WG for Transportation Issues Guide (PC57.

150) Task force for Truck Rigging & Crane: Craig Swinderman volunteered as TF Chair. Tom Bassett, Shawn Galbraith, Ingo Schmidt (subject to agreement), and Jerry Murphy also on Task force. HEAVY HAULING, TRANSPORTATION AND RIGGING GUIDELINES FOR POWER TRANSFORMERS
1. 0 Introduction This document is intended as a guide for the movement of power transformers via heavy hauling methods, with additional information on rigging of transformers for loading and offloading procedures. It should be noted that the movement of a large piece of heavy equipment such as a power transformer is a demanding task that requires great care in planning and execution in order to safely and successfully move the equipment to its desired destination. Only persons or parties that are trained, skilled and experienced with such work should plan this type of movement. Severe damage, injury or worse can result if such moves are planned and/or executed by inexperienced or ill-equipped parties. This document serves only as a guide for the end user in understanding many of the considerations made and actions performed during the movement of power transformers via heavy hauling and rigging techniques. The use of this guide will hopefully provide the user with a better appreciation and understanding of the requirements and considerations for moving power transformers. Hopefully with this understanding, the user will be better able to verify that transformer moves are being planned and executed properly, thereby minimizing risks associated with potentially improper planning or execution of the work by other parties. It is important to note that continuous attention, communication and cooperation should be maintained between all involved parties during the planning and execution of large power transformer moves in order to better ensure the success of the move.

2.0 Planning for Heavy Haul transport The following is a discussion of some of the various considerations for the heavyhaul transport of power transformers, shown as a list of procedures that are presented in a sequential order. It should be noted that these procedures are often part of an iterative process, and many of the procedures and steps are repeated several times until an accurate and safe transportation plan is obtained. 2.1 Situations when Heavy Haul methods may be needed. When power transformers are transported from an initial location, such as a transformer factory, repair facility, storage facility or existing substation, to a new destination, there are several methods that can be used to accomplish this transport need. Some methods include shipment via ocean vessel, barge, railroad, heavyduty trailer transport or heavy-haul transporter to name a few. However, if the shipping weight of the transformer is generally roughly a few tons to a few tens of tons and dimensions of the transformer when loaded on a heavy-duty trailer are

within typical roadway/highway clearance dimensions, it may be more convenient and cost-effective to transport the transformer via roadway/highway on a suitably equipped heavy-duty tractor trailer where applicable. Often times however, the most effective and economical way of transporting a larger transformer, which can often weigh up to several hundred tons, is to move the transformer between inland locations via railroad due to the extreme weight and size of the shipping dimensions of the transformer. A detailed study must be performed to verify which transportation method is most suitable. When larger transformers are shipped, frequently a heavy haul transport method is employed for at least some portion of the move to the final destination. Heavy haul transport is the transportation mode where large pieces such as transformers are loaded on a specialized transport system consisting of a multi-wheeled heavy-duty trailer containing several axle groups, and are usually transported over the road, or in some instances off-road. Some of the situations during movement of a transformer that may require heavy haul transport are: When suitable rail access is not available at the initial location or the final destination of the transformer. When the transformer shipping dimensions and weight are too large to gain dimensional clearance to be handled by existing rail lines that serve the initial location or end destination of the transformer. It should be noted that allowable rail clearance dimensions and weights vary widely depending on the actual location and condition of the route that the transformer will travel, and rail clearance dimensions must be verified and checked with the proper parties in order to determine when rail is feasible and when other methods of transport must be considered. When a transformer is moved a relatively short distance and rail shipment access is not available or is impractical. For example, when a transformer is moved between two different locations in the same or a nearby substation, switchyard, power plant or industrial site.

