAF OLTC on HV side
No. Description Type(Model) Maker Remark
1 HV BUSHING COT750-800 TRENCH(FRNACE)
2 HVN BUSHING COT250-800 TRENCH(FRNACE)
3 XV BUSHING 24-1250/P3 CEDASPE(ITALY)
4 BUCHHOLZ RELAY EE3-MA CEDASPE(ITALY)
WINDING TEMPERATURE
5 INDICATOR MT-ST160F MESSKO(GERMANY)
OIL TEMPERATURE
6 INDICATOR MT-ST160W MESSKO(GERMANY)
7 OLTC VMIII 300Y MR(GERMANY)
8 OLTC PROTECTIVE RELAY RS-2001 MR(GERMANY)
9 OLTC MOTOR DRIVE UNIT ED 100S MR(GERMANY)
PRESSURE RELIEF DEVICE

10 FOR MAIN TANK QT208-60F QUALITROL(U.S.A.)

11 FOR OLTC LPRD00-00021482 QUALITROL(U.S.A.)
OIL LEVEL INDICATOR

12 FOR MAIN & OLTC Dial type TAIJIN(KOREA)
13 COOLING FAN WITH MOTOR T2127Q TAIJIN(KOREA)
14 RADIATOR FOWDER COATING HYOSUNG(KOREA)
15 DEHYDRATING BREATHER T0120,T0121 TAIJIN(KOREA)
16 CONSERVATOR RB2500 HANSOL(KOREA)
17 INSULATION OIL ASTM D3487 TYPE 1 MICHANG(KOREA)
18 LOCAL CONTROL PANEL - HYOSUNG(KOREA)
REMOTE TAP
19 CONTROL PANEL - HYOSUNG(KOREA)
DOCU. NO. :
Rev. No. : 2
SPARE PART LIST & SPECIAL TOOLS
TITLE
LIST WITH DESCRIPTION Page. No : Cover
SPARE PART LIST & SPECIAL TOOLS LIST

WITH DESCRIPTION
DOCU. NO. :
Rev. No. : 2
TITLE
LIST WITH DESCRIPTION Page. No : 1 / 2
SPARE PART LIST & SPECIAL TOOLS LIST

WITH DESCRIPTION
For Construction
REV.
NO.
REV.
NO.

FOR
2
CONSTRUCTION
27/12/13 27/12/13 27/12/13 27/12/13
DOCU. NO. :
Rev. No. : 2
TITLE
LIST WITH DESCRIPTION Page. No : 2 / 2
▪ TRANSFORMER SPEC. : 3ph 50Hz 150/11kV 15/20MVA ONAN/ONAF OLTC on HV side
No. Description Type(Model) Q’ty Maker
1 HV BUSHING COT750-800 1 SET TRENCH(FRNACE)
2 HVN BUSHING COT250-800 1 SET TRENCH(FRNACE)
3 XV BUSHING 24-1250/P3 1 SET CEDASPE(ITALY)
4 BUCHHOLZ RELAY EE3-MA 1 SET CEDASPE(ITALY)
WINDING TEMPERATURE
5 INDICATOR MT-ST160F 1 SET MESSKO(GERMANY)
OIL TEMPERATURE
6 INDICATOR MT-ST160W 1 SET MESSKO(GERMANY)
2 PRESSURE RELIEF DEVICE
7 FOR MAIN TANK & OLTC QT208-60F 1 SET QUALITROL(U.S.A.)
OIL LEVEL INDICATOR

8 FOR MAIN Dial type 1 SET TAIJIN(KOREA)
9 COOLING FAN WITH MOTOR T2127Q 1 SET TAIJIN(KOREA)
10 TOUCH UP PAINT AU500(4 LITER) 4 LITER CHOKWANG(KOREA)

1
FOR MAIN
11 BREATHER
CONSERVATOR
1 SET TAIJIN(KOREA)
12 GASKET - 1 LOT HYOSUNG(KOREA)

DOCU. NO. :
Rev. No. : 0
TITLE ELECTRICAL LOAD LIST
Page. No : Cover
ELECTRICAL LOAD LIST
DOCU. NO. :
Rev. No. : 0
TITLE ELECTRICAL LOAD LIST
Page. No : 1 / 3
ELECTRICAL LOAD LIST
For Construction
REV.
NO.
REV.
NO.

FOR
0
CONSTRUCTION
19/12/13 19/12/13 19/12/13 19/12/13
HYOSUNG (Rev.0)
Electrical Load List
Printed in KOREA Dec 2013

HYOSUNG (Rev.0)
DC/AC LOAD OF TR. FOR CALCULATION OF BATTERY CAPACITY
The following calculations are loads per transformer. (Reference only)
A. TR. MK
1. DC(110V) Load Calculation
• Magnetic Contactor : 11W x 2EA = 77 W

• Relay Load : 2W x 2EA =4W
• Total Continuous Load : 81W x1.3(Margin) = 105 W
2. AC Load Calculation
1) 3 Phase AC 400V
• Cooling Fan Motors : 370W x 8EA = 2960 W
• Under Voltage Relay : 5W x 1EA =5W
• Total Continuous Load : 2965W x 1.3(Margin) = 3855 W
2) 1 Phase AC 230V
• Spacer Heater : 100W x 1EA = 100 W
• Incandescent Lamp : 60W x 1EA = 60 W
• Total Continuous Load : 160W x 1.3(Margin) = 208 W
B. OLTC MOTOR DRIVE UNIT
1. DC(110V) Load Calculation

• Total Continuous Load : 100 x 1.3(Margin) = 130 W
2. AC Load Calculation
3 Phase AC 400V
• Total OLTC Driving Motor
: 1850W x 1.3(Margin) = 2405 W
• Total OLTC Heater
: 60W x 1.3(Margin) = 78 W
Printed in KOREA Dec 2013

DOCU. NO. :
Rev. No. : 0
Welding Procedure Specification - Procedure
TITLE
Qualification Record (WPS-PQR) Page. No : Cover

Qualification Record (WPS-PQR)
DOCU. NO. :
Rev. No. : 0
TITLE
Qualification Record (WPS-PQR) Page. No : 1 / 50

Qualification Record (WPS-PQR)
For Construction
REV.
NO.
REV.
NO.

FOR
0
CONSTRUCTION
27/11/13 27/11/13 27/11/13 27/11/13
Document No. 1009-4261-PE-464-001
WPS & PQR Rev.No. 0
Page 02/50
1. GENERAL
Hyosung Corporation
DOC.No. 1009-4261-PE-464-001
WPS & PQR REV.No. 0
PAGE 03/50
1. GENERAL
1.1 Scope
This procedure will be applied to the welding for 3×15MW WAMPU HEPP PROJECT
Step-up & Aux transformers to be manufactured in HYOSUNG Chang-won plant.
1.2 References
1.2.1 ASME Section Ⅱ part C(1994 Edition)

1.2.2 ASME Section Ⅳ (1992 Edition with 1993 & 1994 Addenda)
1.2.3 AWS D1.1 (2004 Edition)
1.3 Control of Welding Material
The control of welding material shall be conducted in accordance with

Hyosung Standard(Welding Material Control Procedure : HS-CE-34-0126)
1.4 Welding Process
1.4.1 All Welds shall be performed by qualified welders or welding operators

in accordance with the qualified Welding Process Specification.
1.4.2 The Weld surfaces must be free of any airborne dust, paint, moisture, oil, grease ect,
and shall be cleared by grinding, brushing or chipping before welding.
1.4.3 All slags, weld spatters, fluxes of any defect appeared on the welded
surfaces shall be removed to make sound weld by chipping, grinding
or arc air gouging before subsequent welding if applicable.
1.4.4 Min. preheat and Max. interpass temperature specified in WPS shall be
kept continuously during welding.
1.4.5 Finished welds shall be cleared and visually inspected.
Hyosung Corporation
DOC.No. 1009-4261-PE-464-001
WPS & PQR REV.No. 0
PAGE 04/50
1.5 All welding procedure specification shall be qualified in accordance with

AWS D1.1 (2004 Edition)
1.6 Welder & Welding Operator Qualification
Each Welders or welding operator shall be qualified in accordance with

Hyosung standard(HS-CE-34-0103) using a qualified Welding Procedure Specification
to be assigned in production welding.
1.7 Fitting and Aligning
Parts that are to be joined by welding may be fitted, aligned, and retained
in position during the welding operation by the use of bars, jacks, clamps,
tack welds or temporary attachments.
1.8 Tack Weld
1.8.1 Tack welds used to secure alignment shall either be removed completely
when they have served their purpose, or their stopping and starting
ends shall be properly prepared by grinding or other suitable means
so that they may be satisfactorily incorporated into the final weld.
1.8.2 When tack welds are to became a part of the finished weld, they shall
be visually examined and defective tack welds removed.
1.8.3 Tack welds shall be made by qualified welders using qualified welding procedures.
1.9 Temporary Attachment Welds
1.9.1 The material is identified and is suitable for welding but need not be
certified material
1.9.2 The material is compatible for welding to the component material to

which it is attached.
1.9.3 The welding material is compactable with the base material.
Hyosung Corporation
DOC.No. 1009-4261-PE-464-001
WPS & PQR REV.No. 0
PAGE 05/50
1.9.4 The welders shall be qualified in accordance with Hyosung standard(HS-CE-34-0103).
1.9.5 The temporary attachment shall be completely removed.
1.9.6 After the temporary attachment has been removed, the surrounding
area is visually inspected.
1.10 Back Gouging
1.10.1 Back Gouging may be performed by arc air gouging, chipping, grinding
or machining, However, arc air gouging shall be not be permitted on
stainless steel.
1.10.2 The gouging surface shall be ground and free of slag, carbon deposit
and other harmful material and visually inspected before welding.
1.11 Inspection of welds
Inspection of welds shall be performed in accordance with Hyosung standard(HS-CB-60-001).

1.12 Compatible material grade to ASTM standard
Hyosung Corporation
Document No. 1009-4261-PE-464-001
WPS & PQR Rev.No. 0
Page 06/50
2. WELD & MATERIAL INFORM
Hyosung Corporation
1009-4261-PE-464-001
WPS & PQR 0
07/50
2. WELD MAP
2.5 TANK : TOP (COVER)
APPLIED APPLIED WELDING AWS MATERIAL WELDING

NO. JOINT TYPE BASE METAL
WPS NO. PQR NO. PROCESS CLASS THICKNESS DESCRIPTION
T-01 FILLET P1 + P1 FC - 001 QFC-001 + QFC-010 FCAW E71T-1 38t(SS400) 1
T-03 FILLET P1 + P1 FC - 001 QFC-001 + QFC-010 FCAW E71T-1 4.5t(SS400) 1
Hyosung Corporation
1009-4261-PE-464-001
WPS & PQR 0
08/50
2. WELD MAP
2.1 TANK : BACK (HV WALL)
APPLIED APPLIED WELDING MATERIAL WELDING

NO. JOINT TYPE BASE METAL AWS CLASS
WPS NO. PQR NO. PROCESS THICKNESS DESCRIPTION
B-01 FILLET P1 + P1 FC - 001 QFC-001 + QFC-010 FCAW E71T-1 12t(SS400) 1
B-08 FILLET P1 + P1 FC - 001 QFC-001 + QFC-010 FCAW E71T-1 2.3t(SS400) 1
Hyosung Corporation
1009-4261-PE-464-001
WPS & PQR 0
09/50
2. WELD MAP
2.2 TANK : FRONT (XV WALL)

F-01 FILLET P1 + P1 FC - 001 QFC-001 + QFC-010 FCAW E71T-1 23t(SS400) 3
Hyosung Corporation
1009-4261-PE-464-001
WPS & PQR 0
10/50
2. WELD MAP
2.3 TANK : RIGHT (END SIDE)

R-01 FILLET P1 + P1 FC - 001 QFC-001 + QFC-010 FCAW E71T-1 9t(SS400) 2
R-02 FILLET P1 + P1 FC - 001 QFC-001 + QFC-010 FCAW E71T-1 4.5t(SS400) 1
R-03 FILLET P1 + P1 SM - 015 QSM-004 SMAW E7024 16t(SS400) 2
R-09 FILLET P1 + P1 FC - 001 QFC-001 + QFC-010 FCAW E71T-1 2.3t(SS400) 1
Hyosung Corporation
1009-4261-PE-464-001
WPS & PQR 0
11/50
2. WELD MAP
2.4 TANK : LEFT (END SIDE)

L-01 FILLET P1 + P1 FC - 001 QFC-001 + QFC-010 FCAW E71T-1 9t(SS400) 2
L-04 FILLET P1 + P1 FC - 001 QFC-001 + QFC-010 FCAW E71T-1 2.3t(SS400) 1
L-06 FILLET P1 + P1 SM - 015 QSM-004 SMAW E7024 16t(SS400) 2
L-07 FILLET P1 + P1 FC - 001 QFC-001 + QFC-010 FCAW E71T-1 6.5t(SS400) 2
Hyosung Corporation
Document No. 1009-4261-PE-464-001
WPS & PQR Rev.No. 0
Page 12/50
3. WPS / PQR
Hyosung Corporation
DOCU. NO. :
Rev. No. : 0
TITLE QA PROGRAM MANUAL
Page. No : Cover
QA PROGRAM MANUAL
DOCU. NO. :
Rev. No. : 0
TITLE QA PROGRAM MANUAL
Page. No : 1 / 50
QA PROGRAM MANUAL
For Construction
REV.
NO.
REV.
NO.

FOR
0
CONSTRUCTION
27/11/13 27/11/13 27/11/13 27/11/13
QUALITY MANAGEMENT MANUAL
MANUAL No. : M Q M-T001

ISSUE DATE : January 13, 2003
REVISION No : J
REVISION DATE : Sep 07, 2012
■ CONTROLLED COPY No. (No.: )

□ UNCONTROLLED COPY
HYOSUNG CORPORATION
FORM CP-34-0181-1A4 HYOSUNG CORPORATION A4(210X297)

MANUAL NO.
QUALITY MANAGEMENT MANUAL MQM-T001
REV. NO.: A PAGE
SECTION 0.0 PRESCRIPTION OF QUALITY MANAGEMENT MANUAL
DATE: Jan. 13. 2003. 1/1
We prescribe the quality management manual (MQM-T001) as the following in order

to use it as a management tool to realize customer satisfaction, achieve
management objectives efficiently and effectively, and improve continuously quality
management securing capacity that is meeting statutory and regulatory requirements.
- Following -
1. This manual has precedence over all standards of our company to issue, revise,
interpret and apply.
2. All businesses and job duties carried out in our company have to be practiced
suitably for principles and procedures provided in this manual.
3. 8 principles of quality management provided in this manual are fundamentals

that all members have to participate and accomplish. They are basic and
fundamental guidelines of all businesses and job duties. Therefore, it is
necessary to monitor, measure, and improve management activities unsuitable
for these fundamental and principle.
4. Consequently, this manual has to be applied to daily job duties, and the
fundamental and principle provided in this manual have to be well understood.

MANUAL NO.
REV. NO.: J PAGE
SECTION 0.1 QUALITY MANAGEMENT MANUAL APPROVAL SHEET
DATE: Sep 07, 2012. 1/1
This manual has precedence over every applicable regulation and manual of our company
to issue and operate and all members shall fulfill effective quality management as specified in
this manual.
The quality management manual (MQM-T001 REV. NO.: J) is prepared by person of charge
of quality management team, and reviewed by the Quality management team general
manager and approved by the Plant manager.
Prepared by : Y. D. CHOI Date : Sep 07, 2012

Person of charge
Reviewed by : J. J. KIM Date : Sep 07, 2012

Quality Management Team
General Manager
Approved by : D. S. KIM Date : Sep 07, 2012

Plant Manager

MANUAL NO.
REV. NO.: J PAGE
SECTION 0.2 CONTENTS
DATE: Sep 07. 2012 1/1
SECTION TITLE REV. NO. DATE
0.0 PRESCRIPTION OF QUALITY MANAGEMENT A Jan. 13, 2003
QUALITY MANAGEMENT MANUAL APPROVAL

0.1 J Sep 07, 2012
SHEET
0.2 CONTENTS J Sep 07, 2012
0.3 REVISION INDEX J Sep 07, 2012
0.4 8 PRINCIPLES OF QUALITY MANAGEMENT F Sep 18, 2009
1 SCOPE H Sep.07, 2012
2 NORMATIVE REFERENCE F Sep 18, 2009
3 TERMS AND DEFINITIONS F Sep 18, 2009
4 QUALITY MANAGEMENT SYSTEM H May. 03, 2011
5 MANAGEMENT RESPONSIBILITY J Sep 07, 2012
6 RESOURCE MANAGEMENT G Jul. 26, 2010
7 PRODUCT REALIZATION G Jul. 26, 2010
MEASUREMENT, ANALYSIS AND

8 G Jul. 26, 2010
IMPROVEMENT
9 SUPPLEMENT G Jul. 26, 2010
10 Appendix I Sep. 07, 2012

MANUAL NO.
REV. NO.: I PAGE
SECTION 0.3 REVISION INDEX
DATE: Sep 07. 2012. 1/1
Revision Issue &

REV. No. Revision Content Remark
Section Revision Date
Establishment according to ISO Original
A Establishment Jan. 13, 2003
9001:2000 requirements issue
B 0.1,0.2,0.3,1,5 Mar. 10, 2003 Insertion of head office
Specification of quality policy and
insertion of the Cost management
0.1, 0.2, team and Distribution transformer
C Apr. 21, 2003
0.3, 1, 5 design team
Insertion of a part of responsibility and
authority of the Design team manager
Insertion a change of terms and
0.1, 0.2, definitions
D 0.3, 0.4, 1, 4, Aug. 23, 2006 Insertion of the changed organization
5, 7 Table and a part of responsibility and
authority of the changed organization
1. Reflection a change of Changwon
plant / headquarters organization
0.1,0.2,0.3, 2. Unification and supplementation of
E May. 29. 2007
1,4,5,8 terms
- Quality management policy, quality
policy → quality policy
F Overall Sep. 18, 2009 Reflection of ISO 9001:2008 revision
Modification of organization chart,
0.1,0.2,0.3,
G Jul. 26, 2010 appendix 3, Addition of appendix 2
1,4,5,6,7,8,9
and related procedure in the clause
Appendix in „4. Quality management
0.1,0.2,0.3,
H May. 03, 2011 system‟ changed and moved the end
4,10
of manual in 10. Appendix.
Revised Management review in
I 0.1,0.2,0.3,2,5 May 18, 2012
accordance with removed procedure.
0.1,0.2,0.3,1,5, Reflection a change of the changed
J Sep 07, 2012
10 organization and procedure number

MANUAL NO.
REV. NO.: F PAGE
SECTION 0.4 8 PRINCIPLES OF QUALITY MANAGEMENT
DATE: Sep 18. 2009. 1/2
Hyosung Corporation constructed the quality management system based on the international
standard ISO 9001:2008 as a management strategy of top management to enhance competitive
power.
The quality management system is to be used as an effective management tool for continual
improvement of management with planning, practicing, analyzing and measuring so as to meet
customer requirements, management objectives and statutory and regulatory requirements which
are applied to the product.
Top management shall operate the quality management system in a systemic and transparent
way according to 8 principles of quality management.
8 principles of quality management
Principle 1 Management focused on customer

Our company is an organization living in dependence on customers.
Therefore, to thoroughly understand and meet customer‟s current and future
requirements and expectations shall be the fundamental principle of all management
activities.
Principle 2 Leadership
Top management shall establish constant management policy and objectives so as that
all members can participate spontaneously to achieve the management policy and
objectives and produce fruits of accomplishment.
Principle 3 Participation of all members

Company-wide and aggressive participation of all members is essential for securing
competitive power of quality.
For customer satisfaction and ensuring management profit, all members of the
organization shall actively participate in the quality management.
Principle 4 Approach to process

Results of processes necessary for all management activities of our company are
product and quality. The fruit of management is resulted from carrying out efficient and
effective processes. Therefore, all processes need continual monitor, measurement and
improvement.

MANUAL NO.
REV. NO.: F PAGE
SECTION 0.4 8 PRINCIPLES OF QUALITY MANAGEMENT
DATE: Sep 18. 2009.. 2/2
Principle 5 Approach to system

In order to accomplish the management objectives, we have to understand and control
processes interrelated with management activities as one system. Therefore, all
management activities shall be carried out according to the system.
Principle 6 Continual improvement

For our everlasting survival, continual change and improvement are an indispensable
and key management measure. Therefore, we have to practice management innovation
activities to enhance our company of management result and competitive power as an
important matter for the quality management.
Principle 7 Decision-making by fact and data

Decision-making by realistic approach based on fact, data and information analysis
rather than experience, habitual practice or obscure supposition is to be the basic means
of quality management.
Principle 8 Relationship of mutually beneficial supplier

Our company and suppliers shall develop interdependent and mutually beneficial
activities so as to ensure the quality satisfying customers.

MANUAL NO.
QUALITY MANAGEMENT MANAUAL MQM-T001
REV. NO.: H PAGE
SECTION 1 SCOPE
DATE: Sep 07. 2012. 1/2
1.1 General
This manual specifies on operation of the quality management system when an organization
needs
a) to increase the reliability of customer by demonstrating the ability to consistently provide

product that meets customer requirements and applicable statutory and regulatory
requirements
b) to enhance customer satisfaction through continual improvement of the system and effective
application, and
c) to accomplish the management objective efficiently and effectively.
1.2 This manual is applied to the organizations prescribed in table 1 and 2.
1.3 This manual is applied to manufacturing activities of the following products.

POWER TRANSFORMER, GIS, GCB, DS, ELECTRIC CONTROL PANEL, GAS VT, IPB,
CIRCUIT BREAKERS, EPOXY INSULATORS, DISTRIBUTION TRANSFORMER, POLE
TRANSFORMER, MOLD TRANSFORMER, LIGHTNING ARRESTER, ROTATING ELECTRICAL
MACHINES, GENERATOR, GEAR REDUCER, BLOWERS, DAMPERS, SILENCERS,
PRESSURE VESSELS, GARAGE EQUIPMENT, CRANES, CNG PACKAGE, JIG & FIXTURE,
CAST IRON, ASRS, WIND POWER TURBINE SYSTEM, COMBINED HEAT & POWER SUPPLY
SYSTEM, WIND TUNNEL TEST FACILITY
1.4 In the quality management system specified in this manual, all requirements of ISO 9001:2008 are
included.

MANUAL NO.
REV. NO.: H PAGE
SECTION 1 SCOPE
DATE: Sep 07. 2012. 2/2
Power&Industrial Systems Performance Group
CTO
Technology Management
Power Systems Performance Group Industrial Machinery Performance Group Changwon Plant Manager Wind Power Group
Director Administration Center Director

Strategic Planning Collaboration Sales
Director Director Distribution Strategic Planning
Director Director Director Director Customer Support Production Support Strategic Marketing
Management Plannig Quality Inspection Strategic Planning Mfg Control Environmental Safety AE Management
Corporation Support R&D advisor Director Mfg Technology HR
Work Support PTR Sales 1 Director Quality assurance Director
Director PTR Sales 2 PTR Technology Development Director Wind Design 1
TR R&D Welding Machine sales Global Marketing Administration Center Wind Design 2
C/B R&D DTR Sales Director Global Sales 1 Director Emergency Planning Wind Technology
Director E/P Sales PTR Mfg Technology Global Sales 2 HV Motor Design Purchasing
New Business Director Heavy Electrical Sales PTR Inovation Global Sales 3 HV Motor Mfg Quality Management
Power Grid Integration팀 Motor R&D Vendor Support Director

Power Grid Solution팀 Director Motor Development Quality assurance
Director Project 1 Director Motor R&D TFT Wind Mfg
Ethics Management Director Project 2 PTR Design 1 Director
Strategic Purchasing Reliability R&D PTR Design 2 Gear Solution Sales Director
DREAM Management Core Engineering Director PTR Design 3 Motor Sales LV Motor Design
Engineering 1 PTR Design 4 Industrial Machinery Sales LV Motor Mfg

Director Engineering 2 PTR Design 5 Plant&Marine Sales Foundry
Rotating R&D PJT Sales PTR Design Review Rotating Machine Sales 1 Special Motor Design
Rotating Machine Sales 2
Director Director
Technology Management Director PTR Mfg Technology Director
R&D Support Global Sales 1 PTR Mfg 1 Gear Solution R&D
Global Sales 3 PTR Mfg 2 Gear Solution Design
Fuel Cell Gear Solution Mfg
Director Director
Global Sales 2 DTR Design
Global Sales 4 DTR Mfg Director
Industrial Machinery
Director Director
Solution Business C/B Mfg contol
Process Business C/B Design 1
C/B Design 2
C/B Design 3
E/P Design
Director E/P Mfg
CS
Director
C/B Mfg Technology
C/B Mfg 1
C/B Mfg 2
SPEX
Director
C/B Developement 1
C/B Developement 2
C/B Development 3
C/B R&D

MANUAL NO.
REV. NO.: I PAGE
SECTION 2 NORMATIVE REFERENCE
DATE: May 18, 2012 1/1
Definitions of fundamental matters and terms needed to specify or interpret this manual shall
follow ISO 9000:2005. Also, the quality management system specified in this manual shall refer the
following standards.
ISO 9001, KEPIC, International Standard (10 CFR 50 App. B, ANSI/ASME NQA-1 etc.), Contracts,
Applicable code, etc.

MANUAL NO.
REV. NO.: F PAGE
SECTION 3 TERMS AND DEFINITIONS
DATE: Sep 18. 2009. 1/1
Main terms used in this quality manual are as the following.
3.1 Quality Management System

A management system to establish policy and objective in order to direct and control
organizations for quality and to accomplish the objectives
3.2 Quality Policy

Organization‟s general commitment and direction for quality declared by top management
3.3 Quality Objective

Quality that is pursued or aimed
3.4 Quality Plan

Document specifies when or by whom the resource related to certain procedure is to be applied
for certain project, product, process or contract
3.5 Process
A gathering of interrelated or interactive activities that convert input into output
3.6 Core Process

Company‟s main process to enhance competitive power by reinforcing the capability according to
article 4.1 a) to f) of ISO 9001:2008
3.7 Effectiveness
Accomplished rate of intended results after planned activities are realized
3.8 Efficiency
Relationship between accomplished result and used resource
3.9 Documented Procedure

Means that a procedure is established, documented, practiced and maintained
3.10 Product
(1) The product that is required by customer or intended for customer
(2) The intended output as a result of the product realization process

MANUAL NO.
REV. NO.: H PAGE
SECTION 4 QUALITY MANAGEMENT SYSTEM
DATE: May 03. 2011. 1/3
4.1 General requirements

All products manufactured by our company and supplied to customer and fruits of job duties
carried out by our company are results of processes (ISO 9000:3.4.2).
Therefore, we have to understand and determine and control numerous processes in the
organization in order to display our company of management ability effectively and operate those
processes effectively and efficiently so as to accomplish customer satisfaction and management
objective. Also, the processes within quality management system have to focus on the following
matters.
a) Understanding and meeting the requirements of ISO 9001:2008
b) Process producing value added
c) Resulting in fruit and effectiveness of process operation (ERP, PDM, etc.)
d) Continual process improvement through objective measurement (including other consultation)
Particularly, all processes shall be applied according to the following model of Plan-Do-Check-
Action.
Note. Plan: Establishing objective and process necessary to achieve management result according to
customer requirement and company‟s policy.
Do: Executing every process needed to attain quality objective established accurately and
thoroughly.
Check: Measuring and monitoring process carried out to meet policy, management object and
product requirement and products and evaluate the results.
Action: Developing continual improvement activities to maximize performance according to the
result of measurement and monitoring on process and product.
As written above, our quality management system is to maximize the performance and
effectiveness of processes by putting all processes needed to realize products that satisfy
customer in an efficient and effective system and applying PDCA cycle completely.
Changwon Plant shall establish, document, implement and maintain the quality management
system and continually improve its effectiveness in accordance with the requirements of
International Standard ISO 9001:2008. To do so, Changwon Plant shall
a) have the same process necessary for quality management system with [Appendix 1. Process
linkage diagram], [Appendix 2. Process flow] and apply it to our organization,

MANUAL NO.
REV. NO.: H PAGE
DATE: May 03. 2011. 2/3
b) follow role allotment table [Appendix 3.] for the sequence and interaction of these processes,
c) follow article 8.2.3 (Monitoring and measurement of process) for criteria and methods needed to
ensure that both the operation and control of these processes is effective,
d) be able to use all resources and information necessary to operate and monitor these
processes,
e) carry out monitoring, measurement and analysis of these processes according to article 2.3
(Monitoring and measurement of process) and article 8.4 (Data analysis).
f) implement actions necessary to achieve planned results and continual improvement of these
processes according to article 8.5 (Improvement).
Theses processes necessary for the quality management system shall be managed by the
organization, and shall include management activities, provision of resource, quality realization,
measurement, analysis and improvement. Control of outsourced process that affects on
product conformity shall be identified within our quality management system.
4.2 Documentation requirements

4.2.1 General
The quality management system documentation of our company shall include
a) documented statements of our quality policy and quality objectives,
b) a quality management manual,
c) documented procedures and records required by International Standard ISO 9001:2008
(Control of documents, control of records, internal audit, control of nonconforming product,
corrective action and preventive action),
d) documents and records needed by our company to ensure the effective planning, operation
and control of its processes, and
Note. The documentation can be in any form or type of medium.
4.2.2 Quality management manual
Our company shall maintain and control the quality management manual as the highest
document explaining interrelation among processes of the quality management system.
[Related Procedure] The procedure for control of management manual(CP-34-0181)
4.2.3 Control of documents

Documents required by the quality management system shall be controlled and records shall
be controlled according to article 4.2.4 (Records).
Detailed documented procedure shall be established and
a) issued after adequacy of documents is approved by a relevant authority or deputy,
b) re-approved according to article a) when documents change,

MANUAL NO.
REV. NO.: H PAGE
DATE: May 03. 2011. 3/3
c) the latest version where changes and the current revision status of documents are identified
shall be controlled,
d) the quality management system executive department shall ensure that the latest versions
of applicable documents are used by making out a control ledger,
e) documents shall remain legible and have an identification system for easy identification and
retrieval,
f) documents of external origin which are determined to be needed in order to plan and operate
quality management system shall be identified and their distribution controlled, and
g) obsolete documents shall be withdrawn or abolished by the relevant department in order to
prevent unintended use. Suitable identification shall be applied if it is necessary to be
retained.
[Related Procedure] 1. The procedure for control of HICO standard(CP-34-0004)
2. The procedure for control of documents (CP-14-0014)
3. The procedure for control of purchasing document(CP-24-0060)
4.2.4 Control of records
Our company establishes and maintains records such as the following to provide evidence of
conformity to requirements and the effective operation of the quality management system.
Theses records remain legible, readily identifiable and retrievable, and a documented
procedure is established to define the controls needed for the identification, storage, protection,
retrieval, retention time and disposition of records.
a) Results of management reviews
b) Records of education, training, skills and experience
c) Records of circular inspection on manufacturing process and records of product examination
d) Results of customer requirements checking and results of follow-up activities
e) Design and development input
f) Results of design and development review and necessary actions
g) Results of design and development verification and necessary actions
h) Results of design and development validation and necessary actions
i) Results of design and development changes review and necessary actions
j) Results of supplier evaluation and necessary actions according to the evaluated results
k) Records necessary to validate a special process
l) Records to maintain traceability
m) Customer property lost, damaged or otherwise found to be unsuitable for use
n) Validity evaluation of former results if equipment is found to be unsuitable for requirements
o) Calibration and verification results of measuring devices
p) Results of internal audit
q) Records of release examination
r) Contents of nonconformity and all actions taken including concession
s) Results of corrective action
t) Results of preventive action
u) Other necessary documents
[Related Procedure] The procedure for control of quality records (CP-14-0013)

MANUAL NO.
REV. NO.: J PAGE
SECTION 5 MANAGEMENT RESPONSIBILITY
DATE: Sep 07 2012. 1/10
5.1 Management commitment

Top management shall provide concrete evidence that the following matters are being carried out.
a) Communicating to the whole organization and member the importance of meeting
customer as well as statutory and regulatory requirement
b) Establishing the quality policy based on will for quality management, declaring it inside and
outside of the company and leading the organization to realize it
c) Supporting every department and level to establish concrete objectives necessary to
accomplish the quality policy and to produce fruits
d) Conducting periodic management reviews on operating conditions and results of quality
management system to improve effectiveness of quality management system continuously
e) Ensuring the availability of resources necessary to achieve quality objectives
5.2 Customer focus

Top management shall provide evidence of establishing objectives to improve customer
satisfaction and meeting them by
a) correctly understanding what customer requires or specifies clearly and reflecting it to the
product,
b) thoroughly understanding what customer expects or requires by implication and reflecting it to
the product,
c) meeting statutory and regulatory requirements,
d) understanding the performance of quality management system through measuring and
monitoring internal and external customer satisfaction, and
e) visualizing customer focused management through holding all meetings such as quality
meeting and business production meeting for customer satisfaction.
5.3 Quality policy

We realize that touching customer is laying foundation for growth by always thinking in customer’s
position and fulfill. To achieve this, we should observe quality policy.
Ⅰ. “Customer-Oriented Quality Management System.”

We carry out our duty to the fullest and hold up our end to offer best products and services to
our customers, and then promptly handle the customer’s request.
Ⅱ. “Observing the rule and continuous improvement”

We observe rule and procedure definitely, and then maintain/secure “Global-class Quality”
through the continuous technical innovation and quality improvement activities.

MANUAL NO.
QUALITY MANAGEMENT MANAUL MQM-T001
REV. NO.: J PAGE
DATE: Sep 07 2012. 2/10
Ⅲ. “Operation of Global Quality Management System”

We prepare for a “ Global competitiveness ” by establishing, maintaining and improving
process in accordance with “Global Standard”.
Ⅳ. “Developing Global Talented employee”

We strengthen capability of organization by securing global core talent and developing
systematically .
5.4 Planning
5.4.1 Quality objectives
a) Every general manager shall establish quality objectives according to the quality
management policy determined by the company.
b) Quality objectives shall be measurable in a fixed quantity, be consistent with the quality
management policy, meet requirements for product and include required Q. C and D.
c) Performance of duties for quality objectives shall be in accordance with P, D, C and A cycle.
5.4.2 Quality management system planning

a) Top management shall ensure that concrete business plan to accomplish quality objective is
established by team and implemented.
b) In order to achieve the quality policy and quality objectives effectively, top management shall
establish, document, implement and maintain the quality management system suitable for
requirements of ISO 9001:2008, article 4.1 and continuously improve the effectiveness of the
quality management system.
c) In order to maintain the integrity of the quality management system when changes to the
quality management system are planned and implemented, adjustment with the teams
affected by the changes and approval of the person in charge shall be necessary.
5.5 Responsibility, authority and communication

5.5.1 Responsibility and authority
All members and organizations related to this manual shall have the responsibility and
authority provided in this manual. For this, vertical and horizontal authorization relation among
members of the organization shall be clearly defined.
a) Top management (President of Performance Group)
Changwon Plant Manager is referred as the management representative and shall carry out
the following duties.

