The method statement for transformer defines the installation of oil-type transformers as per quality procedure, project specifications, and health, safety & environmental requirements.
Table of Contents
Scope of Work
The scope of this document includes, but is not limited to the following:
a) Methodology for installation of transformers
b) Equipment used
c) Inspection and Test Plans
d) HSE Assessment & Job Hazard Assessment
Definitions/Abbreviations
IFC-Issued for Construction
SUB-Subcontractor
IR-Inspection Request
ITP-Inspection and Test Plan
HSE-Health, Safety, and Environment
PPE-Personal Protective Equipment
RA-Risk Assessment
MIR-Material Inspection request
MST-Method Statement
NCR-Non-Conformance report
QA/QC-Quality Assurance/ Quality Control
PQP-Project Quality Plan
RAMS-Risk Assessment Method Statement
PTW-Permit To Work
LV-Low Voltage (415 V)
VFD-Variable Frequency Drive
MV-Medium Voltage
SMDB-Sub Main Distribution Board
Sequence of Works
The following is the step-by-step procedure for the installation of the transformer.
Prior to installation, it will be ensured that:
a. All relevant documentation such as (Approved Shop drawings, Checklist Approved Method Statement, etc.) and the material applicable to a particular section of work will be checked by the Site engineer prior to the commencement of work ensuring that these are of the correct type as reviewed by the Engineer.
b. Before the commencement of installation of the transformer, a material inspection of the transformer will be carried out prior to being withdrawn from the storage area i.e. quantity, physical damage, and brand/make.
c. Before the beginning of the installation, it will be ensured that the approved valid permit to work (PTW) is available on site.
d. Engineer in charge will ensure that approval and standard tools and tackles are available to carry out the work.
e. Safe access to work areas will be provided and will be approved by the competent safety person prior to the commencement of works if applicable.
f. Check the work area tidy and remove flammable materials if any and a safe environment will be ensured.
g. Where the Risk Assessment identifies high-risk works a permit to work will be obtained from the safety department.
h. Competent manpower will be employed to carry out the installation work.
i. Prior to installation, It will be ensured that all the civil works are completed with the necessary protective floor coating (if needed).
j. Necessary civil clearance will be obtained (if applicable) prior to the start of installation.
k. For loading and unloading operations, the proposed crane location is to be ready with the compacted floor for safe positioning of crane and boom trucks.
l. The boom truck loading capacity and certificates will be ensured prior to the start of the loading.
m. The transformer will be unloaded in a pre-identified place for necessary material inspections prior to installation.
n. Once the inspection is completed the transformers will be shifted and positioned by using a boom truck.
Material Transport
a. Transformers and other related accessories will be handled and transported and unloaded at the site strictly as per manufacturers’ instructions.
b. After delivery, equipment will be inspected for any transport both internal and external components casing damage, in compliance with project specification & materials submittal.
c. The transformers and accessories will be tagged, crated, and protected for shipping as per the manufacturer’s recommendation.
d. Approved shop drawings will be posted at the workplace for site reference used and installation works.
Delivery and Storage
a. When the transformer cannot be installed immediately, Transformers and other related accessories will be stored at a dry location in the laydown area. They will be protected and covered by polythene sheeting.
b. The transformers will be handled with care to prevent mechanical damage to the body, fitments, enclosures, and core-coil assemblies.
c. The transformers are factory packed for transport and will be protected as per manufacturers’ instruction.
d. Check for the transformer packing for any damages while transportation will be done.
e. A material delivery to the site will be inspected for delivered equipment for approval from the engineer.
f. On receipt of the transformer, It is necessary to carry out the following check:
- To check there are no signs of damage on packing or the transformer that occurred probably during the transport.
- The characteristics of the transformer detailed on the rating plate must correspond to those of the shipping documents and with those of the test report, which is attached to the transformer.
- Check the nameplate details against the technical datasheet to confirm the correct materials.