It should be stressed that great care, research and planning are needed to determine the most suitable method, or combination of methods, of transporting the transformer 2.2 Identifying a suitable heavy hauling company. Once it has been determined that heavy haul transport of the transformer will be necessary in order to move the transformer to the final destination, one of the first steps required is the selection of a suitable heavy hauling and rigging company to perform the services required. Some important criteria to evaluate when comparing and selecting a heavy haul and rigging company are as follows: Experience with similar projects: It is a good idea to consider companies that have performed moves of equipment or items of similar weight and dimensions to those of the transformer required to move. This will help to ensure that the company has the knowledge, skills, know-how and equipment needed in order to accomplish the move. It is particularly helpful

if the company has previous experience in moving large transformers and is familiar with some of the inherent special needs and considerations with moving a large transformer. Access to proper equipment: It is important to verify that the heavy haul company owns adequate equipment, or has access to adequate equipment that can handle the weights and dimensions of the transformer to be moved. Care should also be taken to verify that such equipment is relatively modern, in good working condition, and has been maintained properly. Familiarity with local requirements and regulations: It is also good to verify that the heavy haul company is knowledgeable and familiar with the local conditions at the end destination location and is also familiar with any local regulations and special requirements for transporting large equipment in the area. Often times, heavy haul contractors will make several inspection visits to the site and the proposed haul route near the site even before beginning actual work, in order to familiarize themselves with the conditions and the local requirements. Adherence to proper policies: It is also a good check to make sure that the heavy haul company has proper quality assurance programs and safety programs in place to ensure that their work is well-planned and is performed safely and according to any regulations or requirements.

2.3 Determination of actual shipping dimensions of the transformer After choosing a heavy haul and rigging company to perform the move, the next task us usually the confirmation of the accurate shipping dimensions of the transformer to be moved. In the case of many large transformers, much or all of the external accessories mounted on the transformer tank are to be removed for shipping in order to aid in reducing the shipping dimensions to meet any dimensional restrictions that may be encountered on the route that the transformer is to be moved. Frequently large power transformers also have the oil drained from the transformer main tank and accessories in order to reduce the shipping weight of the transformer and reduce the risk of having an oil leak or oil spill during the movement of the transformer. In order to confirm clearance of the transformer when being moved through the shipping route, it is necessary to obtain an accurate profile, weight and dimensions of the transformer in its shipping condition. In the case of new transformers, most manufacturers provide shipping drawings of the transformer showing the critical dimensions of the shipping profile, dimensions and shipping weight of the unit, along with other pertinent information regarding the shipment of the transformer. In the case of older transformers, this data should be found in the transformers associated instruction book or drawing package. If this data is lost or unavailable, other methods must be used to determine the shipping dimensions and shipping weight of the transformer. 2.4 Selection of proper heavy haul equipment After determination of accurate shipping weights and dimensions, the heavy haul company must select a suitable heavy haul method and equipment in order to properly accomplish the move. The first concern is that the equipment can safely

and properly accommodate the weight and dimensions of the transformer, and move the transformer the required distance in a feasible manner. An example of possible equipment that can be used for heavy haul transport includes the following: Heavy-duty flatbed or low-bed trailers, available with various numbers of wheels and axles, for moving smaller to mid-size transformers. The trailers are pulled using prime moving equipment such as large trucks and tractors. These trailers are suitable for moving over relatively long distances of up to several miles. Specialized trailers for handling extra-heavy weights associated with midsize and larger transformers. These can include platform trailers with up to several axles and multiple wheel sets per axle in order to achieve better weight distribution and axle loads for heavier transformers. These specialized trailers are suitable for moving over relatively long distances of up to several miles. Platform trailers. The platform trailers can be modular, in which multiple trailers can be connected together in order to provide proper weight distribution. These specialized trailers are also pulled with large prime moving equipment such as large, specialized trucks and tractors. These specialized trailers are suitable for moving over relatively long distances of up to several miles. Specialized trailer/ dolly systems with center decks or beams, with multiple axles spread over a large distance in order to achieve adequate weight distribution for large loads. The trailer systems can sometimes be configured to lower the ride height of the transformer as far as possible by using a central span that supports the transformer, sometimes from the sides of the tank as opposed to the transformer sitting on top of a trailer. Thus the transformer base can ride as low to the ground as possible, while maintaining adequate clearance during transport. These specialized trailer systems are pulled using specialized prime movers, and are suitable for moving over relatively long distances of up to several miles. Self-propelled hydraulic, modular, platform trailers. These specialized trailers have multiple axles with several wheels per axle, with hydraulic control on the ride height of each wheel independently. These trailers have multiple steering axles and are self-propelled, which allow the transporter to make very sharp turns and maneuver within small areas. They are also modular, and several groups of trailers can be connected together, depending on the weight of the load and the weight distribution needed. These self-propelled platform trailers are generally used to move over relatively short distances, as they only travel at a walking speed.