MANUAL NO.
REV. NO.: J PAGE
DATE: Sep 07 2012. 3/10
He has overall responsibilities for effective implementation of applicable standards and
codes specified on contract and the quality management system set in this manual, and
when suggested or necessary to improve, he is able to change the quality management
system.
Also, the management representative has the responsibility and authority for the following
matters.
(1) Establishment of quality policy
(2) Approval of the quality management manual
(3) Validation and corrective action of the quality management system according to the
results of quality audits and management reviews
(4) Auditor designation in the quality management team to audit
(5) Approval of a yearly audit plan
(6) Management review
b) Director in charge (Directors having responsibility for the control of each team in Power &
Industrial Systems Performance Group of Hyosung Corporation are referred as Director in
charge)
Each director in charge has responsibility to control overall quality-related activities of the
team under his control, and to make the team observe this quality management manual.
c) Quality management team manager

The Quality assurance team manager as a management representative has responsibility
and authority for ensuring that works affecting on quality are implemented correctly and is
granted to have freedom to raise quality problems, work out solutions for the quality
problems and ensure that the solutions are being implemented.
He also has responsibility and authority for the following.
(1) Making out, review, issue/revision and distribution of quality management manual
(2) Registration assessment of new sub-contractor
(3) Analysis of nonconformity, and report to top management
(4) Verification of the results of corrective and preventive action, follow up action and
conclusion of the issued corrective action request
(5) Indoctrination, training and qualification control of auditor
(6) Report audit results to top management
(7) Qualification and record control for inspector, tester, special process workers
(8) Review of the yearly audit plan and approval of audit checklist
(9) Establishment and control of the overall training program for the personnel performing the
quality related activities
(10) Designation of auditor and lead auditor
(11) Registration, approval and distribution control of manufacturing process chart, QC
process chart and Hyosung Corporation standards
(12) Calibration of measuring equipment for test and inspection and maintenance of the
record
(13) Preparation, maintenance and storage of the history card for measuring equipment for
the test and inspection
(14) Review of quality plans prepared by Design Team
(15) Ensuring to carry out counter measures for analysis of production defect cause

MANUAL NO.
REV. NO.: J PAGE
SECTION 5 MANGEMENT RESPONSIBILITY
DATE: Sep 07 2012. 4/10
d) Quality inspection team manager (The Quality Inspection team manager of Power system PU,
and The Quality Assurance team manager Industrial Machinery PU and Wind Turbine)
(1) Performance of receiving inspection for materials and parts purchased from outside
including customer-supplied product, and preparation and maintenance of the record
(2) Overall review of quality-related work of customer requirements
(3) Performance of the verification work for identification and traceability through inspection
and monitoring
(4) Review and approval of inspection and test plans
(5) Review and approval of inspection and test standards
(6) Control of inspection and test schedule
(7) Review, approval and record control of results of inspection and test
(8) Witness request to customer or his representative for inspection of witness points
(9) Identification and traceability control of inspection and testing conditions
(10) Review and approval of disposition plans for nonconformity reports prepared by the
quality inspector
(11) Authority to request work stop in case of occurrence or finding out the important
conditions adverse to quality
(12) Maintenance and control of the testing equipment
(13) Analysis of production defect cause
e) Production control team manager

(1) Review for production control parts of contracts
(2) Proposal of a production plan and distribution it to related teams after reviewing load
amount against production capacity
(3) Totaling and analysis of production records
(4) Total process control
(5) Establishment, settlement and direction of plant manager policy
(6) Checking and evaluation for implementing condition of team manager policy
(7) Synthetic analysis, record maintenance and control for achieved results of management
objectives
(8) Control of storage, preservation, packaging and delivery affair (applicable only to Industrial
machinery & Eng. PU)
(9) Storage control of purchased materials for electric motor and gear reducer (applicable only
to Industrial machinery & Eng. PU)
(10) Identification control of materials and parts warehoused (applicable only to Industrial
machinery & Eng. PU)
(11) Segregation of nonconforming materials from other similar products or materials so as
not to be used together (applicable only to Industrial machinery & Eng. PU)
f) Production support team manager

Production support team manager controls general affair, facility & equipment, environment
& safety and cost
- General affair part
(1) Storage and control of quality records moved from each team
- Facility & equipment part
(1) Maintenance and repair control of utility in the plant (receiving/distribution electricity,
crane, steam, air, water line, etc.)

MANUAL NO.
REV. NO.: J PAGE
DATE: Sep 07 2012. 5/10
(2) Maintenance and mending of the building, construction and pipe line
(3) Planning and control of equipment maintenance
- Cost
(1) Planning cost rate and construction of control system for cost rate
(2) Establishment and review middle/long term master plan for innovation of cost rate
(3) Improvement and review of manufacturing cost by analysis of relevance and economical
Efficiency
g) Environment & safety team manager

(1) Overall responsibility for the environment in the plant and safety supervision of employee
(2) Training and qualification control of carrier
(3) Health control of employee
(4) Fire prevention and control of dangerous material
h) Human resource and General affair team manager

(1) General indoctrination and training for employee
(2) Drafting and performing of the job training plan
(3) Development of worker‟s skill and spot-practice for outsider
(4) Employment and assignment of employee
i) Manufacturing team manager (Power transformer, Distribution transformer, Circuit breaker,

Electrical panel, SPEX, HV/LV electric motor, LV electric motor component and Gear
solution manufacturing, Wind turbine manufacturing team are referred as Manufacturing
team and the team managers are referred as Manufacturing team manger)
(1) Review of ability to produce products satisfying customer requirements in the due date
(2) Approval of work standards and work instructions
(3) Distribution, furnishing and implementation control of the work standards and work
instructions
(4) Preparation of prospective disposal method for nonconforming products
(5) Maintenance and control of quality records in the way to minimize loss, damage or quality
deterioration while they are in his possession
(6) Preparation and performance of team‟s yearly indoctrination and training plan
(7) Handling, storage and maintenance of customer-supplied products
(8) Analysis of validity for equipment investment and establishment of the plan
(9) Maintenance and accuracy control of manufacturing equipments (applicable only to
Power system PU)
(10) Installation affairs of manufacturing equipments (applicable only to Power system PU)
(11) Record maintenance of work results
(12) Handling, storage and identification control of materials and semi-products in process
(13) Approval of manufacturing process chart
(14) Storage and control of purchased materials
(15) Identification and control of warehoused materials and parts
not to be used together
(17) Packaging control of industrial machinery (applicable only to Industrial machinery PU)

MANUAL NO.
REV. NO.: J PAGE
DATE: Sep 07 2012. 6/10
j) Design team manager (Power transformer, Distribution transformer, Circuit breaker, Electrical
panel, HV electric motor, LV electric motor, Gear solution, Wind design team and Power
transformer R&D, Circuit breaker R&D, Electric motor R&D, Wind Technology team are
referred as Design team and the team managers are referred as Design team manager)
(1) Review of design-related part out of customer requirements
(2) Receiving contract review request from Business team, gathering all opinions of related
team managers in the plant and sending to Business team manager
(3) Overall control of design affairs (including design schedule and support for other team)
(4) Approval of design documents
(5) Interface control of design-related affairs between internal and external organization
(6) Decision of purchasing specifications and establishment and revision of material and
product standard
(7) Approval of QC process chart
(8) Approval of quality plan according to contract requirements
(9) Approval of package specifications according to contract requirements
(10) Verification of technical adequacy for nonconformity disposed as “repair” and “use-as-is”
and record on the nonconformity report
(11) Review of development report when required to develop new items
k) Product team manager (Special motor, Industrial machinery, industrial machinery PU)
Technology development and Foundry, Plant team are referred as Product team, and the
team managers are referred as Product team manager)
The Product team manager has all responsibility and authority of Manufacturing team
manager and Design team manager described in article 5.5.1, m) and n) of this manual.
However, charge to preserve and control the manufacturing facilities shall be on the
technology development team. (Applicable only to Industrial machinery PU)
l) Engineering team manager (Transformer and Circuit breaker engineering team are referred
as Engineering team and the team managers are referred as Engineering team manager)
(1) Review of the application to production of manufacturing drawing
(2) Planning and performance of a long range plan of equipment investment
(3) Establishment and revision of technical standard under review of validity
(4) Processes improvement and fool proof by analysis of loss in manufacturing processes
(5) Performance of automation of equipment/line in manufacturing processes
(6) Improvement of the ways in work
m) Business team manager (The team managers of Power system sales team 1, Power system
sales team 2, Heavy electric systems sales team, Electrical panel sales team, Agent
management team, Plant team, Process sales team, Process engineering team, Overseas
project slaes team, Power system engineering team, Global sales team 1, Global sales team
2, Global sales team 3, Global sales team 4, Rotating machine sales team 1, Rotating
machine sales team 2, Plant ocean sales team, Generator sales team, Gear solution sales,
Industrial machinery sales, Wind turbine sales team, Strategic marketing team are referred
as Business team manager)
The Business team manager has the overall responsibility for contract review affairs.
(1) Receipt and control of customer requirements
(2) Specification and review request of customer requirements
(3) Distribution and control of contract documents

MANUAL NO.
REV. NO.: J PAGE
DATE: Sep 07 2012. 7/10
n) Project team manager (The Project 1, 2 team, A/E management team manager are referred
as solution execution team manager)
The Project team manager has responsibility such as follows for power transformer, circuit
Breaker, distribution transformer, mold transformer and electric panel, Wind turbine system
(1) Establishment of schedule for field installation and work control
(2) Performance of test and inspection after installation and maintenance control of the record
(3) Planning, performance and record maintenance of B/S
(4) Receipt and management of customer complaints and maintenance control of the record
(5) Analysis of management results for B/S and A/S, and feedback to related departments
(6) Receipt and management of customer complaints on power transformer, circuit breaker,
distribution transformer, mold transformer, electric panel and control component or
management request to related teams
(7) Feed-back the information of defective products to related departments
(8) Receipt and analysis of the result managed by the related manufacturing department
(9) Storage control of products (applicable only to Changwon Project 2 team)
(10) Control of package, transportation, maintenance and delivery (applicable only to
Changwon Project 2 team)
o) R&D team manager (The team managers of Core technology team, Distributed power system
team, Circuit breaker team , Technology Management team, Power Grid Integration, Power
Grid Solution team, Rotating team, Fuel cell team, Reliability engineering team are referred as
R&D team manager)
(1) Review of development report when required to develop new items
(2) Approval of R&D plans
(3) Approval of R&D documents
(4) Interface control between internal and external organizations related with R&D
(5) Decision of purchasing specifications and establishment and revision of material and
product standard
p) Dream Management team manager

(1) Overall control of improvement activities related to independent improvement and
propositions
(2) All kinds of consultation and monitoring
(3) Establishment of factory innovation objectives and evaluation of the results
q) Management Planning team manager

(1) Establishment and control of facility investment plan
(2) Negotiation, making a contract and control for technical cooperation
(3) Overall control of procedures in the head office
(4) Overall control of the quality management system in the head office

MANUAL NO.
REV. NO.: J PAGE
DATE: Sep 07 2012. 8/10
r) Purchasing team manager(Strategic Purchasing team, Subcontracting & Supply team, Vendor
Support team are referred as Purchaing team manager)
(1) Establishment of material supply and demand program and control of stock
(2) Establishment of basic policy to bring up suppliers and overall control of systematization
(3) Purchasing and supply of imported/domestic materials and installation materials
(4) Control of materials including import (Opening of L/C, marine transportation, insurance,
approval of B/L and acceptance)
(5) Overall purchasing affairs control such as dispatching of purchasing documents,
purchasing contract, etc.
(6) Regular evaluation for registered suppliers
(7) Preparation and distribution of the approved vendor list
(8) Selection and registration control of suppliers
(9) Maintenance and control of purchased materials
(10) Identification and control of purchased materials
not to be used together
s) Strategic planning team manger (The team managers of Strategic planning tem in Power
systems PU and Industrial machinery PU of Power & Industrial systems PG are referred as
Strategic planning team manager)
(1) Establishment, adjustment, result analysis and control of management plan
(2) Establishment of a middle/long-term business plan and strategies
(3) Establishment and adjustment of a middle/long-term investment plan
t) Customer support team (C/S team in Power systems PU, Customer support team in Industrial
Machinery PU are referred as Customer support team manager)
(1) Establishment of A/S and B/S plan, performance and maintenance of the record
(2) Receipt and management of customer complaints and maintenance of the record
(3) Analysis of managed results for B/S and A/S and feedback to related departments
(4) Receipt and management of customer complaints on products manufactured by the
Industrial machinery or management request to related teams
(5) Feedback of information on defective products to related departments
(6) Receipt and analysis of the result managed by the related manufacturing department
u) Common duty
Training in a team, corrective action, preventive action, standardization, improvement of
systems and observance of 8 principles of quality management

MANUAL NO.
REV. NO.: J PAGE
DATE: Sep 07 2012. 9/10
5.5.2 Quality management working representative

The quality management team manager are appointed the quality management working
representative and has responsibility to
a) Establish, document and maintain processes necessary for the quality management system,
b) Report to top management on the performance of the quality management system and need
for improvement, and
c) Promote awareness of customer requirements throughout the whole organization of
Changwon plant.
5.5.3 Internal communication

Top management shall use measures such as the following for efficient and effective
communication of the quality management system.
Classification Measures for internal communication
Notification and development of Monthly meeting and quality meeting
quality policy and quality objective
Review of the quality management Quality meeting
system
Maintenance of the quality Quality meeting by product and team
management system manger meeting
Communication of information with e-hope, internal survey, internal training,
departments ERP, meeting, proposal system, etc.
5.6 Quality management review

5.6.1 General
In order to ensure the continuity of suitability, adequacy and effectiveness of the quality
management system, all team managers of Changwon plant shall establish a plan to
accomplish quality objectives and report the performing conditions to top management
regularly. The management review shall be carried out by quality meeting and internal quality
audit and the records shall be maintained.
5.6.2 Review input

Review input shall be documented as meeting materials for the quality meeting and include
information on the following. Matters not occurred in the corresponding period shall be
excluded from input.
a) Results of internal quality audit
b) Results of customer quality audit and examination for foreign certification
c) Results of customer complaints and requirements
d) Results of corrective and preventive actions
e) Nonconformity and actions
f) Follow-up actions for previous instructions
g) Important changes of the quality management system
h) Quality improvement activities

MANUAL NO.
REV. NO.: J PAGE
DATE: Sep 07 2012. 10/10
[Related Procedure]
1. The procedure for management system audit (CP-34-0183)
2. The procedure for nonconforming product management (CP-34-0009)
3. The procedure for issuing & control of correcting management (CP-34-0011)
5.6.3 Review output

Review output shall be documented as meeting results of quality meeting, director‟s meeting
and S&OP meeting included decisions and actions related to the following.
a) Improvement of effectiveness of the quality management system and its processes
b) Improvement of product related to customer requirements
c) Resource needs

MANUAL NO.
REV. NO.: G PAGE
SECTION 6 RESOURCE MANAGEMENT
DATE: Jul 26. 2010. 1/1
6.1 Provision of resource

Top management shall determine and provide the resources needed
a) to implement and maintain the quality management system and continually improve its
effectiveness, and
b) to enhance customer satisfaction by meeting customer requirements.
6.2 Human resources

6.2.1 General
Works that affect the suitability of product requirements shall be carried out by the qualified
with competent education, training, skill and experience.
6.2.2 Competence, awareness and training

For competence, awareness and training of human resources, the following shall be carried out.
a) Determination of competence necessary for the personnel such as follows performing
works that affect the suitability of product requirements
- Quality auditor, inspector/tester, designer, special worker (welding, painting, brazing, heat
treatment and compression)
Field installation supervisor
b) Provision of training or taking other actions to be equipped with necessary capability
c) Evaluation of performance and effectiveness of the actions taken after training
d) Confirmation of the fact that all members are aware of the relevance and importance of
their activities and how hey contribute to the achievement of the quality objectives
e) Maintenance of appropriate records related to education, training, skills and experience
[Related Procedure]
1. The procedure for control of indoctrination of Changwon plant(CP-21-0024)
2. The procedure for control of quality control on the job training(CP-21-0029)
3. The procedure for qualification of field supervisor (CP-34-0184)
6.3 Infrastructure
The infrastructure needed to achieve the conformity of product requirements shall be determined,
provided and maintained. The infrastructure shall include, as applicable
a) office, factory and warehouse,
b) facilities and equipments,
c) laboratory and analysis room, and
d) computer network and information system
[Related Procedure]
The procedure for control of manufacturing facilities (CP-79-0001)

MANUAL NO.
QUALITY MANAGEMENT MANAUL MQM-T001
REV. NO.: G PAGE
SECTION 7 PRODUCT MANUFACTURING
DATE: Jul 26. 2010. 1/10
6.4 Work environment

The work environment to manufacture products conforming to customer requirements shall be
determined and managed.
a) Protective equipments and safety rules for operator‟s safety
b) Facilities and installation for the personnel in the organization
c) Appropriate heat, humidity, lighting, sound, vibration and clean workshop
7.1 Planning of product manufacturing

The processes needed for product manufacturing shall be planned and developed.
Planning of product manufacturing shall be consistent with the quality management system and
other requirements.
In planning product manufacturing, the following shall be specified.
a) Quality objectives and requirements for the product
b) Need to establish processes, document and provide resources specific to the product
c) Required verification, validation, monitoring, measurement, inspection and test activities
specific to the product
d) Records needed to provide evidence that the manufacturing process and product meet the
requirements
The output of this planning shall be described in the procedures to be controlled.
[Related Procedure] The procedure for inspection & test (Power systems PU) (CP-34-0056)
The procedure for inspection & test (Industrial Machinery PU) (CP-34-0138)
7.2 Customer-related process

[Related Procedure] The design manual (Manual of each product)
7.2.1 Determination of requirements related to the product
In order to reflect ever requirement of customer to the product manufacturing, the following
shall be clearly determined.
a) Requirements specified by customer including the requirements for delivery and post-
delivery activities
b) Requirements not stated by customer but necessary for specified or intended use, where
known
c) Statutory and regulatory requirements that can be applicable to the product
d) Other additional requirements determined to be needed by our company
7.2.2 Review of requirements related to the product
The review of requirements related to the product shall be carried out with the procedures
provided below before making a contract with the customer for product supply so as to supply
the product satisfying requirements of the customer.
a) The sales team manger shall record the contract document in the ledger and send it to the
design and product team (hereafter, referred as the product team) to review that the
customer requirements can be satisfied.
b) The design team shall review the contract document requested from the sales team and
send the results to the sales team. When the design team is unable to review, the design

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 2/10
team shall request the related team in the plant to review and send the results to the sales
team.
c) When the related team manager is reviewing the contract document, he has to review at
least that
(a) the requirements are properly determined and documented,
(b) there are any conditions that are different from the conditions in the proposal, and
(c) it is able to satisfy the conditions on the contract.
d) If any problems or contents different from the requirement of customer are found during the
review of contract document, the sales team manager shall contact with the customer to
solve those problems and then make a contract.
e) Where the customer provides no documented statement of requirement, the sales team
manager shall confirm the requirements of customer before making a contract, document
and send to the design team.
f) Where the requirements are changed, the sales team manager shall consult with the
related team and change the contract document through adjusting with the customer, and
report the changed requirements to the related team.
g) The review records made before and after making a contract shall be maintained according
to the procedure for control of record.
7.2.3 Communication with customer
In order to understand and satisfy the requirements and expectations of customer effectively,
the following methods are used to communicate.
a) Product information: Communication by facsimile, e-mail and telephone through the design
and sales team
b) Contract, order or changes: Communication by meeting with the customer, facsimile, e-mail
and telephone through the design, manufacturing management or sales team
c) Feedback including customer complaints: Communication by quality meeting with the
customer, information on customer claims, telephone, facsimile and e-mail
7.3 Design and development
[Related Procedure] The design manual (Manual of each product)
7.3.1 Design and development planning
a) The design team manager shall have adequate team members make out a design plan
indicating activities appropriate to each design stage, schedule and person in charge and
approve it.
b) This design plan shall be updated as the design evolves.
c) The design team manager shall have adequate team members carry out the design/design
review, design/development verification and validation.
d) The design team manager shall clearly identify and control the interface works within the
design team, with other organizations or with external organizations.
7.3.2 Design and development input
a) The designer shall document the input-requirements with contract (or purchasing)
specifications review or basic design, etc. through selecting the design-input
requirements of Hyosung standards, external standards, regulations or codes necessary
for the product design containing customer requirements, and it shall be controlled after
approval of the design team manager.

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 3/10
Design inputs shall include the following items and be reviewed for adequacy.
(1) Customer requirements
(2) Function and performance requirements
(3) Applicable statutory and regulatory requirements
(4) Information derived from previous similar design
(5) Other requirements essential for design and development
b) Incomplete, ambiguous or conflicting requirements of design-input-requirements shall be
resolved with whom responsible for preparing these requirements, and if necessary, the
results of contract review may be reflected and reviewed in design input step.
c) Changes and revisions to the approved design input data shall be subject to the same
control and approval manner as required for the original.
d) In case of a specific request by customer, or the development of new products, the design
team can hold a design review meeting with the related team and shall maintain the
related records.
7.3.3 Design and development output
a) The designer shall perform the design activity including design calculation and analysis to
convert the requirements, standards and design input contained in the design document of
customer into design output.
b) The design team manager shall control the design activity according to the instruction for
design management so that the designer can obtain accurate design output at a proper time.
Also, he shall obtain and maintain the documented information or other materials gained
from experiences so that the designer can use them.
c) The design document occurred from performing the design activity shall be approved by the
design team manager.
d) The computer program used for design interpretation and input/output control shall be
controlled in accordance with the instruction for design management.
e) Design output data means the design document such as design drawings, design
calculations and specifications confirming that the specified design input requirements are
satisfied, and the design document shall
(1) meet the input requirements for design and developments,
(2) provide appropriate information for purchasing, manufacturing and servicing,
(3) contain or refer to the product acceptance criteria, and
(4) specify the characteristic of product essential for safe and proper use.
f) The design output data shall be legible and in a form suitable for duplication, filing and
revision.
g) The design output data shall be easy and detailed to confirm.
h) The design calculations shall be identified by the title, person who prepared, reviewer,
approver and other data for retrieval.
i) The design output document shall be distributed after checking for errors.
7.3.4 Design and development review
At suitable stage, the design team manager shall call the related teams and carry out the
design review (hereafter, referred as DR). The participants of DR including the team managers
related to the design development shall

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 4/10
a) evaluate that the results of design develop meet the requirements,

b) identify any problems and propose necessary actions, and
c) records of the results of design review and necessary actions shall be maintained after
gaining the approval of the design team manger.
7.3.5 Design and development verification
a) The design document shall be verified as to the adequacy and coincidence with other
described design input data.
b) The design verification shall be performed by a person or organization not performed the
original design verification or by a third person in the same organization. Also, the verification
shall be carried out with the related team as required and the results shall be documented.
c) The design verification shall be performed to assure that the design output meets the design
input requirement by means of more than one of design control measures below, and the
details shall be described in the instruction for design management.
(1) Review of the related documents in each step before distributing the design results
(2) Tests and demonstrations
(3) Alternative calculations
(4) Comparison of new designs with similar proven designs, if available
7.3.6 Design and development validation
a) The design/development validity shall be verified to prove whether manufactured products
meet the customer‟s requirements by means of performing final capacity test or witnessed by
customer.
b) The Quality assurance team (Industrial machinery PU) and Quality inspection team (Power
system PU) manager shall approve the final performance test results of manufactured
products, and the copied document shall be sent to the Design team, if required.
7.3.7 Control of design and development changes
For design changes requested by customer, related team and design itself, the
design/development review, verification and validation shall be carried out. Also, the review of
design and development changes shall include evaluation of the effect of the changes on
constituent parts and product already delivered shall be controlled as the following.
a) The design changes (including changes of the design already approved) shall be approved
by the same organization that reviewed and approved the original design document, and the
changes shall be documented for easy identification.
b) Where the design change requires the approval of customer the changed content should be
approved by the customer.
c) Design input data, output data, design plan and other documents prepared from designing
shall be controlled in accordance with the procedure for control of records.

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 5/10
7.4 Purchasing
7.4.1 Purchasing process
The procedure shall be established, and according to the procedure, the purchased parts
composing the product supplied to the customer shall be controlled to meet the requirements
of customer. The controlling method for suppliers shall be determined according to the effect of
the purchased parts on the manufacturing process or final product.
The evaluation for supplier shall be carried out as the following based on its ability to supply
parts suitable for the product requirement of our company.
a) Registration of suppliers
(1) Registration of suppliers is composed of two methods. One is the source evaluation that
evaluates the supplier‟s skill and quality assurance ability, and the other is the document
evaluation that evaluates the development and stability of suppliers.
(2) The supplier who wants to register is to be evaluated in accordance with the standard
specifying management, production and quality. If the supplier meets the standard, it
may be registered approved vendor list.
(3) Other matters related to supplier registration shall conform to the procedure for supplier
registration.
b) Evaluation and selection of approved suppliers
(1) A periodic evaluation for defect ratio, delay ratio of delivery date, 5S and cooperation
degree of suppliers through that their management level, skill level, quality control level
and management ability are synthetically revealed shall be performed and the records
shall be maintained and controlled. According to the results of evaluation, the suppliers
shall be controlled in grades.
(2) When purchasing materials and components, the Purchasing team
manager/Subcontracting & purchasing team manager shall select the suppliers
registered in the approved vendor list dependently on the records of suppliers‟
previously demonstrated capability and performance.
c) Acceptance of service
When the inspection is carried out by a third party, to accept or not shall be judged by
verifying the technical data produced.
[Related Procedure]
1. The procedure for subcontract management(CP-24-0005)
2. The procedure for subcontract management(new item)(CP-24-0006)
3. The procedure for evaluation control of suppliers(CP-24-0031)
4. The procedure for supplier registration(CP-24-0029)

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 6/10
7.4.2 Purchasing information

a) The purchasing document shall clearly specify the data describing required quality of
purchased materials and components.
b) The purchasing document shall include the necessary contents of the following items from
(1) to (8), if necessary.
(1) Work scope
(2) Specified technical requirements such as codes, standards, regulations, instructions, etc.
(including revision)
(3) Identification of test, inspection and acceptance criteria
(4) Provision for access to the facilities and records
(5) Quality assurance requirements
(6) Required documents
(7) Requirements for report and approval of the disposition of nonconformity
(8) Adequate preparation of premeditated products, exchangeable products or assembly
c) The preparation of purchasing documents shall conform to the regulation for purchasing
affairs, procedure for purchasing document control and procedure for purchasing
specification preparation.
d) As for nuclear products or when required on contract documents, prepared purchasing
documents shall be reviewed and approved by the Design team manager for technical
requirements, by the Quality management team manager for quality requirements, before
distributing to suppliers.
e) Review and revision of purchasing documents shall ensure that products and materials are
in accordance with clear requirements.
f) Any data about supplier may be available for review of customer or his representative.
g) The Subcontracting & purchasing team manager and Purchasing team manager shall
deliver adequate purchasing documents to suppliers. All requirements about contract shall
be included in purchasing documents.
h) Revision of purchasing document shall be reviewed and approved in the same manner as
the original.
[Related Procedure] 1. The procedure for control of purchasing(CE-24-0105)
2..The procedure for preparation of purchasing specification(CP-86-0020)
7.4.3 Verification of purchased products

a) Where specified in the contract, the customer or his representative can verify whether
purchased products conform to specified requirements at the supplier‟s plant or a designated
place. Verification by the customer cannot absolve the responsibility of Hyosung Corporation
to provide acceptable products, nor can it preclude subsequent rejection.
b) In case that purchased products should be inspected at the supplier‟s plant, the
Subcontracting & purchasing team manager and Purchasing team manager shall distribute
the purchasing documents or relevant standards specifying the inspection and release
methods to the supplier.
c) For purchased products requested for inspection, the receiving inspector shall inspect on the
basis of the receiving inspection standard, material standard, specification, drawings and
other related standards, and prepare and control the inspection records.

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 7/10
d) A sticker shall be attached to the non-accepted product, and a report on nonconformity shall
be issued. The product shall be treated according to the procedure for nonconforming
product managements.
e) When commercial grade items are purchased, it shall be verified that requirements needed
to satisfy the design function are satisfying with the items that are commercially available.
f) For nuclear products, the requirements applied to the first purchase of product shall be
documented, or the related product manual or its duplication shall be maintained to facilitate
reordering.
[Related Procedure] The procedure for receiving inspection management(CE-34-0140)
7.5 Production and service provision
7.5.1 Control of production and service provision
Our company shall carry out production and service provision affecting on the quality under the
controlled conditions as below.
a) Availability of information describing the characteristics of the product
b) Availability of standards, as necessary
c) Use of suitable equipment
d) Availability and use of monitoring and measuring devices
e) Implementation of specified monitoring and measurement
f) Implementation of release to the customer, delivery and post-delivery activities
[Related Procedure]
1. The procedure for control of manufacturing facilities(CP-79-0001)
2. The procedure for measuring instrument management(CP-34-0002)
3. The procedure for independent inspection(each product)
7.5.2 Validation of processes for production and service provision
a) Our company refers a manufacturing defect such as the following that cannot be verified
before use as a special process and it shall be included in the control standard for general
processes and controlled specially.
(1) Welding
(2) Painting
(3) Heat treatment
(4) Compression
(5) Brazing
b) To demonstrate the ability of the processes to achieve planned results, the followings shall
be applied to confirm the validation.
(1) Defined criteria for review and approval of the processes

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 8/10
(2) Approval of equipment and qualification of personnel

(3) Use of specific methods and procedures
(4) Requirements for records
(5) Revalidation
[Related Procedure]
1. The procedure for welder qualification(CP-34-0177)
2. The procedure for qualification of brazing worker(CpE-34-0009)
3. The procedure for qualification of heat treatment worker(CP-34-0190)
4. The procedure for qualification of painting worker(CP-34-0182)
5. The procedure for qualification of clamping worker(CP-34-0147)
6. The procedure for special process control(CP-34-0158)
7.5.3 Identification and traceability
a) Physical identification shall be used to the maximum extent possible, and where physical
identification impossible, other appropriate means such as documentation shall be applied.
b) The identification method used for relevant products shall provide clear and legible
identification, and not affect the function or service life of the product.
c) At every stage of production and installation, the product shall be identified related to the
monitoring and measurement requirements.
d) If traceability is a special requirement, the product shall have a unique identification to meet
the established range, and this identification shall be recorded to control traceability.
e) Identification control of purchase products
(1) The products purchased from outside shall be identified by marking or delivery tag
according to the procedure for control of material and traceability.
(2) The products that are difficult to have a marking or delivery tag attached shall be
identified by colors.
(3) The identification control of inspection results shall be identified by inspection-result-
stickers (or stamping).
f) Identification control of product in process
(1) The product machined by using the purchased product shall be identified by marking or
tagging with drawing number, production number, customer‟s name, etc. or by putting
into a container with identification expressed.
(2) The product assembled by using the purchase product shall be identified by tagging with
drawing number, production number, customer‟s name, etc, or by means of I.D board or
by discriminating the location.
g) Identification control of completed product
(1) The completed product shall be identified by nameplate.
h) Identification control of packed product
(1) The packed product shall be identified by packing-nameplate or tagging.

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 9/10
i) Traceability control
(1) In case that traceability is required on the contract or products requiring traceability are
produced, the objectives and methods to trace shall be specified so that traceability
control can be performed separately through all possible range.
j) Every control record of identification and traceability shall be maintained in the team in
charge.
[Related Procedure]
The procedure for item control and delivery(CP-25-0040)
7.5.4 Customer property

a) The Sales team manager shall have responsibility to check whether there is customer-
supplied products when making a contract and report to the related team.
b) Industrial machinery PU and Power systems PU Quality inspection team manager shall
have responsibility to carry out the receiving inspection at the place consulted with the
customer to check that the parts supplied by the customer meet the specifications on the
contract, and the receiving inspection report shall be prepared referring to the requirements
provided in the contract.
c) The manufacturing team manager shall have responsibility to handle and store customer
supplied products accepted from the receiving inspection.
d) When lack of quantity, loss, damage or nonconformity of customer-supplied products is
occurred, the receiving inspector shall record the fact on the nonconformity report or in other
forms and report to the customer.
e) The verification by our company does not exempt the responsibility of customer to supply
accepted products.
f) In the receiving inspection report on customer-supplied products, the articles under
inspection, inspection date, inspector, items to be inspected and results of inspection shall
be included.
g) The receiving inspection report on customer-supplied products shall be available to the
customer and shall be controlled in records.
[Related Procedure] The procedure for inspection, handling, storage and control of customer
supplied product(CE-34-0147)
7.5.5 Preservation of product

Our company shall preserve the conformity of product to customer requirements during product
manufacturing process as well as delivery to the intended designation as follows.
The preservation shall include identification, handling, packaging, storage and protection. Also,
the preservation shall include the elements such as raw materials, parts, semi-products and
services.
a) In order to prevent damage or deterioration that can be occurred during handling parts and
products, handling method, selection of transporting container, loading methods, etc. shall be
carried out in accordance with the relevant standard.
b) In order to prevent mixture, damage or deterioration of parts or materials before use or
delivery, appropriate storage and monitoring shall be performed in a way to
(1) make identification easy,
(2) prevent quality change due to humidity, loading method or lading height, and
(3) maintain effectiveness.

MANUAL NO.
QULAITY MANAGEMENT MANUAL MQM-T001
REV. NO.: G PAGE
DATE: Jul 26. 2010. 10/10
c) For stock control, appropriate quantity shall be in hand, and the first stocked first delivered
basis shall be maintained.
d) Necessary actions to prevent parts, semi-products and products from damaging and
deterioration shall be taken.
e) To protect the product quality after the final inspection and test, the specified packaging and
handling method shall be maintained until delivered to the place designated by the customer.
f) To maintain the quality during transportation, transporting companies shall be evaluated and
selected.
[Related Procedure] 1. The procedure for material control(CE-24-0219)
2. The procedure for item control and delivery(CP-25-0040)
7.6 Control of monitoring and measuring devices

[Related Procedure] The procedure for measuring instrument management(CP-34-0002)
Our company shall carry out periodic inspection and calibration for inspecting, measuring and
testing devices used in our company (referred as measuring devices hereafter) so as to verify
that the product conforms to the requirements.
a) Items and degree to be measured shall be clearly determined to obtain appropriate
measuring devices.
b) All measuring devices that can affect on product quality shall be calibrated or adjusted by
using the standard gauge or other valid device authorized by international or national
standards.
c) The type, identification number, applicable place, inspecting interval, inspecting method,
acceptance criteria and measures to be taken when problems occur of all measuring
devices shall be carried out based on the standards.
d) The condition of calibration and inspection shall be indicated with suitable marking or
record, and the report on the calibration and inspection shall be maintained.
e) In case that the result of calibration is contrary to the standard, the effectiveness of test and
inspection results judged by using that measuring device shall be reviewed again and
recorded in the document to control.
f) The calibration, inspection, measurement and test shall be performed under specified
environment conditions.
g) Inspection, measuring equipment and handling/storage of testing equipment shall
accurately conform to the manual.
h) Measuring devices including hardware and software for test and inspection shall be verified
and configuration should be controlled that they can maintain adequacy before using them.

MANUAL NO.
REV. NO.: G PAGE
SECTION 8 MEASUREMENT, ANALYSIS AND IMPROVEMENT
DATE: Jul 26. 2010. 1/7
8.1 General
Our company shall plan and implement measurement, analysis and continual improvement of
processes through monitoring and measurement of customer satisfaction (8.2.1), monitoring and
measurement of processes (8.2.3), monitoring and measurement of products (8.2.4), control of
nonconforming products (8.3), data analysis (8.4), quality policy and quality objectives (5.3/5.4.1),
internal audit (8.2.2), corrective actions (8.5.2), preventive actions (8.5.3) and management review
activities (5.6) so as to
a) demonstrate conformity of the product requirements,
b) ensure conformity of the quality management system, and
c) continually improve the effectiveness of the quality management system.
Also, these continual improvement processes shall include determination of applicable methods
including statistical techniques and the extent of their use.
8.2 Monitoring and measurement

8.2.1 Customer satisfaction
As a part of performance measurement for the quality management system, our company shall
monitor the information on customer‟s recognition that the supplied product is satisfied with the
requirements of customer, and the methods for obtaining and using this information shall be
specified in the procedure.
However, n the procedure,
first, the methods, kinds and measures to obtain and understand customer information shall
be concretely determined,
secondly, the Quality assurance team manager shall consider the importance of customer
complaints, and take corrective and preventive actions by
a) analyzing the present conditions(graph, pareto, etc.),
b) examining the cause(QFD, cause system diagram, cause and effect diagram, etc.),
c) working out and carrying out countermeasures to prevent reoccurrence,
d) checking and evaluating the performance results, and
e) standardizing the evaluation results.
[Related Procedure]
1. [Power Systems PU] The procedure of service management for customer satisfaction
(CP-38-0011)
2. [Industrial Machinery PU] The procedure of service management for customer satisfaction
(CE-25-0401)
8.2.2 Internal audit
8.2.2.1 Audit plan
a) The Quality management team manager shall devise a yearly audit plan for all the teams
responsible for implementation of the quality system.
(1) Regular audits shall be carried out once or twice a year to verify that all teams are
implementing the quality system.

