1 PURPOSE.
2 REFERENCE STANDARDS.
3 RESPONSIBILITY.
3.1 The Site Manager.
3.2 The Quality Control Inspector.
3.3 Field Engineer.
3.4 Electrical Superintendent.
3.5 HSE Officer.
3.6 Vendor Representative.
4 MATERIALS AND CONTROL.
5 QUALITY REQUIREMENTS.
6 METHODS AND GUIDELINES FOR TRANSFORMER OIL FILLING.
6.1 Work Site Preparation Prior Oil Filling.
6.2 Transformer Oil Filling Procedure.
6.3 Oil Test.
7 TOOLS AND EQUIPMENT.
8 INSPECTION.
1 Transformer Oil Filling Procedure and Method Statement
This procedure covers the Method Statement pertaining to Transformer Oil Filling to be carried out in Buildings, Plants and Refinery Projects. This procedure shall be applied to the method and criteria for installation work carried out by the Electrical Department. Field installation personnel must verify the feasibility of this procedure with the approved construction drawing, actual site condition and project specification.
2 Transformer Oil Filling Codes and Standards
• IEC International Electro-technical Commission
• IEC 60296 – Specification for New Insulating Oils for Transformers
• NEC (NFPA 70) National Electrical Code
• Project and Manufacturer’s Specifications.
• Project Technical Specifications
• Applicable/ Approved International Standards
• Approved / Issued for Construction Drawings
• GEMS-G-05Quality Control and Quality Assurance
GEMSS-G-01 General Requirements for Equipment/Material
• NETA – International Electrical Testing Association
3 RESPONSIBILITY
3.1 The Site Manager
Responsible for the Quality Procedure to ensure that construction work is carried out as per Project requirements. His Superintendent/Supervisor shall check that work is ready for inspection and prepare Internal Inspection Request. The Superintendent/Supervisor shall inform all parties concerned for any of inspection and the time schedule.
3.2 The Quality Control Inspector
Responsible for conducting surveillance and inspection duties for work and ensuring quality compliance and efficient recording and reporting of results as required. He shall review all relevant documents, material conformance certificates and non-conformance reports and shall receive all internal requests for inspection from various sections of implementing work and prepare (RSI) Request for Site Inspection as per schedule work priorities and proceeds with the Quality inspection with the client, owner representative as required. He shall also prepare Witness / Hold Point inspection and the corresponding work releases by reviewing records and results as proof that work inspected conforms to contract requirements. He shall also be responsible to ensure that an approved detailed IFC/ AFC or shop drawing is available prior to commencement of the work and all materials to be used are in compliance with the approved project specifications or requirements.
3.3 Field Engineer
Ensure that all related works are carried out in accordance with approved Issued for Construction drawings, specifications, schedule, quality and safety. Check Design and Construction details in reference with the project standard and specification. See to it that the design drawings provide adequate information for purchasing and site construction. Report to Site Manager.
3.4 Electrical Superintendent
Ensure that work once started is carried out as planned and that the applicable standards are complied with. Check working methods and precautions to be taken by the supervisors/foreman before commencing work. In charge of planning and preparation of manpower, materials, tools and equipment together with his supervisors prior to start of any activity. Monitors project completion schedule and the discipline supervisors under him.
3.5 HSE Officer
Supervise the project activities relating to health, safety and environmental compatibility. He shall carry out regular inspection at site and workplaces whether work is being carried out according to the given instructions and those personnel are wearing the necessary protective equipment (PPE). Perform, in co-operation with the Site Supervisors and Foremen regular Tool Box meetings. Report any adverse condition to health and safety.
3.6 Vendor Representative
Lead testing and commissioning activities for the equipment supplied in accordance to project specification and contract requirements. He shall ensure that project requirements are complied, with the necessary test to be performed and results are recorded and acceptable with the manufacturer’s data, project standards and specifications.
4 MATERIALS AND CONTROL
a) Ensure that materials and equipment are stored and handled in accordance with project and vendor requirements.
b) Checked if all supplied materials are in conformance with Purchase Order or Specifications or Drawings. Any discrepancies will be reported immediately to CGA Materials Department.
c) When oil immersed transformer is delivered oil filled, the oil level will be checked to ensure no leakage.
d) Receiving, off-loading, inspecting, storing and handling all material and equipment will be in accordance with vendor/supplier’s procedure (General Material Handling Procedure).
5 QUALITY REQUIREMENTS
- The grade of oil for the transformers shall comply with the requirements specified by Project specification and can be in reference with IEC 60296, be processed to IEC 60422 standard and contain no more than two [2] parts per million of polychlorinated biphenyl.
- An inspection of test equipment shall be conducted prior to any test activities. Each piece of the test equipment shall have the calibration labels intact. Test equipment manual should be available and that calibration certificates are valid. All test equipment must be tested for proper operation before starting any test.
- Defective test equipment must not be used.
It shall be isolated and removed for calibration of the approved third party Metrology Laboratory Company for re calibration. Also, periodic checks of test equipment will be conducted by QC Department to ensure that all equipment is within the calibration period and record shall be maintained and updated.
