1 SCOPE
2 REFERENCE DOCUMENTS
3 DEFINITIONS AND ABBREVIATIONS
4 REFERENCE STANDARDS
5 AUTHORITIES AND RESPONSIBIUTlES
6 MATERIAL INSPECTION, STORAGE, AND HANDLING
7 METHOD OF INSTALLATION WORKS
7.1 Work Site Preparation prior to Installation
7.2 Transport, Loading and Unloading of Equipment
7.3 Positioning and Installation of Transformer’s Main Body
7.4 Installation and Assembly of Transformer and it’s Accessories
8 UST OF EQUIPMENT TOOLS AND CONSUMABLES TO BE USED
9 SAFETY PRECAUTION
10 INSPECTION
MV LV DISTRIBUTION TRANSFORMER INSTALLATION PROCEDURE
1 SCOPE
This method covers the assembly and installation of power and distribution transformer to be implemented in SEC Construction of Waad Al-Shamal ISCCPP — Electrical Installation Works This method outlines the assembly of power/distribution transformer hence. the work site personnel must review the feasibility and applicability of this method relative to the actual site condition and approved field changes
2 REFERENCE DOCUMENTS
a) Applicable/ Approved International Standards
b) Issued For Construction Drawings
c) Manufacturer Instructions
3 DEFINITIONS AND ABBREVIATIONS
IEC International Electro-technical Commission
NEC National Electrical code
NEMA National Electrical Manufacturers Association
RSI Request for Site Inspection
MRR Material Receiving Report
NCR Non-Conformance Report
4 REFERENCE STANDARDS
NFPA 70 National Electric Code
IEEE 399 Recommended Practice for Power Systems Analysis
7 METHOD OF INSTALLATION WORKS
7.1 Work Site Preparation prior to Installation
a) Check availability of the latest approved engineering drawing, general arrangement drawing and manufacturer’s manual. It must be readily available prior to installation works
b) Prepare tools and materials to be used Broken or damaged tools must not be used.
c) Acquire work permit. All work personnel must wear complete PPE (hard hat, safety shoes, hand gloves etc )
d) Conduct toolbox meeting for all working personnel prior to start of work. Discuss the sequence of work to be done and safe practices to be made.
e) Ensure that foundation and area was cleared by civil for installation works. Check if area is also clear for access; check if obstruction and foreign materials are removed.
f) Survey the area for installation. Consider the bus duct layout for the positioning of transformer. Check and mark the positioning of HV/1. V terminal boxes in reference to bus duct and cable trench arrangement.
g) Ensure that scaffolding to be used is approved and other safety requirement for work at height is followed.
7.2 Transport, Loading and Unloading of Equipment
a) Check manufacturer’s instructions for transporting, loading and unloading requirement for transformer.
b) Check the equipment’s identification tag. Check for completeness and verify that for dent, oil leakage, damages to indicators, meter, switches and paint scratches or deterioration.
c) When transporting the equipment to work site, ensure that the equipment is firmly secured on the trailer/truck.
d) Loading and unloading must be performed by a competent rigging crew and performed in accordance with the company’s safety requirements.
e) Weight of the equipment (esp transformer body) must be considered in selecting the fting equipment needed for the activity. All lifting equipment especially crane which is usually used for lifting activity must follow the safety requirements of the project.
f) Equipment will be lifted through the lifting members provided to the equipment. Crane must lift and unload it safely to the concrete foundation.
g) Lifting activity must not be done during bad weather condition All hfting activity must follow the safety requirement initiated by ABENER HSE department
h) Check that loading and unloading area has enough space for the activity
7.3 Positioning and Installation of Transformer’s Main Body
a) Area must be prepared, install warning sign and barricade the area Unauthorized person must not be allowed in the activity area.
b) Verify if the area was released by civil contractor prior to placing of transformer
c) Monitor the lifting and placing of transformer body to the concrete foundation. Check proper levelling and alignment of transformer body.
d) Transformer body must be positioned where the bus duct/cable from trench is aligned with the HVLV connection boxes. Check phase positioning (R-Y-B-N)
7.4 Installation and Assembly of Transformer and it’s Accessories
a) Shifting of parts and accessories of transformer to the site can be as per instruction from the Vendor or Client’s representative.