Often, the process of selecting the most suitable heavy haul equipment becomes an iterative process in conjunction with the determination of the most feasible transportation route (as discussed in section 2.5). Many times, a specific

transportation route will require a particular weight distribution our maximum shipping dimension in order to safely move the transformer along certain parts of the route. Depending on the route, the type of surface that the equipment will move over, and any special features such as bridges, overpasses, etc., a specific maximum wheel weight or axle-weight must be maintained in order to prevent damage to the road surface, bridge, and to provide stability during the movement of the transformer.

2.5 Route inspections and verification of transportation route Once the accurate shipping dimensions of the transformer have been confirmed and the proper heavy haul equipment suitable for movement of the transformer has been identified, typically the next process is the study and determination of the most feasible transportation route for moving the transformer. The heavy haul company will verify the allowable axle-loadings on the proposed transportation routes that the transformer will be moved, and also verify that all other obstacles in the transportation route can be negotiated safely. Often times, actual route inspections are performed to make sure that no unidentified or hidden obstacles are present in the route, and that the move can be performed safely. Some areas of concern to watch for when determining the transportation route are:

Verification of transportation clearance dimensions of transformer and transporter along route. Verification of any required bridge crossings, overpasses or tunnels or other challenges to be negotiated along the transportation route. If there are bridge crossings, care must be taken to make sure that the bridge is still in good condition and capable of handling its rated load. The maximum allowable axle loading while crossing the bridge is often a key consideration when determining if the bridge can be crossed safely. If it is determined that the bridge cannot safely support the weight of the loaded transporter, it may be necessary to reinforce the bridge or in extreme cases even have the bridge re-built if no other transportation route alternative exists. Verification of maximum allowable axle loading on the road surfaces of the transportation route. Verification of road surface conditions along the transportation route. The transporter must be supported by a solid road surface capable of handling the axle loading of the transporter while moving the transformer. Loose soil at the edges of roadways can sometimes cause the transporter to lose stability, causing the transformer load to shift or fall off the transporter completely. Identification of any road surface modifications needed. If the transformer and transporter are to be moved across unpaved areas, it is often required to lay matting or steel plates down on the ground surface in the area that the