6 METHODS AND GUIDELINES FOR TRANSFORMER OIL FILLING
6.1 Work Site Preparation Prior Oil Filling
a) Check and review records of transformer and installation in accordance to project specification and approved drawings. Check manufacturer’s manual instruction and requirements prior to oil filling activities.
b) Prepare safety requirements for oil filling activities. Warning and safety precautions at the transformer and instruction manual must be adhered. Ensure that worksite location and condition has been approved for oil filling activities. Oil Processing and Filling Safety Considerations:
• Fire extinguisher must be on site and readily available whenever any oil handling is performed
• High voltage can be induced in transformer and static charges can be generated when mineral oil is pumped through hoses and equipment if they are not properly grounded
• Workers must not be permitted to stand or work on the transformer cover when the transformer oil filling activities is ongoing.
• There must be no electrical tests at any voltage level to be performed when the transformer oil filling activities is ongoing to avoid risk of fire or explosion.
• Oil filling must be performed by technically qualified person c) Prepare all tools required for oil filling activities. Tools must be inspected, clean and free of damage.
d) Check for parts assembly, tank sealing and ensure that all joints are tight.
Check all gasketed joints for leaks with liquid soap solution or other suitable leak detector. All leaks must be eliminated before starting filling.
e) Preliminary test required in accordance to the manufacturer’s instruction must be performed prior to oil filling activities
I) Oil Acceptance. Test report of oil supplied must be verified and must meet requirements for acceptance. The dielectric strength of oil must also be tested before being placed. Oil that fails to meet the manufacturer’s acceptable criteria must be rejected or processed on-site and retested before being placed into the transformer. If no oil leakage is observed, the oil level is correct.
6.2 Transformer Oil Filling Procedure
Verify with the manufacturer’s manual instruction for the requirements in filling of oil to the transformer before energization.
a) Verify that oil-filling and test activities are performed according to vendor instructions
b) Check for equipment’s assembly, tank sealing and verify that all joints are tight. Check all gasketed joints for leaks, use liquid soap solution or other means required by the Vendor/Client. All leaks must be eliminated prior to filling process.
c) Check oil monitoring devices and gauges. Bushing, bus and cable connection may be disconnected when required.
d) Sample oil will be tested for each drum of transformer to be used in this process. Oil filtration machine will be used when oil fails the test.
e) During oil-filling, the process must be check for any leaks.
I) Further test of oil will be carried out in accordance to manufacturer’s instruction and the approved inspection and test plan
6.3 Oil Test
a) Measurement of Breakdown Voltage
Di-electric test for the oil should be performed as per IEC I 56 using de-electric machine.
Except for the dielectric breakdown all other tests must be performed as per project specification and technical requirements and the results are to be submitted to Client’s inspection representative for review and approval.
• Dielectric strength(Breakdown voltage)
• Moisture content
Water content is expressed in parts per million, and although water will settle to the bottom of the tank and be visible in the sample, the presence of free water is not an indication of high water content, and it is usually harmless in this.
7 TOOLS AND EQUIPMENT
a. Standard electrician’s toolkit and hand tools
b. Pipe wrench
C. Open and closed wrench
d. Ratchet wrench
e. Torque wrench
f. Vacuum pump/oil pump with gauge
g. Oil hoses with internal static discharge wires
h. Pump hose, valves and fittings
i. Air compressor
j. Hand operated air pump
k. Oil filtration machine
I. Oil Dielectric Strength Tester (Oil BDV Tester)
m. Multi-tester
n. Barricade, warning sign
o. Fire extinguisher
Note: Materials listed above must be verified for manufacturer/contractor supplied equipment or other requirements
8 Transformer Oil Filling Inspection
All inspections shall be coordinated by QA/QC Inspector, who will implement the inspection program and notify all parties involved in advance of the scheduled dates of inspection to enable them to participate. Relevant records shall be signed by all the required parties and originals kepi by Site QA/QC Department. Final erection checks shall be carried out in accordance with approved ITP. Inspections shall be done per level, area or drawings.
Inspection of Transformer Oil Filling shall be carried out in accordance with the Inspection Checklists. Records must be maintained for each test. Acceptance criteria for inspection shall be within Project specification and standards and manufacturer’s specified criteria.
Step by Step Guide of Transformer Oil Filling Procedure
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 manner)
A. Verify IFC drawing and Manual Instruction for oil Filling
B. Verify Document for QC material receiving inspection
C. Transport of Materials Loading & Unloading
D. Assembly & arrangement of Equipment & Material for oil Filling
E. Transformer Oil filling
F. oil BDV Test
G. Housekeeping
A. Transport of materials loading & Unloading (Get approval to the security for access follow site speed limits follow proper traffic signs & signals, turn 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. Follow manual instructions for proper handling and lifting of oil drums)
B. Assembly and Arrangement of Equipment & Materials for Oil Filling (Only qualified personnel to perform the task,
ensure wearing of proper PPE. Equipment and materials checked and conditions verified. Third party calibration certificate necessary for testing equipment. Manufacturer’s instruction/ MSDS are followed during handling of oil.).
C. Transformer 011 Filling (Only qualified personnel to perform the task, ensure wearing of proper PPE. Area must be barricaded during oil filling. Oil filling machine, vacuum pump and other equipment in good condition. Third party calibration certificate necessary for testing equipment. Manufacturer’s instruction/ MSDS are followed during handling of oil. Environmental protection/drip tray for oil spillage. Operation to be stopped when oil leak is observed)
D. Transformer Oil BDV Test (Only qualified personnel to perform the task, ensure wearing of proper PPE. Oil tester is calibrated and in good condition. Careful handling of oil to prevent oil spillage)
E. Dally 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 Materials must be properly segregated and slacked where it will cause no obstruction or hazard to other construction activity and worker)