METHOD STATEMENT FOR DRY TYPE POWER TRANSFORMER INSTALLATION

TABLE OF CONTENT

1. PURPOSE
2. SCOPE
3. REFERENCES
4. RESPONSIBILITIES
5. MAJOR PLANT & EQUIPMENT
6. MATERIAL HANDLING
7. CONSTRUCTION METHODOLOGY
8. EQUIPMENT AND TOOL
9. PARTICULAR SAFETY PRECAUTIONS
10. ATTACHMENT

10.1 Quality Record No.0007 – “Dry-Type Power Transformers”.

10.2 HSE Risk Assessment

1. PURPOSE

1.1 The purpose of this procedure is to describe the methods of inspection in the installation of Dry-Type power transformers in accordance with the Project Specifications and Code.

1.2 To ensure that safety precautions shall be applied throughout the installation.

2.0 SCOPE

2.1 This procedure covers the inspection and test procedure pertaining to the installation of dry type power transformers.

3.0 REFERENCES

3.1 [Company Name] Site Safety Plan

3.2 Project Manuals – Project Technical Specifications

3.3 [Company] QWP-Form – Quality Control Work Procedure

3.4 [Company Name]-Form – Electrical Work Procedure

3.5 [Company Name ]Project Quality Plan

3.6 Approved Installation drawings (As applicable)

3.7 Approved Material Submittal (As applicable)

4.0 RESPONSIBILITIES

4.1 Project Manager / Director

4.1.1 Shall be responsible for the overall construction activities.

4.2 Supervisor / General Foreman

4.2.1 Implementation of safe work method statement and risk assessment plan.

4.2.2 Arrange TBT prior to commencement of work.

4.2.3 Visit the area of work for no hazard items exist.

4.2.4 Organizing the site and work places so as to ensure that work is carried out to the required standard, with minimum risk to men, equipment and materials.

4.2.5 Ensure that the employees under his responsibility do not engage in unsafe work practices or take unnecessary risks.

4.3 Safety Officer

4.3.1 Enforce the Project HSE rules and regulation.

4.3.2 Implement HSE requirements as set out in [Company Name] HSE Plan

4.3.3 Ensure work permit has been obtained and implemented if applicable.

4.4 Tradesmen / Drivers / Operators / Welders

4.4.1 Follow Supervisor’s / General Foreman’s instructions.

4.4.2 Only authorized drivers / operators can operate the plants.

4.4.3 Only Electricity Authority, Authorized Technician can work on Termination /Splicing / Testing & Commissioning of MV/HV Cable /Wire.

5.0 MAJOR PLANT & EQUIPMENT

5.1 All equipment/tools shall be inspected prior to use at site and [Company Name] ID tag shall be placed on equipment where applicable.

5.2 No modified tools may be used for any task.

5.3 All test equipment shall be checked to assure that they are in good condition and valid calibration certificates are maintained and available for review.

5.4 Operator’s documentation shall be verified as applicable.

6.0 MATERIAL HANDLING

6.1 The QC Inspector shall carry out an inspection of the equipment when it arrives in the warehouse. The inspector shall ensure the equipment conforms to the Project Specifications and Code, Shop Drawings and Purchase Order.

6.2 The inspector shall ensure that the equipment is free from damage. Any damage noted shall be identified on the Over Short & Damage Report (OS&D Report).

6.3 When the transformer is received, the following points should be checked:

6.3.1 The characteristics of the transformer, indicated on the Name Plate, should coincide with those that appear on the test record sheet and these, at the same time, should match the order specifications.

6.3.2 Check that the transformer has all relevant safety warnings.

6.3.3 Check the general state of the equipment. There should be no dents in encapsulated phases or connections.

6.3.4 The state of the paint: check that there is no flaking, scratches, etc. on the enclosure (if the transformer is of this type) or on metallic parts.