transporter will travel. If done properly, this can spread out the load of the transporter across a larger area and prevent the transporter from losing stability or sinking into the ground. Verification if any re-grading of the transportation route is needed. Sometimes, especially when moving on an unpaved or off-road surface, regrading of certain parts of the route may be needed in order to safely move the loaded transporter. Too much of an incline can put strain on the tiedowns that secure the transformer to the transporter during movement, and can also strain the prime mover trying to pull the transporter up the incline. Verification of any utility services that must be cleared. Sometimes when transporting a transformer along the transportation route, some utility services such as distribution power lines, telephone lines and cables may interfere with the transportation dimensions of the transformer. Care must be taken to check that the utility services can be moved, lifted or relocated during the movement of the transformer. Additional precautions must be taken to move electrical wires, keeping proper insulation from grounded parts. Verification that all electrical clearances will be maintained between electrical wires and grounded parts. Especially when moving through areas where overhead electrical wires exist, care must be taken to ensure that proper electrical clearance is kept between the electrical wires and grounded parts. When moving in substations or areas with high voltage lines, heavy hauling companies may not be very familiar with the required clearance distances, and may not be able to distinguish between lines of extra high voltage levels compared with lower voltage lines. In such cases where movement in areas with high voltage electrical wires will occur, it is a good practice that the utility party involved with the move be consulted to verify that proper electrical clearances are kept, especially when the transportation height of the transformer is relatively high, and/or the overhead lines are relatively close to the ground, and when any cranes are planned to be used in the area. In some cases, lines may need to be de-energized in order to complete the move safely, or another alternate route must be found. Verification of adequate space for maneuvering. Once the transporter nears the end destination, it must be verified that there is enough available space in the area for the transporter to be maneuvered accordingly. Especially when the transformer final position is a different orientation than the position while being transported, there is only one entrance/ exit to the site, or there are many obstacles that must be negotiated, care must be taken to verify that the transport equipment can be maneuvered and turned safely within the confines of the site. Verification of permission to transport over to private property. In some cases, the proposed transportation route will pass over areas of privately owned property. In such cases, it is necessary to check that permission can be obtained for movement of the transformer across the private property. The owner of the private property must be identified and contacted to verify that permission can be obtained.

2.6 Verify that all applicable safety and environmental requirements, regulations and laws are met. Care must be taken to ensure that the transportation plan will comply with all applicable safety, environmental, and other requirements and regulations are met in all areas that the transportation route passes through. In addition, it should be confirmed that the transportation plan complies with the additional safety and handling requirements of the transformer manufacturer and end owner of the transformer, as well as the owner of any equipment being used. The heavy haul company should also verify with the transformer manufacturer that the transportation plan will not risk damaging the integrity of the transformer and its internal or external components, especially when non-conventional movements are planned. 2.7 Obtain necessary permits It is important to make sure that all necessary permits for moving the transformer along the proposed transportation route have been obtained prior to beginning the actual move of the transformer. Depending on the size of the transformer and the roads that the transportation route follows, it may be necessary to transport the transformer on sections of the route only at night, or during off-peak traffic times, or the road may have to be closed completely to other traffic during the movement of the transformer. Additionally, sometimes part or all of the proposed transportation route will travel across private property. In such cases it is necessary to obtain permission to transport the transformer across such private property. This must be coordinated and obtained in advance of the actual movement of the transformer. 2.8 Confirm that the transformer design is suitable for transport/handling requirements Prior to the completion of the design and manufacture of the transformer, the heavy haul transportation company should check to make sure that appropriate information is available to confirm that the transformer can be moved and handled in the means necessary during execution of the transportation plan. Such information should be clearly shown on the shipping outline drawing provided by the transformer manufacturer. Important features such as the jacking points, pulling eyes and lifting lugs should be clearly marked and easily identifiable to the heavy haul company. Also, a shipping center of gravity should also be shown on the shipping outline drawing and confirmed with an indication mark on the actual transformer tank, as this is an important piece of information for safely handling the transformer. Sometimes, a transformer that has already been installed will need to be moved to a new location during its lifetime. In such cases, it may be beneficial to transport the transformer in a configuration that is different from the original shipping configuration. Examples of this would include the transport of a transformer while fully assembled, transported a relatively short distance to a new location in the

