Draft Transportation Issues Guide

7/31/2019 Draft Transportation Issues Guide

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WG for Transportation Issues Guide (PC57.150)Task force for Truck Rigging & Crane: Craig Swinderman volunteered as TFChair. Tom Bassett, Shawn Galbraith, Ingo Schmidt (subject to agreement), andJerry Murphy also on Task force.

HEAVY HAULING, TRANSPORTATION AND RIGGING GUIDELINES FORPOWER TRANSFORMERS

1. 0 IntroductionThis document is intended as a guide for the movement of power transformers viaheavy hauling methods, with additional information on rigging of transformers forloading and offloading procedures. It should be noted that the movement of alarge piece of heavy equipment such as a power transformer is a demanding taskthat requires great care in planning and execution in order to safely andsuccessfully move the equipment to its desired destination. Only persons orparties that are trained, skilled and experienced with such work should plan thistype 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 ofthe considerations made and actions performed during the movement of powertransformers via heavy hauling and rigging techniques. The use of this guide willhopefully provide the user with a better appreciation and understanding of therequirements and considerations for moving power transformers. Hopefully withthis understanding, the user will be better able to verify that transformer moves arebeing planned and executed properly, thereby minimizing risks associated withpotentially 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 andexecution of large power transformer moves in order to better ensure the successof the move.

2.0 Planning for Heavy Haul transportThe following is a discussion of some of the various considerations for the heavy-haul transport of power transformers, shown as a list of procedures that arepresented in a sequential order. It should be noted that these procedures are oftenpart of an iterative process, and many of the procedures and steps are repeatedseveral 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 atransformer factory, repair facility, storage facility or existing substation, to a newdestination, there are several methods that can be used to accomplish this transportneed. Some methods include shipment via ocean vessel, barge, railroad, heavy-duty trailer transport or heavy-haul transporter to name a few. However, if theshipping weight of the transformer is generally roughly a few tons to a few tens oftons and dimensions of the transformer when loaded on a heavy-duty trailer are


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within typical roadway/highway clearance dimensions, it may be more convenientand cost-effective to transport the transformer via roadway/highway on a suitablyequipped heavy-duty tractor trailer where applicable. Often times however, themost effective and economical way of transporting a larger transformer, which canoften weigh up to several hundred tons, is to move the transformer between inlandlocations via railroad due to the extreme weight and size of the shipping dimensions

of the transformer. A detailed study must be performed to verify whichtransportation method is most suitable.

When larger transformers are shipped, frequently a heavy haul transport method isemployed for at least some portion of the move to the final destination. Heavy haultransport is the transportation mode where large pieces such as transformers areloaded on a specialized transport system consisting of a multi-wheeled heavy-dutytrailer containing several axle groups, and are usually transported over the road, orin some instances off-road. Some of the situations during movement of atransformer 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 gaindimensional clearance to be handled by existing rail lines that serve theinitial location or end destination of the transformer. It should be noted thatallowable rail clearance dimensions and weights vary widely depending onthe actual location and condition of the route that the transformer will travel,and rail clearance dimensions must be verified and checked with the properparties in order to determine when rail is feasible and when other methodsof 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 ismoved 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 todetermine the most suitable method, or combination of methods, of transporting thetransformer

2.2 Identifying a suitable heavy hauling company.Once it has been determined that heavy haul transport of the transformer will benecessary in order to move the transformer to the final destination, one of the firststeps required is the selection of a suitable heavy hauling and rigging company to

perform the services required. Some important criteria to evaluate when comparingand selecting a heavy haul and rigging company are as follows:

Experience with similar projects: It is a good idea to consider companiesthat have performed moves of equipment or items of similar weight anddimensions to those of the transformer required to move. This will help toensure that the company has the knowledge, skills, know-how andequipment needed in order to accomplish the move. It is particularly helpful


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if the company has previous experience in moving large transformers and isfamiliar with some of the inherent special needs and considerations withmoving a large transformer.

Access to proper equipment: It is important to verify that the heavy haulcompany 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 verifythat the heavy haul company is knowledgeable and familiar with the localconditions at the end destination location and is also familiar with any localregulations and special requirements for transporting large equipment in thearea. Often times, heavy haul contractors will make several inspection visitsto the site and the proposed haul route near the site even before beginningactual work, in order to familiarize themselves with the conditions and thelocal requirements.

Adherence to proper policies: It is also a good check to make sure that theheavy haul company has proper quality assurance programs and safetyprograms in place to ensure that their work is well-planned and is performedsafely and according to any regulations or requirements.