- To check that each transformer is complete with the accessories foreseen in the contract (wheels, thermo-controller, etc.).
g. All the delivered spare parts as per project specifications to be stored properly till handover.
h. The transformer should not be placed, close to the ground where water might accumulate. In such cases, the transformer should be placed on wooden or similar beams in order to prevent rust formation due to scratches and contact with wet soil/ground directly.
i. Any discrepancies, damage, etc, found to the materials will be notified and reported to QA/QC Engineer.
j. Materials found not suitable for site use will be removed immediately.
k. No materials will be permitted to enter the work location without being inspected and approved by the Engineer.
Handling
a. During the transport or the handling, only the recommended special lifting eyes and tow attachments are used.
b. All lifting equipment will be rated for the purpose, checked for damage, and certified by a third party before any attempts are made to lift the transformers.
c. If a crane will be used to lift the equipment, it will be ensured that the slings are harnessed in such a way that the equipment is centered to the gravitational force to avoid wobbling and jerking which may cause fatal and serious troubles in unloading.
a. For lifting the upper frame of the transformer is complete with lifting eyes for slings. Lift with a maximum sling angle of 60 degrees.
b. Always move the transformer in its upright (top end up) position.
c. Lifting operations will be performed by trained people using cranes.
d. Lifting will also be performed by a forklift with a sufficient capacity if the transformer is placed on a pallet. It will be operated by a trained person.
e. For movement by forklift the position of the forks under the bottom clamping profile will be as far apart as practicable. This has to be lifted only a small amount above the floor surface at all times during transit.
f. The transformers cannot be moved to push the coil and the connections.
g. Care will be taken by the site team that no tools or bits of metal hardware are dropped into the coils or not damage the cast resin during handling and installation.
Methodology
Transformer Installation
a. It will be ensured that installation of the liquid-filled medium voltage transformers will be strictly in accordance with the manufacturer’s recommendations, as per approved shop drawings, relevant IEC (International Electrotechnical Commission) standards, and project specifications.
b. It is ensured that the access is clear to shift the transformer. The substation doors are checked to ensure that the door openings are enough to move the transformer inside the substation.
c. The transformers will be unloaded adjacent to the respective substation.
d. Move the transformer manually to the transformer location.
e. For manual handling, rollers are used to facilitate forward motion to find the erection place.
Note: The transformer should not be moved by pushing the coils and connection.
f. After the transformer positioning, all wheels will be locked to arrest any movement of the transformer by providing the necessary stopper.
g. Recommended shims will be installed if required for transformer leveling.
h. All the incoming and outgoing cable supports, cable ends, and termination fittings required for MV, LV, and control cables will be installed.
i. Inspection request for transformer installation prior to the start of any cable termination work will be done.
j. The transformers will be mounted on wheels.
k. The transformer skids shall have rounded-off beam ends and shall be provided with pulling lugs/holes to enable site movements.
l. It will be ensured that concrete bases and foundations provided for the installation of equipment are constructed in accordance with approved shop drawings, construction drawings, and equipment manufacturers’ drawings. All the holes for fixings bolts and provisions for the passage of cables etc. are provided as required.
m. It will be ensured that trench construction and covers provided for the installation of power and control cables are in accordance with approved shop and construction drawings.
n. The installation of cables, wires, raceways, supports, cable ends, and termination fittings will be done in accordance with the appropriate sections of the project specification and/or as shown on the approved shop drawings. All the electrical connectors and terminals will be tightened according to the manufacturer’s published torque-tightening values.
Cable Connections
Cable Connecting Boxes
a. The cables which are connected to the transformer will be fixed properly to avoid any mechanical stress on the transformer terminals.
b. Cable connecting boxes shall be made of steel and shall be dimensioned to allow termination of the specified cables.
c. The enclosures will be offered a minimum degree of protection IP55, in accordance with IEC 60529 and as per project specifications.
d. The cable ends should be flexible enough to prevent mechanical strains that could be caused by expansion and contraction, which could break the isolators, when available.
e. Contact surface of the cable terminations will be checked. If it is necessary, it will be brushed and wiped with a dry cloth.
f. Separate cable connecting boxes shall be provided for the connection of the specified cables to:
- Medium–voltage side of the transformer
- The low–voltage side of the transformer
- The transformer auxiliary circuits (direct measuring alarm/ trip devices, CT secondaries, etc.).