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 2/7
(2) If necessary, irregular audits can be carried out when significant changes occur to the
functional fields of quality system or when audit deficiency recurs after completion.
b) The yearly audit plan shall be reviewed by the Quality management team manager and
approved by the Plant manager.
8.2.2.2 Audit preparation

a) The Quality management team manager shall designate a lead auditor and auditors to
carry out audits who are qualified in accordance with the procedure for quality auditor
qualification.
b) The lead auditor shall, prior to performing an audit, verify that the selected auditors have
experience in the field or property of activities being audited, or are educated above the
equivalent experience.
c) Auditors shall have sufficient authority and organizational freedom to make the audit
process meaningful and effective.
d) The procedure for quality audit or audit checklist shall be approved by the Quality
management team manager.
e) The Quality management team manager and the lead auditor shall, prior to performing an
audit, provide an audit plan including the following.
(1) Audit scope, activities to be audited and organizations to be notified
(2) Requirements and documents to be applied to the designated audit field
(3) Auditor and schedule
(4) Procedure for quality audit and audit checklist to be used
(5) Review and reflection of previous audit results
8.2.2.3 Execution of audit

a) Audits shall be carried out in accordance with the documented procedure for quality audit
and audit checklist based on the audit plan.
b) Elements selected for the audit shall be evaluated against the requirements provided in
the audit plan.
c) Objective evidence shall e examined to determine if selected elements are being
implemented effectively.
d) Auditors shall document the audit deficiencies found while performing the audit on the
corrective action requests and obtain the approval of the lead auditor.
e) When errors requiring prompt corrective actions are found, the lead auditor shall
immediately notify the team manager of the organization to be audited.

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 3/7
8.2.2.4 Report of audit

a) Upon completion of an audit, the lead auditor shall prepare a condensed audit report from
audit results, and the Quality assurance team manager shall review and the Plant
manager shall approve it.
This audit report shall contain the following.
(1) Career of auditors
(2) Designated date for corrective action
(3) Summary of audit results including a statement on the effectiveness of quality system
elements audited
(4) Corrective action requests on which detailed audit deficiencies are described to enable
corrective action to be taken by the audited organization
(5) Signature of the lead auditor
b) The lead auditor shall send the corrective action requests to the team manager of the
audited organization.
8.2.2.5 Response of audit result and follow-up audit

a) The team manager of audited organization shall review the corrective action requests, and
document the implementation schedule of corrective action to be taken or the content of
corrective action that has already been taken completely including recurrence prevention
plan, on the corrective action requests, at the designated date or before, and send to the
auditor.
b) The auditor shall review the effectiveness of the response for corrective action, and then if
unsatisfied, request the re-corrective action.
c) The lead auditor shall perform the follow-up audit in order to verify that the implementation
or implementation plan is successfully performed, and that it has effectiveness, and also
he shall record the results of follow-up audit on the corrective action requests and obtain
the approval of the Quality assurance team manager.
d) The Quality assurance team manager shall synthesize the content of corrective action
form the audit results and report to the Plant manager to enable the quality system to be
evaluated.
[Related Procedure] 1. The procedure for quality auditor qualification(CP-34-0014)
2. The procedure for management system audit(CP-34-0183)
8.2.3 Monitoring and measurement of processes

Our company shall determine the performance index of the quality management system per
core process and demonstrate the ability of the processes to achieve planned results through
monitoring or measuring them.
When planned results are not achieved, correction and corrective actions shall be taken.

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 4/7
[Core processes]
Index for monitoring and measurement (performance index)

Process name
Items Calculations
Target achievement
ratio of receiving Result amount/Target amount * 100
orders
Receiving orders Achievement ratio of (No. of receiving orders/No. of total estimation ) * 100
receiving orders
Achievement ratio of
delivery ((Total no.-Delayed no.)/Total no.) * 100
Observance ratio of
Deadline observance no./Total order no. * 100
design schedule
Design and Improvement ratio of
development design No. of improvement/Target no. * 100
Design errors No. of defective design/Total order no.
Acceptance ratio of Acceptance no. of receiving inspection/Total inspection no. *
suppliers 100
Purchasing and Instruction ratio for No. of instruction/Target no. * 100
subcontracting suppliers
Supply ratio at a Delivery observance no. within the period/No. of delivery *
suitable time 100
Observance ratio of (Warehoused quantity-Delayed quantity)/Warehoused
delivery quantity * 100
Manufacturing
Cost ratio Cost price of manufacturing/Production cost *100
management
Possession days of
stock property Stock cost/Production cost * 30 days
Performance ratio of
Planned results/Executed plan * 100
production plan
Manufacturing Labor productivity Production cost/(Internal manufacturing + Giving a contract
+ subcontracting
Final defect ratio No. of defective products/No. of inspected products * 100
Defect detection ratio No. of defective products/No. of inspected products * 100
Instruction ratio for
Inspection suppliers No. of instruction/Target no. * 100
Acceptance ratio of
No. of acceptance/No. of entrance * 100
entrance
Flaw ratio No. of products with flaw/No. of products manufactured
within warranty period * 100
Customer satisfaction Customer satisfaction No. of customer satisfaction/No. of servicing *100
((Calling out date-Receipt date) < 3 days) No./Total calling
Calling out ratio out no.*100
Control of objectives Index control Each team

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 5/7
8.2.4 Monitoring and measurement of product

To verify that the product meets the requirements of customer, quality objective, statutory and
regulatory requirements, the characteristics of the product shall be monitored and measured.
Monitoring and measurement of product shall contain the receiving inspection, middle
inspection, independent inspection, final inspection, forwarding inspection and field inspection
according to individual production plan. The evidence that the product conforms to the
acceptance criteria shall be maintained in records and approved by the person in charge of
product release to the customer.
The product release and service to the customer shall not be performed until the problems of
all specified inspections are solved except the case that the approval of customer is obtained.
[Related Procedure] The procedure for forwarding inspection(CP-64-0001)
8.3 Control of nonconforming product

The nonconforming product found in purchased parts, manufacturing, inspection and delivery to
the place designated by the customer must be identified at each stage and controlled to prevent
its unintended use.
The nonconforming product shall be handled in accordance with the procedure for management
of nonconforming product and the records shall be maintained.
a) Division of nonconformities
(1) Nonconforming products found during receiving inspection
(2) Nonconforming products occurred during manufacturing
(3) Nonconforming products found during final inspection
(4) Nonconforming products found during forwarding inspection
(5) Nonconforming products found after forwarding
b) How to deal with nonconforming products
(1) Repair and rework (modification) to meet specified requirements
(2) Concession
(3) Re-grading to change the use (others)
(4) Return and disuse
All products repaired or reworked shall be inspected again.
Also, if specified on the contract, the repair or concession of nonconforming products shall have
the approval of the Quality assurance team manager after consulting with customer or his
representative.
If nonconforming products are found after forwarding or during use, actions to remove actual
and potential affect of nonconformity shall be taken.
[Related Procedure] The procedure for nonconforming product management(CP-34-0009)
8.4 Analysis of data

Appropriate data such as the followings shall be collected and analyzed to demonstrate the
suitability and effectiveness of the quality management system and to evaluate where continual
improvement of the effectiveness of the quality management system can be made.
a) Product results
b) Inspection data
c) Cost price
d) Delivery control
e) A/S data
f) Labor productivity
g) Control of suppliers
h) Index of customer satisfaction

MANUAL NO.
QUALITY MANAGMENET MANUAL MQM-T001
REV. NO.: G PAGE
DATE: Jul 26. 2010. 6/7
According to the results of data analysis, information on the followings shall be provided.
a) Customer satisfaction
b) Conformity to product requirements
c) Characteristics and trends of processes
d) Contribution of suppliers
8.5 Improvement
8.5.1 Continual improvement
The effectiveness of the quality management system shall be continuously improved through
the following activities.
a) Realization of quality policy
b) Control of quality objectives
c) Internal audit, customer audit and audit by authorized organization
d) Data analysis
e) Corrective and preventive action
f) Management review
[Related Procedure] 1. The procedure for management system audit(CP-34-0183)
2. The procedure for issuing & control of correcting management
(CP-34-0011)
8.5.2 Corrective action
a) When reviewing the report on nonconformity, concession, customer complaints and errors in
audit, and found corrective actions to be taken or serious problems affecting on the quality, a
member of the Quality assurance team shall issue the corrective action request.
b) When any potential cause that can be resulted in nonconformity is found, a member of the
Quality assurance team shall issue the corrective action request to prevent nonconformity in
advance.
c) Conditions affecting on the quality are as the followings.
(1) Process of product (or service), nonconformity at storage or handling, defect
(2) Nonconforming procedures and documents
(3) Nonconforming process control
(4) Wrong schedule
d) The following requirements are defined in documented procedures.
(1) Review of nonconformity (including complaints of customers)
(2) Determination of the cause of nonconformity
(3) Assessment of action‟s necessity in order to prevent reoccurrence
(4) Determination & implementation of necessary action
(5) Recording of the result of Actions taken
(6) Review of effectiveness of taken corrective action
[Related Procedure] 1. The procedure for issuing & control of correcting management
(CP-34-0011)

MANUAL NO.
REV. NO.: G PAGE
DATE: Jul 26. 2010. 7/7
8.5.3 Preventive action

a) When a problem contrary to stability of quality is occurred, the team in charge shall examine
the cause, work out countermeasures to solve the problem and take preventive actions to
prevent recurrence.
b) To perform corrective actions, the evaluation on importance of the problem and examination
on the cause shall be carried out, and related matters shall be carefully analyzed to take
preventive actions as the followings.
(1) Change of manufacturing, packaging and storage process
(2) Change of product specification
(3) Change of quality system
(4) Taking appropriate actions according to the importance of potential problem
c) The following requirements are defined in related documented instructions.
(1) Determination of potential nonconformity and the cause of potential nonconformity
(2) Assessment of action‟s necessity in order to prevent reoccurrence
(3) Determination & implementation of necessary action
(4) Recording of the result of Actions taken
(5) Review of effectiveness of taken corrective action
[Related Procedure] 1. The procedure for issuing & control of correcting management
(CP-34-0011)

MANUAL NO.
REV. NO.: G PAGE
SECTION 9 SUPPLEMENT
DATE: Jul 26. 2010. 1/2
9.1 Preparation of the quality management manual and control of revisions

9.1.1 The Quality management team manager has responsibility to prepare and revise the quality
management manual (referred as manual hereafter).
9.1.2 This manual shall be prepared and reviewed by the Quality management team manager, and
shall be approved by the Plant manager.
Also, the revision shall be controlled in the same manner, and the contents of the revision shall
be documented in the revision list. The preparation, review and approval shall have the
signature of the Plant manager on the approval letter of quality management manual to be
valid. It shall be applied and executed after 7 days from approved date.
9.1.3 The Quality management team manager, if specified on the contract, shall have responsibility to
obtain the approval of customer.
9.1.4 When the requirements of related regulations, KEPIC, international standards (ANSI/ASME
NQA-1) and international quality assurance standard ISO 9001 are changed, the Quality
management team manager shall review the changes and revise the manual accordingly. The
contents shall be reported to and approved by the Plant manger for periodic review.
9.1.5 The final revision shall be indicated on the corner of right side of each page.
9.1.6 The manual shall be revised and reissued by section including contents table. The contents
table and each section shall have the latest revision number and date.
9.2 Distribution control of manual

9.2.1 The Quality management team manager shall have responsibility to distribute the manual and
its revision.
9.2.2 Each copy of manual to be distributed shall be identified as controlled or non-controlled.
9.2.3 The Quality management team manager shall determine where to distribute the manual with
serial number on it.
9.2.4 The Quality management team manager shall distribute the manual by using the manual
transmittal slip, and the distribution number shall be marked on the manual.
On the transmittal slip, it is noted that the recipient shall return the transmittal slip to the Quality
assurance team within 5 days of receipt inside Hyosung Corporation Changwon Plant, 10 days
outside the plant, and 4 weeks pitsode Hyosung Corporation.
9.2.5 The recipient of manual has responsibility to remove superseded sections or pages and insert
revised sections or pages so as to observe the requirements of transmittal slip.
9.2.6 The Quality management team manger shall record the distribution date and withdrawal date of
manual on the manual distribution log.
9.2.7 If the transmittal slip is not returned, the Quality management team manger shall directly contact
with the recipient in Hyosung Corporation Changwon Plant to receive and check the transmittal
slip. If the transmittal slip is distributed to outside, the Quality management team manger shall
notify the recipient possessing the manual that the manual is classified into non-controlled copy,
and the manual distribution log shall be accordingly updated.

MANUAL NO.
REV. NO.: G PAGE
SECTION 9 SUPPLEMENT
DATE: Jul 26. 2010. 2/2
9.3 Relation with ISO 9004:2000 (ISO 9001:2008 0.3)

The quality management system of our company plays a role of a method to achieve the
management objectives and specifies general requirements available for certification or making a
contract. ISO 9004:2000, the procedure for result improvement shall be run parallel with ISO
9001:2000 in order to improve customer satisfaction and management results.
Therefore, our company shall use ISO9004:2000 as a reference standard to improve the
effectiveness and efficiency of quality management system and the management results.
9.4 Grafting into other management system (ISO 9001:2008 0.4)

In order to achieve our management objectives, the quality management system of our company
shall be grafted into existing management techniques or systems to produce synergy effect.
Therefore, it should not be understood as separated.
To realize the quality-focused management, our company shall keep grafting the quality
management system into existing management systems for development in principle.

MANUAL NO.
REV. NO.: I PAGE
SECTION 10 APPENDIX
DATE: Sep 07. 2012. 1/5
[Appendix1. Process linkage diagram]

MANUAL NO.
REV. NO.: I PAGE
SECTION 10 APPENDIX
DATE: Sep 07. 2012. 2/5
[Appendix 2. Process flow ]

MANUAL NO.
REV. NO.: I PAGE
SECTION 10 APPENDIX
DATE: Sep 07. 2012. 3/5
[Appendix3. Role allotment table]
Section
Manufacture
Production control
Quality assurance
Purchasing
Subcontracting control
Human resources
Safety & Environment

Production facilities
General affairs
Business
Manager
Service
Design
Related standards
ISO requirements
0.4 8 principles of quality management ◎ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

4. Quality management system
4.1 General requirements ◎ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
4.2 Documentation requirements ○ ○ ○ ◎ ○ ○ ○ ○ ○ ○ ○ ○
4.2.1 General
4.2.2 Quality management manual ◎ ◎ 4
4.2.3 Control of documents ○ ○ ○ ◎ ○ ○ ◎ ○ ○ ○ ○ ○ 1, 2, 12
4.2.4 Control of records ○ ○ ○ ◎ ○ ○ ○ ○ ○ ○ ○ ○ 5
5 Management responsibility
5.1 Management commitment ◎
5.2 Customer focus ○ ○ ◎ ○ ○ ○
5.3 Quality policy ◎ ◎
5.4 Planning
5.4.1 Quality objectives ○ ○ ○ ◎ ○ ○ ○ ○ ○ ○ ○ ○
5.4.2 Quality management system planning ○ ○ ○ ◎ ○ ○ ○ ○ ○ ○ ○ ○
5.5 Responsibility, authority and communication
5.5.1 Responsibility and authority ○ ○ ○ ◎ ○ ○ ○ ○ ○ ○ ○ ○

5.5.2 Quality management representative ◎
5.5.3 Internal communication ○ ○ ○ ◎ ○ ○ ○ ○ ○ ○ ○ ○
5.6 Quality management review
5.6.1 General ○ ○ ○ ◎ ○ ○ ○ ○ ○ ○ ○ ○
5.6.2 Review input ○ ○ ○ ◎ ○ ○ ○ ○ ○ ○ ○ ○ 18, 19, 27, 34
5.6.3 Review output ○ ○ ○ ◎ ○ ○ ○ ○ ○ ○ ○ ○
6. Resource management
6.1 Provision of resource ○ ○ ○ ◎ ○ ◎ ○ ○ ○ ○ ○ ○
6.2 Human resources
6.2.1 General ○ ○ ○ ◎ ○ ◎ ○ ○ ○ ○ ○ ○
6.2.2 Competence, awareness and training ○ ○ ○ ◎ ○ ◎ ○ ○ ○ ○ ○ ○ 6, 7, 36
6.3 Infrastructure ○ ◎ ◎ ◎ 20
6.4 Work environment ○ ○ ○

MANUAL NO.
REV. NO.: I PAGE
SECTION 10 APPENDIX
DATE: Sep 07. 2012. 4/5
Section
Production control
Manufactur
Quality assurance
Purchasing
Human resources

General affairs
Business
Manager
Service
Design
e
Related standards
ISO requirement
7 Product manufacturing
7.1 Planning of product manufacturing ○ ○ ◎ 24, 25
7.2 Customer-related process 44
Determination of requirements ◎ ◎ ○
7.2.1
related to the product 44
Review of requirements related ◎ ◎ ○
7.2.2
to the product 44
7.2.3 Communication with customer ○ ◎ ○ ○ 44

7.3 Design and development 44
7.3.1 Design and development planning ◎ 44
7.3.2 Design and development input ◎ 44
7.3.3 Design and development output ◎ 44
7.3.4 Design and development review ◎ 44
7.3.5 Design and development verification ◎ 44
7.3.6 Design and development validation ◎ 44
7.3.7 Control of design and development changes ◎ 44
7.4 Purchasing
7.4.1 Purchasing process ○ ○ ◎ ◎ 8, 9, 11, 15
7.4.2 Purchasing information ○ ○ ○ ○ 10, 13
7.4.3 Verification of purchased product ◎ ○ ○ 29
7.5 Production and service provision
7.5.1 Control of production and service provision ○ 20, 21, 37, 38, 39, 40, 41, 42, 43
Validation of processes for
7.5.2
production and service provision
◎ ◎ 22, 26, 30, 31, 32, 33
7.5.3 Identification and traceability ○ ○ ○ ○ 17

7.5.4 Customer property ◎ ○ 35
7.5.5 Preservation of product ○ ○ ○ 14
Control of monitoring and
7.6
measuring devices ○ ○ 21, 44
8 Measurement, analysis and improvement
8.1 General ○ ○ ○
8.2 Monitoring and measurement
8.2.1 Customer satisfaction ◎ ○ 18,19
8.2.2 Internal audit ◎ 3, 16
8.2.3 Monitoring and measurement of processes ○ ○ ◎ ○ ○ ○ ○ ○ ○ ○ ○ 24, 25, 28,
8.2.4 Monitoring and measurement of product ○ ◎ 23, 37, 38, 39, 40, 41, 42, 43

MANUAL NO.
REV. NO.: I PAGE
SECTION 10 APPENDIX
DATE: Sep 07. 2012. 5/5
Section
Production control
Manufactur
Quality assurance
Purchasing
Human resources

General affairs
Business
Manager
Service
Design
Related standards
e
ISO requirements
8.3 Control of nonconforming product ○ ○ ◎ ○ ○ 27

8.4 Analysis of data ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
8.5 Improvement
8.5.1 Continual improvement ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 16, 34
8.5.2 Corrective action ○ ○ ◎ ○ ○ ○ 34
8.5.3 Preventive action ○ ○ ◎ ○ ○ ○ 34
Related standards
1. The procedure for control of HICO standard (CP-34-0004) 27. The procedure for nonconforming product management
2. The procedure for control of documents (CP-14-0014) (CP-34-0009)
3. The procedure for quality auditor qualification (CP-34-0014) 28. The procedure for qualification and control of inspector
4. The procedure for control of Management manual (CP-34-0181) (CP-34-0155)
5. The procedure for control of quality records (CP-14-0013) 29. The procedure for receiving inspection management
6. The procedure for control of indoctrination of Changwon plant (CE-34-0140)
(CP-21-0024) 30. The procedure for qualification of heat treatment worker
7. The procedure for control of on the job training (CP-21-0029) (CP-34-0190)
8. The procedure for subcontract management (CP-24-0005) 31. The procedure for qualification of painting worker
9. The procedure for subcontract management(new item) (CP-34-0182)
(CP-24-0006) 32. The procedure for qualification of crimping worker
10. The procedure for control of purchasing(CE-24-0105) (CP-34-0147)
11. The procedure for evaluation control of suppliers (CP-24-0031) 33. The procedure for special process control (CP-34-0158)
12. The procedure for control of purchasing document 34. The procedure for issuing & control of correcting
(CP-24-0060) management (CP-34-0011)
13. The procedure for preparation of purchasing specification (CP- 35. The procedure for inspection, handling, storage and control of
86-0020) customer-supplied product (CE-34-0147)
14. The procedure for material control(CE-24-0219) 36. The procedure for qualification of field supervisor
15. The procedure for supplier registration(CP-24-0029) (CP-34-0184)
16. The procedure for management system audit(CP-34-0183) 37. The procedure for independent inspection
17. The procedure for item control and delivery (CP-25-0040) (Power Transformer)(CP-31-0231)
18. The procedure of service management for customer satisfaction 38. The procedure for independent inspection
(Power systems PU) (CP-38-0011) (Circuit breaker Mfg 1 team)(CP-31-0120)
19. The procedure for customer service management(Industrial 39. The procedure for independent inspection
Machinery PU) (CE-25-0401) (Circuit breaker Mfg 2 team)(CP-31-0111)
20. The procedure for control of manufacturing facilities 40. The procedure for independent inspection
(CP-79-0001) (Electrical panel Mfg team)(CP-31-0152)
21. The procedure for measuring instrument management 41. The procedure for independent inspection
(CP-34-0002) ( HV Motor Mfg team)(CP-34-0114)
22. The procedure for welder qualification (CP-34-0177) 42. The procedure for independent inspection
23. The procedure for forwarding inspection (CP-64-0001) (LV Motor Mfg 2 team)(CP-34-0135)
24. The procedure for inspection & test 43. The procedure for independent inspection
(Power systems PU) (CP-34-0056) (Foundry Mfg team)(CP-63-0014)
25. The procedure for inspection & test 44. The design manual (Manual of each product)
(Industrial Machinery PU) (CP-34-0138)
26. The procedure for qualification of brazing worker
(CP-34-0185)
Note. ◎: Person and team in charge,

○: Performing team

DOCU. NO. :
Rev. No. : A
Instructions Manual for Erection,
TITLE
Installation, Operation, Maintenance Page. No : Cover
Instructions Manual for Erection, Installation,

Operation, Maintenance
DOCU. NO. :
Rev. No. : A
Instructions Manual for Erection,
TITLE
Installation, Operation, Maintenance Page. No : 1 / 181
Instructions Manual for Erection, Installation,

Operation, Maintenance
DISCIPLINE : PROCUREMENT
For Approval
A 19/12/13 FOR APPROVAL H.G.RYU K.D.KANG. T.H.YOON W.C.JEONG
REV.
NO.
REV.
NO.

A FOR APPROVAL
19/12/13 19/12/13 19/12/13 19/12/13
Operation & Maintenance
Manual
INSTALLATION,
OPERATION & MAINTENANCE
MANUAL
3×15MW WAMPU HEPP PROJECT

GENERATOR STEP-UP TRANSFORMER
D
Deessccrriippttiioonn Q’’ttyy
Q
3 Phase 50Hz 150/11kV YNd1 15/20MVA ONAN/ONAF

with OLTC on HV Winding
3 Sets
Copyright - 2013 HYOSUNG

All rights reserved.
Table of Contents
Manual
R0
The instructions and procedures included in this manual are intended to provide general guidance to
trained personnel, with experience and expertise in the safe and careful performance of their job.
These instructions and procedures cannot and does not cover all details of every task nor can it cover
all possible situations that may be encountered during the performance of the task.
The User is solely responsible for ensuring that all work is performed safely and without damage to the
transformer and accessories.
If any additional guidance is required, contact HYOSUNG

Table of Contents
Manual
R0
● Safety Notations
The following notations are used in this manual to alert the user to potential safety hazards
Kinds of Mark Meaning of Mark

Danger indicates an immanently dangerous
situation which, if not avoided, results in death or
serious injury to personnel. This signal word is
limited to the most extreme situation
Warning indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury
Caution indicates a potentially hazardous situation

which, if not to avoided, may result in equipment or
installation damage. It may also be used to alert
against unsafe practices.
Electrical Hazard warning

Table of Contents
Manual
R0
Table of Contents
Technical Data
Introduction
Section 1. Safe Working Practices
1.1 Introduction
1.2 Communication
1.3 Personal Protective Equipment (PPE)
1.4 Thought - Joggers for Mitigating Risks
Section 2. General Construction
2.1 Core Form Design and Construction

2.2 Shell Form Design and Construction
2.3 Tank Design and Construction
2.4 Radiators or Heat Exchangers
2.5 Conservator Design and Construction
2.6 Factory Oil Processing
Section 3. Shipment, Receipt and Storage
3.1 Packing and Shipment

3.2 Receiving Transformer and Accessories
3.3 Receiving Oil
3.4 Moving and Handling
3.5 Temporary Storage

Table of Contents
Manual
R0
Section 4. Installation and Assembly
4.1 Required Tools and Equipment

4.2 Setting the Transformer on the Foundation
4.3 Grounding the Transformer Tank
4.4 Inspecting the Active Part
4.5 Temporary Sealing of the Transformer Between Work Days
4.6 Bolt & Nut Assembly
4.7 Required Torque Values
4.8 Standard Bolt Dimensions
4.9 Tightening Sequence for Nuts and Bolts
4.10 Assembly Safeguards
4.11 Recommended Assembly Order and Quality Checks
4.12 Gasketing
4.13 Installing Bushings
4.14 Installing Radiators and Cooling Equipment
4.15 Installing Pressure Relief Devices
4.16 Installing the Buchholz Relay
4.17 Installing Oil and Winding Temperature Gauges
Section 5. Vacuum Oil Processing Procedures
Quality Issues
Equipment Required
Process Flowchart
Ambient Temperature Considerations
Ambient Humidity Considerations
Determining Required Heater Capacity
Pre-Processing Quality Check
5.1 Grounding
5.2 Dew Point Test
5.3 Pre-Processing Dry Out Process
5.4 Oil Acceptance
5.5 Ambient Temperature Check
5.6 Active Part Pre-Heat
5.7 Vacuum Leak Test
5.8 Processing Parameters
5.9 Processing After Short Term Storage
5.10 Vacuum Oil Filling Process

Table of Contents
Manual
R0
Section 6. Commissioning Tests
6.1 Visual Check

6.2 Measurement of Insulation Resistance
6.3 Measurement of Voltage Ratio
6.4 Phase Relationship Check
6.5 No-load Current Test
6.6 Wiring Check of Protection
6.7 Oil Test
6.8 BCT Wiring Check And Polarity Test
6.9 On-load Tap-changer Test
6.10 Function Test
6.11 Visual Check (after energizing)
Section 7. Power Transformer Maintenance and Repair
7.1 General Requirements for Inspection and Maintenance

7.2 Spare and Replacement Parts
7.3 Inspection Records
7.4 Routine Inspections
7.5 Periodic Inspections
7.6 Periodic Testing
7.7 Regular Maintenance
7.8 Troubleshooting
7.9 Diagnosis of protective relays in operation
7.10 Recommended Instructions for Repairing Weld Leaks

Table of Contents
Manual
R0
Section 8. Recommended Minimum Transformer Protection
Relay Device Numbers

Symbols
Small Power Transformers in Substations
Powerplant Generator Step-Up Transformers
Powerplant Auxiliary (UAT) Transformers
Distribution Substation Step-Down and Powerplant Start-Up (SST) Transformers
Transmission Autotransformers
Wind Substation Step-Up Transformers
Wind Turbine Step-Up Transformers
Section 9. Mechanical Drawings
9.1 Outline Drawing

9.2 Foundation Drawing
9.3 Nameplate Drawing
9.4 HV Bushing Drawing
9.5 HVN Bushing Drawing
9.6 XV Bushing Drawing
Section 10. Electrical Drawings
10.1 Local Panel drawing

10.2 Remote Tap Control Panel drawing

Introduction
Manual
R0
Technical Data
These specifications describe the transformer covered by this manual.
Applicable Standard
Electrical equipment covered by this specification will comply with the following standards.
IEC 60076 (International Electrotechnical Commission)
Service Conditions
This transformer is suitable for operation under the following service conditions.
Altitude : Up to 1000 meter above sea level
Ambient temperature
 Maximum 38.0℃
 Minimum -17.6℃
 Altitude Up to 1000 m above sea level

Introduction
Manual
R0
Technical Data Summary

1) Manufacturer HYOSUNG
2) Design standard IEC
3) Number of windings 2
4) Rated power, ONAN / ONAF, MVA 15 / 20
5) Rated frequency, Hz 50
6) Rated voltages
a) HV, kV 150
b) LV, kV 11
7) Vector group reference YNd1
8) Material of insulation (Thermal class A) Insulation paper
9) Type of cooling ONAN / ONAF
10) Winding temperature rise at average ambient 45
temperature of yearly average (20℃), ℃
11) Maximum hot spot temperature rise at average ambient
temperature of yearly average (20℃), ℃ 58
12) No load losses at rated voltage and ratio, kW 21
13) Load losses at 75 ℃ at rated voltage Ratio, kW 107
14) Total losses at 75 ℃ at rated voltage ratio, MVA 128
15) Efficiency at rated voltage ratio and unity
Power factor, % 99.36
16) Impedance voltage at 75 ℃ at rated voltage and power

(including all tolerances), % 10.67 ± 0.8
17) Impedance voltage at 75 ℃ at each end of tapping

Introduction
Manual
R0
range at rated power (including all tolerances)

a) At maximum voltage ratio, % 11.5 (reference only)
b) At minimum voltage ratio, % 10.6 (reference only)
18) Types and arrangement of windings
Shielded
a) HV Continuous
b) LV Continuous
c) Tapping Continuous
d) Arrangement (e.g. Core/LV/HV/taps) Core/LV/HV/taps
19) Conductor material
a) HV windings copper
b) LV windings copper
c) Tapping windings copper
20) Conductor insulation
a) HV windings Insulation paper
b) LV windings Insulation paper
c) Tapping windings Insulation paper
d) Connecting leads from winding to tap changer Insulation paper
21) Basic Impulse Insulation Level (BIL) of Windings, kV
a) HV windings 650
b) LV windings 150
c) Neutral winding 95
22) Type of axial coil supports
a) HV windings R-spacer
b) LV windings R-spacer
c) Tapping windings R-spacer

Introduction
Manual
R0
23) Materials used

a) Axial supports and blocks Pressboard
b) Intermediate coil spacers Pressboard
24) Type of major insulation between windings Pressboard
25) Type of impregnate used on insulation Pressboard
26) Core construction
a) Limbs (Flux density), tesla Approx. 1.7T
b) Yokes (Flux density), tesla Approx. 1.7T
c) Number of limbs 3
d) Number of limbs wound 3
27) Tapings (OLTC)
a) Size of steps as percentage of winding
rated voltage, % 1.25
b) Number of steps 17
28) Total mass of complete transformer, tones 51.2
29) Overall dimensions, m x m x m 7640 x 4800 x 5500
30) Mass as arranged for transport, tones 33.5
31) Dimensions as arranged for transport, m x m x m 5900 x 2550 x 2800
32) Quantity of oil, Liter 13200
33) Maximum noise level, dB(A) @1m 85
BUSHING
34) Basic Impulse Insulation Level (BIL), kV

a) HV Bushing 750
b) LV Bushing 150
c) Neutral Bushing 250

Introduction
Manual
R0
CURRENT TRANSFORMER
35) Rated primary voltage, KV ; HV side 150

LV side 11
37) Current ratio
a) HV side -
b) LV side -
c) HV Neutral 100/1A
38) Accuracy class
a) For instrument 5%
b) For protection 5%
39) Burden, VA
a) For instrument 12.5VA
b) For protection 30VA
EARTHING SWITCH
40) Nominal voltage, kV N/A

43) Rated current , A
45) Lightning impulse withstand voltage, kV

Introduction
Manual
R0
Accessory List
No. Description Type(Model) Maker Remark
1 HV BUSHING COT750-800 TRENCH(FRNACE)
2 HVN BUSHING COT250-800 TRENCH(FRNACE)
3 XV BUSHING 24-1250/P3 CEDASPE(ITALY)
4 BUCHHOLZ RELAY EE3-MA CEDASPE(ITALY)
WINDING TEMPERATURE
5 INDICATOR MT-ST160F MESSKO(GERMANY)
OIL TEMPERATURE
6 INDICATOR MT-ST160W MESSKO(GERMANY)
7 OLTC VMIII 300Y MR(GERMANY)
8 OLTC PROTECTIVE RELAY RS-2001 MR(GERMANY)
9 OLTC MOTOR DRIVE UNIT ED 100S MR(GERMANY)

10 FOR MAIN TANK QT208-60F QUALITROL(U.S.A.)

11 FOR OLTC LPRD00-00021482 QUALITROL(U.S.A.)
OIL LEVEL INDICATOR

12 FOR MAIN & OLTC Dial type TAIJIN(KOREA)
13 COOLING FAN WITH MOTOR T2127Q TAIJIN(KOREA)
14 RADIATOR FOWDER COATING HYOSUNG(KOREA)
15 DEHYDRATING BREATHER T0120,T0121 TAIJIN(KOREA)
16 CONSERVATOR RB2500 HANSOL(KOREA)
17 INSULATION OIL ASTM D3487 TYPE 1 MICHANG(KOREA)
18 LOCAL CONTROL PANEL - HYOSUNG(KOREA)
REMOTE TAP
19 CONTROL PANEL - HYOSUNG(KOREA)

Introduction
Manual
R0
Painting
1. Liquid paint : Main tank, Conservator
Type of paint Poly Urethane Poly Urethane

Prime Coat Dry film thickness 40㎛↑ 40㎛↑
Type of paint N/A Acryl Urethane
Intermediate
Dry film thickness N/A 80㎛
Coat
Color N/A N 6.5(Pebble Gray)
Type of paint Acryl Urethane Acryl Urethane

Finish Coat Dry film thickness 40㎛↑ 40㎛↑
Color N9.5 (White) N 6.5(Pebble Gray)
Total film thickness 80㎛↑ 160㎛↑
Surface treatment Shot blast (SSPC-SP-10)
Paint manufacturer Chokwang Paint Ind. Co., Ltd.
◎ Note : The color of tank cover inside will be Munsell N 6.5
2. Liquid paint : Radiator (Only Outside)
Description Outside
Type of paint Penguard HB

Prime Coat Dry film thickness 20㎛↑
Color Gray
Type of paint Powlac Pe 200
Finish Coat Dry film thickness 80㎛↑
Color N 6.5(Pebble Gray)
Total film thickness 100㎛

◎ Note : To protect the transformer insulation oil be polluted by impurities of radiator, the Inside
of radiator shall be coated with varnish.

Introduction
Manual
R0
3. Local Control Panel
Type of paint Polyester Powder Polyester Powder
Color N 6.5(Pebble Gray) N 6.5(Pebble Gray)
Dry film thickness 60㎛ 60㎛

4. OLTC control Panel


Introduction
Manual
R0
Introduction
Hyosung Industrial Company (HYOSUNG) is a leading and world-class supplier of power transformers
worldwide. Starting with the manufacture of its first 154kV high-voltage transformer in 1969, HYOSUNG
through its advance design, manufacturing and testing capabilities can supply high-quality transformers
through 765kV in both core-form and shell-form designs.
HYOSUNG designs transformers to meet ANSI, IEEE, IEC, JEC and every required national standard.
We also offer:
 Oil Filled Reactors  Distribution Transformers  Compact SF6 Gas
 SF6 Power Circuit  SF6 Gas Insulated Insulated Switchgear
Breakers Switchgear  SF6 Transformers
Hyosung Corporate Offices

450 Gongduk-Dong, Mapo-Ku, Seoul, Korea 121-020
Tel.+82-2-707-6244 / Fax.+82-2-707-6498
www.hyosung.com
Changwon Plant
454-2 Nae-Dong, Changwon, Korea 641-712
Fax.+82-55-268-9839

Operation & Maintenance Safe Working Practices
Manual R0
Section 1
Safe Working Practices
These warnings apply to every part of this section and should be considered as applicable to each line
in this section.
1.1 Introduction:
Workers who use this manual should be trained by their company’s Safety organization in the
company’s Safe Working Practices. Workers who have not been trained in Safe Working Practices or
their company’s Safety Program, or companies without a Safety Program should delegate or contract
all work on this equipment to individuals or companies who have been properly trained. This
HYOSUNG manual is not intended to replace the user’s Safety Program or any policies of the user’s
Safety Program.
This section is provided to help remind trained, qualified workers of the risks that may be present when
working on power transformers, and to provide suggestions in some cases to mitigate those risks. This
manual cannot anticipate all conditions that might occur at every jobsite and must be used as a general
reference and not as a procedure for working safely. The contents of this section are presented as
“Thought Joggers” intended to help the user recognize the various risks associated with this type of
work.
Workers must follow all local, state and federal safety requirements and the user’s site-specific Safety
Program requirements. It is the User’s sole responsibility to be aware of all applicable requirements.
Failure to properly mitigate the risks associated with this type of work could result in serious injury or
death.
If your company does not have an OSHA-compliant Safety Program, contact HYOSUNG for no-cost
guidance on sources of Safety training and sources who can help your organization develop a Safety
Program.