2.3 Determination of actual shipping dimensions of the transformerAfter choosing a heavy haul and rigging company to perform the move, the nexttask us usually the confirmation of the accurate shipping dimensions of thetransformer to be moved. In the case of many large transformers, much or all ofthe external accessories mounted on the transformer tank are to be removed forshipping in order to aid in reducing the shipping dimensions to meet any

dimensional restrictions that may be encountered on the route that the transformeris to be moved. Frequently large power transformers also have the oil drainedfrom the transformer main tank and accessories in order to reduce the shippingweight of the transformer and reduce the risk of having an oil leak or oil spill duringthe movement of the transformer.

In order to confirm clearance of the transformer when being moved through theshipping route, it is necessary to obtain an accurate profile, weight and dimensionsof the transformer in its shipping condition. In the case of new transformers, mostmanufacturers provide shipping drawings of the transformer showing the criticaldimensions 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 transformersassociated instruction book or drawing package. If this data is lost or unavailable,other methods must be used to determine the shipping dimensions and shippingweight of the transformer.

2.4 Selection of proper heavy haul equipmentAfter determination of accurate shipping weights and dimensions, the heavy haulcompany must select a suitable heavy haul method and equipment in order toproperly accomplish the move. The first concern is that the equipment can safely


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and properly accommodate the weight and dimensions of the transformer, andmove the transformer the required distance in a feasible manner.

An example of possible equipment that can be used for heavy haul transportincludes the following:

Heavy-duty flatbed or low-bed trailers, available with various numbers ofwheels and axles, for moving smaller to mid-size transformers. The trailersare pulled using prime moving equipment such as large trucks and tractors.These trailers are suitable for moving over relatively long distances of up toseveral miles.

Specialized trailers for handling extra-heavy weights associated with mid-size and larger transformers. These can include platform trailers with up toseveral axles and multiple wheel sets per axle in order to achieve betterweight distribution and axle loads for heavier transformers. Thesespecialized trailers are suitable for moving over relatively long distances ofup to several miles.

Platform trailers. The platform trailers can be modular, in which multipletrailers can be connected together in order to provide proper weightdistribution. These specialized trailers are also pulled with large primemoving equipment such as large, specialized trucks and tractors. Thesespecialized trailers are suitable for moving over relatively long distances ofup to several miles.

Specialized trailer/ dolly systems with center decks or beams, with multipleaxles spread over a large distance in order to achieve adequate weightdistribution for large loads. The trailer systems can sometimes beconfigured to lower the ride height of the transformer as far as possible by

using a central span that supports the transformer, sometimes from thesides 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, whilemaintaining adequate clearance during transport. These specialized trailersystems are pulled using specialized prime movers, and are suitable formoving over relatively long distances of up to several miles.

Self-propelled hydraulic, modular, platform trailers. These specializedtrailers have multiple axles with several wheels per axle, with hydrauliccontrol on the ride height of each wheel independently. These trailers havemultiple steering axles and are self-propelled, which allow the transporter tomake 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 overrelatively short distances, as they only travel at a walking speed.

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


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

of the transformer.

2.5 Route inspections and verification of transportation routeOnce the accurate shipping dimensions of the transformer have been confirmedand the proper heavy haul equipment suitable for movement of the transformer hasbeen identified, typically the next process is the study and determination of themost feasible transportation route for moving the transformer.

The heavy haul company will verify the allowable axle-loadings on the proposedtransportation 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 hiddenobstacles 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 andtransporter along route.

Verification of any required bridge crossings, overpasses or tunnels or otherchallenges 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 goodcondition and capable of handling its rated load. The maximum allowableaxle loading while crossing the bridge is often a key consideration whendetermining if the bridge can be crossed safely. If it is determined that thebridge cannot safely support the weight of the loaded transporter, it may benecessary to reinforce the bridge or in extreme cases even have the bridgere-built if no other transportation route alternative exists.

Verification of maximum allowable axle loading on the road surfaces of thetransportation route.

Verification of road surface conditions along the transportation route. The

transporter must be supported by a solid road surface capable of handling theaxle loading of the transporter while moving the transformer. Loose soil atthe 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 transformerand transporter are to be moved across unpaved areas, it is often required tolay matting or steel plates down on the ground surface in the area that the


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transporter will travel. If done properly, this can spread out the load of thetransporter across a larger area and prevent the transporter from losingstability 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, re-

grading of certain parts of the route may be needed in order to safely movethe loaded transporter. Too much of an incline can put strain on the tie-downs that secure the transformer to the transporter during movement, andcan also strain the prime mover trying to pull the transporter up the incline.