same substation or plant. In such cases, extra care must be taken to ensure that the transformer is capable of being safely moved in such condition. Some areas to confirm are: Obtain approval from the original manufacturer, if possible. When planning to move a transformer in a manner different from the original shipping configuration, it is best to check with the transformer manufacturer to confirm that the plan is feasible and safe. Often, the transformer manufacturer will require certain precautions such as installing internal shipping braces on the critical parts of the internal assembly, removing certain parts susceptible to damage. Verify that accessories can handle the forces associated with the move. If large accessories are installed on the transformer, such as high voltage bushings, large radiators, large conservator tanks, etc., it is best to confirm that these components can survive the forces applied to them when moving the transformer. Care should be taken to find out the maximum forces allowable to the bushings and other accessories, and make sure that these forces are not approached or exceeded during the movement of the transformer. Verify the shipping weight and center of gravity location of the transformer. If the transformer is to be moved while in a configuration that is different from the original shipping condition, an accurate calculation of the new actual shipping weight, shipping dimensions and center of gravity location should be performed. Provide containment precautions if transformers are moved while oil-filled. If a partially or fully assembled transformer is to be moved while oil-filled, there is a risk of developing an oil leak while moving the transformer. The leak could be caused by the extra strain put on joints in the tank or cooling system of the transformer during the move, as such forces are not seen under stationary conditions. It is important that before planning such a move, it should also first be permitted by the transformer manufacturer to move the transformer while filled with oil. If such movement is to be performed, adequate spill-prevention and containment procedures should be created and implemented in order to address this risk.

3.0 Heavy Haul Transportation The following describes some considerations and procedures once the transformer move is ready to be performed. 3.1 Verification that heavy haul equipment is in proper w orking order, and has been adequately maintained. Prior to beginning any planned transformer move using heavy haul equipment, it is important that all equipment to be used should be checked to confirm that it is in proper working order. Records should be made available and reviewed to verify that the equipment has been maintained properly as well.

If a piece of equipment such as a trailer or other critical component should break down during the execution of the transformer move, this could lead to a very dangerous situation, including severe damage to the transformer, injury to personnel or worse. A few precautionary measures, safety checks and maintenance actions performed in advance of the move can eliminate much of this unnecessary risk. 3.2 Inspection of transformer prior to receiving When performing a heavy haul move of a transformer, the transformer is usually first transferred from another means of transport, such as an ocean vessel, barge or rail car. Therefore, one of the first steps is to inspect the transformer for any signs of shipping damage prior to receiving the unit and moving it onto the heavy haul transporter. This inspection process should include: Verification of impact recorders. Make sure that impact recorders have been attached to the transformer prior to moving the transformer. If the transformer was moved on another mode of transportation (ocean vessel, barge, railcar) prior to the receiving and loading onto the heavy haul transporter, the impact recorder should be checked to see if any severe impacts have occurred to the transformer on the previous mode of transportation. If a large impact that exceeds the transformer manufacturers criteria is observed, the proper parties should be notified in order that further inspections or actions can be taken. After checking the impact recorder that uses a paper reel as the recording medium, it is a good idea to place a mark on the paper at the point where the handling of the transformer begins in order to provide a later reference that can pinpoint which mode of transportation the transformer was on when an impact occurred. In addition, it is usually a good practice to attach two impact recorders to the transformer as a backup in the case that one of the impact recorders malfunctions during the move of the transformer. Verification that positive pressure is maintained inside the transformer. During the receiving inspection, the transformer should be checked to verify that (a) no oil has leaked in the case of a unit shipped oil-filled, or (b) that positive pressure has been maintained in the case of a unit filled with a dry gas for shipping. The gas pressure can be confirmed by checking the pressure gage, and additionally recording the ambient temperature at the time of the measurement. Check for signs of physical damage to the transformer. Perform a visual inspection in order to check for signs of physical damage that may have occurred during the previous mode of transport. If any damage is observed, document the damage and notify the proper parties so that further inspections or actions can be taken. Check to make sure that proper handling instructions are marked on the transformer. Before handling the transformer, be sure that critical handling instructions are clearly marked and visible on the transformer, including the