6.3.5 Check all of the transformer’s accessories (wheels, thermometer, etc.).

6.3.6 Before unpacking the transformer, especially during winter or when the difference in temperature between indoors and outdoors considerable, a prudential period of time should be waited (8 to 24 hour) so that the transformer’s temperature can stabilize. This is to prevent undesired condensation on the transformer surface.

6.4 Electrical equipment shall be hauled, transported and unloaded to job site on a safe and most efficient manner.

Transport and Handling of Transformer;

6.4.1 During transport the transformer should not be moved by pushing on coils or connections. The transformer is fitted with four lugs rings on the wheel base profiles where cables for dragging can be attached. If the transformer has to be pushed, then this can be carried out by pushing on the flanges that hold the magnetic circuit in place.

6.4.2 The top flanges have four lifting lugs and hoisting can be carried out by attaching slings that form an angle of 50-70 degree to the lifting lugs or to the transformer enclosure walls.

6.4.3 The name plate indicates the total weight of the transformer. This must be taken into account when deciding on the device used for lifting.

6.4.4 The attachment holes or lifting lugs have a minimum diameter of 40 mm.

6.4.5 The base and cooling elements (in case of fans) are designed to ensure that the transformer can be moved using a lever and do not impede handling; however, care must be taken not to push on the encapsulated phases. If levers are used, we using wooden stops to protect those elements.

6.5 Transformers shall be protected against atmospheric conditions, humidity & temperature. The internal heaters shall be turned on to protect the equipment when necessary.

6.6 The Dry-Type Transformer is for indoor installation. Do not store in places where it is exposed to effects of the weather.

6.7 The handling and store of transformer shall follow to the manufacturer recommendation:

6.7.1 The temperature in the storage place cannot be below than negative 25 degree centigrade.

6.7.2 The place will be dry, clean and good ventilated. When is stored, the transformer should remain inside its plastic packaging cover.

6.7.3 Damp places, bags with humidity absorbing products like silica gel should be placed near the coils and to provide adequate ventilation.

7.0 CONSTRUCTION METHODOLOGY

7.1 QUALITY CONTROL:

7.1.1 The Construction department shall inform the Quality Department of the placement/installation activities by issuing a Request for Inspection.

7.1.2 The Inspector shall witness the placement/installation of the transformer by performing inspections as per the Inspection and test plan and shall record his findings on Quality Record No.0007. Any defects noted during the inspection shall be informed to the Construction Department (Construction Manager) by the Inspection / Walkdown / Punch List (IWP) Report.

7.2 TRANSFORMER LIFTING OPTION

7.2.1 It will be necessary to allow access for a crane, in the area immediately outside the building. The area as designated in the attached drawing will require to be cleared to facilitate the crane and the transformer transporter. A detailed lifting study will be undertaken by a heavy lift specialist and forwarded in due course. It will be necessary for the transformer room to be structurally complete. All floors, cable duct’s and transformer wheel channels will be required to be completed. The transformers will be lifted in sequence, the first being the furthest from the access door.

