Transformer components

O Plus C bushings 15 to 72.5 kV

Instructions for changing an oil fill hole gasket

Product Group Insulation and Components

Doc number:

1ZUA275100-226R4

Alamo, TN USA

Status
of document

Active

Issued by
department:

Engineering

Doc. Type:

Procedure BE077

Date:

9.24.2013

Creator name:

Huan Dinh

Lang.:

EN

Revision:

Page:

1/5

Original Date
01/04/13

Procedure
Number
BE077

Alamo Systems Procedure

Administering Agent

Title: Instructions for Changing an Oil Fill-Hole Gasket for

Engineering Dept.

By: Huan Dinh

O Plus C Bushings Up To 72.5 kV at a Customers Site.

Date Superseded

Page 2 of 5

N/A

I. Required tools/materials for changing an oil fill-hole gasket at a customers site:

Fill plug location

Picture 1: Fill plug location

1. An aerial lift capable of elevating one or more operators. Operators should be equipped with their own personal
safety equipment such as safety belts, hard hats, steel- toe shoes and safety glasses to meet all regulations and
good judgment.
2. A 7/32 (0.219 in) hexagon wrench (see Picture 2 for a sample). It is recommended that the wrench have a torque
indicator.
3. A dehydrated nitrogen (dew point -50C or lower) supply with regulator.
4. A nitrogen purging hose that has a maximum outside diameter (OD) of 0.312 (7.9 mm). The material of the hose
must not be compromised by transformer oil. A recommended hose is 0.260 (6.6 mm) OD nylon hose.
The hose should have an appropriate length and capability of connecting to the nitrogen bottle.
5. Cleaner (denatured alcohol).
6. Rags, absorbent pillows and/or pads.
7. Part number and description for replacement of the gasket as in the Table 1. A sealing sticker is also provided.
Table1: Parts list
Application
O Plus C

Item
1

bushings
72.5 kV

Old part to be replaced

Part number
Description
Nitrile gasket
0.406 ID x
1C30500H900
0.636 OD x
0.140 Thickness
0.375-24UN
1C30530H02
Hex. flat head
Steel fill plug

Picture 2:
A 7/32
hexagon
wrench with
torque
indicator.

BE077 Revision Date: 09/19/13

Part number
1C31998H206

1C30530H03

New Part
Description
Synthetic fluoropolymer
O-ring
0.484 ID x 0.139 W
(See Picture 3)
0.375-24UN
Hex. flat head
Stainless steel fill plug

Picture 3:
Synthetic fluoropolymer
O-ring has a light buff
color, while nitrile gasket
is in black.

Quantity

Original Date
01/04/13

Procedure
Number
BE077

Alamo Systems Procedure

Administering Agent

Title: Instructions for Changing an Oil Fill-Hole Gasket for

Engineering Dept.

By: Huan Dinh

O Plus C Bushings Up To 72.5 kV at a Customers Site.

Date Superseded

Page 3 of 5

N/A

II. The following steps detail the changing of an oil fill-hole gasket at a customers site:
Warning: Obviously, the changing should be performed in dry weather, without rain or condensing moisture.
The transformer on site must be visibly de-energized, disconnected, grounded, and its internal pressure
equalized if applicable. Allow the bushing to cool down to ambient temperature to avoid oil splashing out when
opening the fill plug. All safety procedures of the site must be followed.
Gasket
Fill plug

Picture 4: Remove the oil fill plug

1/ Slowly remove the oil fill plug: (Picture 4)
Use cleaner (item 5) and rags (item 6) to clean up all contaminations at the fill plug location before removing the fill
plug. Do not allow solvent to enter bushing.
The plug is located on the bushing as in Picture 1. Remove the fill plug and the gasket as shown in Picture 4.
Tool: The 7/32 hexagon wrench (item 2).
2/ Visually inspect inside the fill hole; make sure there are no scratches on the O-ring/gasket sealing surfaces and that
there is no contamination.
3/ Purging Nitrogen and replace the fill plug (Picture 5):
Place one Synthetic fluoropolymer O-ring (item 1 in Table 1) on the new stainless steel fill plug (item 2 in Table 1.)
Put the nitrogen purge hose (item 4) through the oil fill hole and several inches inside bushing; connect the hose to the
nitrogen supply (item 3) to purge nitrogen into the gas space of the bushing for about one cubic foot of nitrogen. The
purging time should be approximately one minute.
After about one minute of nitrogen purging, remove the purge hose and quickly install the prepared fill plug (with Oring) into the fill hole. Use the hexagon wrench (item 2) to tighten the fill plug at a recommended torque in Table 2
below. For proper sealing of the plug, it should be tightened to a metal-to-metal condition.
Table 2: Recommended torque
Fill Plug Size
0.375-24UN

BE077 Revision Date: 09/19/13

Recommended Torque
60-70 lb-in ( 6.8-7.9 N-m)

Original Date
01/04/13

Alamo Systems Procedure

Administering Agent

Title: Instructions for Changing an Oil Fill-Hole Gasket for

Engineering Dept.

By: Huan Dinh

O Plus C Bushings Up To 72.5 kV at a Customers Site.

Page 4 of 5

Procedure
Number
BE077
Date Superseded
N/A

Purging
nitrogen

Nitrogen
purge hose

Picture 5: Purging nitrogen and replace the fill plug

4/ Use cleaner (denatured alcohol) and rags to clean the fill plug area thoroughly. Inspect
for leaks. Place the provided sticker (Picture 6) over the fill plug to cover.
The sealing sticker is to identify the reworked bushings, also to protect the O-ring from UV
and ozone.

Picture 6: Sealing sticker

5/ Clean up the work place. Reset the transformer internal pressure to previous conditions (if needed), reconnect the
transformer. No additional set time is required before re-energizing.

BE077 Revision Date: 09/19/13

Contact us
ABB Inc.
1133 South Cavalier Drive
Alamo, TN 38001-3813
Phone: +1 800 955 8399
Fax: +1 731 696 5377
www.abb.com/electricalcomponents

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