shipping weight and the location of the shipping center of gravity. Also, key handling points on the transformer such as lifting lugs, jacking pads, pulling eyes, etc. should also be labeled by painted marks or other methods of permanent marking on the transformer. 3.3 Loading the transformer onto heavy haul transportation equipment Once the transformer has been inspected, the next step is to transfer the transformer from the previous mode of transportation onto the heavy haul transport equipment. The transfer is usually accomplished by one of the following methods: Using hydraulic jacks to lift the transformer up, placing cribbing and sliding beams beneath it, and then sliding onto the heavy haul transporter. Using a crane to lift the transformer and move it to the heavy haul transporter. Using a gantry system to lift the transformer and move it to the heavy haul transporter. When preparing to move the transformer from the previous mode of transportation, care should be taken to make sure that each of the transport equipment has the proper braking in place to make sure that there is no movement of either piece of transportation equipment during the movement of the transformer. In addition to proper braking, blocks should be placed in front and behind of wheels on a wheeled transportation vehicle such as a trailer system. Measures should be taken to ensure that barges remain stable and in place during transfer movements involving offloading from barges. When moving the unit from a previous mode of transportation that includes a suspension system for the transporter, such as a rail car or another trailer system, the rail car or trailer should be jacked up to remove the weight from the suspension system (springs, etc.). After the weight has been removed, blocking should be placed under the rail car or trailer to make sure that it does not move while the transformer is being transferred to the heavy haul transport system. 3.3.1 Offloading using hydraulic jacks and sliding system When preparing to move the transformer from the heavy haul transporter, care should be taken to make sure that the transport equipment has the proper braking in place to make sure that there is no movement of either piece of transportation equipment during the movement of the transformer. In addition to proper braking, blocks should be placed in front and behind of wheels on a wheeled transportation vehicle such as a trailer system. When moving the transformer from the heavy haul transporter, the transporter should be jacked up to remove the weight from the suspension system (springs, etc.). After the weight has been removed, blocking should be placed under the trailer to make sure that it does not move while the transformer is being transferred to the end destination. If hydraulic jacks are used to lift the transformer, care should be taken to make sure that the transformer is lifted evenly at all four jacking points in order to make sure the transformer does not become unstable during the jacking process. Also, care should be taken to make sure that the hydraulic jacks are located on firm areas capable of handling the weight of the transformer over the concentrated area

of the footprint of the hydraulic jack. There should also be adequate pieces of hardened blocking or plywood placed between the interface point of the hydraulic jack and the transformer jacking plate in order to prevent the jack from slipping during the lifting of the transformer. 3.3.2 Offloading using cranes or a gantry system When cranes or a gantry system are used to lift the transformer, care should be taken to ensure that all rigging materials are in good condition and are adequate for lifting the transformer. In general it is a good practice to use a high factor of safety in determining the size and capacity of the rigging materials used to lift the transformer, such as a factor of safety of at least 7 between the rigging materials maximum load capacity and the load actually placed on them during the lifting of the transformer. This will reduce the risk of having a catastrophic accident while lifting the transformer with rigging materials. When using cranes, it is also important to verify that the capacity of the crane can handle moving the transformer, taking into account the weight of the transformer and the reach over which the crane must be extended to move the transformer to its desired location. 3.4 Securing of load to the transporter Once the transformer has been positioned onto the heavy haul transporter, the transformer must be secured firmly to the transporter to ensure that the transformer does not shift or slide during the movement on the transporter. The transformer should be secured via adequate means that provide for bracing in all possible directions of movement of the transformer. The bracing materials should be sized properly, taking into account the size and weight of the transformer. After the securing of the transformer to the transporter, but prior to the movement of the transporter, the bracing structures and materials that secure the transformer to the transporter should be inspected, verified and approved by an appropriately trained professional.

3.5 Transportation to the destination During the transportation of the transformer on the heavy haul transporter, the transporter should remain on the designated and permitted route at all times. The driver of the transporter should make sure that the transporter remains on a stable road surface during the movement of the transformer, and make sure that all traffic laws and special permit requirements are followed. Care should be taken when moving the transformer near overhead wires or tree branches. It is for this concern that often times long, flexible wooden strips will be placed on top of the transformer during movement. The strips will face parallel to the direction of travel and will extend well beyond the front and rear of the transformer, and as a result will sag at the ends of the strip so that the ends are at a lower elevation than the top of the tank. If a wire or other obstacle hits one of the strips, this will allow a warning that the obstacle is in the path of the transformer. This warning system will also help to prevent some wires or trees from potentially

impacting and causing damage to the top of the transformer during movement. The transformer and heavy haul transporter must be moving very slowly for this warning system to be effective.