- The off-load tap changer.
g. Auxiliary and low voltage cable connecting boxes shall be air-insulated as per project specifications.
h. The covers of all cable boxes will be secured, using non-loosening bolts or screws. The cover of all cable boxes will not be removable without the use of tools.
Main Cable Connecting Boxes
a. Minimum clearance between the live metals of different phases: 127mm.
b. Minimum clearance between live metal and earth: 76mm.
c. Minimum creepage distance over insulator: 127mm.
d. Connection boxes for multicore cables shall be of a type that minimizes the cable bending requirements (e.g. split type box).
e. Gland plates shall be constructed from a non-magnetic material.
f. M.V. and L.V. cable boxes shall be positioned on the sidewalls of the transformer. Top-mounted cable boxes are not acceptable as per project specifications.
g. All cable connections shall be by a combination of Elastimold-type bushings and elbow connectors as per project specification.
h. Cut cable to length and prepare end for glanding. Adopt reducer rings and fit the cable if needed.
i. Prior to installation of cable, check the necessary cable tray/ladder are ready for cable laying and obtain the necessary civil clearance.
Final Works
a. On completion of the installation, inspect the components.
b. Wipe all the bushing insulators of the bus bars and the current transformers of the connection compartment using a soft, lint-free dry cloth.
c. The bushing type insulators and the current transformers must be free of grease and other contamination.
d. It will be ensured earthing is completed as per requirements.
e. It will be ensured that the work area will be clean after the completion of the works.
Identified Hazards/Risks and Control in Place
The Job Hazard Analysis identifies the hazards and the safe systems of work to be followed when conducting the activity.
Emergency Preparedness
The Project Manager & Project HSE Manager shall ensure that all employees are aware of the correct response to various emergency situations.
The response guidelines applicable to these works are the following:
Upon discovering the incident, take the time to assess the situation to make the area safe and prevent further injury to those involved. Take appropriate precautions according to the type of damage and cause of accident like:
Vehicle Accident
a) Switch off the vehicle’s ignition and warn the people not to smoke.
b) Make use of bystanders to control traffic or crowds, to call for help, and if they are capable, to assist with first aid.
Electrical Accident
a) Switch off the current or break contact between the injured person and the power source.
b) Do not touch the victim or any live wires! Use non-conducting material, such as dry sticks to remove wires from the casualty.
c) Ensure that the current is turned off or that loose wires are kept at a safe distance until the casualty is removed from the safe area.
d) Do not approach fallen high-tension power lines until a power company official gives permission.
e) Apply artificial respiration if necessary.
Machinery Accident
a) Shut off running or moving machinery
Gas, smoke, and poisonous fumes
a) Shut off the source and remove the casualty to fresh air.
b) Do not enter a confined space and become another victim.
Fuels & oil chemical spills
a) Switch off any likely sources of ignition.
b) Build a bund or dig a hole to contain the fluids.
c) Contain the split material and isolate the area.
Chemical splash/Chemical inhalation
a) First Aider shall be available at the work location.
b) First Aid Box shall be placed at the work location.
c) Use eyewash in case of a chemical splash on the face or eyes.
d) Shift the patient to a well-ventilated area in case of chemical inhalation.
e) Call for paramedic assistance or the affected person or shall be shifted to the clinic as required, in any type of emergency.
f) Shift the patient to the hospital if required.
Electricity
a. Before using an electric tool, check the tool and its plug and connecting cable.
b. Do not use damaged tools.
c. Do not use an electric tool unless its connecting cable is well protected.
Load Shifting Machinery
a. Unless you are a worker concerned, do not work in an area where a lifter, crane (mobile/tower), etc. is in operation.
b. Do not operate any load-shifting machinery without training and approval.
c. Operators of forklift trucks, bulldozers, loaders, excavators, and trucks should possess appropriate certificates/ Passes.
Portable Power Tool
a. Power tools inspection program will be in place with periodic training and skill development for operators.
b. Where ever possible battery-operated tools or 110V power tools will be used which will reduce the risk levels.