Verification of any utility services that must be cleared. Sometimes whentransporting a transformer along the transportation route, some utility servicessuch as distribution power lines, telephone lines and cables may interferewith the transportation dimensions of the transformer. Care must be taken tocheck that the utility services can be moved, lifted or relocated during themovement of the transformer. Additional precautions must be taken to moveelectrical wires, keeping proper insulation from grounded parts.

Verification that all electrical clearances will be maintained between electricalwires and grounded parts. Especially when moving through areas whereoverhead electrical wires exist, care must be taken to ensure that properelectrical clearance is kept between the electrical wires and grounded parts.When moving in substations or areas with high voltage lines, heavy haulingcompanies may not be very familiar with the required clearance distances,and may not be able to distinguish between lines of extra high voltage levelscompared with lower voltage lines. In such cases where movement in areaswith high voltage electrical wires will occur, it is a good practice that the utilityparty involved with the move be consulted to verify that proper electricalclearances are kept, especially when the transportation height of the

transformer is relatively high, and/or the overhead lines are relatively close tothe ground, and when any cranes are planned to be used in the area. Insome cases, lines may need to be de-energized in order to complete themove safely, or another alternate route must be found.

Verification of adequate space for maneuvering. Once the transporter nearsthe end destination, it must be verified that there is enough available space inthe area for the transporter to be maneuvered accordingly. Especially whenthe transformer final position is a different orientation than the position whilebeing transported, there is only one entrance/ exit to the site, or there aremany obstacles that must be negotiated, care must be taken to verify that thetransport equipment can be maneuvered and turned safely within the

confines of the site.

Verification of permission to transport over to private property. In somecases, the proposed transportation route will pass over areas of privatelyowned property. In such cases, it is necessary to check that permission canbe obtained for movement of the transformer across the private property.The owner of the private property must be identified and contacted to verifythat permission can be obtained.


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2.6 Verify that all applicable safety and environmental requirements, regulationsand laws are met.Care must be taken to ensure that the transportation plan will comply with allapplicable safety, environmental, and other requirements and regulations are met

in all areas that the transportation route passes through. In addition, it should beconfirmed that the transportation plan complies with the additional safety andhandling requirements of the transformer manufacturer and end owner of thetransformer, as well as the owner of any equipment being used.

The heavy haul company should also verify with the transformer manufacturer thatthe transportation plan will not risk damaging the integrity of the transformer and itsinternal or external components, especially when non-conventional movements areplanned.

2.7 Obtain necessary permitsIt is important to make sure that all necessary permits for moving the transformer

along the proposed transportation route have been obtained prior to beginning theactual move of the transformer.

Depending on the size of the transformer and the roads that the transportationroute follows, it may be necessary to transport the transformer on sections of theroute only at night, or during off-peak traffic times, or the road may have to beclosed completely to other traffic during the movement of the transformer.

Additionally, sometimes part or all of the proposed transportation route will travelacross private property. In such cases it is necessary to obtain permission totransport the transformer across such private property. This must be coordinatedand obtained in advance of the actual movement of the transformer.

2.8 Confirm that the transformer designis suitable for transport/handlingrequirementsPrior to the completion of the design and manufacture of the transformer, theheavy haul transportation company should check to make sure that appropriateinformation is available to confirm that the transformer can be moved and handledin the means necessary during execution of the transportation plan.

Such information should be clearly shown on the shipping outline drawing providedby the transformer manufacturer. Important features such as the jacking points,pulling eyes and lifting lugs should be clearly marked and easily identifiable to theheavy 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 actualtransformer tank, as this is an important piece of information for safely handling thetransformer.

Sometimes, a transformer that has already been installed will need to be moved toa new location during its lifetime. In such cases, it may be beneficial to transportthe transformer in a configuration that is different from the original shippingconfiguration. Examples of this would include the transport of a transformer whilefully assembled, transported a relatively short distance to a new location in the


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same substation or plant. In such cases, extra care must be taken to ensure thatthe transformer is capable of being safely moved in such condition. Some areas toconfirm are:

Obtain approval from the original manufacturer, if possible. When planningto move a transformer in a manner different from the original shipping

configuration, it is best to check with the transformer manufacturer toconfirm that the plan is feasible and safe. Often, the transformermanufacturer will require certain precautions such as installing internalshipping braces on the critical parts of the internal assembly, removingcertain parts susceptible to damage.