4.0 Offloading considerations: After successfully transporting the transformer to the desired destination, the next step is to offload the transformer from the heavy haul transporter to the end destination such as a designated concrete foundation at the site. Prior to offloading the transformer to the final destination, it should be confirmed that the final destination is ready to accept the transformer. Offloading of the transformer to the final destination is usually accomplished by one of the following methods: Using hydraulic jacks to lift the transformer up, placing cribbing and sliding beams beneath it, and then sliding onto the end destination. Using a crane to lift the transformer and move it to the end destination Using a gantry system to lift the transformer and move it to the end destination. 4.1 Offloading using hydraulic jacks and sliding system When preparing to move the transformer from the heavy haul transporter, care should be taken to make sure that the transport equipment has the proper braking in place to make sure that there is no movement of either piece of transportation equipment during the movement of the transformer. In addition to proper braking, blocks should be placed in front and behind of wheels on a wheeled transportation vehicle such as a trailer system. When moving the transformer from the heavy haul transporter, the transporter should be jacked up to remove the weight from the suspension system (springs, etc.). After the weight has been removed, blocking should be placed under the trailer to make sure that it does not move while the transformer is being transferred to the end destination. If hydraulic jacks are used to lift the transformer, care should be taken to make sure that the transformer is lifted evenly at all four jacking points in order to make sure the transformer does not become unstable during the jacking process. Also, care should be taken to make sure that the hydraulic jacks are located on firm areas capable of handling the weight of the transformer over the concentrated area of the footprint of the hydraulic jack. There should also be adequate pieces of hardened blocking or plywood placed between the interface point of the hydraulic jack and the transformer jacking plate in order to prevent the jack from slipping during the lifting of the transformer. 4.2 Offloading using cranes or a gantry system When cranes or a gantry system are used to lift the transformer, care should be taken to ensure that all rigging materials are in good condition and are adequate for lifting the transformer. In general it is a good practice to use a high factor of safety in determining the size and capacity of the rigging materials used to lift the

transformer, such as a factor of safety of at least 7 between the rigging materials maximum load capacity and the load actually placed on them during the lifting of the transformer. This will reduce the risk of having a catastrophic accident while lifting the transformer with rigging materials. When using cranes, it is also important to verify that the capacity of the crane can handle moving the transformer, taking into account the weight of the transformer and the reach over which the crane must be extended to move the transformer to its desired location.

4.3

Up-righting of large shell-form transformers In some cases, large single-phase shell-form transformers for EHV applications may be shipped to the end destination in a lay-down configuration that requires up-righting of the transformer to its proper orientation for operation prior to setting it on the final destination foundation. These transformers have been designed specifically for transportation in the lay-down configuration, and should have handling points that enable them to be up-righted into the final orientation at site. The up-righting process is usually performed using a gantry system or two large cranes. The transformer manufacturer should provide details and instructions for the up-righting procedure, and care should be taken to make sure that these procedures are followed correctly during the up-righting of the transformer at site.

4.4 Inspection of transformer after offloading After completing the movement of the transformer and placing it on the end destination, a careful inspection should be performed to check for any possible signs of damage that the transformer may have sustained during the moving process. This inspection process should include: Verification of impact recorders. The impact recorders should be checked to see if any severe impacts have occurred to the transformer during the movement process. If a large impact that exceeds the transformer manufacturers criteria is observed, the proper parties should be notified in order that further inspections or actions can be taken. Verification that positive pressure is maintained inside the transformer. During the receiving inspection, the transformer should be checked to verify that (a) no oil has leaked in the case of a unit shipped oil-filled, or (b) that positive pressure has been maintained in the case of a unit filled with a dry gas for shipping. The gas pressure can be confirmed by checking the pressure gage, and additionally recording the ambient temperature at the time of the measurement. Check for signs of physical damage to the transformer. Perform a visual inspection in order to check for signs of physical damage that may have occurred during the previous mode of transport. If any damage is observed, document the damage and notify the proper parties so that further inspections or actions can be taken.