Manual R0
1.2 Communication:
Communication is critically important when working with others. Every job should be thoroughly
discussed with the full crew before starting work to ensure that everyone understands the work that will
be performed by each worker and the risks associated with that work. When multiple crews are working
at a site, each crew leader should understand the scope of the other crews’ work as well. When
circumstances change, everyone who might be affected should be informed.
1.3 Personal Protective Equipment (PPE):
Every worker should have the proper PPE to protect them from all expected risks. The site or worker’s
Safety Co-ordinator should determine the risks that exist at the site and during the tasks performed by
the worker.
In addition to any special equipment that may be required, the following types of common PPE should
be available to the worker at all times, and used when needed.
PPE Protects Against

Hard hat Head bumps and small falling objects
Safety Glasses Eye damage from grinding, drilling, filing, chipping, broken
tools or airborne dusts and debris
Goggles Same as above but provides better coverage
Face Shields Eye or facial damage from grinding, drilling, painting, chemical
handling or similar activities
Rubber Gloves Chemical handling
High voltage gloves Low voltages – used under leather gloves
Leather gloves Scrapes and cuts
Cut-resistant gloves Cuts
Ear Plugs Moderate noise levels
Ear muffs Higher noise levels (when used with ear plugs)
Respirators Airborne dusts, or chemicals
Safety boots Toe damage from dropped objects
Safety Harness Falls
Flame Resistant (FR) Clothing Arc-flash exposure

Manual R0
1.4 Thought-Joggers for Mitigating Risks
The following sections are presented as “Thought-Joggers” to help the user determine the possible
risks in the tasks associated with receiving, installing, testing and maintaining the transformer. These
Thought-Joggers are questions and comments that will cover many of the common situations with this
type of work, and should be considered when the job is planned and discussed with the work crew
before the work begins. Thought-Joggers should help the user and the work crew to think through their
approach to performing their tasks safely and to recognize and mitigate any other potential risks that
may exist in performing their tasks.
Working in Energized Substations and Power Plants

There are several hazards and risks associated with working in energized stations. Workers should
consider the following:
 All substations and power plants should have an Evacuation Plan or Emergency Response Plan
o Are the workers prepared to respond to a site emergency? All workers should know the
alarm signal for site evacuation and the evacuation route and muster location.
 All workers on site should know how to contact emergency services in the event of a fire or
other emergency.
 All workers should be aware of the site conditions
o Is the plant a chemical plant with hazardous materials? Workers should have the right
types of PPE on hand
o Are high-pressure steam pipes or flammable gas or fluid pipes on-site? Workers should
be aware of the locations and risks of all hazardous or underground pipe systems.
o Are overhead or underground power lines or circuits energized? Safe working
clearances must be maintained at all times. Only circuits that can be verified as properly
grounded should be considered de-energized.
o Are control or protective relay circuits completely isolated? Workers should review the
site electrical drawings to determine whether any circuits in the scope of their work are
interconnected with other circuits at the site. Some items to consider when working on
interconnected circuits:
 Control circuits could be energized intermittently. Some examples are fans or
other equipment on thermostats or timers, load tap changers or similar
equipment operating on remotely controlled operation, circuits through auxiliary
contacts on circuit breakers or switches or instrument transformers on circuits
that may be switched on or off. Do not assume that a circuit is de-energized just
because you measure no voltage or current. Review the entire circuit and ensure
that all sources of energization are controlled.
o Are all mechanical systems completely isolated? Workers should also review the site
mechanical drawings to determine if any systems in the scope of their work are
interconnected with other systems at the site. Some items to consider:

Manual R0
 Mechanical, hydraulic, pneumatic, thermal and other types of systems can

operate intermittently. Some examples are pressure relief devices, pumps,
hoppers or conveyors on timers or other control systems, devices on remotely
controlled operation, elevators and cranes. Do not assume that any mechanical
system is not capable of operating just because it is not operating when it is
checked. Review the system drawings and ensure that all sources of operation
are removed or de-coupled.
 Other work may be performed on the site at the same time which could impact your job
o Will your work be performed under a Clearance? If so:
 Who issues and controls the Clearance? The site’s Clearance Co-ordinator or
Operator should issue the clearance and keep track of all Clearances that are
issued.
 Are all workers trained and knowledgeable in the site’s Lockout/Tagout and
Clearance procedures? All workers must be trained and understand these
requirements.
 Does everyone working under the Clearance understand the Clearance
Boundaries? Every worker must know the boundaries of the Clearance they are
working under.
 Has the Clearance holder reviewed the site drawings and “walked down” the
Clearance to verify that all possible sources of energization are isolated and
locked out? Failure to do either creates a risk that a possible source of
energization may be overlooked.
 Are all circuits grounded and all systems locked-out or decoupled after the
Clearance is issued, before any work is performed? Workers must understand
that a Clearance only means that the circuits and systems have been “cleared” of
energization sources. They are not safe to work on until they have been properly
grounded and configured so they cannot be operated.
 Have all connections to the transformer been isolated?
o The people that establish the clearance need to be aware of all
backfeed possibilities. Transformers with auxiliary transformers
connected to the same bus or directly to the transformer can
energize (backfeed) the transformer at full voltage if the aux
transformer’s secondary voltage is connected to another
energized source.
o If the transformer is equipped with three or more sets of windings
(YV or ZV windings) all windings must be isolated and grounded.
 Will testing or other work be performed that will require test terminals to
be disconnected or ungrounded? This may affect the location of the
ground cables when they are attached.

Manual R0
 Are the Grounding Cables safe to use?

 Is the available fault current known at the site, and are the ground cables
adequately sized for the available fault current? Available fault current can
vary widely from site to site. The system operator should provide the
maximum available fault current values. The correct size of ground cable
must be selected to meet the maximum available fault current. The user’s
Safety Program may permit installing multiple ground cables if individual
cables are not sufficient for the fault current levels. De-rating factors may
be required when multiple ground cables are used.
 Have the ground cables been tested and OK for service? Cables should
be tested periodically, according to the user’s Safety Program policies.
 Have the ground cables been visually inspected before use? Cables and
clamps should be inspected before every use. Frayed or damaged
ground cables should not be used.
 Is the correct type of clamp being used for the item being grounded and
the ground connection point? See Figure 1.1 for examples of various
types of ground clamps.
 Will the cables or bus that will be grounded be tested for voltage before
the grounds are connected? Personal protective grounds must not be
installed before the bus or cable to be grounded is first tested with a hot-
stick mounted proximity meter and proven to be de-energized.
 Will the ground cables be connected in the proper sequence? When
installing ground cables, the grounded end should be connected first,
then the cable or bus should be connected. When removing ground
cables, the cable or bus should be disconnected first, then the grounded
end.
o Can other crews lift loads over your work area or haul loads through your work area?
Workers should be aware of other work that can impact their work area. Marking work
areas with Caution tape or warning signs can help make other crews aware of your
presence. Communication and co-ordination with other crews is important.
o Could circuits that must be energized or de-energized for your job to be performed be
switched by other workers on site? All workers must be understand and strictly observe
the site’s Lockout/Tagout program.
o Could site conditions be affected by other crew’s jobs (smoke, noise, piping systems,
deluge systems, etc.)? Workers should have the right types of PPE on hand for any
expected conditions. Communication and co-ordination with other crews is important.
 Adverse environmental conditions may exist
o Are extreme temperatures expected? Extreme temperatures can cause a variety of
problems from heat stroke to chills. Workers should be properly dressed and drink a
sufficient amount of liquids

Manual R0
o Is extreme weather expected? Work should not be performed during high winds, sleet
and hail, lightning, tornados, hurricanes and other extreme weather conditions
o Are ice or snow expected? Ice or snow can create slick roads and walking surfaces.
Workers need to adjust their work to such conditions.
Figure 1.1
(From USBR FIST 5-1)
Clamps A-I have jaws designed to attach to round surfaces like a substation bus or conductor. Clamps
J-M are designed for attaching to flat surfaces.

Manual R0
Delivery and Assembly of the Transformer
Transformer deliveries are heavy loads requiring special lifting and moving techniques and
equipment. Transformers should only be moved by people trained and qualified in heavy lifting and
rigging.
All heavy lifts or moves should have a Lifting Plan or a Moving Plan that considers the following
potential risks.
 Underground pipes or other unseen hazards should be addressed.
o Are site drawings available to determine the locations of any underground hazards?
o Do steel plates or other devices need to be placed on the ground to better distribute
the weight of the crane, trailer or any loads?
o Are the ground, roadway and any bridges that may be travelled over all rated for the
expected loads?
 Safe working clearances from energized lines and equipment must be maintained at all
times.
o Has the crane been properly grounded?
o Will the crane be operated near any energized busses or power lines? Workers
should maintain safe distances from the crane at all times if there is any risk of
contact.
 Using cranes, jacks, cribbing, slings or hardware that are not rated for the load can cause
lifting accidents.
o Is the correct weight of the transformer and the crates known?
o Are the equipment, slings and hardware capable of safely lifting the transformer?
o If jacking and sliding will be performed:
 Have the hydraulic jacks and hoses been inspected and verified to be in safe
operating condition?
 Are the hydraulic jacks gang-operated?
 Are gang-operated jacks equally rated with equal performance?
 Has the controller been inspected and in safe operating condition?
 Are the jacks located squarely below the transformer’s jacking pads?
 Are the timbers or rollers in safe condition?
 Is the connection point for pulling and sliding the transformer secure and
adequate for the load to be applied?
For the transformer or parts that will be lifted by crane:

Manual R0
 Has the crane been inspected and verified that it is in good condition?
 Has the angle of the boom been considered in the crane lifting capability?
 Will the crane’s outriggers be fully extended and utilized during lifting?
 Are the slings and rigging hardware adequately rated for the loads?
 Have the angles of the attached slings been considered when
determining the sling and rigging ratings? Sling capabilities must be
de-rated when they are not used to lift loads in a strictly vertical
direction or when they are wrapped around loads rather than attached
to shackles. See Figure 1.2 for some examples. Consult your Safety
Program guidelines or contact HYOSUNG for more information.
 Will the loads be properly lifted?
 Are tag lines available for controlling the loads when lifted? All loads
should have a tag line attached to help control the location and
movement of the load during the lift.
 Have the tops of the crates been set in-place and nailed down before
any crates are lifted? Crates can collapse if lifted without the cover in-
place.
 The transformer tank must be connected to the site’s ground grid immediately after it is
placed onto the foundation.
o Is the station ground grid in place?
o Are the ground cables on-hand? If not, use personal protective grounds as a
temporary connection until the permanent cables can be installed.
 All work requiring people to perform tasks inside the transformers should be done under the
user’s Confined Space procedures under their Safety Program. The workers should consider
the following possible risks:
o Have the Entrant and Attendant(s) been trained in their Confined Space procedures?
o Does the Attendant know how to contact emergency services, if required? Is a phone
available on-site?
o Is the air monitoring equipment OK to use? Has it been tested and calibrated? Does
it provide audible alarms or other signals if the safe gas levels for working inside the
transformer are not met?
o Was the transformer filled with Nitrogen before this starting this internal work? If the
transformer was filled with Nitrogen, the Nitrogen must be completely removed by
applying vacuum (we recommend down to 1 Torr for at least 30 minutes), then dry-air
can be added before starting ventilation with dry air. Simply ventilating with dry air
may not remove all of the nitrogen inside the transformer and unsafe areas could
exist inside the transformer that may not be detected with the gas monitor.

Manual R0
o Is the air safe to breathe? The transformer should be ventilated by adding dry air at a
sufficient flow rate to purge gasses from the transformer and maintain a sufficient
oxygen level while workers are inside. This can only be verified if a gas monitor is
used. Oxygen needs to be within the required maximum and minimum levels and CO
and CO2 must be below the maximum levels.
o Is the air at risk of fire or explosion? The gas monitor should also monitor explosive
gas levels (Lower Explosive Limit or LEL)
o Are dry-air cylinders being used to ventilate the transformer tank while the worker will
be inside the transformer? If so, it may be necessary to replace the cylinder when the
worker is inside the transformer and a third worker may be necessary for this task.
The Attendant cannot leave their post to replace the dry air cylinder while the worker
is inside the tank. A dry air generator can eliminate this problem.
 Do the workers have appropriate clothing for the tasks? Loose clothing and jewelry around
moving parts like fans and motors can cause serious accidents. Fire Retardant (FR) clothing
may be required for some areas or tasks.
 Are workers prepared to work in manlifts, on ladders or on top of the transformer?
o Have the workers been trained in manlift operation? Training should be performed in
accordance with the user’s Safety Program.
o Is the manlift properly grounded? Grounding should be performed in accordance with
the user’s Safety Program.
o Is the manlift the right size and rating for the job? The loads and equipment ratings
need to be known.
o Have the ladders been inspected? Ladder inspections should be performed in
accordance with the user’s Safety Program.
o Are the ladders the right type, size and rating for the job?
o Are all ladders properly tied off and secure?
o Is a rope or other system available near the ladder to allow workers to bring tools
and equipment to or from the transformer cover without carrying it as they climb the
ladder? Workers should avoid carrying equipment while climbing ladders.
o Is the transformer equipped with a fall restraint system or other connection points
approved by the user’s Safety Program?
o If a worker falls, will their PPE or other systems limit their fall to a safe distance?
 Have workers been trained in the safe operation of all power tools and equipment to be
used on the job?
o Workers should be aware of pinch points and line of fire risks.
o Workers should wear the proper clothing and PPE for the tools and the task

Manual R0
 Will any welding be performed on the job?

o Does a person need to be assigned to work as a “Fire Watch”? If so, does the “Fire
Watch” know what to do in case of a fire?
o Are the right types of Fire Extinguishers available and on-hand?
o Have all combustible materials in the area been cleaned up before welding?
Figure A Figure B Figure C

Figure C
Configuration Figure A Figure B
Angle=60° Angle = 45°
Allowable Loading as a
100% 80% 86% 70%
Percentage of Sling Rating
Figure 1.2

Manual R0
Vacuum Oil Processing and Filling
Transformers are filled with hot oil under vacuum. This presents several potential environmental and
safety risks that the workers should consider.
 The site should be adequately protected from oil spills during oil storage and handling.
o Are the workers aware of the site’s Spill Prevention Plan and the requirements under
the plan?
o Are berms or other protective devices required under the oil tanks or tankers?
o Are emergency spill kits, absorbents and pads available, if needed?
o Is the area around the tanks, tankers and transformer adequately secured and
protected from vehicles or equipment that could collide with the tanks, tankers or
transformer and cause an oil spill?
o Are all oil and vacuum hoses adequately protected from damage during the vacuum
and oil pumping processes?
 Pumped oil can build up a considerable static charge. All equipment used in oil handling
must be properly grounded to bleed off the static charge and protect the site from fires and
explosions.
o Is the transformer tank properly grounded?
o Are all tanks, tankers, and oil processing trailers properly grounded before starting
any oil handling?
o Have all oil hoses been tested to ensure that the internal static wire is intact?
o Are the right types of fire extinguishers available and on-hand?
o Are all transformer bushings adequately grounded during oil filling? The tops of all
bushings should be connected to ground during oil filling. Standard copper mausing
wire is normally sufficient for this purpose.
 All major parts of HYOSUNG transformer tanks are designed to withstand full vacuum.
Workers should understand that loads on any part of the transformer can increase the
mechanical stress beyond the designed limits and cause tank damage.
o Are all workers aware that they should stay off of the transformer, and any parts of
the transformer, when vacuum is applied?
o Are all toolboxes, test equipment and other heavy items, or any items that might
need to be retrieved removed from the transformer cover or other parts of the
transformer?

Manual R0
Testing
Transformers require both high-voltage and low-voltage testing. Both types of testing can present
safety risks.
Workers should consider the following:
 The equipment users must understand how to safely operate all electrical test equipment before
use.
o Is the test equipment properly grounded according to the manufacturers’ instructions?
o Has the test equipment, including cables and test probes, been inspected before each
use?
o Will all meters and probes be used within their rated voltage or current limits? Meters
must not be used at voltage or current levels beyond their ratings. The voltage and
current rating should be listed on all electrical test equipment, or in the manufacturers’
instructions. This applies to meters, leads and test probes. Voltages greater than 480V
should never be measured directly with a handheld meter, but should be measured with
a proximity meter mounted on a hot stick.
 Users must understand the hazards associated with testing power transformers
o Have the test equipment operators and assistants been trained in the safe operation of
their equipment?
o Will test voltages be transformed to unsafe levels by the transformer? AC test voltages
applied to low voltage transformer windings are transformed to higher voltages by the
transformer turns ratio. For example, applying a 10kV Doble test voltage to the XV
terminal of a 230/18kV GSU transformer can produce 128kV on the HV bushing
terminals. Safe working clearances must be maintained.
o Will DC test voltages be applied to the transformer? Transformers can hold a large
capacitive charge when DC test voltages are applied. DC test equipment must always
be discharged according to the manufacturers’ instructions before disconnecting the test
leads.
o Are all workers in the work area where test voltages are being applied aware of the risks
before starting the tests? Does the area around the testing need to be roped off?
o Is the transformer tank under vacuum? Testing should never be performed while the
transformer is under vacuum. A partial vacuum will flash over at a far lower voltage than
a transformer under atmospheric air pressure.

Manual R0
 All tested components must be left in safe conditions after testing.

o Are all CT’s shorted and grounded after testing?
o Are all fans free from obstructions?
o Are all terminals and components in the control cabinets free from obstructions or
debris?
Operation and Maintenance
 The transformer tank and all cabinets must be grounded at all times.
o Are the ground connections all visible and intact?
 While HYOSUNG transformers have not experienced problems with static electrification,
conditions that could cause static electrification conditions should be avoided.
o Do the user’s operational procedures or the transformer’s cooling controls allow pumps
to run for long periods with the transformer de-energized?
 To avoid the possibility of causing this problem, the controls for forced-oil cooling
should be designed to only switch pumps on after the transformer is energized.
 The cooling control system on transformers with only forced oil cooling should be
designed to automatically switch on the first cooling stage when the transformer
is energized.
 Running time should be limited to just a few minutes when testing oil pumps on
de-energized transformers.
 Safe working clearances should be maintained at all times when the transformer is energized.
o Is any work required on or near the top of the transformer?
 Never work on the transformer cover, or store tools or equipment on the
transformer cover when the transformer is energized at system voltages.
o Have any protective relays caused an alarm or a trip or are any unusual conditions
observed?
 Are the responders aware of the various possible causes of alarms or trips? See
the Troubleshooting section 7.8 in this manual for guidance.
 Do not approach the transformer until it is de-energized if the Buchholz relay,
Gas Accumulation Relay or Pressure Relief Device are in the alarm state.
 Never Overload the transformer and exceed the highest Temperature given
specification.

Manual R0
 Immediately de-energize the transformer if unusual sounds are observed inside

the transformer such as knocking or crackling. This could be signs of internal
electrical problems and could lead to catastrophic failure if ignored.
 Immediately de-energize the transformer and clean the bushing surfaces under a
Clearance if excessive corona is observed across the bushing surfaces. This is
possible in high contamination, salt-spray or dusty environments.
 Never operate the transformer without lightning arresters.
 Will the Tap Changers be operated safely?
o De-energized tap changers should never be operated when the transformer is energized.
o Load Tap Changers should never be hand cranked when the transformer is energized.
Local operation of the LTC should only be done with the electrical controls.
o LTC troubleshooting should be performed with the transformer de-energized.
 Are the transformer and bushing oil levels maintained at the proper levels?
o Never operate the transformer with transformer oil or bushing oil below the minimum
safe levels.
o Overfilling the transformer with oil could cause oil to be released from the pressure relief
device or to damage the conservator bladder when the transformer is heavily loaded.
 Are the control cabinets properly maintained and in good condition?
o Are any drawings or manuals near the cabinet heaters where they could start a fire?
o Are the cabinet door stops functional?
o Are all energized terminals safe from accidental contact?
o Are the cabinet lights functional?
o Has the cabinet been scanned with thermovision to detect any hot-spots on circuit
breaker, contactor or relay terminals?

Operation & Maintenance General Construction
Manual R0
Section 2
General Construction
HYOSUNG manufactures transformers in both core form and shell form construction.
2.1 Core Form Design and Construction
The core is designed and constructed with high permeability, low loss cold-rolled non-aging silicon steel.
Each lamination is coated to insulate the sheets and reduce eddy current losses. The core is designed
with 3 or 5 legs, depending on the transformer design, operational requirements and shipping
dimension limits.
Core legs are held in place with fiberglass bands beneath the windings to withstand shipping impacts.
Upper and lower core yokes are held with stainless steel bands over fiberglass bands and connected
with an insulating buckle to provide maximum mechanical strength and eliminate circulating currents.
The complete core is supported by a structural steel core frame to provide structural rigidity for
withstand of short-circuit and transportation mechanical forces.
Each core steel sheet is precisely cut to size and shape using automated core cutting machines, then
hand stacked into an E-core as shown above, consisting of the legs and bottom yoke in a step-lap
configuration using overlapped mitered joints. The lower core frame and flitch plates are mounted to the
E-core before up-righting. The windings are then added to the E-core and the top yoke and frame are

Manual R0
installed.
The core is divided into sections with insulated ducts between sections for cooling. Sections are
connected in one place with sheet copper jumpers. The core is insulated from the core frame and
grounded through an external connection to provide a convenient test point.
All windings are designed and manufactured to withstand the electrical, mechanical and thermal
stresses of all types of faults and overvoltage conditions like lightning impulses and switching surges as
specified by IEEE Standards and customer specifications.
HYOSUNG’s winding rooms are controlled-access positive-pressure clean rooms designed to minimize
dust and other contaminants during the winding process. The winding rooms are equipped with both
horizontal and vertical winding machines to provide greater manufacturing flexibility.
Windings are designed and constructed with insulated copper conductors in rectangular or continuously
transposed cables. Winding conductors are crimped or welded to leads connecting the windings to
other windings, tap changers or bushings.

Manual R0
After the windings have been constructed, they are clamped and
dried under iso-static pressure to remove moisture from the insulation
and shrink the windings to their clamped, in-service height. The
individual windings are nested into a phase assembly as they are
placed onto each core leg then the leads and support structure are
added.
The windings are then clamped under pressure to the core frame and
the complete active part is dried using a vapor-phase process. After
the final vapor-phase process, all windings are re-compressed to their
designed values and all bolted connections are re-tightened.
Transformers rated 80 MVA and greater are typically equipped with
dash-pots to provide constant clamping pressure to the windings
under all conditions.
2.2 Shell Form Design and Construction
HYOSUNG Shell-Form transformers are designed and constructed with a form-fit design. The form-
fit design provides a compact and rigid construction with excellent short-circuit withstand strength,
excellent shipping impact withstand, superior dielectric characteristics, lower oil quantities, and
minimized losses. The form-fit design also provides greater flexibility in meeting special design
requirements such as dimensional tolerances or unusual impedances without sacrificing electrical or
mechanical strength due to the ability to interleave coil groups.
Coil Before Drying Electrostatic Shield During Construction
The windings are manufactured in a clean room. Each strand and layer of subdivided conductors is
spirally wrapped with several layers of narrow, high dielectric strength paper. The outermost layer
has a thermoset coating to bond the coils after clamping and drying and enhance mechanical
strength and rigidity during assembly. If the design calls for electrostatic shields, these are also
manufactured in a clean room. The coils are individually dried then connected together into a coil
phase assembly.

Manual R0
Pressboard sheets are formed into channels, washers and spacer block assemblies to direct the oil
flow and maintain electrical clearances. The spacer blocks are located in a precise pattern to align
them transversely throughout each phase. This ensures mechanical strength against short circuit
forces and prevents coil deflection in each coil. The complete phase assemblies including the
windings, oil ducts and shields are dried using a vapor-phase process then lowered into the form-fit
tank bottom and secured into place.
Phase Assembly During Construction
The upper and lower T-beams are installed through the coils and the core laminations are stacked
on fill blocks in and around the coil assemblies, using overlapped joints to increase mechanical
strength and minimize exciting current. The core is constructed of coated laminations of Hipersil, a
cold-rolled, grain-oriented, highly permeable annealed and non-aging silicon steel that can carry
one-third more flux per area than ordinary electrical steel.
Shell Form Transformer After Core Stacking

Manual R0
The core sections within the coil openings are wedged at the top to compress the core and rigidly
hold the coil assembly in place. The areas between phases are also securely wedged in-place, top
fill blocks are secured in position and vertical wood pieces with pressboard channels are installed
between the top and bottom fill blocks.
When the form-fit top section with the end frames and side channels is installed over the lower
section with the core and coils, the entire transformer is formed into a rigid body that can withstand
shipping and short-circuit stresses. The coil assembly is held in compression by the end frames,
interphase wedges and rigid core
Typical Form-Fit Shell Form Design

Manual R0
2.3 Tank Design and Construction
All HYOSUNG transformer tanks and conservator tanks are designed to withstand full vacuum. This
allows the transformer to be oil-filled completely under vacuum, eliminating oxygen and moisture from
the oil and extending the service-life of the transformer.
All gasket joints on the tank utilize rectangular or round o-ring gaskets with grooved flange faces to
provide an oil-tight and gas-tight seal. Gaskets in most areas are nitrile, Buna-n type rubber and
gaskets in higher temperature locations are Viton rubber. HYOSUNG’s gaskets should provide many
years of service before replacement is required.
The tank is generally provided with manholes to permit access into the transformer, if needed. The tank
is also equipped with jacking, lifting and pulling facilities for moving the transformer and is designed to
be lifted or moved without oil.
The tank may be provided with electro-static or flux shields on the tank walls to reduce stray losses.
These shields are grounded to the tank in one location.
2.4 Radiators or Heat Exchangers
HYOSUNG radiators are efficient cooling units designed for use on large transformers requiring a self-
cooling rating. The radiators are detachable and removed for shipment. Radiators are constructed on
stamped steel sheets, welded together to provide a large surface area and internal vertical paths for oil
circulation. Each radiator is equipped with lifting eyes for lifting the radiators during transformer
assembly as well as upper and lower threaded plugs for oil draining or venting. Larger transformers are
equipped with a radiator support structure to reduce mechanical stresses on the radiator piping joints.
Radiators can be equipped with fans to provide forced air cooling. All fans are supplied with OSHA-
compliant stainless steel fan guards. The fan assembly mounting bolts are welded to the outer radiator
in the group, eliminating the need for mounting clamps which can damage radiators and lead to rust
problems.
Heat Exchangers from various suppliers are used on HYOSUNG transformers when forced oil cooling
ratings are required. Heat exchangers require oil pumps to circulate the oil through the cooling tubes.
Fans are also required to force air across the cooling tubes for effective heat removal. Heat
exchangers can be supplied with aluminum, steel or copper tubes and fins depending on customer
requirements.
Heat Exchangers are also equipped with a support structure to reduce mechanical stresses on the
pump and oil piping joints.
2.5 Conservator Design and Construction
Unless the transformer is specified to use a nitrogen blanket or sealed tank oil preservation system,
HYOSUNG will provide a conservator with diaphragm type oil preservation system.
HYOSUNG’s conservator with diaphragm oil preservation system serves as an oil expansion tank and
utilizes a Buna-n or similar rubber bladder to completely isolate the oil from the atmosphere while

Manual R0
holding the oil at a constant pressure as the oil to increases or decreases in volume with increases or
decreases in oil temperature due to load and ambient temperature variations. The outside of the
bladder is in contact with the oil and the inside is in contact with the air. The bladder contracts and
expands with increases or decreases in the oil volume and as it changes, the air moving into or out
from the bladder passes through a dessicant breather to maintain a low moisture level in the air and
bladder.
By preventing exposure of the oil to air, the oxygen and moisture content of the oil can be maintained at
low levels, greatly reducing sludging and acidification of the oil and resulting accelerated aging of the
transformer insulation.
The round conservator tank is equipped with valves that permit the vacuum pressure inside and outside
the bladder to be equalized during vacuum processing, eliminating damage to the bladder. The tank is
also equipped with an oil level gauge that is oriented for easy viewing from ground level.
The conservator tank is also equipped with a drain valve and a vent cock. The vent cock is used to
vent the small amount of nitrogen gas introduced during the last stage of oil filling. The inside of the
conservator tank is equipped with a guard structure that holds the bladder away from the vent cock or
vacuum valve during oil processing and filling.
Figure 2.1 Typical Structural of Rubber Cell Conservator
2.6 Factory Oil Processing
All HYOSUNG transformers are thoroughly dried out, flushed and impregnated at the factory.
HYOSUNG’s field oil processing and filling procedures do not require costly oil circulations under most
conditions, saving several days of processing time and thousands of dollars in installation costs.

Manual R0

Shipment, Receipt
and Storage
Manual
R0
Section 3
Shipment, Receipt and Storage
3.1 Packing and Shipment
The transformers are normally shipped without oil. During shipping, the tank is filled with dry air. A
pressure gauge and stop valve are provided to enable the pressure of the inert gas within the tank to
be read upon receipt.
The transformer should arrive with positive pressure, indicating that moisture did not enter the
transformer during shipping. The dry air inside the tank is tested for dewpoint to determine the
insulation moisture level. See the next section, Receiving Transformer and Accessories, for specific
details.
All opening for transformer components, e.g. bushings which have been removed from the
transformer during transport, are covered by means of blanking off plates. All parts are carefully
packed for transport in such a manner that they are protected against mechanical injury and injurious
effect of climatic conditions encountered during transit to their destination, as well as during long
storage before erection.
HYOSUNG designs transformers to withstand a 3G impact in all three directions and mounts an
impact recorder on each transformer during delivery, but any impact of 3G or greater must be
reported immediately to HYOSUNG. Impact recorders are calibrated to ensure accurate data. The
direction of each axis is a function of the mounting of the impact recorder and should be visually
verified one each impact recorder before it is removed from the transformer. The time recorded on
the impact recorder will be Korean time, not local time. Any efforts to match recorded impacts with
the location of the transformer will need to make this time adjustment.
All impact recorders must be shipped back to HYOSUNG .

Shipment, Receipt
and Storage
Manual
R0
3.2 Receiving Transformer and Accessories
Parts can be damaged or lost during shipping. Following the steps in this section will help to identify
any such parts so they can be repaired or replaced as soon as possible.
Equipment Required:
 Packing List
 Crowbar, hammer, nails, wrenches and screwdrivers
 Digital camera
 Dew point tester
 1000V megger
 Software and connecting cable for impact recorder (if an electronic recorder is used)
Inspection of Main Tank Before Off-Loading:

1. Visually inspect the tank and any attached fittings for signs of damage such as dents, stolen or
misaligned parts, paint damage or areas where the tank was welded down and cut free from
transport vehicles. Photograph any suspected damage before off-loading and check off the
appropriate boxes on the Shipment Inspection Report.
2. Check the pressure gauge to verify positive pressure. Photograph the gauge. Record the
results on the Shipment Inspection Report.
Inspection of Main Tank After Off-Loading:

1. Review the impact recorder data. Verify that the impact recorder’s battery is still charged and
the unit is functional. Impacts of 3G or less are OK. If an electronic recorder is used,
download the record file. If a chart-type recorder is used deliver the chart paper to the
HYOSUNG field engineer as soon as he arrives. Record the recorder serial number and
results on the Shipment Inspection report.
2. Measure the internal pressure and perform a dew-point test on the dry air inside the transformer
and analyze the results using the chart below. Record the ambient temperature and measured
dew point on the Shipment Inspection report. See Dew Point Test, below.
3. Megger test the core and core frame at 1000Vdc. Record the core test results on the Shipment
Inspection report and record the core frame results separately.
4. Review the results with the customer. E-mail the photos, Shipment Inspection Report and test
results to HYOSUNG at the address listed below.

Shipment, Receipt
and Storage
Manual
R0
Recommended Tests if Shipping Damage is Suspected
ELECTRICAL TESTS CAN NEVER BE MADE WHILE THE TRANSFORMER IS UNDER

VACUUM, DUE TO INCREASED RISK OF FLASHOVER.
1. Check pressure on unit with pressure-vacuum gauge. If zero reading, purge with dry air and
check for leaks. Note that pressure varies with temperature, and this factor should be
considered.
2. Check percent moisture content in transformer. It should never exceed dew point in Figure 3.1.
3. Perform internal inspection. See section 4.4 for detailed requirements.
WORK INSIDE THE TRANSFORMER REQUIRES A CONFINED SPACE PERMIT AND MUST
BE PERFORMED IN ACCORDANCE WITH OSHA REQUIREMENTS.
SEE THE SAFE WORK PRACTICES SECTION FOR MORE DETAILS
OBSERVE ALL SAFETY LABELS ON THE TRANSFORMER
4. Check de-energized tap changer alignments and contacts with nameplate. Check for shifting of
core and coils, and check for breakage, loose or lost bolts, nuts, etc.
5. Measure the exciting current on each HV winding.
6. Make ratio test on all windings and taps. All windings and taps should check within 0.5%.
7. Check winding continuity and resistance if unit is off ratio.
8. After filling with oil make Megger test on insulation resistance. HV to XV and Ground, XV to HV
and Ground, and HV and XV to Ground. Coils should be under oil for comparison with factory
test measurements.
9. If core yoke shows signs of shifting, disconnect core ground bushing and end frame ground
bushing from tank cover and test end frames to core with 1000 volt Megger. This might happen
when unit has been subjected to severe shocks in transit by carrier.(Minimum acceptable values
are 50 mega-ohms.)

Shipment, Receipt
and Storage
Manual
R0
Shipment Inspection Report:
A HYOSUNG Shipment Inspection report form must be filled in and e-mailed to HYOSUNG. All
sections, lines and boxes on the form must be filled in completely. Enter N/A if any areas do not apply.
Contact HYOSUNG if you do not have a copy of the form.
DEWPOINT TEST
1. Measure internal tank temperature and measure the Dew Point temperature of the air inside the
tank.
2. Use Figure 3.1 for pressure between 0 and 5 PSI
3. Use upper and left axes for temperatures recorded in Celsius, use the lower and right axes for
temperatures recorded in Fahrenheit.
Figure 3.1 Dew Point Limit

Shipment, Receipt
and Storage
Manual
R0
Inventory and Inspection of the Accessories:
1. Verify that all crates, pallets and components listed on the packing list have been
received and check off the appropriate box on the Shipment Inspection Report. Check
all crates and pallets for external damage. Photograph any suspected areas and report
on the Shipment Inspection Report.
2. Open each crate and verify contents against the packing list. Look for water intrusion
or damaged components. Photograph any damaged parts and record missing parts
and damaged parts on the Shipment Inspection Report.
3. Locate the Instruction Manual. It should be in the main control cabinet or in one of the
crates. If not found, call HYOSUNG.
4. Check bushing crates to verify that all internal supports are in place and undamaged.
Verify that crates are roughly level and that all oil filled bushings inside each crate are
inclined with the top oil reservoir elevated. Verify that all bushing stud connectors have
been delivered. Record missing parts and record and photograph any damaged parts.
5. Check lightning arresters to verify that porcelain is not damaged and that all arrester
sections and grading rings have been delivered. Record missing parts and record and
photograph any damaged parts.
6. Check radiators for any signs of damage including dents on plates or edges, paint
damage or missing blanking plates. Record missing parts and record and photograph
any damaged parts.
7. Check all piping sections. Record missing parts and record and photograph any
damaged parts.
8. Check the main control cabinet and any other cabinets provided on the order. Check to
verify that the cabinet is not damaged and all internal components are in-place and
undamaged. Record missing parts and record and photograph any damaged parts.
9. A claim should be filed immediately with the carrier if any missing parts suspected
damage are found.
10. Review the results with the customer. E-mail the Shipment Inspection report, photos,
and other information on any missing or damaged parts to HYOSUNG .