Verify that accessories can handle the forces associated with the move. Iflarge accessories are installed on the transformer, such as high voltagebushings, large radiators, large conservator tanks, etc., it is best to confirmthat these components can survive the forces applied to them when movingthe transformer. Care should be taken to find out the maximum forcesallowable to the bushings and other accessories, and make sure that these

forces are not approached or exceeded during the movement of thetransformer.

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 differentfrom the original shipping condition, an accurate calculation of the newactual shipping weight, shipping dimensions and center of gravity locationshould 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 coolingsystem of the transformer during the move, as such forces are not seenunder stationary conditions. It is important that before planning such amove, it should also first be permitted by the transformer manufacturer tomove the transformer while filled with oil. If such movement is to beperformed, adequate spill-prevention and containment procedures shouldbe created and implemented in order to address this risk.

3.0 Heavy Haul TransportationThe following describes some considerations and procedures once the transformermove is ready to be performed.

3.1 Verification that heavy haul equipment is in proper working order, and hasbeen adequately maintained.Prior to beginning any planned transformer move using heavy haul equipment, it isimportant that all equipment to be used should be checked to confirm that it is inproper working order. Records should be made available and reviewed to verifythat the equipment has been maintained properly as well.


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If a piece of equipment such as a trailer or other critical component should breakdown during the execution of the transformer move, this could lead to a verydangerous situation, including severe damage to the transformer, injury topersonnel or worse. A few precautionary measures, safety checks andmaintenance actions performed in advance of the move can eliminate much of thisunnecessary risk.

3.2 Inspection of transformer prior to receivingWhen performing a heavy haul move of a transformer, the transformer is usuallyfirst transferred from another means of transport, such as an ocean vessel, bargeor rail car. Therefore, one of the first steps is to inspect the transformer for anysigns of shipping damage prior to receiving the unit and moving it onto the heavyhaul transporter. This inspection process should include:

Verification of impact recorders. Make sure that impact recorders havebeen attached to the transformer prior to moving the transformer. If thetransformer 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 severeimpacts have occurred to the transformer on the previous mode oftransportation. If a large impact that exceeds the transformermanufacturers criteria is observed, the proper parties should be notified inorder that further inspections or actions can be taken. After checking theimpact recorder that uses a paper reel as the recording medium, it is agood idea to place a mark on the paper at the point where the handling ofthe transformer begins in order to provide a later reference that canpinpoint which mode of transportation the transformer was on when animpact 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 recordersmalfunctions during the move of the transformer.

Verification that positive pressure is maintained inside the transformer.During the receiving inspection, the transformer should be checked toverify 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 adry gas for shipping. The gas pressure can be confirmed by checking thepressure gage, and additionally recording the ambient temperature at thetime 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 haveoccurred during the previous mode of transport. If any damage isobserved, document the damage and notify the proper parties so thatfurther inspections or actions can be taken.

Check to make sure that proper handling instructions are marked on thetransformer. Before handling the transformer, be sure that critical handlinginstructions are clearly marked and visible on the transformer, including the


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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 othermethods 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 thetransformer from the previous mode of transportation onto the heavy haul transportequipment. The transfer is usually accomplished by one of the following methods:

Using hydraulic jacks to lift the transformer up, placing cribbing and slidingbeams beneath it, and then sliding onto the heavy haul transporter.

Using a crane to lift the transformer and move it to the heavy haultransporter.

Using a gantry system to lift the transformer and move it to the heavy haultransporter.

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 oftransportation equipment during the movement of the transformer. In addition toproper braking, blocks should be placed in front and behind of wheels on awheeled transportation vehicle such as a trailer system. Measures should betaken to ensure that barges remain stable and in place during transfer movementsinvolving offloading from barges.

When moving the unit from a previous mode of transportation that includes asuspension 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 suspensionsystem (springs, etc.). After the weight has been removed, blocking should beplaced 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 systemWhen preparing to move the transformer from the heavy haul transporter, careshould be taken to make sure that the transport equipment has the proper brakingin place to make sure that there is no movement of either piece of transportationequipment during the movement of the transformer. In addition to proper braking,blocks should be placed in front and behind of wheels on a wheeled transportationvehicle such as a trailer system.

When moving the transformer from the heavy haul transporter, the transportershould be jacked up to remove the weight from the suspension system (springs,

etc.). After the weight has been removed, blocking should be placed under thetrailer to make sure that it does not move while the transformer is being transferredto the end destination.