Personal Injury Incident
Do not panic, the first priority in the case of any accident is to obtain proper medical assistance for the victim. The following steps should be followed in the event of an accident.
a. Upon discovering an accident, call to attract the attention of others nearby to assist and ensure any injured person is in no further danger.
b. Assess the hazards at the scene and make the area safe for yourself, the victim, and others.
c. Typical hazards to be aware of are; live electrical lines, moving equipment or machinery, traffic, hazardous chemicals, and fire. Only moved the victim if they are in immediate danger.
d. Send someone to call for emergency help. Locate the nearest First Aiders or any personnel trained in first aid. If no available qualified personnel, locate the nearest radio or telephone and call the office or ambulance.
Information required for ambulance assistance
a. Circumstances of the incident and condition of the victim(s).
b. Number of casualties involved.
c. The exact location of the accident.
d. Help that has been given or is being given.
e. Name and telephone number from which the call is being placed (if applicable).
f. Wait to be told what to do before hanging up the call.
g. Protect and shelter the victim until medical help arrives and post somebody at the site entrance to direct the ambulance to the accident.
h. Immediately after attending to the victim, the Project HSE manager or crew supervisor shall complete an Accident Report.
i. In the case of fatal accidents, the Police and the nearest HSE Authorities shall be informed immediately.
Fire
Raise the alarm at once. Proceed to the nearest telephone or radio and ask whoever is present to call the fire services or do so yourself. Attack the fore with correct firefighting extinguishers or other suitable firefighting equipment.
A roll call of all employees shall be taken when premises have had to be evacuated. Each section shall nominate a Fire Warden who, in case of an emergency shall undertake the following duties:
a. Keep a check on personnel movements so that an accurate roll call can be made.
b. Alert the remainder of the office of the emergency.
c. Supervise the orderly exit as per the emergency exit plan.
d. Check the staff numbers.
e. Ensure the personnel does not leave the assembly area until counted.
f. Advise emergency services if any person remains unaccounted for. The emergency exit plan shall be prepared by the HSE Manager and will show the positions of all exits.
Environmental Consideration and Impact Control Measures
Waste Management
Good waste management practice is essential in order to achieve regulatory compliance. It can also lead to improved business efficiency and cost savings. The following waste management practices will ensure the preservation of environmental resources.
a. Waste should be reduced and recycled where possible.
b. Water drained after pressure testing shall be collected and reused for curing or damping down the dust.
c. Disposal area should be well prepared to receive the waste. And all waste areas and containers should be landed with their content.
d. All containers must be in good condition, not leaking, and stored on hard standing.
e. Do not allow containers to overflow and remove them regularly.
f. Do not dispose of burn, bury or treat waste on-site.
g. Do not mix regulated and non-regulated wastes.
h. Wastes cannot be disposed of directly into landfills or to the sea unless it meets the local regulatory authorities.
i. Untreated sewage shall not be disposed of without treatment. At the site, it shall be confined in septic tanks and removed via sewage tankers, and disposed of in an approved location.
j. The emergency procedure described earlier shall be applied in any case of chemical spillage.
k. All chemicals and environmentally hazardous material shall be isolated by storing them within bund walls on top of paving pads to prevent any leakage into the water table.
l. In case of dewatering and unsuitable water is encountered, the engineer’s site representative shall be immediately notified to advise further course of action.
Noise Control
a. Use silencers for high noise-generating equipment whenever possible.
b. Regular maintenance of equipment and machinery.
c. Wear earplugs if the workplace noise level exceeds 85 dbA for TWA 8 hours.
d. Noise level to be measured and recorded every day at the workplace.
e. Avoid dropping materials like scaffold accessories and plywoods at the work area.
Dust Control
a. Regular water spraying on unpaved roads to avoid dust dispersion.
b. Limiting the speed at the site to 20 Km/h.
c. Maintenance of roads whenever required to alleviate dust accumulation.
d. Vehicles, machinery, and equipment control.
e. Regular maintenance of vehicles, machinery, and equipment to avoid excessive smoke emissions.
Mandatory PPE for the work activity
PPE is the last line of defense not the first: however, every contractor should provide adequate suitable, sufficient PPE to protect the workforce wherever possible. As a minimum for all personal during the abutment works will be the hat, safety boots, coveralls, goggles, and gloves will be provided and used at all times. Additional task-specific PPE will be provided and worn in line with risk assessments.