5.0 Considerations for Shipment of transformer accessories

In addition to moving the main body of the transformer via a heavy haul transport trailer, often times the accessories that have been removed from the transformer for shipping are also transported separately by packing the accessories in crates and cases and shipping them via more-conventional flatbed trailers. Just as with the movement of the transformer itself, care must be taken to ensure that the accessories and components of the transformer are not damaged or destroyed during transport. Some of the considerations for safely transporting the accessories are as follows: 5.1 Packing the accessories in properly designed crates and cases When shipping the accessories separately, care must be taken to properly design the shipping crates and cases to adequately support the accessories during the shipping, handling and transportation process. The crates should be designed with the ability to be lifted and handled easily, while safely supporting the weight of the accessories contained within them. The crates should firmly hold the contents secure and should also prevent any accidental damage from occurring to the contents while they are handled. In the case where the transformer accessories are packed in a location outside of the United States and are shipped for importation, it should be advised that the assembled crates must meet certain guidelines associated with export packaging. The most important aspects of this involve proper labeling and documentation to allow inspectors and handlers to identify the contents of the crates, handle them properly and ship them to the proper location. Only fumigated wood or other approved materials should be used in the construction of the crates. This will allow the crates to pass import inspection and ensure that no non- US native plants, animals, insects, etc. are accidentally contained in the packing materials. Materials that are not packed in shipping containers that meet these requirements can greatly delay the delivery of the accessory components by having the materials held up or rejected by US Customs inspectors. 5.2 Proper shipping marks In order to ensure the proper handling of the accessory crates, care should be taken to verify that the proper shipping marks are contained and are visible on the outside of the crates. The shipping marks show information on how to identify the contents of the crates and also show the end destination of the crates. In addition, instructions for any required special handling of the crates should be clearly marked on them to make sure that the contents of the crates are not damaged during shipment. 5.3 Detailed packing lists and documentation A detailed packing list should be attached to the accessory crates for easy identification during the shipping and handling of the crates. The packing list should show a description and quantity of each component contained within the case, as well as the total shipping weight of the case in order to ensure that it is handled properly.

A proper packing list will aid in accounting of all components of the transformer, and is useful in inventorying and determining if there are any missing parts at the site. 5.4 Adequate marking on packaging containing fragile and sensitive components Any crates that contain components or materials that require special care when handling should be clearly labeled as such. For example, all crates containing bushings, surge arresters or other large porcelain parts should be clearly labeled Fragile-handle with care, and should contain the proper warning indications to clearly show this. Other instructions for special handling of the crates should be attached as needed to ensure that sensitive components are not damaged during shipping. Some other special handling instructions for crates containing certain transformer accessories could include: This way up Fragile-handle with care Sling here Use no hooks Keep dry Keep away from heat Center of gravity other warning labels as necessary 5.5 Offloading of accessory crates Once the accessory crates have arrived at the destination, they are usually offloaded using a mobile crane or a forklift, depending on the size and weight of the crate. When using a crane for offloading the crates, it is important to verify that the crane has the lifting capacity to safely move the crate when considering the weight of the crate and the reach that the crane must extend to move the package from the trailer to the final resting place. In general, it is best to make sure that the crane hook is located over the center of gravity of the crate or part being lifted, in order to make sure that the part does not sway, tilt excessively or lose stability when being moved by the crane. Only an appropriately trained operator should operate the crane. When using a forklift to offload the crates, it is important to verify that the crates have been designed to facilitate offloading via a forklift without damage. Especially be careful when considering to lift crates containing fragile porcelain products such as bushings or surge arresters with a forklift, as improper positioning of the forks can easily damage the porcelain if the forks come in contact with the bushings or surge arresters. Only an appropriately trained operator should operate the crane.