If hydraulic jacks are used to lift the transformer, care should be taken to makesure that the transformer is lifted evenly at all four jacking points in order to makesure 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 firmareas capable of handling the weight of the transformer over the concentrated area


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of the footprint of the hydraulic jack. There should also be adequate pieces ofhardened blocking or plywood placed between the interface point of the hydraulic

jack and the transformer jacking plate in order to prevent the jack from slippingduring 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 betaken to ensure that all rigging materials are in good condition and are adequatefor lifting the transformer. In general it is a good practice to use a high factor ofsafety in determining the size and capacity of the rigging materials used to lift thetransformer, such as a factor of safety of at least 7 between the rigging materialsmaximum load capacity and the load actually placed on them during the lifting ofthe transformer. This will reduce the risk of having a catastrophic accident whilelifting the transformer with rigging materials.

When using cranes, it is also important to verify that the capacity of the crane canhandle moving the transformer, taking into account the weight of the transformerand the reach over which the crane must be extended to move the transformer to

its desired location.

3.4 Securing of load to the transporterOnce the transformer has been positioned onto the heavy haul transporter, thetransformer must be secured firmly to the transporter to ensure that the transformerdoes not shift or slide during the movement on the transporter.

The transformer should be secured via adequate means that provide for bracing inall possible directions of movement of the transformer. The bracing materialsshould be sized properly, taking into account the size and weight of thetransformer.

After the securing of the transformer to the transporter, but prior to the movementof the transporter, the bracing structures and materials that secure the transformerto the transporter should be inspected, verified and approved by an appropriatelytrained professional.

3.5 Transportation to the destinationDuring the transportation of the transformer on the heavy haul transporter, thetransporter should remain on the designated and permitted route at all times. Thedriver of the transporter should make sure that the transporter remains on a stableroad surface during the movement of the transformer, and make sure that all trafficlaws and special permit requirements are followed.

Care should be taken when moving the transformer near overhead wires or treebranches. It is for this concern that often times long, flexible wooden strips will beplaced on top of the transformer during movement. The strips will face parallel tothe direction of travel and will extend well beyond the front and rear of thetransformer, and as a result will sag at the ends of the strip so that the ends are ata lower elevation than the top of the tank. If a wire or other obstacle hits one of thestrips, 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


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

4.0 Offloading considerations:After successfully transporting the transformer to the desired destination, the nextstep is to offload the transformer from the heavy haul transporter to the enddestination such as a designated concrete foundation at the site.

Prior to offloading the transformer to the final destination, it should be confirmedthat the final destination is ready to accept the transformer.

Offloading of the transformer to the final destination is usually accomplished by oneof the following methods:

Using hydraulic jacks to lift the transformer up, placing cribbing and slidingbeams 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 systemWhen preparing to move the transformer from the heavy haul transporter, careshould be taken to make sure that the transport equipment has the proper brakingin place to make sure that there is no movement of either piece of transportationequipment during the movement of the transformer. In addition to proper braking,blocks should be placed in front and behind of wheels on a wheeled transportationvehicle such as a trailer system.

When moving the transformer from the heavy haul transporter, the transportershould be jacked up to remove the weight from the suspension system (springs,etc.). After the weight has been removed, blocking should be placed under thetrailer to make sure that it does not move while the transformer is being transferredto the end destination.

If hydraulic jacks are used to lift the transformer, care should be taken to makesure that the transformer is lifted evenly at all four jacking points in order to makesure 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 firmareas capable of handling the weight of the transformer over the concentrated areaof the footprint of the hydraulic jack. There should also be adequate pieces of

hardened blocking or plywood placed between the interface point of the hydraulicjack and the transformer jacking plate in order to prevent the jack from slippingduring the lifting of the transformer.

4.2 Offloading using cranes or a gantry systemWhen cranes or a gantry system are used to lift the transformer, care should betaken to ensure that all rigging materials are in good condition and are adequatefor lifting the transformer. In general it is a good practice to use a high factor ofsafety in determining the size and capacity of the rigging materials used to lift the


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transformer, such as a factor of safety of at least 7 between the rigging materialsmaximum load capacity and the load actually placed on them during the lifting ofthe transformer. This will reduce the risk of having a catastrophic accident whilelifting 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 transformerand the reach over which the crane must be extended to move the transformer toits desired location.

4.3 Up-righting of large shell-form transformersIn some cases, large single-phase shell-form transformers for EHV applicationsmay be shipped to the end destination in a lay-down configuration that requiresup-righting of the transformer to its proper orientation for operation prior to setting iton the final destination foundation. These transformers have been designedspecifically for transportation in the lay-down configuration, and should havehandling 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 largecranes. The transformer manufacturer should provide details and instructions forthe up-righting procedure, and care should be taken to make sure that theseprocedures are followed correctly during the up-righting of the transformer at site.