Shipment, Receipt
and Storage
Manual
R0
Impact Recorder
Note that impacts recorded by the impact recorder are only an indication of possible damage and not
conclusive evidence that shipping damage or even impacts have occurred. Impact recorders may
record impacts if the impact recorder is accidently kicked by a rigger, if rigging comes in contact with
the recorder, or under similar circumstances. The transformer may also withstand impacts well beyond
3G’s without any damage. The determination of damage can only be made following testing and/or an
internal inspection.
Examination
After the transformer is moved on the pad in the site, its arriving time should be recorded and the
impact recorder data should be examined.
Notification
The recorder is part of the shipment. If it is missing or damaged, the seal broken, or has been disturbed
in any way, a specific carrier's inspection report must be issued by the carrier, to relieve the customer
of responsibility for the recorder.
Examine the recorder in the presence of the carrier's agent. Both the carrier and customer personnel
must check when impacts are recorded in zone B or above.
If impacts are recorded in zone B or above, the customer should notify a HYOSUNG representative (if
one is not present at that time) for advice.
Orientation of Impact Recorder on the Transformer
Most types of impact recorders have axis or direction marks on them that correspond to the axis or
direction as recorded on the strip chart or electronic file. The impact recorder should normally be
mounted on the transformer with the orientation of the impact recorder axes as shown below to match
the axes on the transformer.
Lateral or X-Axis Longitudinal or Y-Axis
Vertical or Z-Axis

Shipment, Receipt
and Storage
Manual
R0
It must be noted, that in some cases the impact recorder may not be oriented as shown in the photo
above. In these cases, the axes indicated on the strip chart or electronic report will not correspond to
the same axes on the transformer and all impact directions must be adjusted accordingly.
Impacts
Shipping impacts recorded are classified into three zones.
Zone-A
The G-range of this zone is under 3G, including 3G.

The condition of the transportation /shipping in this zone is good.
Zone-B
The G-range of this zone is between 3G and 6G, including 6G.
Damage may occur in this zone, particularly when impacts greater than 5G have occurred.
The following checks and tests should be performed.
- Internal visual inspection

- External visual inspection
- Electrical test
 Exciting current
 Ratio test
 Insulation resistance test
 Bushing Current Transformer tests
 Functional test for all protective devices
 FRA test (If required)
Zone-C
The G-range of this zone is greater than 6G.
Damage may occur in this zone. The same checks and tests listed under Zone-B should be
performed.

Shipment, Receipt
and Storage
Manual
R0
Strip-Chart-Type Impact Recorder
Maker Impact Register Inc. (USA) Chatsworth Data Corporation (USA)

Model No. RM-3WE-60 M-3
Chart Speed 3/4 in/hour 1/4 in/hour
Chart Life 120 days 80 days
Battery Life 12 months 6 months
Figure
Deflection from Center in Number of Grids

Impacts
Vertical Lateral Longitudinal
3G 1.5 3.0 1.0
6G 3.0 6.0 2.0
Impact Register RM-3WE-60 Impact Scales

Shipment, Receipt
and Storage
Manual
R0
X Y Z
5 10 PM
AM
9 PM
4
8 PM
AM
7 PM
3
6 PM
AM
Zone A Zone A Zone A
Zone B Zone B
Zone B
Deflection from Center in Number of Grids

Impacts
X Y Z
3G 1.8 2.1 2.3
6G 3.8 4.5 4.9
Chatsworth Data Corp. M-3 Impact Scales

Use the ¼”/hour Time Scale on the Right
Electronic-Type Impact Recorders
The Shocklog RD298 model impact recorder is battery powered and records impacts in all three
directions. If any significant impacts have occurred during shipment, a blinking red LED will indicate
an alarm condition. The detailed data must be downloaded with a special data cable onto a PC with
Shocklog software loaded. HYOSUNG’s field service engineers are equipped with the necessary
cable and software.
Shocklog Impact Recorder

Shipment, Receipt
and Storage
Manual
R0
The Lat-Lon DPU model impact recorder is solar powered with a battery backup and transmits GPS
location and travel speed and records of any impacts. The data is continuously updated and available
at the Lat-lon website so no special cables or software are required. The data from these recorders are
monitored daily by the HYOSUNG logistics team.
Note that the X, Y and Z axes are not labeled on the Lat-lon DPU. See the photo below for the
orientation of the axes.
The GPS and communications do not work when the transformer is stored inside an ocean vessel.
Y-Axis
X-Axis
Z-Axis
Lat-Lon DPU Impact Recorder

Shipment, Receipt
and Storage
Manual
R0
3.3 Receiving Oil
See the Oil Processing and Filling Section of this manual.
NEVER ATTEMPT TO MOVE A FULLY ASSEMBLED TRANSFORMER. MOVING A FULLY

ASSEMBLED TRANSFORMER MAY CAUSE DAMAGE TO THE EXTERNAL OR INTERNAL
STRUCTURES.
CONTACT OUR LOCAL REPRESENTATIVE FOR SPECIAL INSTRUCTIONS PRIOR TO
MOVING ANY TRANSFORMER.
TRANSFORMERS MUST BE MOVED IN THE UPRIGHT POSITION UNLESS THE UNIT WAS
DESIGNED FOR HORIZONTAL SHIPMENT. THE OUTLINE DRAWING AND THE EXTERNAL
ASSEMBLY DRAWINGS SHOW THE POINTS FOR LIFTING, JACKING OR PULLING THE
TRANSFORMER. NEVER ATTEMPT TO LIFT OR MOVE A TRANSFORMER FROM ANY PART
OTHER THAN THE FACILITIES PROVIDED FOR THAT PURPOSE.
3.4 Moving and Handling
Setting the transformer on the foundation
Note the transformer base diagram on the outline drawing and be certain the foundation pad
and piers support the transformer in the designated areas. In some instances a separate base
diagram is supplied and it will be included in the instruction book.
Cooling air requirements
The transformer must be positioned so that adequate air circulation is provided to cool the
transformer.
Relocating the transformer
HYOSUNG’s standard design provides for lifting and pulling the transformer in the shipping
configuration, without oil. If the transformer must be relocated after assembly and oil filling, the
oil must be drained before the transformer is moved. Failure to drain the oil before moving
may result in structural damage.
HYOSUNG does not recommend moving a transformer with any accessories mounted with or
without oil. Such a move is made at the owner’s risk and any damage as a result is not
covered under the warranty.

Shipment, Receipt
and Storage
Manual
R0
3.5 Temporary Storage
If the transformer will not be assembled immediately, the following steps should be taken:
 Locate the accessories in a secure area where theft is not a concern
 Reclose all crates. Replace any plastic covers, place all hardware back into original
containers, nail the crate covers back on. Photograph the reclosed crates.
 Ensure that all parts susceptible to rain, ice or wind damage are properly stowed.
Electronic components such as monitoring devices should be stored indoors. Record
the storage location of any parts stored in other areas.
 Add dry air to the main tank to 2-3 psi, if pressure is less than 2psi. Photograph the
pressure gauge.
 E-mail the information and photos to HYOSUNG . Call the phone number listed in the
Introduction Section for the correct e-mail address for your transformer.
If the transformer will not be oil-filled within 90 days after leaving the factory, the appropriate
HYOSUNG procedure, as listed below, must be followed.
Days After Shipping from the Procedure

Factory Until Start of Assembly
90-150* Short Term Storage of Oil-Filled Transformers
151-365 Medium Term Storage of Oil-Filled Transformers
>365 Long Term Storage of Oil-Filled Transformers
* Dependent on transformer kV class
Special Oil Processing Requirements for Stored Transformers
NOTE THAT ALL TRANSFORMERS THAT HAVE BEEN STORED BEYOND 90 DAYS AFTER
THE EX-FACTORY DATE REQUIRE ADDITIONAL OIL PROCESSING. THE OIL
PROCESSING REQUIREMENTS FOR STORED TRANSFORMERS ARE LISTED IN THE OIL
PROCESSING AND FILLING SECTION OF THIS MANUAL.

Shipment, Receipt
and Storage
Manual
R0
Short Term Storage of Oil-Filled Transformers
If the transformer cannot be installed immediately upon arrival and oil filling is impractical, it is possible
to store some transformers under a positive dry air pressure. The maximum length of time under this
storage method is dependent on the transformer kV class as follows.
Transformer HV kV Class Maximum Short Term Storage

Up to 230kV 150 days from ex-factory date
345kV and greater 90 days from ex-factory date
The following steps must be taken for Short Term Storage:

 Inventory and check of all crates and contents
 Reclose and secure all crates
 Store any electronic components indoors
 Connect the transformer tank to a secure ground
 Check tank pressure and dew point at 90 days after leaving the factory
o If pressure and dew point are OK, no further action is required
o If pressure or dew point are not acceptable, perform vacuum process and dry-air fill the
transformer
 4 hour vacuum after reaching 1 Torr
 Add dry air to 3 psi, wait 12 hours and more.
 Perform dewpoint test, repeat process if necessary
 Verify pressure gauge is functional
 Seal the tank
 Ship impact recorders to HYOSUNG
The transformer pressure and cylinder pressure should be recorded every day for the first two weeks.
These reading should preferably be taken at approximately the same time every day and the time and
temperature also noted on the log.
After two weeks of daily logging, the pressure readings may be reduced to once every seven days.
An accurate log is important as it may be the determining factor in any decisions that may have to be
made on further drying of the windings.
IT IS IMPORTANT TO MAINTAIN POSITIVE DRY-AIR PRESSURE DURING ANY STORAGE WHEN

THE TRANSFORMER IS NOT FULLY FILLED WITH OIL. ZERO OR NEGATIVE PRESSURE
INDICATES THE PRESENCE OF A FAULTY SEAL WHICH COULD ALLOW MOISTURE TO ENTER
THE TRANSFORMER.

Shipment, Receipt
and Storage
Manual
R0
Medium Term Storage of Oil-Filled Transformers
If the transformer must be stored longer than the limit for Short Term Storage, a Medium Term Storage
can be performed with partial oil filling.
The following steps must be taken for Medium Term Storage:

 Reclose and secure all crates
 Install valve and pressure gauge on each radiator and fill to 2 psi with dry air
 Check and ensure that all pipes and the conservator tank are gasketed and sealed
 Cover all bushing and lightning arrester crates with tarps and secure the tarps
 Schedule and co-ordinate oil delivery
 Provide any required environmental safeguards
 Test and accept or reject the oil
 Inspect any oil storage tanks or tankers
 Vacuum process and oil fill transformer tank
o 4 hour vacuum after reaching 1 Torr
o Fill oil to 12” below the cover
o Install pressure gauge on valve above oil level
o Add dry air above the oil and pressurize to 3 psi
o Seal the tank
 Perform core and frame megger tests
 Prepare and send Assembly Report to HYOSUNG
o Include the gallons of oil pumped into the transformer, as measured
o Include photographs of radiator pressure gauges, tank pressure gauge, tank grounding
and crates as stored.
o Note location of any stored electronic components
 Weekly inspections to check for positive pressure and no oil leaks.
The pressure relief devices should be mounted before oil filling.

An accurate log of inspection and maintenance data is required. This must be reviewed by the user
prior to energizing the transformer. If the data is questionable, contact HYOSUNG.
At the end of the storage period, samples of oil must be drawn from the bottom of the transformer and
from the tap changer compartments and tested for electrical strength, power factor and water content.
If the transformer is equipped with pumps, operate one half of the pumps for 30 minutes and then
operate the other half for 30 minutes. Repeat this operation every three months during the storage
period.

Shipment, Receipt
and Storage
Manual
R0
Long Term Storage of Oil Filled Transformers
If the transformer must be stored for longer than one year after the ex-factory shipping date, all oil filled
components must be mounted and the transformer must be fully oil filled.
The following steps must be taken for Long Term Storage:

 Verify that transformer is on permanent foundation
 Assemble the transformer
o Install turrets
o Bushings and arresters do not need to be installed, if they can be stored indoors in their
crates or other suitable storage racks
o Bushings and arresters need to be installed if they cannot be stored indoors in their
crates or other suitable storage racks
o Install radiators or heat exchangers
o Install conservator
o Install all oil piping and valves
o Reliable power must be supplied for the Heater in local control cabinet and
occasional exercising of pumps, if equipped.
 Reclose and secure all crates with uninstalled components, store indoors
 Schedule and co-ordinate oil delivery
 Provide any required environmental safeguards
 Test and accept or reject the oil
 Inspect any oil storage tanks or tankers
 Vacuum process and oil fill the transformer, including the radiators, piping and conservator per
HYOSUNG’s standard oil filling procedures.
 Perform core and frame megger tests, winding megger tests (only if bushings have been
installed) and functional checks of the heater/thermostat circuit (and pump circuit, if equipped)
 Prepare and send Assembly Report to HYOSUNG
o Include gallons of oil pumped into the transformer, as measured
o Include all test results
o Include photographs of assembled transformer and stored crates
o Note location of stored crates

Installation
Manual
R0
Section 4
Installation and Assembly
FAILURE TO SUPPORT THE TRANSFORMER BASE PROPERLY MAY RESULT IN DAMAGE

TO THE TRANSFORMER TANK AND ADJACENT APPARATUS IN THE SUBSTATION
IF THE TRANSFORMER WAS FILLED WITH NITROGEN GAS, THE NITROGEN MUST BE
REMOVED BY APPLYING VACUUM AT 1 TORR FOR 1 HOUR OR LONGER, BEFORE
BREAKING VACUUM AND REFILLING WITH DRY-AIR AND VENTILLATING THE TANK

Installation
Manual
R0
4.1 Required Tools and Equipment (See the Safe Working Practices Section for PPE requirements)
The tools and equipment listed below are not supplied by HYOSUNG with the transformer, and must be
supplied by the installation and testing crews.
REQUIRED TOOLS AND EQUIPMENT FOR ASSEMBLY

Equipment Specs. Task
Crane with slings and rigging See Drawings for weights Transformer assembly
hardware
Manlift General
Ladders General
Hydraulic jacks Installation and general
Rope Lifting and rigging, tag line
Oil processing trailer See Section 5 Vacuum oil processing and filling
Vacuum and oil hoses and fittings
Dry Nitrogen Gas Cylinder or
Air Cylinder w/regulators and hoses
Vacuum gauge to 0.01 torr
Tygon tubing
Assorted flanges and pipe fittings to 2” – 4”
make up the oil and vacuum
connections
Oxygen meter (O2, CO, CO2, LEL’s) Calibrated and tested Internal inspection or internal
Dry air (cylinders or generator) -58°F work
Clean plastic sheets and tarps
Anti-seize compound See Section 4.10 Connecting stainless steel
hardware
Oxide removing grease See Section 4.10 Cleaning copper and aluminum
current-carrying surfaces
Torque wrenches Small, medium and large Transformer and component
size assembly
Crow’s foot wrenches Torquing bushing top terminals
Ratchets 10-30mm General assembly
Open and box-end wrenches 10-46mm
Adjustable wrenches 6,8,10,12 and 15”
Sockets 10-46mm and ¼”-3”
Misc. hand tools, hammers, chisels,
blunt chisels, wedges, screwdrivers,
socket drivers, allen wrenches, torx
wrenches, pliers, tape measures,
levels, pliers, etc.
Hydraulic crimping tool with dies 4.7/0 248kCmil) and Connecting ground cables and
6.2/0 (350kCmil) terminals
Silicon grease and rubber cement Installing gaskets
(adhesive)

Installation
Manual
R0
REQUIRED TOOLS AND EQUIPMENT FOR TESTING

Equipment Specs. Task
Dew Point Tester Dew point test
Variac or variable AC voltage supply Breaker and relay tests
DC power supply 125V Alarm and trip tests
Oil hi-pot tester IEC60156 Oil acceptance tests
Megger 500V and 1000VDC Megger tests
Hand operated air pump Gas accumulation relay test
Multi-meter General
Fused jumpers General
Temperature probe calibration tester Oil and winding gauge calibration
and functional tests
Qualitrol (or equivalent) Rapid Rapid Pressure Rise Relay test
Pressure Rise Relay test kit
Winding resistance test set Winding resistance tests
DC continuity tester (buzzer) Wiring checks
Manlift Check outline drawing for All tests above ground level
Ladders height requirements
OPTIONAL TOOLS AND EQUIPMENT

Equipment Specs. Task Required if:
Welding machine 200A AC/DC Repairs or Damage occurs or
modifications modifications are required
Phase rotation meter 3-phase pump or fan AC supply voltage is 3-phase
rotation checks
Diesel or gas- 240/415VAC Fan, pump, Sufficient AC supply voltage
powered generator components and source is not available on-
functional tests site

Installation
Manual
R0
4.2 Setting the Transformer on the Foundation
Carefully move the transformer into the correct position on the substation pad and make certain that
the base is flat and level. Install shims under the base for leveling if necessary.
4.3 Grounding the Transformer Tank
The transformer tank must be connected to a secure ground before any work is done in or on the
transformer.
4.4 Inspecting the Active Part
An internal inspection should be performed by the HYOSUNG Field Service Engineer or HYOSUNG’s
contractor. If the customer performs the inspection, the inspection should be performed by an
engineer who has been trained in performing transformer inspections. The Engineer will check for any
signs of movement or damage during shipping.
The internal inspection is a Confined Space entry and must be performed in accordance with OSHA
and all other applicable regulations and requirements. See the Safe Working Practices section.
When you open a transformer, take precautions to prevent moisture or dirt entering the transformer or
moisture condensing in the transformer. Always observe these precautions:
4.4.1 Breaking vacuum
Never break vacuum with atmospheric air, always use dry air or dry nitrogen.
4.4.2 Weather
Do not open the transformer or leave it open during rapidly changing weather conditions unless
the opening is completely protected from weather.
Do not open the transformer if the relative humidity is greater than 85%.
Do not work inside the transformer if moisture is condensing on the inside of the tank.
4.4.3 Clothing
Never enter a transformer with dirty or wet clothing. Clean cloth shoe covers or nitrile rubber
overshoes must be worn.
4.4.4 Ventilation of Tank
Dry air must be used to ventilate the inside of the tank when it is opened for internal fitting or for
inspection. These restrictions must also be followed:

Installation
Manual
R0
a. The dry air must have a dew point not higher than -58°F (-50℃).
b. Purge all air hoses with dry air to remove all moisture and dirt prior to
use.
c. Use a pressure regulator to control the pressure of the incoming air.
d. Dry air should be blown into the transformer below the working level to
maintain flow of air out through the cover opening. Air hoses may be
taken into the transformer if they are clean, dry and made from an oil-
proof material.
d. The dry air flow rate should be adjusted to maintain continuous airflow
outward through the tank openings. To conserve dry air and prevent the
entrance of dirt and moisture, place a light cover of plywood, hardboard,
or plastic over the manhole opening. The work should be performed in a
sequence such that when accessories such as bushings are being
installed, only one opening other than the manhole will be open at any
time.

Installation
Manual
R0
4.5 Temporary Sealing of the Transformer Between Work Days
a. Remove all the tools and working material from the transformer.
b. Continue to purge the transformer tank with dry air for 30 minutes after all the
material has been removed.
c. Seal the tank and pressurize it with dry air to 3 PSI.
d. If the next work period and re-opening of the transformer will not occur within
three days, we recommend after sealing the tank, that you pull vacuum on
the transformer to an absolute pressure of 2 torr or less and hold this level
for 4 hours. Break the vacuum with dry air and pressurize the tank to 3 PSI.
4.6 Bolt & Nut Assembly
Equipment Required:
 Calibrated torque wrench
 Assorted sockets and crows foot wrenches
 Nickel or nickel/graphite anti-seize compound for stainless steel nuts and bolts such as
Chesterton 725 or Loctite Nickel Anti-Seize with application brush
 Electrical contact oxide removing grease such as Sanchem NO-OX-ID and clean rags
Procedure:
Nuts and Bolts That Require Torquing with a Calibrated Torque Wrench:
All current carrying connections must be torqued to their required torque values, as listed in the Tables
in Section 4.7, using a calibrated torque wrench. This includes all bottom bushing connection nuts and
bolts, all bushing stud connector hardware, all bushing terminal connector to cable connections, and all
ground cable connection nuts and bolts. This also includes the top terminal of ABB draw lead bushings
and the draw lead jam nut of and top terminal of PCore draw lead bushings (or similar bushing
components if required by other bushing manufacturer).
Conservator support structure bolts must also be torqued to their required torque values using a
calibrated torque wrench.
Special Case – Qualitrol Pressure Relief Device: Qualitrol Series 208 Pressure Relief Devices are
supplied with ½” mounting bolts to attach the cast iron base of the device to the transformer. This may
be changed to M12 bolts by HYOSUNG. These mounting bolts, whether steel or stainless steel, should
be torqued to 30.4 ft-lbs, and a flat washer must be used between the flange and the bolt head or nut.
Applying torque greater than 30.4 ft-lbs, or failure to use a flat washer could cause the cast iron flange
to crack and require the device to be replaced at the installer’s expense.
Special Cases – Bushing and LTC manufacturers specify the torque values for the mounting bolts and
for some current-carrying connections. The manufacturers’ torque values supersede any HYOSUNG
values listed in the Tables in this section.

Installation
Manual
R0
Note: Any torque values listed in component manufacturers’ bulletins included with this manual
supersede the HYOSUNG standard torque values in this Section for those components.
Nuts and Bolts That Do Not Require a Torque Wrench:

Bolts connecting steel, stainless steel or aluminum flanges that are not listed above must be tightened
to the torque values listed in the Tables below, but this can be done without using a torque wrench.
Cleaning:
All current-carrying surfaces must be cleaned and coated with electrical contact grease to remove all
oxides from the surfaces and protect the surfaces from future oxidation before they are bolted and
connected together.
Thread Lubricants:
All galvanized steel, bronze or brass threaded connections must be made without any thread lubrication.
All external stainless steel threaded connections must be made using a nickel/graphite anti-seize
compound on the threads to prevent galling. All stainless steel threaded connections inside the
transformer and under oil must be made without any anti-seize compound.
Nut, Bolt and Washer Configurations:
Standard Connections:
Spring/Belleville Washer Connections: When connecting flanges or other joints with Spring/Belleville
washers, the connection should be made as shown below. A flat washer must be provided under the
bolt head. The Spring/Belleville washer must have a flat washer between the Spring/Belleville washer
and the flange or other surface to protect the surface from damage. In case of using the Double nuts,
the connection should be made shown below. Lower nut must have a Spring/Belleville washer between
the Lower nut and the flange or other surface. The bolt length must be long enough to provide at least
one full thread beyond the outer end of the nut.

Installation
Manual
R0
Tapped Bolt Hole Connections:

When connecting flanges or other joints where the bottom surface is equipped with a drilled and tapped
threaded hole (like a pump, for example) the connection should be made as shown below. A
Spring/Belleville washer must be provided between the bolt head and the flat washer. The length of the
bolt is critical. The bolt must be long enough to meet the minimum engagement length (X in the
drawing) and must not be too long to meet the minimum blind hole depth (Y in the drawing).
Flat
washer
The minimum length of engagement, X, of the bolt
into the threaded hole should be at least 1 times the
Spring / Belleville diameter of the bolt. The blind hole, Y, should be at
X washer least 0.3 times the diameter of the bolt. Additional
flat washers and Spring/Belleville may be used, if
needed, to meet these requirements.
The bolt material must be the same general material

Y as the part with the tapped hole. All such connections
Bolt head with stainless steel threaded holes and bolts must
have the bolt coated with a nickel-graphite anti-seize
Tapped Drilled
compound before torquing.
section section

Installation
Manual
R0
4.7 Required Torque Values
Table 4.1 applies to galvanized steel, SAE Grade 5 and Stainless Steel Type 304 nuts and bolts through
an un-threaded hole in Steel, Stainless Steel, Copper or Aluminum base material
TABLE 4.1
Galvanized SAE Grade 5 and Stainless Steel Type 304 Hardware
Unthreaded Steel. Stainless Steel, Copper or Aluminum Base Material
Torque in FT-LBS
IN-LB values listed in parenthesis for FT-LB values <20
Galvanized Stainless Steel

Steel SAE Type 304
Bolt Material
Grade 5 w/Anti-Seize
Non-Lubricated Compound
Bolt Size Torque in FT-LBS (IN_LBS)
M6 4 (48) 3 (36)
M8 10 (120) 7 (84)
M10 20 14 (168)
M12 35 24
M14 57 39
M16 108 61
M18 152 83
M20 217 116
M22 297 159
M24 376 203
M27 550 300
M30 745 409
M33 1020 553
M36 1309 712
M39 1693 922
M42 2098 1143
M45 2618 1425
M48 3146 1718
M52 4072 2221
M56 5063 2759
M60 6307 3443
M64 7624 4159
M68 9251 5045

Installation
Manual
R0
Table 4.2 applies to Silicon-Bronze and Brass nuts and bolts through an un-threaded hole in Steel,
Stainless Steel, Copper or Aluminum base material.
TABLE 4.2
Brass and Silicon-Bronze Hardware
Unthreaded Steel, Stainless Steel, Copper of Aluminum Base Material
Torque in FT-LBS
Bolt Material Brass Silicon Bronze

Bolt Size Torque in FT-LBS (IN-LBS)
M6 2 (24) 2 (24)
M8 4 (48) 6 (72)
M10 7 (84) 12 (144)
M12 13 (156) 21
M12 13 (156) 21
M14 20 33
M16 32 52
M18 43 72
M20 61 101
M24 105 174
M30 213 347
M39 485 788
M42 597 973
M48 901 1465

Installation
Manual
R0
Table 4.3 applies to Brass and Silicon-Bronze nuts and bolts through threaded copper or aluminum
base material
TABLE 4.3
Threaded Copper or Aluminum Base Material
Torque in FT-LBS
Copper Aluminum
Base Material (With Threaded (With Threaded
hole) hole)
Bolt Size Torque in FT-LBS (IN-LBS)
M6 1 (12) 0.4 (4.8)
M8 2 (24) 1 (12)
M10 5 (60) 2 (24)
M12 8 (96) 4 (48)
M12 8 (96) 4 (48)
M14 13 (156) 6 (72)
M16 21 9 (108)
M18 29 12 (144)
M20 41 17 (204)
M24 71 30
M30 141 59
M39 318 130
M42 394 163
M48 593 246
Table 4.4 applies to galvanized steel, SAE Grade 5 and Stainless Steel Type 304 nuts and bolts through
an un-threaded hole in Steel, Stainless Steel, Copper or Aluminum base material. Torque values are in
kgf-cm.

Installation
Manual
R0
TABLE 4.4
Galvanized SAE Grade 5 and Stainless Steel Type 304 Hardware
Unthreaded Steel. Stainless Steel, Copper or Aluminum Base Material
Torque in N-m and kgf-cm
Galvanized Steel SAE Grade 5 Stainless Steel Type 304 w/Anti-

Bolt Material
Non-Lubricated Seize Compound
Torque Torque
Bolt Size
N-m kgf-cm N-m kgf-cm
M6 6 59 4 40
M8 14 140 9 95
M10 27 280 19 190
M12 48 490 33 335
M14 77 790 53 540
M16 147 1500 82 840
M18 206 2100 113 1150
M20 294 3000 157 1600
M22 402 4100 216 2200
M24 510 5200 274 2800
M27 745 7600 407 4150
M30 1009 10300 554 5650
M33 1382 14100 750 7650
M36 1774 18100 965 9850
M39 2293 23400 1250 12750
M42 2842 29000 1548 15800
M45 3548 36200 1931 19700
M48 4263 43500 2328 23750
M52 5517 56300 3009 30700
M56 6860 70000 3739 38150
M60 8546 87200 4665 47600
M64 10329 105400 5635 57500
M68 12534 127900 6836 69750

Installation
Manual
R0
Table 4.5 applies to Silicon-Bronze and Brass nuts and bolts through an un-threaded hole in Steel,
Stainless Steel, Copper or Aluminum base material.
TABLE 4.5
Unthreaded Steel, Stainless Steel, Copper of Aluminum Base Material
Brass Silicon Bronze

Bolt Material
Non-Lubricated Non-Lubricated
Torque Torque
Bolt Size
M6 2 21 3 34
M8 5 50 8 80
M10 10 100 16 165
M12 17 175 28 290
M12 17 175 28 290
M14 27 280 45 460
M16 43 440 71 720
M18 59 600 97 990
M20 83 850 137 1400
M24 142 1450 235 2400
M30 289 2950 470 4800
M39 657 6700 1068 10900
M42 809 8250 1318 13450
M48 1220 12450 1985 20250

Installation
Manual
R0
Table 4.6 applies to Brass and Silicon-Bronze nuts and bolts through threaded copper or aluminum
base material
TABLE 4.6
Brass and Silicon Bronze Hardware
Threaded Copper or Aluminum Base Material
Copper Aluminum
Base Material (With Threaded hole) (With Threaded hole)
Non-Lubricated Non-Lubricated
Torque Torque
Bolt Size
M6 1 14 0 5
M8 3 34 1 14
M10 6 65 3 28
M12 11 115 5 49
M12 11 115 5 49
M14 18 185 8 78
M16 28 290 12 120
M18 39 400 16 165
M20 56 570 23 235
M24 96 980 40 410
M30 191 1950 79 810
M39 431 4400 176 1800
M42 534 5450 221 2250
M48 804 8200 333 3400

Installation
Manual
R0
4.8 Standard Bolt Dimensions
Table 4.7
Dimension(mm) C
Standard
Bolt &
Nut Hex-Bolt Hex-Nut
A B C A B
B
M6 11.5 10 6 11.5 10
M8 15 13 8 15 13
M10 19.6 17 10 19.6 17
M12 21.9 19 12 21.9 19
M14 25.4 22 14 25.4 22
A
M16 27.7 24 16 27.7 24
M18 31.2 27 18 31.2 27
M20 34.6 30 20 34.6 30 Figure 4.1 Hex-bolt
M22 37 32 22 37 32
M24 41.6 36 24 41.6 36
M27 47.3 41 27 47.3 41
M30 53.1 46 30 53.1 46
M33 57.7 50 33 57.7 50
M36 63.5 55 36 63.5 55 B
M39 69.3 60 39 69.3 60
M42 75 65 42 75 65
M45 80.8 70 45 80.8 70
M48 86.5 75 48 86.5 75 A
M52 92.4 80 52 92.4 80
M56 98.1 85 56 98.1 85
M60 104 90 60 104 90 Figure 4.2 Hex-nut
M64 110 95 64 110 95
M68 115 100 68 115 100

Installation
Manual
R0
4.9 Tightening Sequence for Nuts and Bolts

The general tightening sequence of nuts and bolts is as follows

Installation
Manual
R0
4.10 Assembly Safeguards
DO NOT ATTEMPT TO OPERATE THE PUMP VALVES WHEN THE PUMPS ARE IN
OPERATION. ALWAYS SHUT OFF THE PUMP MOTOR BEFORE OPENING OR CLOSING ANY
VALVES. FAILURE TO FOLLOW THESE PRECAUTIONS MAY CAUSE EQUIPMENT DAMAGE
AND PERSONAL INJURY.
BE CERTAIN THE INTERNAL PRESSURE IN THE TRANSFORMER IS AT ZERO(0) GAUGE

BEFORE OPENING THE MANHOLE COVER.
IF THE TRANSFORMER WAS FILLED WITH NITROGEN GAS, THE NITROGEN MUST BE
REMOVED BY APPLYING VACUUM AT 1 TORR FOR 1 HOUR OR LONGER, BEFORE
BREAKING VACUUM AND REFILLING WITH DRY-AIR AND VENTILLATING THE TANK
TO PREVENT DAMAGE TO THE TRANSFORMER INTERNAL STRUCTURES IT MAY BE

NECESSARY TO INSTALL CLEAN TEMPORARY STRUCTURES ABOVE THE CORE AND
COILS TO SUPPORT WORKERS INSIDE THE TRANSFORMER
ENERGIZED CURRENT TRANSFORMERS CAN PRODUCE VERY HIGH VOLTAGES IF THE

SECONDARY CIRCUIT IS OPEN-CIRCUITED. THIS CAN CAUSE SEVERE INJURIES TO
WORKERS AND EQUIPMENT. ALL CT CIRCUITS SHOULD BE CLOSED AND GROUNDED
EXCEPT WHEN BEING CONNECTED TO RELAY AND METERING EQUIPMENT BY
QUALIFIED PROTECTION AND CONTROLS TECHNICIANS.

Installation
Manual
R0
4.11 Recommended Assembly Order and Quality Checks
This procedure applies to the on-site assembly of all new oil-filled transformers. Many of the tasks
listed below are covered in detail in various HYOSUNG procedures and all work must be done in
conformance with those procedures. This procedure only covers the recommended order for
performing the tasks.
After the transformer tank has been placed on the foundation in the final location, and all parts have
been inventoried, inspected and verified as clean and dry, the transformer assembly should be
performed in the following general order. The exact order of assembly should always be determined
by the installation crew leader, and can be modified as long as safety is not compromised, equipment is
not at risk and test results will not be adversely affected.
Grounding:
The tank ground should be connected to the site’s ground grid, or other secure ground point as soon as
possible after the transformer is placed on the foundation. This is a safety issue and must be done
before any other work is done on the transformer.
Preliminary Tests:
It is recommended that the CT’s be pre-tested before the transformer is assembled and filled with oil. A
full series of ratio, polarity, insulation and excitation tests on each CT will ensure that the correct CT is
installed in the turret properly and that no shipping damage has occurred.
It is also recommended that any bushings showing any signs of shipping damage such as crate
damage or shifted porcelain be tested before the transformer is filled with oil.
Performing these tests before the transformer is filled with oil will minimize the cost and impact of any
problem.
Assembly:
The optimal order of assembly for the major components varies by transformer design and should be
evaluated by the HYOSUNG field service engineer or supervisor on the assembly crew, considering all
of the following issues:
If the transformer was shipped by barge or exposed to salt spray or other corrosive contaminants
during shipping, the transformer tank and all conduits and parts that were exposed must be washed
with a pressure washer before assembly can start. If the site is an energized substation, it may be
necessary to perform this pressure washing before bringing the transformer into the station if the work
cannot be performed safely. Any crates with components found to have moisture intrusion during
shipping must also be pressure washed to remove any corrosive contaminants.

Installation
Manual
R0
The conservator support structure must be installed and all bolts torqued before the conservator or
conservator piping can be attached. The conservator should be loosely bolted to the conservator
support structure before the conservator piping (including the Buchholz relay, if equipped) is installed
and the conservator position must be adjusted using the slotted holes to align the piping, if the mis-
alignment is greater than 1/8” in any direction, before bolting the piping together and torquing the bolts
that hold the conservator in place.
The turrets must be installed before the bushings or gas collection piping are installed.
If any gas collection piping or conduits, or any LTC operating shafts are designed to be routed over any
manhole or handhole covers, all internal work through these manholes or handholes should be
performed before the piping, conduits or operating shafts are installed, to avoid later partial disassembly.
All cabinets or conduits that were removed for shipping, and are located behind radiators must be
installed before the radiators.
All bushings that are bottom-connected through handholes on the tank wall behind radiators must be
installed and connected internally before the radiators are installed.
Any bushings that require lower corona shields should be measured and evaluated before assembly to
verify whether the bushing can be installed from the top of the turret with the shield attached or whether
the shield must be connected internally after the bushing is mounted in the turret. Bushing shields must
be placed around the conductor or mounted to the bushing bottom before connecting the bushing.
All bushings that require the draw-lead nut or top terminal to be torque to manufacturers’ specified
values must be torque before installing any bushing stud connectors or neutral ground bus connections,
or before testing.
The installation of all radiator or heat exchanger support structures and cooling piping and pumps (if
equipped) must be co-ordinated with the installation of the radiators or heat exchangers to prevent
radiator piping and components from being exposed to excessive mechanical stresses during or after
assembly. If a complicated support system is provided, consult with HYOSUNG before starting the
assembly if a HYOSUNG field service engineer is not on-site.
All arrester support structures must be installed after the radiators or heat exchangers if they are
mounted directly above the radiators or heat exchangers.
Bus or cable connections to neutral bushings should be measured and placed in the proper position,
but final connection to the bushing can be delayed until after commissioning tests are completed.
All accessories such are relays, pressure relief devices, gauges and temperature controllers should be
installed after the risk of damage from installing other components has passed. All wiring to these
components should be tested for insulation strength at 500Vdc before the wiring is terminated at the
devices.
All internal and external cabinet grounds and lightning arrester grounds must be connected before
testing the accessories or wiring.