Emergency Procedures
This procedure describes the company’s guidelines on emergency responses to ensure prompt and safe action is taken. This procedure applies to all health, safety, and environmental emergencies with particular emphasis on the company’s requirement in the event of personal injury accidents or fire emergencies.
General
The Project Manager in coordination with the Project HSE Manager shall ensure that the project has in place a viable and up-to-date Emergency Response plan. This plan shall include allocated responsibilities, contact detail for project personnel, contact details for local authorities, contact details for group personnel off-site, emergency response action, and maps as a minimum.
Communication
As a minimum HSE manager shall ensure that HSE communication Flow and Emergency Telephone numbers are complete, kept up to date, and circulated on Project HSE Notice Boards. The PM with close coordination with the HSE manager shall take all necessary steps to ensure that this information is communicated and understood by all employees and sub-contractors working on site. It takes all necessary steps to ensure that the workplace has adequate reliable means of communication internally and as required outside communication.
Emergency Response
The emergency response shall be initiated by Authorized Person. Emergency response as per the HSE plan shall be followed.
In case of an emergency, the following actions shall be activated: Stop the activity.
Call the emergency number for help.
Provide first aid and call an ambulance.
Alert site clinic / Nurse/ First aider.
Quality Controls
The Inspection and Test Plan (ITP) for this Method Statement For Transformer Installation summarizes various characteristics to be checked. The concerned Site Engineer or Site Supervisor will be responsible to ensure compliance for these operations and the site QA/QC Engineer will carry out quality control checks and report the inspection results.
Quality Records
Quality records will be provided as identified in the ITP and maintained as per ISO 9001/2015 & Standard form of records, quality checklists, and QA/QC reports requirements are defined in the Inspection and Test Plan.
Submission of as-built records will be done after completion.
Specific Quality Measurements
a. All works will be undertaken in compliance with the quality requirements of the Contract and “Project Quality Management Plan”. Where non-conformances are found/identified to demonstrate their conformity. All works requiring inspection and testing to demonstrate conformity with requirements will be undertaken in accordance with the “Control of Inspection and Testing”.
b. Where non-conformities are found/identified, they will be addressed in accordance with “Procedure for Control of Non-Conformances”. The quality control activities associated with the works will be conveyed to all personnel involved in the execution of the works by the Project QA/QC Manager prior to the commencement of the work.
c. The equipment and instruments used for measurements on-site will be calibrated and certified. The relevant documents will accompany the corresponding equipment and instruments. Necessary internal and external training is provided to the staff carrying out the job to ensure that the quality standards required on the project are met. Skilled and competent personnel are deployed to undertake the job.
Resource Planning
Project Manager
a. Project Manager (MEP) will be responsible to manage, executing, completing, and handover the construction activities within approved budgets and resources in compliance with Project requirements as specified in Project Specifications. He will be overall in charge of implementing the method statement for transformer installation in accordance with QA/QC and HSE requirements.
b. Responsible for controlling the project’s entire activities & for the overall coordination with the consultant/client.
c. Ensure that adequate welfare facilities and equipment are provided to the project to avoid injury, health impairment, or damage & to ensure providing quality work within the planned time scale.
d. All responsibilities stated in the Project’s Quality Assurance Plan.
Construction Manager
a. Organize the site so that work is carried out to the required specifications with minimum risk to men, equipment, and materials.
b. Coordination with different functions of the project.
c. Expediting area of concern to achieve project schedule.
d. Adhere to the project-specific quality management program and HSE requirements.
e. Delivering the overall works in a safe and timely manner, ensuring conformance with the approved design. Leading the team of engineers and surveyors, guiding them in the delivery of the works. Acquire, allocate, and maintain resources.
QA/QC Manager
a. Responsible for the work of entire quality assurance, quality control & inspection programs.
b. Produce all quality-related documents & reports necessary as requested by the Owner/Consultant/Engineer.
c. Provide written procedures & coordinate in formalizing the Method Statements with the Project Manager/ Construction Managers/Site Engineers to describe the job-specific work for each stage/activity.
d. All responsibilities stated in the Project’s Quality Assurance Plan.