4.4 Inspection of transformer after offloadingAfter completing the movement of the transformer and placing it on the enddestination, a careful inspection should be performed to check for any possiblesigns of damage that the transformer may have sustained during the movingprocess. 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 themovement process. If a large impact that exceeds the transformermanufacturers criteria is observed, the proper parties should be notified inorder 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 verifythat (a) no oil has leaked in the case of a unit shipped oil-filled, or (b) thatpositive pressure has been maintained in the case of a unit filled with a drygas for shipping. The gas pressure can be confirmed by checking thepressure gage, and additionally recording the ambient temperature at thetime of the measurement.

Check for signs of physical damage to the transformer. Perform a visualinspection in order to check for signs of physical damage that may haveoccurred during the previous mode of transport. If any damage isobserved, document the damage and notify the proper parties so thatfurther inspections or actions can be taken.

5.0 Considerations for Shipment of transformer accessories


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In addition to moving the main body of the transformer via a heavy haul transporttrailer, often times the accessories that have been removed from the transformerfor shipping are also transported separately by packing the accessories in cratesand 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 ordestroyed during transport. Some of the considerations for safely transporting theaccessories are as follows:

5.1 Packing the accessories in properly designed crates and casesWhen shipping the accessories separately, care must be taken to properly designthe shipping crates and cases to adequately support the accessories during theshipping, handling and transportation process. The crates should be designed withthe ability to be lifted and handled easily, while safely supporting the weight of theaccessories contained within them. The crates should firmly hold the contentssecure and should also prevent any accidental damage from occurring to thecontents while they are handled.

In the case where the transformer accessories are packed in a location outside ofthe United States and are shipped for importation, it should be advised that theassembled crates must meet certain guidelines associated with export packaging.The most important aspects of this involve proper labeling and documentation toallow inspectors and handlers to identify the contents of the crates, handle themproperly and ship them to the proper location. Only fumigated wood or otherapproved materials should be used in the construction of the crates. This will allowthe crates to pass import inspection and ensure that no non- US native plants,animals, insects, etc. are accidentally contained in the packing materials. Materialsthat are not packed in shipping containers that meet these requirements cangreatly delay the delivery of the accessory components by having the materials

held up or rejected by US Customs inspectors.

5.2 Proper shipping marksIn order to ensure the proper handling of the accessory crates, care should betaken to verify that the proper shipping marks are contained and are visible on theoutside of the crates. The shipping marks show information on how to identify thecontents of the crates and also show the end destination of the crates.

In addition, instructions for any required special handling of the crates should beclearly marked on them to make sure that the contents of the crates are notdamaged during shipment.

5.3 Detailed packing lists and documentationA detailed packing list should be attached to the accessory crates for easyidentification during the shipping and handling of the crates. The packing listshould show a description and quantity of each component contained within thecase, as well as the total shipping weight of the case in order to ensure that it ishandled properly.


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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 thesite.

5.4 Adequate marking on packaging containing fragile and sensitive componentsAny crates that contain components or materials that require special care when

handling should be clearly labeled as such. For example, all crates containingbushings, surge arresters or other large porcelain parts should be clearly labeledFragile-handle with care, and should contain the proper warning indications toclearly show this.

Other instructions for special handling of the crates should be attached as neededto ensure that sensitive components are not damaged during shipping. Someother special handling instructions for crates containing certain transformeraccessories 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 cratesOnce the accessory crates have arrived at the destination, they are usuallyoffloaded using a mobile crane or a forklift, depending on the size and weight of thecrate.

When using a crane for offloading the crates, it is important to verify that the cranehas the lifting capacity to safely move the crate when considering the weight of thecrate and the reach that the crane must extend to move the package from the trailerto the final resting place. In general, it is best to make sure that the crane hook islocated over the center of gravity of the crate or part being lifted, in order to makesure that the part does not sway, tilt excessively or lose stability when being movedby 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 crateshave been designed to facilitate offloading via a forklift without damage. Especiallybe careful when considering to lift crates containing fragile porcelain products suchas bushings or surge arresters with a forklift, as improper positioning of the forkscan easily damage the porcelain if the forks come in contact with the bushings orsurge arresters. Only an appropriately trained operator should operate the crane.


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Documents

Draft Transportation Issues Guide