• The transformers shall be received at site fully assembled.
• The transformers will be delivered directly to site, where they will be inspected in compliance with the QA/QC procedures and the Procurement and Materials Management Manual. Each item of equipment will be inspected for conformance with the specifications and compliance with the terms and conditions as set out on the purchase order.
• On satisfactory inspection of the Transformers, all crating (if applicable) and packing will be removed to allow for the removal from the delivery truck.
• Note: A detailed lift study will be completed by the heavy lift specialist, taking into account the reach requirements and the crane camber, with regard to the site conditions that will prevail at the time of the lift.
• The Transformers are provided with lifting eyes built into the top of frame. Shackles will be provided for these lifting eyes, which will be attached to the slings, which in turn are attached to the crane. All slings, shackles will be certified and in good condition.
• Guide ropes will then be attached to the transformer to prevent the load from swinging and osculating while in the air.
• All rigging will be under taken by qualified riggers.
• The crane will be certified, with the valid certificate available for inspection.
• The crane will be operated by a qualified/certified driver.
• The crane driver will operate the lift under instruction from a banks-man, who is positioned as such, that he has a clear and unobstructed view of all the lifting operation and of all personnel required for the lifting operation.
• The location of the lift will be taped off with warning tape and only essential personnel may enter the demarcation zone.
• All personnel within the demarcation zone will function as directed by the banks-man/lift supervisor.
• The transformer will then be lifted from the truck and lifted on to the temporary platform, under the direction of the banks-man. The load will be rotated to the opening. At all times the load will be restrained from osculating/swinging by the guide ropes.
• When the transformer is directly opposite the opening and prior to lowering it on to the platform, it will be orientated in the direction in which it will be placed.
• Prior to lowering the transformer it will be necessary to remove the wheel carriage, to accommodate the moving skates and ensure sufficient clearance for head height.
• The Transformer can then be lowered to the platform and as this is done the four (4) skates will be located under the weight. The skates will be located equidistant from the corners of the base. A metal plate (6 mm) will be placed over the floor area between the landing point and the location within the transformer room, to prevent the rollers from being obstructed and accommodate ease of movement.
• The transformer will then be moved very slowly into the transformer room by means of a winch which will be anchored through the door opening at the far end of the room. As this anchor point is off-center from the final location of the transformer, it will be necessary to compensate for the off-center pull by adjusting the moving skates. As well as the pulling, weight will also be applied to push, this should ensure that a minimal amount of pull is required and the load will not deviate from its required line.
• Once the transformer is located in place, directly above the wheel channels, it will be jacked up and the wheel carriage replaced.
• On reinstatement of the wheels the transformer will be jacked into place on the embedded channels.
• When the transformer has been placed on the channels it will be chocked in place for final placement. Final location adjustment will be achieved using toe-jacks if required.
• This operation will be repeated for all transformers.

8.0 EQUIPMENT & TOOLS

8.1 1 x 20 T – 2 Leg chains (adjustable)

8.2 50 Ton Crane (To be reviewed as necessary)

8.3 Adequate rope for guiding.

8.4 2 x 10T Shackles

8.5 Spanner

8.6 Wrenches

8.7 Hand Tools

9.0 PARTICULAR SAFETY PRECAUTIONS

The contents of this method statement shall form the basis of a toolbox talk for all operatives before the commencement of such works.

9.1 RISK ASSESSMENT

9.1.1 There are risks associated with unloading and moving the transformers from the delivery vehicle to their location within the building. The risks as listed here under have been taken into account when preparing this method statement. A tool box talk will be given to all personnel involved in the installation.

9.1.2 Risk of injury to personnel during the un-crating and inspection phase of the operation.

9.1.3 Risk of injury to personnel and/or damage to the transformers by failure of the lifting equipment or the lifting eyes, during the unloading phase.

9.1.4 The risk of injury to personnel or damage to the equipment or the structure during the moving phase of the operation.

9.1.5 The risk of the equipment falling over and crushing personnel or damaging the structure.

9.2 RISK MANAGEMENT

9.2.1 All personnel, including riggers, crane drivers & banks-man will be suitably qualified.

9.2.2 Access to the work area will be restricted to personnel required to carry out the installation safely.

9.2.3 The un-crating of the equipment will be supervised by the appropriate supervisor/foreman and the safety officer.

9.2.4 All the lifting equipment will be examined for damage prior to use and all the certificates verified as valid and current.

9.2.5 All phases of the moving will be carefully monitored and supervised.

9.3 SAFETY PRE-CAUTION

9.3.1 Barricades and warning signs shall be provided.

9.3.2 Ensure the work permit is issued and valid.

10.0 ATTACHMENT

10.1 Quality Record No.0007 – “Dry-Type Power Transformers”.

10.2 HSE Risk Assessment