QA/QC Engineer
a. Responsible for the work of entire Quality Assurance, Quality Control & inspection programs.
b. Produce all Quality related documents & necessary quality reports as requested.
c. Provide written procedures & coordinate in formalizing the Method Statements with the Construction Manager/Site Engineers to describe the job-specific work for each stage/activity.
d. Will make sure that all the works mentioned in this method statement will carry out in approved shop drawings and as per the project specification.
e. Will make sure IR for all these activities are raised and approved by the consultant and recording those documents for testing, commissioning, and handing over the procedure.
Safety Manager
a. Manage Safety Engineers and Safety Officers to be in strict conformance with project policies and procedures.
b. Must ensure safe work method of stated in the method statement for transformer installation and RA is fully implemented during activity.
c. Responsible for controlling HSE personnel for effective monitoring of work.
d. Over-see site safety orientations/inductions, toolbox talks, safety training certifications, job site inspections, working at heights, scaffolding tagging systems are fully functional, rigging, etc.
e. Report to Project Manager all personal injuries and near-miss incidents (aligned with Safety Engineers / Officers) as well as property damages immediately. Produce investigative reports and summaries to senior management.
Safety Officer
a. Provide advice and coordination in line with the project HSE Plan, legislation, and standards to workgroups as required/directed.
b. Input into the preparation and maintenance Risk Register at the project level which will form the basis of risk management on the project for the RAMS.
c. Monitoring and reporting compliance with the Project HSE Plan.
d. Conducting regular HSE inspections and participating in HSE audits.
e. Reporting as required, HSE incidents, including near-miss events, injuries, and any other HSE issues.
f. Regularly attending toolbox and other HSE meetings.
g. Will ensure that the work site has been examined, and all precautions specified to be taken in the PTW before work commences have in fact been taken.
h. Will ensure that the works are examined on completion of the works and the PTW is correctly closed.
Site Engineer
a. Adheres to the project-specific method statements, procedures, inspection programs & HSE instructions to get the activities performed to Client satisfaction with full coordination with the HSE & Quality personnel.
b. Responsible to ensure that correct drawings, materials, tools, and equipment are provided site.
c. Liaising with sub-contractors, supervisors, planners, quantity surveyors, and the general workforce involved in the project.
d. Responsible for planning the work and efficiently organizing the plan and site facilities in order to meet agreed-on deadlines.
e. Site engineer is responsible to coordinate with QA/QC Team engineers/ inspectors, and to handover daily site progress works report/highlighted drawings & present during inspection/site visit with QA/QC Inspectors & consultant/client.
Foreman
a. Performed the activities instructed by the Supervisor/Engineer at the site and follow the safety procedures to make it safe for his workers.
b. In charged to lead the work execution send the focal point in coordinating with the site Supervisor/Engineer related to overall site activity, materials, tools, and equipment.
Technician
a. Carry out Installation work as per the concerned foreman’s instructions with all the safety requirements.
b. The workforce to attend daily toolbox talks, morning task brief briefs prior to starting any works EHS (Environment Health Standard) plans and policies.
Workforce
a. Carry out their work in such a way that they don’t create for themselves or any other person risk to health safety, and don’t impact the environment to the maximum extent possible or affect the quality of work.
Document Controller
a. Documenting, distributing, and maintaining data in the prescribed format.
b. Making the necessary data available as requested by the team or the client.
Tools and Equipment
a. Hand tools box (Spanner set, cutting pliers, tube cutter, screwdriver set, hammer, hacksaw frame & flat file, cleaning brush, spirit levels)
b. Adjustable wrench
c. Splice kit
d. Mobile scaffold
e. Ladder
f. Pallet jack
g. Drilling machine
h. Crowbars
i. Torque wrench
j. Plumb bob, nylon thread
k. Heavy air compressor/vacuum cleaner
l. Sling ropes
m. Ratchet and spanners-various sizes and extensions
n. Crimping tool
o. 3rd party certified lifting equipment (Chain pulley, A-frame chain hoist and etc.)
p. Boom truck
q. Forklift
The foremen and engineers on-site will ensure that all necessary equipment is available as well as fit and safe prior to commencement of work.
All above equipment will comply with:
a. All Equipment used on the works will have a valid certificate of operation provided by a recognized licensing authority.
References
a. Project Specifications
b. Approved Shop Drawings