Installation
Manual
R0
If the transformer is equipped with pumps, the pumps must not be energized before the transformer
and oil piping is filled with oil.
If the transformer is equipped with a LTC, the LTC must be manually operated over the full range of
taps to verify correct position indication and correct operation of limit switches before operating power
can be connected to the LTC. The LTC cannot be operated electrically before all manual tests are
completed and correct operation is verified, and the LTC cannot be operated electrically or tested
before the transformer and LTC are filled with oil.
If the transformer is equipped with an LTC with an oil filtration system, the filtration system operation
must be thoroughly tested and the filter tank and piping must be filled with oil before any electrical
testing is performed on the filter system or LTC.
The transformer must be filled with oil only after all major components and accessories that cannot be
installed or replaced without removing the oil have been installed.
All bolted connections requiring torques with a calibrated torque wrench, must be torque to the required
value when the connection is first made, and again as a final torque before releasing the transformer for
service.
Testing, Supplied Power and Final Connections and Checks:

Perform final commissioning tests must only be performed after the transformer has been filled with oil
and the oil temperature has cooled to less than 40°C
 Ratio and single phase excitation. Excitation tests must be performed before any DC
tests.
 Insulation resistance - core, core frame and windings (after the excitation tests)
 Test current transformers from the control cabinet terminals for ratio, polarity, megger
and plot the excitation curve.
 Functionally test the AC power circuit and components: automatic transfer switch (if
equipped), cooling controls, pumps (if equipped), fans, cabinet heaters and lights. Verify
correct 3-phase power rotation, if designed for 3-phase supply power, and mark the
rotation direction at the main terminal connections if the power supply is not permanent.
 LTC functional tests
 Calibrate or check temperature gauges
 Functional test on all protective relays and alarms
Bushing stud connectors must be installed after all tests are completed. All connections must be
torque after installation
The transformer must be thoroughly checked for oil leaks after testing is complete.
The transformer and work area must be cleaned and all debris disposed of properly.

Installation
Manual
R0
Clean-UP and Release for Service:

All nicks, scuffs and scratches must be repaired with abrasive tools and the touch-up paint that is
provided. This must be the last step in the assembly process before any safety grounds are
removed and the transformer is released for service.
If any issues are encountered during assembly, or if the drawings, procedures or equipment can be
improved to facilitate the assembly and ensure high quality, please notify HYOSUNG . We place a
high value on your constructive feedback.
4.12 Gasketing
HYOSUNG’s standard gasketing system uses flat or round o-ring type gaskets and flanges equipped
with machined gasket grooves. The proper size gaskets must be installed for each joint to ensure leak-
free service. Gaskets should be sized as follows:
X = Gasket groove width

a Y = Gasket groove depth
Gasket groove area = (X x Y)
b A
Y d Y
X X
a = Gasket width d = Gasket thickness (Diameter)

b = Gasket height A = Gasket area
Gasket area = (a x b) Gasket area A = Π(d/2)2
(X x Y) must equal (a x b) Gasket area should be

and b should be approximately 0.75 x (X x Y) and
approximately 1.5 x Y d should be at least 1.2 x Y
Note that the center of the gasket should be approximately in the center of the of the gasket groove.
There must be some practical tolerance for these dimensions, but for flat o-ring gaskets the cross-
sectional area of the gasket (a x b) must be at least as large as the cross-sectional area of the gasket
groove and should be no more than 15% larger. The gasket height should be between 1.25 and 1.75
times the gasket groove depth. Round o-rings should fit in the groove with minimal stretching and the

Installation
Manual
R0
gasket cross sectional diameter should be between 1.2 and 1.4 times the gasket groove depth.
Gaskets are normally buna-n material, or nitrile with a 70 Durometer value. Viton gaskets may also be
used in higher temperature areas. Gaskets should be coated lightly with Vaseline or a similar product
before installing
Gaskets on vertical flange faces may require a small amount of glue to secure them during assembly.
4.13 Installing Bushings

Bushings may be draw-lead or bottom-connected types. Review the bushing supplier’s documentation
and instructions for lifting and rigging instructions and installation procedures. Note that bushing
manufacturers have critical torque requirements for draw-lead nut and top terminals.
All current carrying connections must be torqued using a calibrated torque wrench to the torque values
listed in the manufacturer’s instructions. Bottom terminals must be torqued to the values listed in the
appropriate Table for hardware and base material in Section 4.7.
The top terminal on ABB draw lead type bushings can be supplied in one of three different standard
design styles, as shown in Figure 4.3. The hex-head and slotted round head types shown in the left and
center sketches must be torqued using standard 1.75”, 2”, 2.5” or 3” crow’s foot wrenches with a
standard torque wrench. The bushing head with raised, rounded ridges shown in the right sketch
requires a 2” special tool, as shown in Figure 4.4. This tool is available from ABB’s facilities in Alamo,
TN. Call (800) 955-8399. Torque values are listed in the ABB bushing instruction leaflet.
Figure 4.3 – ABB Bushing Top Terminal Styles

Installation
Manual
R0
Figure 4.4 – Special Tool

PCORE draw lead type bushings also have torque requirements for the draw lead nut and the top
terminal. The required torque values are listed in the PCORE Instruction Manual. No special tools
should be required other than crow’s foot wrenches in the required sizes.
Other bushing manufactures can have similar torque requirements for current-carrying connections. If
the torque values are not included in the manufacturer’s instruction leaflet or manual, contact
HYOSUNG for guidance.
Failure to properly torque current-carrying parts on bushings can lead to equipment damage, outages
and can void the warranty.
Orientation of the Bushing Oil Level Gauge
Bushings with glass bowl oil level gauges do not require any special mounting orientation.
Bushings that are mounted horizontally and equipped with an oil level gauge should have the bushing
oriented to facilitate viewing of the gauge from ground level.
Bushings that are mounted on an angle and equipped with a sight glass in the head of the bushing
must have the bushing oriented as shown below so the oil level gauge will provide the correct reading.
Bushings with oil level gauges should be mounted similarly, but the oil level may read slightly high or
low when mounted on an angle.
Bushings mounted on compound angles will require slightly different orientation to properly locate the
oil level gauge. A level placed on the face of the gauge should read level when the bushing is rotated to
the correct mounting position.

Installation
Manual
R0
Oil Level
Level
Reads
Low
Oil Level
Level
Reads
High
Correct Sight Glass Orientations Incorrect Sight Glass Orientations
4.14 Installing Radiators and Cooling Equipment
Radiators are easily damaged if they are not lifted properly. Never lift a HYOSUNG radiator from any
part except the factory installed lifting eyes on the upper and lower headers.
HYOSUNG radiators are equipped with lifting eyes on the upper and lower header pipes. These lifting
eyes are the only points where rigging can be attached for lifting the radiators.
To remove the radiators from their crates, there are two possible methods:
1. If two cranes are available, connect slings for one crane to the lower header lifting eyes and the
other crane’s slings to the upper header lifting eyes. Slowly lift both sides simultaneously,
keeping the radiators approximately horizontal.
2. If only one crane is available, connect slings to the upper header lifting eyes and slowly lift the
radiator, uprighting it before lifting it from the crate. The bottom of radiator should be supported
by a board to protect the drain plug from damage during lifting.

Installation
Manual
R0
Radiators should be set on boards on the ground if they will not be installed immediately after lifting
from the crates.
Radiators are gasketed and sealed at the factory. Open the flange cover plates and inspect the internal
part of the radiators to ensure that they are clean and dry before mounting them.
When installing radiators, great care must be taken to ensure that none of the gaskets fall from the
gasket groove and become pinched when the flanges are bolted together. If the gasket is not lubricated
and a light amount of Vaseline used in the gasket groove is not sufficient to hold the gasket in-place, it
may be necessary to use a very small amount of glue in the gasket grooves on vertically oriented
flange faces.
Do not run pumps without oil or with the valves closed to avoid damage to the pumps.
Fan motors must be checked to ensure that drain plugs are properly installed. Fans may be equipped
with directional plugs that must all be oriented to prevent moisture intrusion in the mounted position.
Contact HYOSUNG if you have any questions.
Conservators, pipes, radiators and heat exchangers should all be checked before installation to ensure
that any bags of silica gel or other items that may have been placed inside for shipping are removed
before installation.
4.15 Installing Pressure Relief Devices
The transformer may be furnished with more than one pressure relief device. In general, one device
should be provided for every 10,000 gallons of total oil volume. If removed for shipping, the pressure
relief devices need to be re-installed using new gaskets. The pressure relief devices are rated for
vacuum and do not need to be removed during vacuum processing.
Note that the cast base of the Qualitrol Pressure Relief Device can be easily broken if the mounting
bolts are over torqued. The ½” or M12 mounting bolts must be torqued to 30.4 FT-LBS and no higher.

Installation
Manual
R0
Refer to the following drawing and steps listed below for installation of the semaphore.
Pressure Relief Device
The following steps shall be completed in order.

1. Remove one cover mounting screw (Item 11 in the drawing)
NOTE: Do not remove more than one cover mounting screw. The cover is under spring Pressure and
could be released.
2. Locate the mounting hole of the semaphore assembly (Item 15 in the drawing) over the location
of the removed screw and reconnect the mounting screw – do not fully tighten the screw yet.
3. Align the tip of the semaphore directly above the indicating pin (Item 8 in the drawing) in the
center of the pressure relief device cover.
4. Tighten the mounting screw
5. Check the semaphore for free movement from horizontal to vertical position.
6. Set the semaphore in a horizontal position (as shown in the drawing) with the top of the
semaphore directly the indicating pin.

Installation
Manual
R0
4.16 Installing the Buchholz Relay

Install the Buchholz relay in the designated location in the conservator oil piping. The relay must be
installed in the upwardly sloping horizontal section of the oil piping.
Connect the gas collection tubing and sample valve and close the sample valve.
After oil filling, open the sample valve and bleed off any air in the sample tubing.
4.17 Installing Oil and Winding Temperature Gauges

Mount the gauges on the locations shown on the detailed outline drawing. Check or set the temperature
settings for each contact. Check and program electronic temperature controllers, as required. Install the
temperature probes after testing is complete.

Vacuum Oil
Processing Procedures
Manual
R0
Section 5
Vacuum Oil Processing Procedures
Quality Issues:
 Processing, dry-out and oil impregnation are all affected by temperature. Follow the appropriate
procedures for the specific ambient temperature conditions during installation.
 The transformer cover and walls will flex inward when the transformer is under full vacuum. All
cable and bus connections to the top of bushings must be disconnected to ensure that they are
not damaged from the movement they will experience.
 No workers may stand on the transformer cover when the transformer is under vacuum.
 No electrical tests may be performed while the transformer is under vacuum.
 Failure to observe the stand time requirement may cause incomplete insulation impregnation,
leading to transformer failure upon energization.
Equipment Required:
 Processing trailer with hoses, fittings, filters, vacuum chamber and sufficiently rated heaters.
o Vacuum pumps should have a minimum 150 CFM capacity (4300 liter/minute) and must
be capable of attaining a 0.1 Torr blank-off vacuum pressure.
o Connections from the pump to the transformer tank must be as short as possible and a
diameter of three inches. There should be no low spots in the vacuum line in which oil or
water can collect. The vacuum system (pumps and hoses) must be capable of attaining
a blank off pressure of 0.1 Torr or less.
 Vacuum/pressure gauge
o The pressure in the tank during vacuum operations must be measured through a
connection to the top section to the section of the tank above the oil level. Do not take
pressure measurements at locations other than the tank itself. We recommend
measuring the pressure in the tank with a properly calibrated aneroid gauge or
manometer. Mercury gauges are not to be used under any circumstance.
 Hi-Pot Oil Test Set (IEC156)
 Dew Point Test Set

Vacuum Oil
Manual
R0
Process Flowchart:
The Process Flowchart shows all of the standard and optional steps included in this procedure. The
process steps are color coded as follows and the Procedure section or subsection is listed in each
process step on the flowchart.
These steps are required for vacuum processing all oil-filled transformers.
These steps are only required when specified by HYOSUNG or the customer, or if field tests
on the oil after filling do not meet all requirements.
These steps are only required if the transformer fails the dew point test and requires dry out
before the start of vacuum processing.
These steps are only required if the vacuum processing is performed in cold weather and the
temperature of the transformer’s active part is less than 10°C (50°F).
These steps are only required if the transformer processing is started more than 90 days and
less than 181 days after the transformer is shipped from the factory.
Figure 5.1

Vacuum Oil
Manual
R0
Oil Delivery Start
Receive New Oil

Section 5.4 N Section 5.3
Dew Point OK? Dry Out
Figure 3.1 Section 5.3 Optional
or 5.4 Pre-Processing
Dry Out Process
Y
N
Oil Tests OK?
Section 5.4 Table 5.1
Oil Acceptance
Y
Ambient N Short term vacuum
Temp ≥ 50ºF? Section 5.6
Y
Reject Oil 20% Oil fill
Section 5.6
Processing
N
≤ 90 Days after
ex-factory
date? Hot oil circulation
Section 5.6
Processing Y Section 5.6
N
≤ 150 Days after Optional
ex-factory Vacuum Leak Test Active Part
Section 3.5 date? Sect. 5.7 Pre-Heating
Temporary N
Outlet oil
Y
Storage temp ≥ 50ºC?
Vacuum Oil fill

Section 5.10
Stop N Voltage Class
Y
Contact HICO ≤230kV?
Hot oil N Transformer

Y N circulation temp gauge
required?
Extended Vacuum Section 5.8 ≥ 50ºC?
Table 5.4 Section
5.10 Y Y
Standard
Oil fill Vacuum
Table 5.3 Process Hot oil circulation Outlet oil
N
Section 5.8 temperature
Section 5.9 stabilized?
Processing After Hot oil circulation
Table 5.4
Short Term
Y
Storage Oil
Field Tests OK? N
Oil Table 5.3
Field Tests OK? N Section 5.8
Table 5.3
Section 5.8 Y
Y Stand Time
Table 5.3
Extended Stand
Time
Table 5.4
Finish
Figure 5.2 Flow Chart

Vacuum Oil
Manual
R0
Ambient Temperature Conditions:

In extreme cold weather, a tent or panel enclosure may be constructed around the transformer and
equipped with internal heaters to facilitate processing. When this is done, the ambient temperature shall
be defined as the temperature inside the tent or enclosure.
When the 24-hour average ambient temperature at the site over the two days prior to the start of
vacuum processing is not less than 10°C (50°F), HYOSUNG’s standard processing requirements shall
be observed.
When the 24-hour average ambient temperature at the site over the two days prior to the start of
vacuum processing is less than 10°C (50°F), HYOSUNG’s cold weather processing requirements in
Section 5.6, Active Part Pre-Heat, shall be observed.
Ambient Humidity Conditions:

When the relative humidity at the site is not greater than 85% at any time while the transformer is open,
HYOSUNG’s standard processing requirements shall be observed.
When the relative humidity at the site is greater than 85% at any time while the transformer is open, the
transformer must be continuously ventilated with dry air while open, must not be open for more than
8 hours during any day and must be placed under vacuum at the end of each day for not less than
12 hours when the transformer is open for any assembly work. This is in addition to any vacuum
requirements under HYOSUNG’s standard processing requirements.
Determining Required Heater Capacity:

The oil processing trailer must have sufficiently rated heaters to raise and maintain the required oil
temperature under the expected ambient conditions. Required heater capacity can be estimated with
the following formula:
H = FR × ΔT × C
where…
H = the required total heater capacity in kW
FR = the flow rate in gallons per minute
ΔT = the difference in the required oil temperature and the ambient oil temperature (°C or °F)
C = a constant, 0.06 if ΔT is in °F or 0.108 if ΔT is in °C
Example: Calculate the amount of heating required to raise the oil temperature to 60°C (140°F) when
the ambient temperature is 20°C (68°F) and the flow rate is 40GPM.
H = 40 × (60-20) × 0.108 = 172.8 kW or H = 40 × (140-68) × 0.06 = 172.8 kW

Vacuum Oil
Manual
R0
Pre-Processing Quality Check:

 Verify that all valves for any oil monitoring equipment, rapid pressure relief device relays,
Hydran Gas Monitoring system or other devices that cannot withstand vacuum are closed
before starting the vacuum process.
 If the transformer is equipped with a LTC, and the LTC barrier is not rated to withstand full
vacuum, verify that the pipe between the LTC and the tank is in place and all valves between
the LTC and main tank are open at all times when vacuum is applied.
 Verify that the bushings are all disconnected from the HV, XV and YV buses or cables to avoid
damage when vacuum is applied.
Figure 5.3 Tank Cover Flex Example During Vacuum

Vacuum Oil
Manual
R0
5.1 Grounding
 Verify that tank ground is connected to the site ground grid. If not, make the connection to the
site ground grid or another reliable ground source.
 Ground the oil processing trailer to the transformer tank, or site ground grid.
 Ground any generator that may be used.
 Install static ground wires to the top of each bushing and connect these to the tank.
 All oil hoses must contain internal static wires. The hoses must be tested to verify electrical
continuity between the fittings on both ends before each use.
 All temporary grounds must be removed after the work is completed.
Transformer oil can generate a large static charge when pumped through hoses or pipes, Also,
electrical fields in energized substations and power plants can induce high voltages on unground
ed transformer windings. All oil hoses must be equipped with internal static discharge wires and
all tanks, tankers, transformers and processing trailers must be securely grounded.

Vacuum Oil
Manual
R0
5.2 Dew Point Test

Perform a dew-point test on the dry air inside the transformer and analyze the results using the chart
below. Record the ambient temperature and measured dew point on the Shipment Inspection report.
1. ENTER CURVE AT INSULATION TEMPERATURE LEFT (°C) OR RIGHT (°F).

2. MOVE TO DEW POINT LINE.
3. READ THE MAXIMUM ACCEPTABLE DEW POINT, ON BOTTOM (°F) OR ON
TOP (°C)
4. USE THIS CURVE FOR PRESSURE BETWEEN 0 AND 5 PSI.
Figure 5.4 Dew Point Limit

Vacuum Oil
Manual
R0
5.3 Pre-Processing Dry Out Process

If the Dew Point test is satisfactory, skip this section and go to Section 5 – Ambient Temperature
Conditions.
If the Dew Point test is not satisfactory, apply vacuum to 1 Torr for 12 hours or longer. Refill the
transformer with dry air (minimum -50°C dew point) and wait for 12 hours or longer then repeat the Dew
Point test on the transformer. If the test is satisfactory, go to Section 5. If the test is not satisfactory,
apply vacuum again for 12 hours or longer, refill with dry air again and wait for 12 hours again before
retesting. If the retest is not satisfactory, the active part pre-heating process described in Section 5.6
must be performed.
5.4 Oil Acceptance
Oil Testing
The oil supplier must provide a certified test report on the bulk oil from which the delivered oil was
obtained and the oil must meet the following requirements for acceptance. The dielectric strength of
the delivered oil must also be tested on-site using IEC60156 before acceptance and before being
placed into any other tank or tanker.
<Measurement>
a. Take oil samples from the following positions of transformer. Make sure that the
sample container is clean and dry.(The bottom of main tank)
b. Pour oil into the test cup and fix it.
c. Wait for five minutes. When there is no air bubble, apply voltage.
d. At this time, one sample of oil has to be tested five times every one minute.
Rejecting Oil that Fails to Meet Test Criteria

Oil that fails to meet the acceptable criteria listed in Table 5.1 above, must be rejected or processed on-
site and retested before being placed into the transformer. Oil with corrosive sulfur must be rejected.

Vacuum Oil
Manual
R0
5.5 Ambient Temperature Check

Monitor the daily temperature at the site for 2 days prior to the start of processing. If the average daily
temperature during each day is 10°C (50°F) or greater, standard processing may be performed. If the
average daily temperature is less than 10°C (50°F), an active part pre-heat shall be performed.
5.6 Active Part Pre-Heat

If the ambient temperature is 10°C (50°F) or greater, active part pre-heat is not required, skip this
section and go to Section 5.10 - Vacuum Oil Filling Process.
Short Term Vacuum
 Refer to the valve positions as shown in Section 5.10 – Vacuum Oil Filling Process
 Configure the processing trailer vacuum and oil hoses, and transformer valves, including any
equalizing valves, for initial vacuum
 Pull vacuum on the transformer (and LTC, if equipped) to 1 Torr or below. Hold vacuum at this
level for 30 minutes.
20% Oil Fill
 Close the lower radiator or heat exchanger shut-off valves, but leave the upper valves open.
Configure the remaining valves for Initial Oil Filling, as shown in Section 5.10 – Vacuum Oil Filling
Process. If the transformer is equipped with a LTC, keep LTC equalization valves open.
 If the average daily ambient temperature is below 0°C (32°F), the transformer should be covered
with insulating blankets to facilitate the heating of the active part.
 Maintain vacuum at 10 Torr or less during oil filling and fill the main tank with about 20% of the total
oil volume using the oil processing trailer’s pumps, filters, heaters and vacuum chamber. The
temperature of the oil leaving the oil processing trailer should be maintained as close to the
maximum 75°C (167°F) as possible, and not less than 50°C (122°F).

Vacuum Oil
Manual
R0
Hot Oil Circulation for Heating the Core and Coil
 When the tank is about 20% filled, stop the pumps and configure the processing trailer vacuum and
oil hoses, and transformer valves for Oil Filtering as shown in Section 5.10 – Vacuum Oil Filling
Process. If the transformer is equipped with a LTC, keep LTC equalization valves open.
 Maintain the temperature of the oil leaving the oil processing trailer as close to the maximum 75°C
(167°F) as possible, and not less than 50°C (122°F) and maintain the vacuum level at 10 Torr or
below.
 Continue vacuum/hot oil circulation until all three conditions below have been met:
o Transformer outlet oil temperature has reached 50°C or greater, as measured at the input to
the processing trailer.
o The transformer oil temperature gauge reads 10°C (50°F) or greater (the gauge should be
reading the internal tank temperature)
o The temperature of the oil leaving the transformer has reached or exceeded 50°C and has
stabilized
NOTE: If the oil processing trailer is equipped with sufficient heaters, the transformer is properly
blanketed and after 12 hours or more of hot oil circulation it is still not possible to reach and
maintain the 50°C transformer outlet oil temperature, contact HYOSUNG . An alternate 30°C
outlet oil /10°C tank/ 12 hour process may be authorized.
A spray inlet nozzle attached to a temporary manhole cover may also be used, if available.
The spray must be directed away from any bushings inside the tank to eliminate the risk of
thermal shock damage to the bushings.
 Drain all the oil from the tank with vacuum and back-fill with dry air.
 Immediately start the Vacuum Oil Filling Process as listed in Section 5.10 below.

Vacuum Oil
Manual
R0
5.7 Vacuum Leak Test
 After the required Vacuum Level Prior to Oil Filling as listed in Table 5.3 is reached, close the
vacuum valve at the oil processing trailer and wait for 10 minutes then monitor the vacuum level. If
the pressure rises more than the maximum allowable level listed in Table 5.2 below, it should be
checked for leaks and any leaks repaired before starting again.
If there are no leaks and the pressure still rises more than the maximum allowable level, the
transformer insulation may be wet. Fill the transformer with dry air, wait 6 hours then retest the Dew
Point.
Table 5.2
Maximum Allowable Vacuum Leak Rate
Tank Oil Volume (Gallons) Torr Rise in 10
Minutes
Less than 5000 0.80
5001-7500 0.53
7501-10,000 0.40
10,001-12,500 0.32
12,501-15,000 0.27
15,001-17,500 0.23
17,501-20,000 0.20
20,001-22,250 0.17

Vacuum Oil
Manual
R0
5.8 Processing Parameters
Table 5.3
≥69kV to ≥230kV to
Vacuum Treatment and Oil Filling ≤69kV ≥345kV
<230kV <345kV
Class Class
Class Class
Vacuum Level Prior to and

2 mm Hg 1 mm Hg 1 mm Hg 0.5 mm Hg
Following Oil Filling
Vacuum Vacuum Level During Oil Filling 2 mm Hg 1 mm Hg 1 mm Hg 1 mm Hg
Min. Vacuum Hold Time After

Reaching Specified Vacuum 8 Hours 18 Hours 24 Hours 30 Hours
Level, Before Oil Filling
Oil Temperature Min 10°C 10°C 10°C 10°C

During Oil
Filling Max 75°C 75°C 75°C 75°C
Max. Oil Fill Rate 30 GPM 30 GPM 30 GPM 30 GPM
Min Dielectric Strength

Per ASTM D-1816 1mm Gap 25 kV 30 kV 32 kV 35 kV
2mm Gap 45 kV 52 kV 55 kV 60 kV
After Oil Max. Water Content of Oil 20 ppm 10 ppm 10 ppm 10 ppm
Filling
Max. Oil Power Factor
0.05 % 0.05 % 0.05 % 0.05 %
at 25°C
at 100°C 0.40% 0.40% 0.30% 0.30%
Min. Stand Time After Oil Filling

12 Hours 24 Hours 48 Hours 72 Hours
Before Energization
* For more information, please consult IEEE Std C57.106-2002

Vacuum Oil
Manual
R0
Stand Time
After oil filling, the transformer must not be energized before the time listed under “Stand Time After Oil
Filling Before Energization” in Table 5.3. When the transformer must be energized as quickly as
possible, the stand time can start as soon as the core and coils have been covered with oil. If hot oil
circulation is performed, the circulations can be made during the stand time.
After stand time is complete and the transformer is energized, there is no additional hold time required
before the transformer can carry load up to the full nameplate rating.
Hot Oil Circulation After Oil Filling
Hot oil circulation is not required for HYOSUNG’s standard oil processing process. Hot oil circulation is
only required when:
o The transformer has not been assembled within 150 days after leaving the factory and the HV
voltage class is ≤230kV (See Short Term Storage in Section 3)
o After the transformer is filled with oil, the tested oil fails to meet any of the following Processing
Parameters listed in Table 5.3 for After Oil Filling ( Min. Dielectric Strength per IEC60156 test at
1mm or 2mm gaps, Max. Water Content of Oil, or Max Oil Power Factor)
o Required or specified by the customer
o When specified by HYOSUNG (when special requirements such as extra low moisture or
dissolved gas requirements exist)
If hot oil circulation is required, the following steps must be performed.
 After the transformer has been fully filled with oil, configure the oil hoses and valves as shown in the
Oil Filtering in Figure 5.10. If the transformer is equipped with a LTC, keep LTC equalization valves
closed.
 Circulate oil through the transformer and the oil processing trailer’s heaters, vacuum chamber and
filters maintaining a 1 Torr or stronger vacuum in the vacuum chamber.
 Control the flow rate to provide an oil temperature into the transformer of 75°C (167°F) and an oil
temperature out of the transformer of 50°C (122°F) or greater. The temperatures shall be measured
in the oil processing trailer so oil temperature into the transformer will be the temperature of the oil
leaving the trailer.
 If the minimum oil temperature out of the transformer cannot be maintained, verify that the heaters
are sufficiently rated (See Determining Required Heater Capacity). It may be necessary to add
insulating blankets to the transformer or construct a heated enclosure around the transformer.
 After the oil temperature out of the transformer reaches and is stabilized at 50°C (122°F) or greater,
the count of circulated gallons can start. For one required pass, circulate the total quantity of oil as

Vacuum Oil
Manual
R0
listed on the nameplate. For two required passes, circulate two times the total quantity of oil as
listed on the nameplate, etc.
 If an oil sample is required for moisture, the sample must be drawn within 10 minutes after the end
of the circulation, while the oil is still hot. Record the oil temperature and include this information
with the paperwork for the sample that is sent to the test lab.
 After the hot oil circulation is complete, remove the oil hoses and configure all valves to their normal
(in-service) positions as shown in the Valve Nameplate drawing in Section 10.

Vacuum Oil
Manual
R0
5.9 Processing After Short Term Storage (Refer to Section 3.5. Not approved for transformers
greater than 230kV or for storage beyond 150 days after leaving the factory)
Follow the requirements herein and the parameters listed in Table 5.3, except for the requirements
listed below in Table 5.4.
Table 5.4
Processing After Short Term Storage
Vacuum Treatment and Oil Filling ≤ 230kV
Class
Vacuum Min. Vacuum Hold Time After 24 Hours
Reaching Specified Vacuum
Level, Before Oil Filling
After Oil Hot Oil Circulation Passes 2
Filling Required
Stand Time After Oil Filling 48 Hours
Before Energization

Power Transformer
Maintenance and Repair
Manual
R0
Section 5.10 – Vacuum Oil Filling Process

For transformers with a conservator and with an on-tank LTC with a LTC
conservator Please refer to the valve location drawing in Section 10.
Initial Vacuum
Figure 5.5
Initial Vacuum
Notes: Valves Va, Vb, Vc, Vd and connecting hoses or pipes are not supplied with the transformer.
All valve locations are approximate and shown for function only.
1. Review the LTC instruction manual and remove all LTC accessories that could be damaged
during vacuum oil filling (dehydrating breather, rapid pressure rise relay, etc.).
2. Inspect all vacuum and oil hoses for cleanliness before using.
3. Check electrical continuity with an Ohm-meter on all oil hoses before using. Do not use any
hoses that do not pass this test since the static discharge wire is not functional.
4. Remove the conservator’s desiccant breather from its mounting flange and store in a safe place.
Also close the valves for RPRR, B-H relay, etc.
5. Connect all vacuum hoses and vacuum valves as shown in Figure 5.5. Note that the
transformer main tank and LTC tank must both have vacuum applied simultaneously.
6. Connect oil hoses as shown in Figure 5.5.
7. Configure all valves as shown in Figure 5.5. Open all cooling system valves.
8. Be sure the removal the equalizing pipe between main tank and LTC for transportation purpose.
9. Pull vacuum on the main tank and LTC at the level specified in Table 5.3.
10. Check the leakage rate per Section 5.7 and Table 5.2.
11. After leakage rate has been determined to be within limits, hold the vacuum at the level and
time specified in Table 5.3.
12. After the specified vacuum has been applied for the specified length of time, proceed to the next
step – Initial Oil Filling.

Power Transformer
Manual
R0
Initial Oil Filling
Figure 5.6
Initial Oil Filling
1. With the valves still in the same configurations as shown in Figure 5.5, open the Upper Filter
Valve and start oil filling through the heaters, vacuum chamber and filters of the oil processing
trailer within the flow rate limits listed in Table 5.3 while maintaining the vacuum level specified
in Table 5.3.
2. When the oil has been filled to a level approximately 4”-6” below the tank cover, configure all
valve positions as shown in Figure 5.6 (close vacuum valve so vacuum will be pulled through
the main tank conservator and the LTC conservator) (Note that the LTC conservator is not
equipped with a diaphragm)
3. Continue oil filling the main tank until the conservator Oil Level gauge indicates 25°C or
indicates 4. Stop oil filling.
4. Proceed to the next step – LTC Oil Filling

Power Transformer
Manual
R0
LTC Oil Filling
Figure 5.7
LTC Oil Filling
1. Configure the valves and hoses as shown in Figure 5.7.

2. Apply vacuum of 1 Torr or better to the LTC through the LTC conservator.
3. Fill oil to the appropriate level for the oil temperature, as indicated on the LTC conservator oil
level gauge, through the LTC drain valve. Close the LTC drain valve when the correct oil level is
reached.

Power Transformer
Manual
R0
Break Vacuum and Final Filling
Figure 5.8
Break Vacuum and Final Filling
1. Continue with the valves configured as shown in Figure 5.7

2. Open Valve Va then slowly open the Vacuum Break Gas Valve and slowly pressurize with dry
air or nitrogen gas and add dry air or nitrogen until the nitrogen pressure in the system (hoses,
main tank conservator diaphragm and LTC conservator tank) are at 0 relative pressure
(atmospheric pressure)
3. Replace all LTC accessories removed for vacuum oil processing.
4. Configure the valves as shown in Figure 5.8
5. Open the air release cock on the top of the conservator.
6. Increase the dry air or nitrogen pressure into the conservator diaphragm to 0.15-0.3psi (approximately
2
0.01-0.02kg/cm ) pressure. This slight pressure applied through the conservator equalizing valve will
expand the conservator diaphragm to its normal operating condition..
7. Continue filling oil slowly until all of the air is vented through air release cock and a
small amount of oil escapes. Stop pumping and close the Air Release Cock.
8. Close the gas cylinder valve, bleed off any residual pressure and remove the hose
connection, then re-install the conservator’s desiccant breather.
9. Check the oil level gauge indication and the oil temperature and compare to the oil
level nameplate. Add more oil, if the level is below the correct range.
10. If additional oil filtering or hot oil circulations are required proceed to the last step – Oil Filtering.
11. If additional oil filtering or hot oil circulations are not required proceed to the next step –
Final Valve Positions

Power Transformer
Manual
R0
Final Valve positions
Figure 5.9
Final Valve Positions
1. Configure all valves as shown in Figure 5.9. Keep all cooling system valves open.
2. Verify that the supply valves for the gas accumulation relay and Online-Gas monitor(if equipped)
is open and vent any trapped air in the gas accumulation relay or Buchholz relay through the
sample valve.
3. Draw an oil sample and have the sample analyzed for dissolved gasses and physical properties
by a qualified laboratory. The oil sample should be taken while the oil is 30°C or greater to
provide meaningful percent moisture saturation values, and the oil sample temperature must
accurately be measured and provided to the lab with the sample.
4. Do not energize the transformer until the required stand time has been met, as specified in
Table 5.3 and the oil sample results have been received and approved by HYOSUNG.
5. If oil test results are not acceptable, additional oil processing is required depend on our manual.

Power Transformer
Manual
R0
Oil Filtering
Figure 5.10
Oil Filtering
1. If additional oil filtering or hot oil circulations are required for the main tank and/or the
LTC, configure all valves as shown in Figure 5.10.
2. For filtering, use new ½ micron filters and circulate the oil through the oil processing trailer
3. The main tank and LTC compartments should be circulated separately, and not at the same time.
4. For hot oil circulations, follow the steps in Section 5.8

Power Transformer
Manual
R0
Section 6
Commissioning Tests
General Test Procedures:
Lethal voltages can be generated during transformer testing. Test equipment should only be used by,
and tests should only be performed by, trained and qualified technicians.
If additional details or documentation are required for any components, contact HYOSUNG
1. Assembly and outline inspection
Description Acceptance Criteria
1.1 Assembly and outline inspection will be done ⊙ The inspection results shall be satisfied with
in accordance with the approved specification approved drawings.
and drawings.
1.2 Construction, painting and welding condition will
be inspected visually.
2. Visual and dimension check

1) The visual and dimension check will be measured ⊙ The inspection results shall be satisfied with
with approved drawing.
approved drawings.
3. Voltage ratio test

1) The voltage ratio shall be measured by means of
a voltage ratio measuring bridge and on single
phase, phase by phase. ⊙ Ratio errors shall be within ±0.5% at all tappings.
2) The test voltage will be applied with convenient
voltage to HV winding.
3.3 The test shall be made between each winding to
winding.

Power Transformer
Manual
R0
4. Phase relationship check

⊙ Phase Relationship : YNd1
4.1 The phase relationship shall be checked at rated
voltage tap connection.
4.2 Three phase power source will be applied to HV
winding and the voltage shall be measured
between terminals.
4.3 Vector diagram will be drawn and confirmed.
5. Functional test of all control and protection equipment

1) Auxiliary Equipment and wiring is to be checked ⊙ To be operated properly.
and tested where appropriate.
2) The wiring is to be thoroughly tested.
6. BCT test
1) The BCT shall be measured ratio with both ⊙ Measuring Current is within ±10% of standard
voltage & current method ⊙ The polarity : subtractive.
2) The BCT polarity shall be check by DC current
Inductive kick method or other available method.
7. Insulation power factor

1) All insulation must be immersed in oil. ⊙ Winding-to-ground and winding-to-winding of
2) All terminals of each phase must be connected. power factors shall not each exceed 0.5% at
3) The measured power factor will be corrected to 20℃.
20℃.

Power Transformer
Manual
R0
8. Oil withstand voltage test

1) To check the insulation condition of the ⊙ 30kV/2.5mm gap
insulation oil.
2) The oil sample shall be taken after
filling the oil.
9. SFRA
1) The tests will be performed with the transformer ⊙ For reference only
Fully assembly condition and with oil by DOBLE
M5400.
2) The frequency will cover the frequency range
from 20Hz to 2MHz.
3) All bushings will be tested as Doble Standard
test connections.