b) Assembly of transformer accessories and loose parts, such as bushings, oil fins, breathers, conservator tanks, and radiator fittings is supervised by the transformer vendor.
c) Prior to assembly, grounding provisions for the transformer must be installed.
d) All loose parts and accessories must be handled carefully at all times.
e) Furthermore, specific installation and assembly will be performed with the Vendor which include the following:
• Current transformer installation
• Installation of turrets
• Installation of conservator tank
• Piping installation for conservator tanks including Buchholz relay and valves
• Lightning arrester installation
• Mounting of relays
e Wiring and cable connections
• Vacuum process
f) Cracks and damage of bushing and other loose parts must be visually inspected.
g) All bolted connections must be torque tested in accordance with the manufacturer’s recommended torque value. Calibrated torque wrench must be used.
h) After assembly of transformer:
• Wooden planks and crates from unpacked material to be removed and placed to the area designated by the Contractor/Client.
• Maintenance and inspection established by the Vendor/Client will be followed • Transformer should be regularly checked for cleanness from oil and dirt stains.
Surface damages caused from transportation and installation will be repainted as per Contractor/Client’s instructions.
• Transformer must be covered after completing the installation to prevent damage caused by other on-going construction activities.
8 LIST OF EQUIPMENT TOOLS AND CONSUMABLES TO BE USED
a) Electrician’s standard tool box (pliers, spanners, screw drivers etc.)
b) Crane of suitable lifting weight, with complete lifting accessories
c) Hydraulic Jack
d) Measuring tape
e) Spirit level and plumb line
0 Calibrated Torque Wrench
g) Chain block
h) Waring sign and barricade tape
i) Electrical drill and drill bits
j) Scaffolding platform and ladder
k) Mechanical Grease
I) Tarpaulin
m) Compact drill (when applicable)
n) Air compressor
o) Pipe wrench
p) Fire extinguishing equipment
9 SAFETY PRECAUTION
a) All work activities to be performed in a safe manner following the Company Safety Policies and Procedures. Safety checks are to be performed before any work is executed.
b) Ensure that work permit is obtained identifying the applicable work to be performed. Safety requirements may also be indicated in the work permit. It must also be kept available and visible to work area.
c) Ensure that all personnel in adjacent areas throughout any system are made aware of the activities and the hazard that could lead to potential danger.
d) Concern working personnel must always wear PPE such as safety hard hat, glasses, safety shoes, hand gloves, cover all, etc. Close supervision of personnel must be done.
e) Perform daily toolbox or safety talk to keep all workers informed regarding safe procedure and safety requirements.
f) Ensure that all tools to be used are free from damage.
g) Observe and strictly follow safety procedure in working in an elevated area. Complete fall protection equipment to be used.
h) All grounding provision must be connected.
10 INSPECTION
Quality Control personnel verify that assembly and installation of switchgear, control gear and panels conforms to the approved engineering drawing, manual instructions and specifications of the project. RFI shall be prepared according to the approved Inspection and Test Plan to
notify Client’s inspection representative and concern person regarding scheduled dates of inspection. Once inspection is done and accepted, checklist must be signed and records are properly kept.
Step by Step Guide of the work plan
Explain in detail the steps that must be taken to ensure that the task is carried out safely (include drawing and sketches where required. include pre commencement of work activities and the work itself in a chronological mane)
A. Verify IFC drawings availability
B. Verify Documents for QC material receiving inspection
C. Transport of materials loading & Unloading
D. Transformer Installation and Assembly
A. Transport of materials loading & Unloading (Gel approval to the security for access follow site speed limits follow proper traffic signs & signals, tum on hazards light. only competent and certified rigger and operator should do the lifting, ensure one flag man for traffic control during activity. Provide barricade with signage’s)
B. Installation and Assembly of Transformer (Ensure permit to work must be obtain, prior to start the activity. Conduct toolbox talk prior to the task to be done. And wearing of PPE to all personnel. All tools and equipment is in good condition. Competent person lo perform the task. Manufacturer’s instruction is understood and followed. Proper handling technique is observed. Third party calibration certificate for testing equipment. )
C. Daily housekeeping (Full supervision on the area remind personnel for safe working and good housekeeping on the area should be done before and after the work )