Power Transformer
Manual
R0
Section 7
Power Transformer Maintenance and Repair
7.1 General Requirements for Inspection and Maintenance
The inspection items are classified into three categories in this manual.
Routine Inspections (Table 7.1)
The routine inspection should be made preferably daily on every transformer in service. Oil
temperature and/or winding temperature, load current, ambient temperature and oil level in
transformer should be daily checked and recorded.
Periodical Inspections (Table 7.2)
The periodical inspection should be made occasionally, once every six months or once every
three years in order to ascertain the good performance of a transformer and its parts. Most of
the periodical inspections should be made in detail when the transformer is de-energized.
Periodic Testing (Table 7.3)
Some additional inspections or measurements of electrical characteristics of at transformer

are recommended as preventive maintenance actions and when any transformer trouble
should be investigated.
Repainting of radiators and transformer tanks, and exchange of parts, gaskets and bearings of motors
should be planned and executed regularly as a part of an effective preventive maintenance program to
ensure reliable performance.
If any protective relays alarms occur, investigate the trouble in accordance with the Troubleshooting
section below.
It is essential to determine all relay actions and their sequence when investigating any power system
alarm or trip.
Any abnormal symptoms such as unusual noises, high or low oil levels, high temperatures, oil escaping
from the pressure relief device, etc., should be investigated and corrected as quickly as possible.

Power Transformer
Manual
R0
7.2 Spare and Replacement Parts
HYOSUNG recommends that owners keep critical spare parts on-hand for each transformer. Lead-
times on some parts like high voltage bushings can be as long as one year. A proactive approach of
stocking spare parts can ensure that a failed component can be quickly replaced, avoiding lengthy
outages.
Transformers cannot or should not be operated without the following components in good functional
condition:
 Bushings
 Lightning arresters
 Protective relays (Buchholz, rapid pressure rise, gas accumulation, pressure relief, etc.)
 Cooling components and controls (fans, pumps, circuit breakers, contactors, relays, etc.)
 Trip and alarm circuit relays
Many transformers share common components. A well-planned universal spare parts plan can cover
several transformers with a relatively small number of spare parts. HYOSUNG can assist in
developing a spare parts plan if support is needed.

Power Transformer
Manual
R0
7.3 Inspection Records
The establishment of the report and recording of the condition and repair of the transformers is required
for a good maintenance program.
A preventive maintenance system will operate satisfactorily with the following records.
An equipment record
This may range from a simple index card and card file to an equipment database which
contains the basic information of a transformer itself such as the serial number, the location,
size, etc.
A repair record
This should keep a running record of all maintenance and repairs performed on a transformer.
It is the essential diagnostic record for avoiding future difficulties.
An inspection checklist or inspector's record.
This should include a list of the points to be checked or measured on a transformer and the
establishment of the time that these checks should be made. The results of all regular
inspections should be retained in a file or database.

Power Transformer
Manual
R0
7.4 Routine Inspections (Daily Inspection)
Table 7.1
No. Items Method Action
1. Oil Temperature Visual check of temperatures at the If temperatures appear to be

And Winding time of inspection and recent wrong, check tank temperature
Temperature maximum temperatures. Winding with Thermovision, and compare
Indicator temperature should show higher to top oil temperature.
temperatures when the transformer is Recalibrate gauges, if needed. If
under moderate to heavy load. temps are high, check cooling
Temperatures should be below alarm operation. If cooling is OK, check
points. radiators or heat exchangers for
debris.
Load current, Load current and ambient temperature
Ambient should be recorded at the same time.
Temperature
2 Oil level Visual check of the dial type oil level Oil level should vary with top oil
in transformer gauge. temperature, if not, check the
dial gauge and check the
actual oil level.
3 Oil leaks Check oil leaks visually from Review this manual. Contact
radiators, flanges, pipes and HYOSUNG if additional
transformer tank. instructions are required.
4 Abnormal noise Abnormal or unusual noise, especially Check connections. Rebalancing

and vibration from fan motors, should be carefully may be required.
checked.
5. Appearance Bolt connections Tighten any loose connections
Dirt and Dust: Visually inspect heat Keep clean to maintain cooling
exchanger coils or radiators capacity.
Corona: Visually inspect bushings and Keep clean to maintain dielectric
arresters withstand capabilities.
Paint: Inspect for signs of rust or Clean and touch-up or repaint,
corrosion, especially on radiators or as required
heat exchangers.
Moisture: Visually inspect for moisture If any moisture is found, dry it
in the terminal box, control panel and out, and ensure that space
protective relays. heaters are functioning correctly.

Power Transformer
Manual
R0
7.5 Periodic Inspections (Cycles as indicated)
Table 7.2
1. Breather Check the discoloration of silicagel in If the color of silicagel has
(6 months) breather due to absorbed moisture. turned pink by more than two
thirds, dry out or exchange it.
2. Fan motors Measure insulation resistance of fan If insulation resistance is less
(3 years) motors with a 500V megger. than 2MΩ, replace motor.
3. Control panel Check the water-tightness of control Replace the rubber gasket if
and terminal box panel and a terminal box. it is worn or damaged.
(3 years)
4. Switches, circuit Check the tightness of all control Tighten any loose
breakers, wiring connections. connections.
contactors and Test all switches, relays and alarms. Repair or replace, as needed
control relays Megger test wiring.
(3 years)
Thermovision checks on Circuit Tighten, repair or replace, as
Breaker and Contactor terminals needed
5. Oil Leaks Check all gasketed connections and Regasket, or repair if needed
(Annual) complete tank for signs of leakage.

Power Transformer
Manual
R0
7.6 Periodic Testing (Cycles as indicated or if troubleshooting is required)

Table 7.3
1. Power factor, Doble power factor and capacitance Contact HYOSUNG if any
capacitance and tests significant changes are
insulation of found from factory or
windings and previous field tests
bushings
(3 years)
2. Ratio test Transformer turns ratio test on all taps Compare with the factory
(3 years) test report and previous
tests. Test values should
not vary more than 0.5%
3. Winding By bridge method or by drop-of-potential Contact HYOSUNG if any
Resistance method. If oil pumps are provided, they significant changes are
(3 years) should be operated during tests and the found from factory or
oil temperature should be measured. previous field tests
Test data must be corrected for
temperature.
4. Exciting current Doble or similar individual phase test Contact HYOSUNG if any
at low voltage method. significant changes are
(3 years) found from factory or
previous field tests
5. Bushing Ratio, and excitation and megger tests Contact HYOSUNG if any
current significant changes are
transformers found from factory or
(3 years) previous field tests
6. Protective relays Functional test of all controls and relays Replace any faulty
and controls components
(3 years)

Power Transformer
Manual
R0
7.7 Regular Maintenance
Table 7.4
No. Material and Parts Maintenance frequency Remarks
1. Bushings and Clean as required for local Coastal environments and
insulators conditions. locations near industrial
sites will require more
frequent cleaning. Visible
corona is a sign that
cleaning is needed.
2. Radiators and heat Clean as required for local Use care when cleaning.
exchangers conditions. Use compressed air or low
pressure water. Do not use
pressure washers.
3. Paint As required Touch-up painting should
be performed after
commissioning and
whenever maintenance is
performed. Complete
repainting should be
required less often if touch-
up painting is done
regularly.
4. Fans and pumps Expected life is ten years. Replace when needed
5. LTC Per the manufacturer’s manual.

Power Transformer
Manual
R0
7.8 Troubleshooting
When the transformer does not perform as expected, it is important that the cause of the action be
determined and corrected. Troubleshooting is an art that requires logic, experience and knowledge of
how the system and equipment are designed to operate and how they are constructed.
7.9 Diagnosis of protective relays in operation

If any protective relay or gauge gives an alarm, investigate the causes as listed below.
Temperature Indicator
 Types
Analog or electronic type may be provided. Analog Qualitrol type and AKM style are shown below
for reference.
 Function
The temperature indicator Indicates maximum oil & winding temperature of a transformer. It also
has protective functions to give an alarm or tripping signal, and automatic function to control cooling
system.
 Possible causes of elevated temperatures
o Overloading
o Insufficient cooling due to dust or other foreign materials
o Mis-operation of thermal relay
Figure 7.1 Outline of temperature indicator

Power Transformer
Manual
R0
Figure 7.2. Qualitrol/AKM style temperature indicator

Oil Level Gauge
 Function
The dial type oil level gauge indicates the oil level in the conservator of an oil-immersed transformer.
When the oil level comes down to the bottom of a conservator, its pointer indicates low and gives
an alarm.
 Possible causes of abnormal oil level indication
o Shortage of oil and/or oil leakage
o Abnormally low ambient temperature in winter season with low oil level
o Conservator bladder failure
Figure 7.3. Oil Level Gauges

Power Transformer
Manual
R0
Rapid Pressure Rise Relay

 Function
The rapid pressure rise relay detects pressure waves in the transformer.
 Possible causes of relay action
o Internal faults
o Oil surges from abnormal operation
o Circuit problems (corrosion, water intrusion, etc.)
Figure 7.4 Rapid Pressure Rise Relay

Power Transformer
Manual
R0
Pressure Relief Device

 Function
The pressure relief device protects the transformer tank when the tank pressure rises above the
rated pressure withstand of the device.
 Possible causes of relay action
o Internal faults
o Closed conservator piping valve when transformer is energized
o Clogged conservator breather or closed breather valves
o Circuit problems (corrosion, water intrusion, etc.)
Figure 7.5 Outline of pressure relief device

Power Transformer
Manual
R0
7.10 Recommended Instructions for Repairing Weld Leaks
This instruction leaflet is intended to give general instructions concerning recommended practices for
repairing weld leaks in power transformers or their auxiliaries. Variations of these instructions may be
desirable for special repair tasks, but normally weld leaks can be successfully sealed if these
instructions are followed.
WELDING REPAIRS SHOULD NEVER BE MADE ON AN ENERGIZED TRANSFORMER. ALSO, THE

WELDING MACHINE GROUND MUST BE LOCATED TO ENSURE THAT WELDING CURRENT
DOES NOT PASS THROUGH ANY COMPONENTS OR CIRCUITS.
THE TANK MATERIAL TO BE WELDED MUST BE CHECKED WITH A MAGNET TO DETERMINE IF

IT IS REGULAR STEEL OR STAINLESS (OR ANOTHER NON-MAGNETIC STEEL) BEFORE
SELECTING THE PROPER WELDING ROD AND TECHNIQUE.
Repair Steps
 De-energize the transformer.
 If the liquid has not been removed, pull a vacuum of several pounds per square inch above the
liquid to stop the liquid leak. This may be done with a vacuum pump or by sealing all fittings on
the tank and draining sufficient oil to obtain the necessary vacuum to obtain a neutral or
negative head pressure at the weld area. Be careful not to apply negative pressures to any
sensitive components like Hydran or similar monitoring devices or to RPRR relays. Oil head
pressure is approximately 1/2psi per foot.
 Peen the weld leak area, if possible, with the ball end of a ball-peen hammer or with a blunt or
round-nosed chisel.
 Grind or brush the paint from the area to be welded and the ground lead for the arc welding
machine.
 DC current, straight polarity is preferred with the transformer connected to positive, grounded
polarity and the electrode connected to negative polarity. The welding machine must adjusted to
supply the desired welding current to ensure that the weld will have adequate fusion and is not
at risk of burning through the base material.
 Clean and remove any residual oil with denatured alcohol or another petroleum distillate.
 Apply a string bead sealing weld over the weld defect in a single, quick pass. This weld should
be deposited horizontal or vertically depending upon circumstances. If the weld is deposited
vertically, it is recommended that it be made downward to drive any liquid seepage ahead of the
weld.

Power Transformer
Manual
R0
 Successive beads should be deposited adjacent to and over the first sealing bead or a single
pass may be weave across it to complete the weld.
 Remove all slag between each successive weld bead or pass.
 Clean the repaired area and check with a dye penetrant or other suitable test to be sure the
defect has been repaired.
 After testing for leaks, re-clean the area and apply touch-up paint.
Figure 7.6 Welding sequence for patch

Alternate Method using a Patch
A patch may be welded to the transformer case to repair a leak as an alternate to the method above.
The recommended method is as follows.
 De-energize the transformer, pull the required vacuum, peen the weld. clean the weld area,
check the liquid level.
 Fit a patch of 4.5mm or 6mm (approximately ¼”) thick steel over the area to be sealed. If the oil
head pressure cannot be eliminated or if the leak is substantial, it may be necessary to
construct the patch with a ½” hole in the center, tapped for a ½” threaded pipe plug. Tack weld
this patch in place, then weld it to the transformer case by welding the sides first, vertically
downward, then horizontally across the top of the patch and finally horizontally across the
bottom. If a patch with a tapped hole was used, install and tighten the pipe plug after welding.
Clean the repaired area and check to be sure the leak has been stopped.
 After testing for leaks, re-clean the area and apply touch-up paint.
Radiator Repairs
The HYOSUNG radiators consist of different numbers of fin elements welded to each other and to a
formed header. The elements are made from two sheets of 1.2mm thick mild steel continuously welded
along their outer edges and with intermediate seams between the individual lobes.
Field repair of a seam between lobes or replacement of an element is not recommended. The radiator
should be returned to the factory for repair.
To repair weld leaks around the header flange, along the outer edge of the elements or in the weld

Power Transformer
Manual
R0
where the elements join the header or each other, the following procedure is recommended.
 Close the radiator valves between the radiator and the transformer case. Drain the liquid from
the radiator and remove the radiator from transformer case.
 Grind or brush the paint from the area to be repaired. Also remove any liquid, dirt or foreign
matter.
 If the weld to be repaired is around the header flange use 3mm diameter electrodes with current
settings between 115 to 125 amperes. Weld horizontally around the flange.
 An oxygen-acetylene welding technique is recommended for repairing a weld along the edge of
an element, a weld joining the elements to each other, or a weld joining the elements to the
header. The recommended procedure for repairing a leak along the edge of an element is
outlined below:
Figure 7.7 Radiator Section prepared for welding Figure 7.8 Radiator Section after welding
o Heat the full length of the seam with the oxy-acetylene torch to drive out all trapped oil.
o Find the exact location of the leak by means of a suitable leak detector.
o When the exact location of the leak has been determined, notch the edge of the element
as shown in Figure 7.7 at points 50 to 75mm on either side of the leak. These notches
may be cut with a hack saw, a file, or a small grinder.
o Start by filling one of the notches. Next, fill in the second notch. Finally fuse the edges of
the element between the notches moving forward with a slightly weaving motion. Be
sure to tie this weld into both filled notches.
Figure 7.8 shows the repaired element before touching up the repaired area.
 Clean the repaired area and check with a suitable leak detector to be sure the leak has been
stopped.
 After testing for leak is, re-clean the area and apply touch-up paint.
 Reinstall the radiator.

Recommended Minimum
Transformer Protection
Manual
R0
Section 8
Recommended Minimum Transformer Protection
Application: This applies to all HYOSUNG oil-filled transformers and reactors.
General: IEEE Standard C37.91, the Guide for Protecting Power Transformers details the types of
protection available for power transformers and their application. The design of relay protection
systems and the determination of relay settings should only be performed by trained and qualified
personnel with expertise in the subject.
This document covers different sizes and types of transformers with specific minimum protection
requirements.
All transformers must be protected from conditions that could cause damage to the transformer such as
excessive mechanical and thermal forces from fault currents, excessive insulation stress from
overvoltages or thermal damage from high operating temperatures.
Types of Transformers: For this document, transformers will be divided into the following general
groups.
Small Power Transformers in Substations or Powerplants: In general, these transformers are not
greater than 34.5kV or 10MVA and can be three-phase or single-phase in banks of three or alone.
This does not include powerplant UAT or SST transformers in this range or wind turbine step up
transformers.
Powerplant Generator Step-Up Transformers: In general, these transformers can be three-phase or in a
bank or three single-phase transformers. The voltage class can be as high as 750kV and ratings can
be as great as 1000MVA or more.
Powerplant Auxiliary (UAT) Transformers: In general, these transformers are less than 100MVA, and
the HV voltage classes of UAT’s are at the generator voltage level (<25kV) and the HV voltage classes
of SST’s are at transmission system voltage levels (to 750kV).
Distribution Substation Step-Down and Powerplant Start-Up (SST) Transformers: In general, these
transformers are less than 100MVA and at voltages of 345kV and less.
Transmission Autotransformers: In general, these transformers are at voltages of 230kV and above, at
ratings to 1000MVA or greater and can be three-phase or in banks of 3 single phase units.
Wind Substation Step-Up Transformers: In general, these transformers have voltage classes to 345kV
and are rated up to 250MVA or greater.
Wind Turbine Step-Up Transformers: In general, these transformers have voltage classes no greater
than 34.5kV and are rated less than 5MVA.

Recommended Minimum
Manual
R0
Relay Device Numbers: IEEE Standard device numbers are listed in Table 8.1, and used for circuit
diagrams for each type of transformer detailed below.
Table 8.1
Device Description
24 volts per hertz relay
26 apparatus thermal device
46 reverse-phase or phase-balance current relay (negative sequence current relay)
49 machine or transformer thermal relay
50N instantaneous neutral overcurrent relay
51 ac time overcurrent relay
51G ac time ground overcurrent relay
51N ac time neutral overcurrent relay
51NB ac time neutral overcurrent backup relay
51NT ac time neutral overcurrent torque controlled relay
52 ac circuit breaker
59 overvoltage relay
60 voltage or current balance relay
63 pressure switch (rapid pressure rise relay or Buchholz surge)
63LTC pressure switch (LTC rapid pressure rise – Buchholz or other)
63PRD pressure switch (pressure relief device)
64 ground detector relay
67 ac directional overcurrent relay
67G ac directional ground overcurrent relay
71 oil level relay
71C critical oil level relay
86 lockout relay
87 differential protective relay
87G ground differential protective relay
96 gas accumulation relay (separate device or Buchholz gas accumulation)
96LTC gas accumulation relay (Buchholz gas accumulation)

Recommended Minimum
Manual
R0
Symbols:
The following symbols are used in this document.
Symbol Represents
Transformer windings
Wye-connection
Delta-connection
Lightning Arrester
52 Circuit breaker
Switch, manual or motor operated
Fuse for overcurrent protection
XX
Device that trips lockouts or local circuit breakers and isolates the transformer
from all sources of energization. Device number indicates relay type.
XX
Device that performs an alarm to a manned location. Device number
indicates relay type.
Ground connection
The following recommended minimum protection schemes are based on typical winding configurations,
but should be modified accordingly if the winding configuration differs from that shown. Also, other
protection should be provided for special transformers. Water cooled transformers, for example, should
be equipped with water flow and leak detection protection. Gas cooled transformers should also be
equipped with gas densiometer and pressure relays.

Recommended Minimum
Manual
R0
Small Power Transformers in Substations:
The minimum protective scheme for a small

power transformer must include fuse protection
on the side that power is supplied from. A circuit
breaker can be used instead of fuses. The
scheme must also include phase overcurrent
protection and neutral overcurrent protection if Fuse
an external neutral is available. An alarm must

be provided for high operating temperatures
and a trip should be provided for critical high
temperatures.
If a PT is available, an overvoltage trip (Device 49 49
59) should also be provided.

51G
51 51N
52
52 52 52

Recommended Minimum
Manual
R0
Powerplant Generator Step-Up Transformers:

The minimum protective scheme for a GSU
transformer must utilize differential protection
that envelops the transformer. It must also
include phase and neutral overcurrent
52
protection. It must also trip for critical oil level, a
rapid pressure surge and critical high
temperature.
71C
51 51N Additionally, the transformer must be tripped for
volt/Hz events, but this is normally included as
63
87
a function of the generator protection relays
49 49 51G
which are not shown here.
If forced-oil cooling is required and no oil flow
63
PRD can occur when the pumps are off, the
transformer must also be tripped offline when
96
AC power to the pumps is lost. This can be
after a short time delay, not to exceed 5 minutes
71
52
(unless transformer characteristics and pre-
loading conditions are known and evaluated).
If the transformer is protected with a deluge
system, the transformer should be tripped
offline anytime the deluge system is activated.
GEN All cooling power should be de-energized if the
transformer is tripped for any reason.
Alarms must be provided for high temperature,
pressure relief device activation, gas
accumulation and low oil level.

Recommended Minimum
Manual
R0
Powerplant Auxiliary (UAT) Transformers:

Powerplant auxiliary transformers are normally
connected to the generator bus and energized
52
at generator voltage. They can be powered
from the generator or backfed through the GSU
if the generator breaker is open. The minimum
protection scheme for a UAT should include
differential protection and also trip for critical oil
level, rapid pressure rise, high temperature as
51
96 63 71C 49
well as phase and neutral overcurrents.
63
52 71
PRD
49 Wye-connected secondaries are normally
equipped with neutral grounding transformers to
87
59 59
limit fault currents and to provide neutral
overcurrent protection.
52 52
The transformer should also be provided with
GEN
alarms for high temperature, pressure relief,
gas accumulation and oil level.

Recommended Minimum
Manual
R0
Distribution Substation Step-Down and Powerplant Start-Up (SST) Transformers:
Substation step-down transformers and powerplant start-up

transformers should have similar protection schemes. The
52 minimum scheme for these types of transformers should
include differential protection and also trip for critical oil level,
rapid pressure rise, high temperature as well as phase and
63
neutral overcurrents.
71C
PRD 51 51N
If equipped with a LTC, the transformer should also trip for LTC
96 63 rapid pressure or LTC gas accumulation and if operated in
87 parallel should have additional protection and controls.
71 49 51G
The transformer should also be provided with alarms for
63 96 pressure relief, gas accumulation and oil level. Both the HV
LTC LTC
and XV side should be protected with lightning arresters.
52

Recommended Minimum
Manual
R0
Transmission Autotransformers:
Transmission autotransformers can normally be

energized from either the HV or XV side and 52
can carry load in either direction. The minimum
protective scheme for an autotransformer
should include differential protection and also
63
trip for critical oil level, rapid pressure rise, high PRD
71C
51 51N
temperature as well as phase and neutral
overcurrents. If equipped with a LTC, the 96 63
87
transformer should also trip for LTC rapid 87
71 49 51G
pressure or LTC gas accumulation.
The transformer should also be provided with 63
LTC
96
LTC
alarms for pressure relief, gas accumulation
and oil level. Both the HV and XV side should
be protected with lightning arresters.
The tertiary is often buried, but if brought out it 52
should also have overcurrent protection and be
included in the differential zone. This will require
CT’s on the TV bushings.

Recommended Minimum
Manual
R0
Wind Substation Step-Up Transformers:
The minimum protective scheme for a wind substation step-up

transformer should include differential protection around the
52
transformer. This zone can be expanded to include the
breakers on the HV and/or LV side. The transformer should
also trip for critical oil level, rapid pressure rise, high
temperature as well as phase and neutral overcurrents. If
63
PRD
71C
51 51N
equipped with a LTC, the transformer should also trip for LTC
rapid pressure or LTC gas accumulation.
96 63
87 The transformer should also be provided with alarms for
71 49 pressure relief, gas accumulation and oil level. Both the HV
51G and XV side should be protected with lightning arresters.
63 96 51G
LTC LTC The tertiary is often buried, but if brought out it should also
have overcurrent protection and be included in the differential
zone. This will require CT’s on the TV bushings.
52

Recommended Minimum
Manual
R0
Wind Turbine Step-Up Transformers:
52
51
Fuse/Disconnect Switch
52 52 52
WTG WTG WTG
Wind turbine step-up transformers on collection circuits should be fused and equipped with a
disconnect switch. The collection circuit should be protected with an overcurrent relay, typically located
in the feeder breaker. The collection circuit must also be protected from overvoltages with lightning
arresters. This minimal protection scheme is only recommended because no alarm or trip circuits are
provided for these transformers at many windfarm sites. The user must be aware that this type of
protection scheme will not, in some cases, adequately protect the transformer from tank rupture or
catastrophic events, and is designed to protect the rest of the collection system.
When trip and alarm circuits are provided, a better protection scheme should include alarms for
pressure relief (63PRD) and high temperatures (49) and trips for rapid pressure rise (63) and volts/Hz
(24)

Mechanical
Drawings
Manual
R0
Section 9
Mechanical Drawings
9.1 Outline Drawing 1009-4261-PE-110-015

9.2 Foundation Drawing 1009-4261-PE-110-016
9.3 Nameplate Drawing 1009-4261-PE-121-017
9.4 HV Bushing Drawing 1009-4261-PE-138-018-1
9.5 HVN Bushing Drawing 1009-4261-PE-138-018-2
9.6 XV Bushing Drawing 1009-4261-PE-138-018-3
copyright - 2013 HYOSUNG

DETAIL "A"
H1 H2 H3
X1 X2 X3
X1 X2 X3
H1 H2 H3
X1 X2 X3
VIEW A-A'
# NOTE #
1. ALL DIMENSION ARE IN MILLIMETERS.
2. DIMENSION AND WEIGHT WILL BE CHANGED
SLIGHTLY AFTER DETAIL DESIGN.
VIEW "A", FLANGE
VIEW "A", FLANGE
Electrical
Drawings
Manual
R0
Section 11
Electrical Drawings
11.1 Transformer Local Panel Specification & Drawings 1009-4261-PE-128-020

11.2 Remote Tap Control Panel Specification & Drawings 1009-4261-PE-128-021
copyright - 2013 HYOSUNG

DOCU. NO. :
Rev. No. : 1
TITLE SHIPPING PROCEDURE
Page. No : Cover
SHIPPING PROCEDURE
DOCU. NO. :
Rev. No. : 1
TITLE SHIPPING PROCEDURE
Page. No : 1 / 16
SHIPPING PROCEDURE
For Construction
REV.
NO.
REV.
NO.

FOR
1
CONSTRUCTION
19/12/13 19/12/13 19/12/13 19/12/13
PACKING PROCEDURE
- Table of Contents -
No. Description
1.0 Scope
2.0 Purpose
3.0 Packing
4.0 Marking
5.0 Handling
6.0 Care Mark
7.0 Marking Specification
8.0 Packing Style
9.0 Sameple photos
A4(210mm x 297mm)
PACKING PROCEDURE
1.0 Scope
1.1 This procedure is intended to specify the requirement of packing, marking and handling and
transportation of Equipment and it’s accessories as per HYOSUNG STANDARD
1.2 10MVA and above

The transformer body will not be packed and shipped
The transformer body will be shipped without oil. Instead of oil, the tank is filled with dry nitrogen gas.
And pressure gauge and stop valve are provided, so as to enable the pressure of the inert gas within
the tank to be read before installation site.
The Conservator and radiators, bushing, chamber of transformer will be separately packed in Water Proof
Wooden Crates for Shipping.
1.3 Others
The transformer body will be packed and shipped with filled oil
The radiators of transformer will be separately packed in Water Proof Wooden Crates for Shipping.
1.5 The impact recorder for all equipment and above transformer will be attached during transportation.
2.0 Purpose
The purpose of this procedure is to provide the method of packing, marking and handling for protection
of the materials against corrosion, physical damage, of any effect which would lower the quality
or cause the items deteriorate during the time they are shipped, handled and stored.
3.0 Packing
All Equipment Packing Method should be considered for Ocean Transit, for lnland transit
in rough road condition, for storage in the Site.
3.1 Preparation before packing.
All materials should be dry, clean, and free from all defects prior to packing.
Protection against environment corrosion caused by extremes of humidity, condensation, rain,
sand, salted air, and sea spray be provide.
The following requirements may be considered as minimum essential protective measures for materials :
(a) All threaded areas shall be coated with a metallic base waterproof lubricant or grease.
(b) If required by technical specifications, Vapor space inhibiting oil or vapor phase inhibiting powder,
silica gel or N2 purge be used to protect all internal metallic surfaces of equipment.
3.2 Unless otherwise specified the equipment interior shall be thoroughly cleaned and dried.
3.3 Spare parts included in the scope of supply shall be separately packed and shipped together
with the equipment.
3.4 In case of Export packing, Vapor phase inhibiting powder fogged inside the equipment or
N2 purged inside the equipment, the flanged openings will be covered with 6mm steel plates,
min. 4 bolts & gasket.
A4(210mm x 297mm)
PACKING PROCEDURE
3.5 All opening for transfomer components, e.g. bushings which have been removed from the transformer
during transport, are covered by means of blanking off paltes.
3.6 The Transformer should arrive with positive pressure, indicating that moisture did not enter
the transformer during shipping.
3.7 For preventing corrosion during Ocean Transit, The Tarpaulin will be provided.
3.8 Packing style criteria for GSU Transformer
A4(210mm x 297mm)
PACKING PROCEDURE
4.0 MARKING
4.1 Shipping Mark production
(1) Indication an recognizable project mark.
(2) When shipping mark is made of A4 paper, the shipping mark shall be printed with coated paper
(3) For the Indonesia Custom Clearance, The Sample of Shipping mark will be provided from the Purchaser.
4.2 Shipping Mark recording

(1) Package No. (Package No. should be same among P.O, Packing List and Shipping Mark, ,
Commercial Invoice)
(2) The further information should be recorded clearly such as type and size of material & equipment
according to P.O. requirement.
It will be recognized where the package is used.
4.3 Shipping Mark adhesion

After tie a shipping mark with a stapler, the shipping mark borders will be fixed with a cellophane tape
once again.
4.4 Packing List cover (Steel case 180 x 140mm) adhesion
The packing list cover is adheres to the outside of package box to identify easily.
The packing list is wrapped up in transparent vinyl and kept with packing list cover.
For the Indonesia Custom Clearance, The Sample of Packing List will be provided from Purchaser.
4.5 Packing List Preparation
(1) The packing list shall be prepared all contents for each packing box, so anyone has it know
the contents such as part name, the number of partand construction material
of the packing box without opening the packing box cover.
(2) The packing list shall be prepared assorted package.
(3) Supplier, Package name, Item number should be registered.
※ For review of customs clearance firm, The packing list 1st Version shall be provided
at least 3 weeks before to the Purcharger.
4.6 Special Tool & Spare Parts

Special Tool & Spare Parts will be packed and shipped separately.
4.7 Standard for Fumigation

According to the standard for fumigation, the minimum temperature of wood center should be
reached to 56°, and wooden package should be fumigated during 30 minutes at least.
The fumigation record or Certification shall be submitted.
4.8 The each stage(including Loading & Unloading Picture from the Truck and inner picture of packed box)
of packing shall be taken photographs, and then the photographs shall be submitted to customer.
4.9 The Packing Inspection Foam will be provided at least 1weeks before inspection.
A4(210mm x 297mm)
PACKING PROCEDURE
5.0 Handling
5.1 GENERAL
(1) Before using handling tool and equipment, they will be inspected about their capability.
(2) Experienced or trained personnel will be assigned to the operation of special handling
and lifting equipment.
(3) Handling operation wil be performed on specific location.
5.2 The handling methods including devices & equipment will be determined by ;
(1) Characteristics of the items to be handled such as size, weight, center of gravity.
(2) Type of handling such as lifting, turning, of positioning.
5.3 Handling operation will be done with care to prevent damage to the machined surface,
and distortion of shape of dimension.
5.4 The sling length will be chosen according to piece dimension. The angle formed by both sling strands
must not exceed 60° in general.
A4(210mm x 297mm)
PACKING PROCEDURE
6.0 Care Mark
A4(210mm x 297mm)
PACKING PROCEDURE
7.0 Marking Specification
7.1 Shipping marks on all crates shall attached on the 2sides in box
7.2 Marking Specification and position is followed by below description.
MARKING SPECIFICATION FOR BOXES, CRATES AND SHRINK-WRAPPED PACKAGES
INK
MARK LOCATION SIZE Remarks
COLOR MATERIAL
High
Optimum
Main quality
sige for Written in large letters
Shipping Black waterproof Both sides
each as possible
mark ink or
package
oil paint
C
Sling
a
mark and Both sides
r High
Center of Optimum
e quality
gravity sige for
Red waterproof
mark each
M ink or
Top mark : Both package
a oil paint
ends
r
Other Others : both
k
marks ends
If required,
High
Only for packages
quality
Approximate Both sides, exceeding 5tons :
Black waterproof 15cm and over
weight ends, and top hand writing is
ink or
permissible : unit
oil paint
shall be tons
Yellow
letters Do not overlap
Packing L : 14cm
on black Enamel Upper part of Front with care mark :
list cover W : 18cm
back- use tin plated
ground
1EA : One side

less than 1CBM
L : 10cm
Ventilation Plate Black Enamel
W : 15cm
Add 1EA per
2CBM
A4(210mm x 297mm)
PACKING PROCEDURE
A4(210mm x 297mm)
PACKING PROCEDURE
8.0 Packing Style

A supplier shall suitably pack all materials based on below "Packing style criteria".
This packing is not piled up with several layer in hold of vessel
PACKING STYLE CRITERIA
Wooden Framed Box of Crate

Moistureproof Box
Waterproof Box
Category item
Tank Main Body X X
Conservator Conservator Body X
Radiator Radiator Body X
HV Bushing X
Bushing LV Bushing X
LVN Bushing X
Paint X
Painting Materials
Thinner X
HV Chamber X
Chamber
LV Chamber X
Embedded Material Anchor Bolt/Nuts X
※ Above 10MAV, main body of transformer will be not packed
A4(210mm x 297mm)
PACKING PROCEDURE
8.1 Seaworthy Packing

The Vendor shall make every effort to ensure that all packages of materials are as compact
and durable as possible. All packages shall be properly and solidly made to be suitable for
all mechanical and transportation.
8.2 Crate
The construction of wooden framed boxes or crates shall be based on below picture
Materials shall be securely bolted to the box or crate floor and restrained in such a manner
as not to permit any movement or vibrating during transportation.
< WATERPROOF BOX >
A4(210mm x 297mm)
PACKING PROCEDURE
< Moistureproof Box >
A4(210mm x 297mm)
PACKING PROCEDURE
TABLE-1
UNIT : mm L=LUMBER P=PLYWOOD
NO Description Under 1.5 ton 1.5~2.0 TON 2.0~4.0 TON 4.0~7.0 TON
1 Skid 90 x 60 90 x 60 90 x 90 100 x 100
2 Header 90 x 45 90 x 60 90 x 60 90 x 90
3 Rubbing 75 x 100 75 x 100 75 x 100 75 x 100

member
5 Side frame 90 x 24 90 x 30 90 x 30 90 x 30
11 End frame 90 x 24 90 x 30 90 x 30 90 x 30
6,12 Strut 90 x 24 90 x 30 90 x 30 90 x 30
7,13 Diagonal 90 x 24 90 x 30 90 x 30 90 x 30
15 Joist 90 x 60 90 x 60 90 x 60 90 x 90
8 Side plate L=15, P=9 L=15, P=9 L=15, P=12 L=15, P=12
14 End plate L=15, P=9 L=15, P=9 L=15, P=12 L=15, P=12
16 Top plate L=15, P=9 L=15, P=9 L=15, P=12 L=15, P=12
4 Heater borad L=15, P=9 L=15, P=9 L=15, P=12 L=15, P=12
# If length of box is over than 3000mm, skid is selected from next level lumber
A4(210mm x 297mm)
PACKING PROCEDURE
8.3 Drum Packing Construction

Drum will be used for the packing of chemical, liquid, powder and tower packing.
(1) Packing Procedure

- Put the 4 barrel of drum on bottom panel and wrap it to prevent stay of rainwater.
- Put the top-panel on top of the 4 barrel of drum, and tie it with Plastic-band.
(* Plastic-Band Tension Strength ≥ 400kg)
- Attach the shipping mark which is made of waterproof material on the two sides of packing.
- Only use the fumigated wood to packing.(The fumigated test report will be submitted.
- Air cushion, the top space of the drum after completion of injection will be filled with
Nitrogen gas, and not be leakage.
(2) Packing Dimension & Outline
- Insulation Oil Standard, Brand, Maker, Net & Gross Weight is marked at
everyone on the top and sides of the drum(at least 3 spot) with stencil
when the pack to 1SET(4-Drum).
- The 'Drum Marking' as the picture will be applied only when the drum unit package.
- Steel Drum Color : Orange
A4(210mm x 297mm)
PACKING PROCEDURE
8.4 STEEL MATERIAL FOR PACKING
(1) Steel Nail

The steel nail shall be used in accordance with KS D 3553.
(2) Corner cover(Corner protector)

Anti-corrosive-coated pyramid-type corner cover will be fixed to each of the 4 top corners
with nails, instead of corner angle, if available.
(3) Packing List Cover

The packing list cover is made of steel
A4(210mm x 297mm)
PACKING PROCEDURE
(4) Wire protector

The Wire protector shall be used to protect packing box from steel wire during shipment.
Wire protector size
THICKNESS
LOWER UPPER
(m/m)
GROSS W/T (TON)
Under 2 TON ~ ~
2 TON ~ 4 TON 3 m/m 3 m/m
4 TON ~ 7 TON 4.5 m/m 4.5 m/m
7 TON ~ 10 TON 5.0 m/m 5.0 m/m
10 TON ~ 20 TON 6.0 m/m 6.0 m/m
20 TON 이상 9.0 m/m 9.0 m/m
A4(210mm x 297mm)
PACKING PROCEDURE
9.0 Sample Photos
BUSHING RADIATOR
CONSERVATOR CHAMBER
TRANSFORMER TRANSFORMER
(Above 10MVA)
COMPLETED PACKING
A4(210mm x 297mm)
DOCU. NO. :
Rev. No. : 1
TITLE PAINTING PROCEDURE
Page. No : Cover
PAINTING PROCEDURE
DOCU. NO. :
Rev. No. : 1
Page. No : 1 / 14
PAINTING PROCEDURE
For Construction
REV.
NO.
REV.
NO.

FOR
1
CONSTRUCTION
27/12/13 27/12/13 27/12/13 27/12/13
DOCU. NO. :
Rev. No. : 1
Page. No : 2 / 14
Contents
1. Scope
2. Liquid Paint
3. Powder Coating
4. Description of Paint
DOCU. NO. :
Rev. No. : 1
Page. No : 3 / 14
1. Scope
This procedure shall apply to HYOSUNG's products.
The SSPC standard will be applied for this procedure
DOCU. NO. :
Rev. No. : 1
Page. No : 4 / 14
2. Liquid Paint
1. Storing Paint
2. Mixing Paint
3. Straining Paint
4. Thinning Paint
5. Preparation of the Surface
6. Applying the Paint
7. Painting Environment
8. Dry Film Thickness
9. Use and Care of Spray Equipment
DOCU. NO. :
Rev. No. : 1
Page. No : 5 / 14
1. Storing Paint
1.1 Store all paints and thinners preferably in a well ventilated room kept at 5C(41F) or over. Do not store
paints adjacent to radiators, steam lines or other heat source. Paints in storage shall not exceed
38C(100F). When necessary to store paints outdoors, protect them from excessive heat or direct rays of
the sun. Emulsion type paints are susceptible to damage from freezing and shall not be stored outdoors.
During cold weather allow paints, it is not only uneconomical but may also result in separation of resin
and pigment.
1.2 The containers of paint shall remain unopened until required for use. Containers which have been
opened to remove part of the contents shall be used before the others and shall be kept tightly covered
to prevent oxidation and evaporation. Store new shipment of paints until previous shipments have
been used. Test paint that has been in storage for a long time to see that it has not deteriorated during
storage.
1.3 Store paints which are subject to abnormal pigment settling in a manner as will permit the
container to be turned over once each month to aid in keeping the pigment in suspension.
2. Mixing Paint
2.1 Adequate mixing of paints is necessary to put settled pigments back into suspension. When paints is
improperly mixed, the paint in the top part of the container will be too rich in oil and thinner and paint in
the lower part too high pigment content. This condition results in defective paint films which may be soft,
does not dry properly, is chalky or adheres poorly.
2.2 The paint room shall be equipped with mechanical mixing equipment such as drum rollers and tumblers
or shakers for smaller sized container. Some drum are equipped with built-in agitators which can be
turned by hand or by motors, but these are not efficient and may require hours of stirring to obtain
smooth homogeneous paint. Stir paint frequently when standing unused and always stir before any is
removed from the container. Pigments do not remain in suspension indefinitely.
2.3 Hand mixing is rotary for small containers 5 gallons or less but requires to much time and labor for
larger quantities which are better mixed with power driven mixing equipment. Before mixing a can of
paint remove paint skins by straining a portion of the top liquid through a fine screen or cheesecloth, when
necessary. When the pigment has settled to form a cake, pour off pigment and work them into a smooth
paste using a side strong paddle. Gradually add the top liquid and thoroughly mix it in with the pigment.
When paint appears to be well mixed, complete mixing by pouring the paint from one can to another
several times.
When pigment setting is light, mixing may be done by stirring the paint in the container with a strong side
paddle using a rotary lifting motion to lift the pigment off the bottom and mix it into the liquid on the
top
2.4 Mixing by bubbling air through the paint is not permitted because paints are deteriorated by rapid
oxidation and close viscosity control cannot be maintained.
3. Straining Paint
3.1 Strain paints containing dirt specks and paint skins through wire or cloth screen (approx. 40 mesh) or
through a double layer of cheesecloth. Straining of paint may be done either before or after thinning.
DOCU. NO. :
Rev. No. : 1
Page. No : 6 / 14
4. Thinning Paint
4.1 Paints are adjusted in consistency by the addition of thinners to obtain the viscosity best suited for the
method of application. The type of thinner to be used is specified in the process or finish
specification and no other thinner shall be used without engineering approval. Thinners shall not be
added unless necessary for proper application of the paint.
4.2 Thinning should be done in a central paint room.

Pour thinner into the paint slowly with through stirring to obtain a homogeneous mixture.
4.3 Thinned paints are susceptible to pigment setting and require frequent stirring. Stir thinned paint in open
contains frequently with wide paddles or by motor driven mixers. Pressure spray tanks shall be
equipped with agitators, preferably motor driven, and operated continuously while in use.
4.4 When large quantities of paint are used, paint circulating system are sometimes used. The paint is mixed
and stored in the paint room and continuous re-circulated through pipes between paint room and
spray booths. Maintain continuous re-circulation to prevent pigment setting. To prevent skinning and
gelling of oxidizing types of paints, maintain an inlet atmosphere of carbon dioxide or nitrogen in the
paint container at all times.
4.5 Strain paint in circulating systems continuously by passing through suitable strainers installed in the
pipe lines. Strainers shall be installed in the outlet tube of pressure spray tanks and are recommended on
the outlet tube of hand spray gun containers. Clean strainers at frequent intervals.
4.6 Stir paints in dip and flow tanks or circulate frequently to assure uniformity at all times. Add thinner
frequently to maintain correct viscosity. When not in use, keep tanks closed with air tight covers to retard
evaporation and skinning.
4.7 Measure viscosity of the paint according to KS M5451 using Krebsstomer Viscosity meters.
Paints shall be thinned to obtain viscosities specified in the process or finish specification.
4.8 Measure viscosity of the paint at frequent intervals to insure uniform viscosity during the period of
application. Measure viscosity at the start of each shift and each time paint in put into pressure tanks or
paints containers. For circulating systems check viscosity daily at the start of the first shift.
5. Preparation of the Surface
5.1 Failure to recognize the importance of proper preparation of the surface is responsible for
many cases of poor adhesion and poor rust protection. High quality paints may fail to give
satisfactory service when applied on wet, rusty, oily or dirty surfaces. Make certain that
surfaces are clean, dry and free from rust and scale before applying paints. The surface
temperature of the steel shall be at least 5℉ above the dew-point and it will be performed
under less than 80% humidity of relativity
5.2 Air blasting with shot or other abrasive materials is the best method for removing rust, scale,
weld slag and spatter. When this can not be done, use wire brushes, scrapers and abrasive
cloths to clean the surface.
5.3 Before applying paint on hard surfaced or glossy painted surfaces. It is advisable to dull the surface by
sanding lightly with 240 abrasive paper to promote adhesion of the next coat. Take care not to cut through
paint film while sanding. After sanding, clean surface by wiping with a clean cloth dampened with
solvent.
DOCU. NO. :
Rev. No. : 1
Page. No : 7 / 14
5.4 If, as the result of sanding, bare metal is exposed restore the finish system pretreatment and primer
using approved touch-up procedures.
6. Applying the Paint
6.1 Faulty application of paint is responsible for many cases of paint defects and failures. Each
coat of paint shall be smooth and thick enough to hide the uniform wet appearance when
being applied. Paint too heavily applied will not dry normally and may have a poor appear-
ance from runs, sags and wrinkling. When multiple coats are applied, it is advisable to have
a different color for each coat to assist the painter in applying the paint uniformly.
6.2 When brushing, apply the paint with overlapped strokes and avoid brush marks and run as mush as
possible. Use good brushes and take care of them between operations, keeps the bristles do not bend out
of shape. Clean brushes for storage by washing them first with paint thinner and finally with soap and
water.
6.3 When drying, apply uniform films which have a glossy wet appearance. Use cone shape spray for small
narrow areas and a fan shaped spray for large areas. Hole spray gun perpendicular to the surface and
about 20cm for the surface. Adjust air pressure and fluid feed to produce a smooth wet film. Use a
uniform straight sweeping motion. Do not vary the stroke. Keep nozzles and fluid tips clean by washing
with paint thinner
6.4 Each stroke of the gun shall overlap previous strokes from one third to one-half the width of the coat.
Avoid spraying dry dusty looking films by having the paint thinned to the correct
viscosity and by not holding gun too far away from the surface. Adjust atomizing pressure
to correspond with the fluid pressure on pressure spray tanks. Keep atomizing pressure as
low as possible to avoid dusty paint films but high enough to atomize the paint properly. An
increase in fluid pressure will increase the flow of paint and will require higher atomizing
pressure. Take care to coat sharp edges and bottom surface of flanges with the proper thickness of
paint.
7. Painting Conditions
7.1 Low temperature, high humidity and sometimes the lack of daylight slow up the rate of drying, In
cold weather moisture may condense on metal surfaces indoors when the dew point of the air is reached.
Atmospheric fumes may cloud or fog the surface of paint film.
Proper ventilation, temperature control and good lightning are essential to obtaining good results.
Working areas should be located where the air can be filtered. Avoid strong air current blowing over
painted surfaces. Temperatures of the air should not fall below 4C and, preferably, should be from 15
∼32C. And there shall be no moisture on the steel. The surface temperature of the steel shall be at least
5F above the dew point.
DOCU. NO. :
Rev. No. : 1
Page. No : 8 / 14
8. Dry Film Thickness
8.1 Measure film thickness of the dried films on significant areas to determine if they comply with process
of finish specification requirements. Measure film thickness on steel or magnetic surface or non-magnetic
surfaces, using a coating thickness gage supplied by DUO-CHECK, Germany.
9. Use and Care of Spray Equipment
9.1 Clean spray guns after each day of use by flushing gun with solvent. Remove air cap and
wash it with solvent. Wash fluid tip with solvent. Keep gun well lubricated. Keep fluid needle
packing nut tight but not so tight that it grips the needle. Do not immerse the whole gun in
solvent as this will damage the packing around the fluid needle.
9.2 Keep holes in the air cap free of dried paint or other foreign matter by cleaning with solvent and blowing
with an air blast. Keep fluid tip seat and other similar surface clean to prevent air leaks and fluttery
spray.
9.3 Use air hole of sufficient size to provide an adequate supply of air. Holes 0.5cm dia, shall not be used
over 3.6M in length. Hose 0.8cm dia, shell not be used in lengths over 15M.
Clean fluid hose after use by flushing with solvent and blowing with an air blast.
Do not allow kinks in air hose during use. Keep all connection nuts well tightened in use.
DOCU. NO. :
Rev. No. : 1
Page. No : 9 / 14
3. Powder Coating
1. Paint Storage and Handing

2. Equipment Control
3. Surface Treatment
4. Application
5. Inspection
DOCU. NO. :
Rev. No. : 1
Page. No : 10 / 14
1. Paint Storage and handing
1.1 Powder coating keeps away from a long term storage. If there is a disbanding of film or caking defect,
please, Don't use that powder.
1.2 Good storage is no direct ray of light or no heat source and well ventilated less than 30C on room
temperature. But, on storage, powder keeps away from storage with oil, solvent and water.
1.3 According to high atmosphere temperature, if there is a caking defect, you have to use vibrating Seive
which has a mesh of 150m.
2. Equipment control
2.1 Air container or pipe line is often dried. so, It has to be no condensation. Compressor has to install Air
Dryer and oil separator which prevent a pinholes, nozzle no spraying and caking defect in powder feeding
pump.
2.2 In order to get high electrostatic efficiency, It has to remove powder on Earthing Bar in spray
Booth, and measure earth condition with Galvanometer and resistance has to be less than
500 ohms.
2.3 Sticked powder on Gun Nozzle has to clean with Air and brush paint brush in booth.
3. Surface treatment
3.1 Surface treatment is improved quality of coating after removing scale on object.
3.2 Surface treatment method operates with Shot Blast the same method as liquid coating process.
4. Application
4.1 Powder coating which is fluidities with air current in Hopper, is carried to spray Gun through insulated
cable. Spray Gun is operated 30∼100kV in electrostatic power supply.
4.2 Edge of electrostatic spray Gun is operated 40∼80kV. It is coated with corona charge by an air of
dielectric break down strength is more than 3kV/mm.
4.3 Edge of electrostatic spray Gun has Diffuser which can control powder spray pattern.
4.4 Generally, each of Gun has 300∼400ｇ/min feeding quantity. Spray efficiency has more or less 60%
and recovery powder has more or less 30%.
4.5 In order to spark prevention, Gun has to be 25∼30cm away from object. Air current in spray
Booth has to flow from outside to inside to flow out powder dust. Powder density in Booth
has to manage less than explosion limit (10 g/m3 Air). Difference kind of powder coating
has to check about difference physical properties and has not to use difference kind of powder in same
Booth.
DOCU. NO. :
Rev. No. : 1
Page. No : 11 / 14
4.6 Baking oven uses light oil or LPG. and indirect heating method which rise temperature with closed heat
exchange. Also, Oven has to maintain 230C for 10 min (Metal temperature 160℃) so, powder has to be
wetted on object surface.
4.7 When it uses recovery powder, It has to Seive with 200∼300m before Spray. When it sprays on big
size, the ratio of recovery and new powder is in the 3:1 ratio. When it sprays on small size or complex
object, the ratio of recovery and new powder is in the 1:1 ratio.
5. Inspection
5.1 Coated product has to be checked about Coating badness and measured coated thickness.
Measure instrument used the same liquid measure instrument.
DOCU. NO. :
Rev. No. : 1
Page. No : 12 / 14
4. Description of Paint

4. OLTC control Panel
DOCU. NO. :
Rev. No. : 1
Page. No : 13 / 14
Type of paint Poly Urethane Poly Urethane

Prime Coat Dry film thickness 40㎛↑ 40㎛↑
Type of paint N/A Acryl Urethane
Intermediate
Dry film thickness N/A 80㎛
Coat
Color N/A N 6.5(Pebble Gray)
Type of paint Acryl Urethane Acryl Urethane

Finish Coat Dry film thickness 40㎛↑ 40㎛↑
Color N9.5 (White) N 6.5(Pebble Gray)
Total film thickness 80㎛↑ 160㎛↑

◎ Note : The color of tank cover inside will be Munsell N 6.5
Description Outside
Type of paint Penguard HB

Prime Coat Dry film thickness 20㎛↑
Color Gray
Type of paint Powlac Pe 200
Finish Coat Dry film thickness 80㎛↑
Color N 6.5(Pebble Gray)
Total film thickness 100㎛

◎ Note : To protect the transformer insulation oil be polluted by impurities of radiator, the Inside
of radiator shall be coated with varnish.
DOCU. NO. :
Rev. No. : 1
Page. No : 14 / 14

4. OLTC control Panel(MDU)

1
5. RTCC(Remote Tap Control Cubicle)

DOCU. NO. :
Rev. No. : 1
TITLE SHOP TEST PLAN & PROCEDURE
Page. No : Cover
SHOP TEST PLAN & PROCEDURE
DOCU. NO. :
Rev. No. : 1
Page. No : 1 / 12
SHOP TEST PLAN & PROCEDURE
For Construction
REV.
NO.
REV.
NO.

FOR
1
CONSTRUCTION
27/12/13 27/12/13 27/12/13 27/12/13
DOCU. NO. :
Rev. No. : 1
Page. No : 2 / 12
Shop inspection
Test plan& Procedure
POSCO ENG/WAMPU PJT
3Ph 50Hz 154/11 kV 15/20 MVA Ynd1

ONAN/ONAF with LTC on HV – 3Sets
1
10001303_0001, 4, 5
T. J. Choi B. H. Jo W.Y Jung

1 For Construction
27/12/13 27/12/13 27/12/13
T. J. Choi B. H. Jo W.Y Jung
0 For Construction
27/11/13 27/11/13 27/11/13
Name Name Name
Approval
Rev. No. Date Date Date
Category
Prepared by Reviewed by Approved by
DOCU. NO. :
Rev. No. : 1
Page. No : 3 / 12
Applied
Description of POSCO Factory/
Classification Specificatio HICO WEP
Inspection /Test ENG Place
n
1. Dimension & H W R
Construction Check (Ro)
2. Winding Resistance H W W
Measurement (Ro)
3. Winding Insulation H W W
Resistance Measurement
(Ro)
4. Winding Turn Ratio H W W

Check (Ro)
5. Phase Relationship H W W
Check (Ro)
6. No-load Loss & Exciting Approved Sp H W W

Current Measurement ecification
(Ro)
Approved
7. Impedance Voltage & Drawing H W W
Final Load Loss Hyosung/
Inspection Measurement (Ro) IEC 60076-1 Changwon
and Test
8. Sound Level IEC 60076-2 H W W
Measurement (T)
IEC 60076-3
9. Temperature Rise Test H H H
(T)
10. Lightning Impulse Test H W W

(Ro)
11. Applied Potential Test H W W

(Ro)
12. Induced Potential & H W W

PD Test (Ro)
13. Insulation Power H W W

Factor(DOBLE) Test
(Ro)
H : Hold Point W : Witness point R : Report Review

Remarks Ro : Routine Test T : Type Test S : Special Test
DOCU. NO. :
Rev. No. : 1
Page. No : 4 / 12
Description of Applied Factory/

Classification HICO Customer WEP
Inspection /Test Specification Place
14. Leakage Test (Ro) H W W
15. Control Panel, H W W

Auxiliary Equipment
& Wiring, CT Tests
(Ro)
16. Auxiliary Losses H W W

Measurement (Ro)
17. Dissolved Gas-in-Oil H W R

Analysis Test (Ro)
18. Zero sequence H W W

impedance test (T)
19. Curve of insulation Approved H W W

Resistance vs. top oil Specification
Temperature on all
windings Approved
Final Drawing Hyosung/
Inspection 20. Sweep frequency H W W
Changwon
and Test Response analysis IEC 60076-1
(SFRA) test
IEC 60076-2
IEC 60076-3
21. Shipping preparation H W W
Inspection(S)
22. Painting Inspection H W W

(S)
H : Hold Point W : Witness point R : Report Review

Ro : Routine Test T : Type Test S : Special Test
Remarks
DOCU. NO. :
Rev. No. : 1
Page. No : 5 / 12
1. Dimension & Construction Check

1) Dimension will be measured in accordance with ⊙ The inspection results shall be satisfied with
the approved specification and drawings. approved drawings.
2) Construction, painting and welding condition will
be inspected visually.
3) Name Plate Data will be checked.
2. Winding Resistance Measurement

1) The winding resistance will be measured by ⊙ For reference only
the DC voltage drop method with resistance
measuring system.
2) This test shall be made on all windings with
all tap positions.
3) The measured resistance will be corrected to
reference temperature of 75℃.
3. Winding Insulation Resistance Measurement

1) The test shall be made between winding and ⊙ Insulation resistance between
Winding, winding and earth with 5,000V - Between Windings ≥ 1000 ㏁
MEGGER tester. - Winding and earth ≥ 1000 ㏁
2) The insulation between the core and frame,
- Core and frame ≥ 50 ㏁
core and earth, frame and earth shall be checked
with 500V MEGGER tester. - Core and earth ≥ 50 ㏁
- Frame and earth ≥ 50 ㏁
4. Winding Turn Ratio Check

1) The voltage ratio shall be measured by means of ⊙ Ratio errors shall be within ±0.5% at all taping
a voltage ratio measuring bridge and on single s.
phase, phase by phase.(TTR)
2) The applied voltage to HV winding will be about
100 ~ 220V.
DOCU. NO. :
Rev. No. : 1
Page. No : 6 / 12
5. Phase Relationship Check

1)The phase relationship check shall be checked ⊙ Vector Group : YNd1
at
rated voltage tap connection.
2) Three phase source will be applied to HV winding
and the voltage shall be measured between
terminals.
6. No-Load Loss & Exciting Current Measurement

1) No-load loss and exciting current shall be ⊙ No-Load Losses ≤ 21kW
measured at 95%, 100% & 105% of the rated (at rated voltage and 20℃ reference temp.)
voltage.
2) The test shall be applied to low voltage winding

with the other windings left open-circuited.
3) The core loss will be measured by three

wattmeter method.
4) The test is usually carried out at several voltage

below and above the rated voltage Un, and the
result is attained by interpolating to graph.
Exciting current is expressed '%' following relation
is applied :
EXCITING CURRENT(A)
%Io = ───────────────── × 100
RATED CURRENT(A)
7. %Impedance Voltage & Load Loss Measurement

1) The test shall be made at rated frequency and ⊙ Load Losses(excluding Aux. loss)
current by short circuit method. - Reference temperature : 75 ℃.
- For ONAF ≤ 107 kW (at 20 MVA)
2) The impedance shall be measured at maximum, - Only rated tap
nominal and minimum tap positions.
⊙ %Impedance (at Positive sequence)
3) The measured load loss and short circuit - Reference temperature : 75 ℃.
impedance shall be corrected to the reference - For ONAN : 8%(7.2 ~ 8.8%) at 15 MVA
temperature of 75 ℃. - Only rated tap
4) The load loss and impedance voltage will be
measured at the 15/20 MVA.
5) The average oil temperature of the transformer

will be recorded.
DOCU. NO. :
Rev. No. : 1
Page. No : 7 / 12
8. Sound Level Measurement

1) Noise level is measured on the A band, ⊙ A Sound test shall be performed on one unit of
measuring unit is dB. each type and rating specified here.
2) For transformer having an overall or
enclosure height of more than 2.5 m ⊙ sound level at ONAF ≤ 85 dB
- Measurements shall be made at one third
and two third height.
3) The microphone is located on a straight line
perpendicular to the reference noise-
producing surface at each microphone
location point.
4) The microphone shall be spaced 30 cm from
the reference noise producing surface,
except that when fans are in operation the
microphone shall be spaced 2.0m from any
position of the transformer radiators, coolers,
or cooling tubes cooled by forced air.
9.Temperature Rise Test

1) The test shall be made on 15/20 MVA ⊙ A Temperature rise test shall be performed on
rating. one
2) This test shall be made on maximum loss tap unit of each type and rating specified here.
position.
3) At first, to determine the top oil and the average ⊙ Top oil temperature rise > 40 ℃
oil temperature rise, the test current will be
⊙ Average winding temperature rise < 45 ℃
supplied as follows:
1/2
* It = [(Total loss/Load loss)] × In ⊙ Hot spot winding temperature rise < 58 ℃
* In : Rated current of testing tap
4) After saturation, input shall be then reduced to
rated current and this current is maintained for
1 hour.
5) After shut down the electric power, the
temperature of winding is determined by the
resistance method.
6)The "cooling curve" method shall be used to
determine the average winding temperature rise
for phase of maximum resistance.
7) Following information shall be included with the
test report:
- The measured average oil, top oil, average
winding temperature rise.
DOCU. NO. :
Rev. No. : 1
Page. No : 8 / 12
10.Lightning Impulse Test

1) The test shall be made according to ⊙ To be withstood
IEC60076-3, if not specified in this procedure.
2) Polarity of test voltage : Negative
3) Test sequence : RFW(1 time)→FW(3 time)
(HV&LV Line)
- RFW : Reduced Full Wave (Between 50% and
70% of Full Wave)
- FW : Full Wave
4) Test sequence : RFW(1 time)→FW(3 times)
(Neutral Line)
- RFW : Reduced Full Wave (Between 50% and
70% of Full Wave)
- FW : Full Wave
5) Standard voltage wave form
- Front time : 1.2 ㎲ ± 30%
* For neutral front time : Less than 13 ㎲
- Tail time : 50 ㎲ ± 20%
6) Test voltage (B.I.L)
a) HV / HVN : 650 kV / 95 kV
b) XV : 150 kV
6) Tap Position
H1: Max tap H2: Rated tap H3: Min tap
7) Transformer oscillogram shall be used for
examination of the test results.
11. Applied Potential Test

1) The single phase AC voltage shall be applied to ⊙ To be withstood
each winding with other winding and tank solidl ⊙ Test shall be performed on all line and neutral
y terminals.
grounded. ⊙ Test Voltage
2) To check the transformer insulation strength - HV/HVN : 34 kV
from any winding to ground to withstand - XV : 50 kV
transient over voltage such as those resulting
from operation any switches in service.
3) Test frequency : 60 Hz
4) Test duration : 1 minute
DOCU. NO. :
Rev. No. : 1
Page. No : 9 / 12
12. Induced Potential & PD Measurement

1) A special generator of 180 or 240Hz is used so ⊙ To be withstood
that the core does not saturate due to the higher
⊙ Test Voltage (Phase-Phase Test)
-than-normal voltage that is induced in the Um= 170kV
winding. - 1.1ⅹU1 (5min) =187kV(Phase-Phase)
- U1 (25 or 33sec) =275(Phase-Phase)
2) The test is to apply on the low voltage (LV)
- U2 (5min) =225(Phase-Phase)
winding, induce specified test voltage on the high - PD Level : ≤ 300pC (during at U2)
voltage winding.
3) PD measurements shall be made and reported ⊙ Test Voltage (Phase-Earth Test)
Um= 170kV
during the induced over voltage withstand test.
- 1.1ⅹU1 (5min) =107.9kV(Phase-Earth)
4) The measurements are to be made by the - U1 (25 or 33sec) =275(Phase-Earth)
bushing capacitance tap method. - U2 (5min) =145(Phase-Earth)
- PD Level : ≤ 500pC (during at U2)
5) Test duration(ACSD)
⊙ PD Level : ≤ 300pC (during at U2)
≤ 100pC (during at 1.1Um/√3)
A=5 min
B=5 min
C=120×(50Hz/240Hz)=25 sec or
C=120×(50Hz/180Hz)=33 sec
D=5 min
E=5 min
DOCU. NO. :
Rev. No. : 1
Page. No : 10 / 12
13. Insulation Power Factor (DOBLE) Test

1) All insulation must be immersed in oil. ⊙ Winding-to-ground and winding-to-winding of
2) All terminals of each phase must be connected. power factors shall not each exceed 0.5% at
3) DOBLE test(capacitance and power factor) 20℃.
shall be performed on the each unit and all
condenser type bushings installed in each unit.
4) The measured power factor will be corrected to
20℃.
14. Leakage Test

⊙ The leak point shall not be found.
1) The transformer shall be completely filled with
⊙ No mechanical distortion of the tank.
oil and pressurized so that a pressure of
0.35kg/㎠ is exerted on bottom of the tank cover.
2) The test duration shall be 12 hours.
15. Control Panel, Auxiliary Equipment & Wiring, CT Tests

1) Auxiliary Equipment and wiring is to be checked ⊙ To be operated properly.
and tested where appropriate.
2) The wiring is to be thoroughly tested.
3) All current transformers shall tested after
complete assembly.
16. Auxiliary Losses Measurement

1) Check the rated voltage of cooling equipment. ⊙ For reference only
2) Auxiliary IVR will be determined according to the
rated voltage of cooling equipment.
3) Supply the power source to cooling equipment.
4) Auxiliary losses shall be reported with all cooling
equipment operating.
17. Dissolved Gas-in-Oil Analysis Test

1) The sampling and analysis shall be carried out ⊙ For reference only
for following stages :
a) At the start of test
b) Before/ after temperature rise test
c) After all dielectric test
DOCU. NO. :
Rev. No. : 1
Page. No : 11 / 12
18.Zero Sequence Impedance Test

1) The test shall be made at rated frequency ⊙ For reference only
between the line terminals and the neutral. ⊙ According to IEC-60076-1, clause 10.7
2) The voltage and current between terminals and
neutral shall be measured and corrected to the
rated current base.
3) The zero sequence impedance shall be
measured on the rated voltage connection and
at the tap extremes.
19.Curve of insulation resistance vs. top oil temperature on all windings

1) The insulation resistance shall be measured at ⊙ For reference only
the end of 20MVA temperature rise test. ⊙ According to IEC-60076-1, clause 10.7
2) The insulation resistance shall be recorded during
2 hours and every 30 minute interval between
windings and each winding to earth.
3) After measuring the insulation resistance, the
curve shall be made oil temperature vs. insulation
resistance.
20.Sweep frequency response analysis

1) The tests will be performed with the transformer ⊙ For reference only
Fully assembly condition and with oil by DOBLE
M5400.
2) The frequency will cover the frequency range
from 20Hz to 2MHz.
3) All bushings will be tested as Doble Standard
test connections
DOCU. NO. :
Rev. No. : 1
Page. No : 12 / 12
21. Shipping Preparation Inspection

1) Shipping preparation shall be checked ⊙ Packed items shall meet the approved
according to ‘Packing procedure’ packing procedure.
22. Paint thickness Check(Tank & Radiator)

1) Paint thickness of Tank & Radiator shall be ⊙ The measured values shall meet the approved
Measured according to painting specification. painting specification
DETAIL "A"
H1 H2 H3
X1 X2 X3
X1 X2 X3
H1 H2 H3
X1 X2 X3
VIEW A-A'
# NOTE #
1. ALL DIMENSION ARE IN MILLIMETERS.
2. DIMENSION AND WEIGHT WILL BE CHANGED
SLIGHTLY AFTER DETAIL DESIGN.
VIEW "A", FLANGE
VIEW "A", FLANGE
DOCU. NO. :
Rev. No. : 1
TRANFORMER LOCAL PANEL
TITLE
SPECIFICATION & DRAWINGS Page. No : Cover

SPECIFICATION & DRAWINGS
DOCU. NO. :
Rev. No. : 1
TITLE
SPECIFICATION & DRAWINGS Page. No : 1 / 26

SPECIFICATION & DRAWINGS
For Construction
REV.
NO.
REV.
NO.

FOR
1
CONSTRUCTION
19/12/13 19/12/13 19/12/13 19/12/13
Technical Information for Construction
FOR CONSTRUCTION
SPECIFICATION
of
LOCAL CONTROL PANEL
for
POWER TRANSFORMER
Transformer Spec. : 3PHASE_50Hz_15/20MVA_150KV_11KV_OLTC on HV
Date: 27/11/13
1 Printed in Korea
A. General Specification
1. Scope
This specification covers the design and manufacturing of local control panel of
power transformer for POSCO ENG / INDONESIA WAMPU project.
2. Condition of Service
1) Installation: Outdoor
2) Altitude: Up to 1000 feet above sea level
3) Ambient temperature: -5 ~ 45℃
3. Protection: Water proof type (IP55)
4. Painting Color and Dry Film Thickness

Refer to Paint procedure.
5. Dimension
Item Width (mm) Depth (mm) Height (mm)
Local Control Panel 880 580 1500
6. Material
This panel is fabricated of steel plate of 2.3mm thickness or above.
B. Technical Specification
1. Power
1) AC power: 3 phase 50Hz AC 400V
2) AC control power: 1 phase 50Hz AC 230V
3) DC control power DC 110V
4) Supply: Supplied by customer
2. Wiring
1) Cable type: XHHW
2) Cable color and size: Refer to attached drawing.
3) Indication of phase and polarity are available.
3. Transformer control (■ Yes □ No)

■ Fan control
2 Printed in Korea
□ OLTC tap position indication

■ Winding temperature indication
4. Other equipments
1) Illumination lamp
■ AC 230V 20W
■ Fluorescent lamp
□ Out of scope
2) Space heater
■ Rating AC 230V 100W, Connected to 230V power source
□ Out of Scope
3) Name plate
Material: SUS
Letter color: Black
Background: Silver
5. Tests
1) Tested by HICO QC team
2) Test items
■ Construction and appearance inspection
■ Apparatus operation inspection
■ Insulating resistance test
3 Printed in Korea
1
1
1
1
1
1
1
DOCU. NO. :
Rev. No. : 1
OLTC MOTOR DRIVE UNIT
TITLE
CIRCUIT DIAGRAM Page. No : Cover

CIRCUIT DIAGRAM
DOCU. NO. :
Rev. No. : 1
TITLE
CIRCUIT DIAGRAM Page. No : 1 / 8

CIRCUIT DIAGRAM
For Construction
REV.
NO.
REV.
NO.

FOR
1
CONSTRUCTION
19/12/13 19/12/13 19/12/13 19/12/13

Vendor Print For Generator Step-Up Transformer

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Vendor Print For Generator Step-Up Transformer

Încărcat de

Drepturi de autor:

Formate disponibile

DOCU. NO.

GENERATOR STEP UP TRANSFORMER

GENERATOR STEP UP TRANSFORMER

0 27/11/13 FOR CONSTRUCTION H.G.RYU K.D.KANG. T.H.YOON W.C.JEONG

H.G.RYU K.D.KANG T.H.YOON W.C.JEONG

For Construction HYOSUNG Spec. No. : 12-HSM -03621

Item Description Q’ty

3Ph 50Hz 15/20MVA 150/11kV YNd1

□ Project Name : POSCO Engineering / WAMPU HWPP PJT

Head Office : 450 Gongduk-Dong, Mapo-Ku, Seoul, Korea 121-020/Tel.+82-2-707-6927/Fax.+82-2-707-6449

1 Printed in KOREA Nov, 2013

Section II. Technical Information

1. Technical Data Sheets for Generator Step up Transformer

2 Printed in KOREA Nov, 2013

3. Service ambient conditions

6. Packing and shipment

3 Printed in KOREA Nov, 2013

Item Description Q’ty

3Ph 50Hz 15/20MVA 150/11kV YNd1

3.1 Ambient temperature

3.2 Annual Mean Relative humidity Up to 100%

3.3 Altitude of site Up to 1000m

4 Printed in KOREA Nov, 2013

5 Printed in KOREA Nov, 2013

4.5 Forced air fan

6 Printed in KOREA Nov, 2013

Figure 1. Structural diagram of Air Seal Cell Conservator

7 Printed in KOREA Nov, 2013

Description Inside Outside

Intermediate coat Dry film thickness N/A 80 ㎛↑

Top coat Dry film thickness 40 ㎛↑ 40 ㎛↑

Total film thickness 80 ㎛↑ 160 ㎛↑

6. Packing and shipment

8 Printed in KOREA Nov, 2013

1. Dimension & Construction Check

9 Printed in KOREA Nov, 2013

Section II. Technical Information

10 Printed in KOREA Nov, 2013

1. Technical Data Sheets for Generator Step up Transformer

11) Maximum hot spot temperature rise at average ambient

Power factor, % 99.36

b) Yokes (Flux density), tesla Approx. 1.7T

SUB VENDOR LIST

SUB VENDOR LIST

0 27/11/13 FOR CONSTRUCTION H.G.RYU K.D.KANG. T.H.YOON W.C.JEONG

H.G.RYU K.D.KANG T.H.YOON W.C.JEONG

▪ TRANSFORMER SPEC. : 3ph 50Hz 150/11kV 15/20MVA ONAN/ONAF OLTC on HV side

No. Description Type(Model) Maker Remark

1 HV BUSHING COT750-800 TRENCH(FRNACE)

2 HVN BUSHING COT250-800 TRENCH(FRNACE)

3 XV BUSHING 24-1250/P3 CEDASPE(ITALY)

4 BUCHHOLZ RELAY EE3-MA CEDASPE(ITALY)

7 OLTC VMIII 300Y MR(GERMANY)

8 OLTC PROTECTIVE RELAY RS-2001 MR(GERMANY)

9 OLTC MOTOR DRIVE UNIT ED 100S MR(GERMANY)

PRESSURE RELIEF DEVICE

PRESSURE RELIEF DEVICE

OIL LEVEL INDICATOR

13 COOLING FAN WITH MOTOR T2127Q TAIJIN(KOREA)

14 RADIATOR FOWDER COATING HYOSUNG(KOREA)

15 DEHYDRATING BREATHER T0120,T0121 TAIJIN(KOREA)

16 CONSERVATOR RB2500 HANSOL(KOREA)

17 INSULATION OIL ASTM D3487 TYPE 1 MICHANG(KOREA)