Method Statement for Power transformer Installation at 3.

0 MLD
STP BIAL

1. PURPOSE
The purpose of this Method statement is to ensure that Installation of Power Transformer
630 kva 2 nos in accordance with the contract requirements, approved method statement
and manufacturer's recommendations / instructions and that all quality assurance
procedures and control methods are practiced and activated in a systematic manner,
works are inspected and finally conformance is verified and documented.

2. SCOPE
This procedure is applicable to the Installation of Power Transformer 630 kva 2 nos for the
project titled “3.0 MLD sewage treatment plant at Bangalore international Airport”

3. DEFINITIONS/ ABBREVIATIONS

 COMPANY/CLIENT : BIAL
 CONTRACTOR : Hydrotech Paryavaran (India) PVT.LTD.
 PROJECT : 3.0 MLD sewage treatment plant at Bangalore international Airport”
 CT : Construction Team
 ST : Survey Team
 ITP : Inspection Test Plan
 QCP : Quality Control Procedure
 HSE : Health, Safety and Environment
 QA/QC : Quality Assurance / Quality Control
 PTW : Permit to Work
 QC Inspector : Company / Contractor / Sub-contractor personnel as applicable
 Site Engineer : Sub-contractor Engineer Responsible for the activity
 GFC : Good For Construction
 MS : Method Statement
 PPE : Personnel Protective Equipment

4. REFERENCE DRAWING

 C00M04-HPL-E_SF-304a-XX-SPC-0001
 C00M04-HPL-E_SF-304a-XX-SPC-0004
 C00M04-HPL-E_DB-304a-XX-DWG-0001
 C00M04-HPL-E_SF-304a-XX-SPC-0006
 C00M04-HPL-E_MC-304a-XX-DWG-0006
  C00M04-HPL-E_MC-304a-XX-DWG-0005
 C00M04-HPL-E_MC-304a-XX-MAR-0005

5. RESPONSIBILITIES

5.1 CONTRACTOR CONSTRUCTION MANAGER AND DISCIPLINE ENGINEERS/

SUPERVISORS- Shall lead the SUBCONTRACTOR Team and coordinate with
COMPANY representative for overall execution of the project.

5.2 SUBCONTRACTOR PROJECT MANAGER – The Subcontractor Project Manager has

the overall responsibility for the execution of the project.

5.3 SUBCONTRACTOR CONSTRUCTION MANAGER - The Subcontractor Construction

Manager has the overall responsibility to carry out the WORK. The Subcontractor
Construction manager has ensure compliance by all labor & equipment operators
and other associated craftsmen in the execution of this activity as per approved
document of this procedure, Project Quality Control procedures/ test plan, relevant
drawings, safety procedure and project specifications. Secure all necessary work
permits

5.4 SUBCONTRACTOR SITE ENGINEER - The Subcontractor Site Engineer is

responsible for the supervision and implementation of any concreting activity on a daily
basis in coordinating with the CM, Surveyor and Foreman. Any discrepancy in the
drawings and site condition and any problem that may arise on the site shall be
resolved by Subcontractor Site Engineer in coordination with other involved persons.

5.5 SUBCONTRACTOR QC ENGINEER / INSPECTOR - Shall be responsible for

preparation of ITP with relevant report forms and obtaining client approval. Monitor daily
civil activities and verify compliance with the client specifications and Issued for
Construction (GFC) drawings. Conduct activities in accordance with the project QA
Manual and Quality Control Inspection Plan. Prepare QC records and final acceptance
documentation.

5.6 SUBCONTRACTOR HSE ENGINEER / OFFICER - Shall ensure all work permits are
available prior to commence of any work. Review personnel and their compliance with
safety requirements, such as wearing Personnel Protection Equipment (PPE). Check
work areas for any unsafe conditions. Liaise with Field Supervisors and Foremen that
work is carried out in accordance with Project Safety Plan / Procedure.
5.7 CONSTRUCTION TEAM (CT) - Subcontractor construction team comprises with
Construction manager, Site Engineers, and Foremen each holds their own
responsibility for the execution of this activity shall directed by Construction Manager
who holds the responsibility to perform the activity by all terms accepted & approved.

6. INSTALLATION
6.1 GENERAL

 Ensure all relevant shop drawings are available at site for execution of work.
 All the materials received at site shall be inspected as per relevant ITP
 Obtain the necessary permit required for the mentioned activity.
 All installation shall be done as per project specifications and project standard.

6.2 LOADING, TRANSPORTATION, UNLOADING AND UNPACKING

 Loading of the equipment shall be done with suitable crane and as per the
manufacturer specification, if any.
 Transporting; while transportation care shall be taken in order to avoid violently
shaken and damage to the equipment and apparatus mounted inside. Also make
sure that the equipment is not placed upside down while loading and transporting,
manufacturer recommendations shall be followed.
 Unloading shall be done with suitable crane and adequate lifting tools.
 Unpacking; prior to unpacking the Vendor representative has to be called
wherever applicable. If upon unpacking any visual damage of the equipment is
observed, the same shall be reported to the Management and Vendor.
 Care shall be taken to see that the water protective packaging is not damaged.
 Wastes - after unpacking the packing materials, has to be collected together and
transported and dumped at the appropriate location.
 Equipment shall be protected from the ingress of sand and water after unpacking.
 Unpacking; prior to unpacking the Vendor representative has to be called
wherever applicable. If upon unpacking any visual damage of the equipment is
observed, the same shall be reported to the Management and Vendor.
 Care shall be taken to see that the water protective packaging is not damaged.
6.3 Unpacking Of Transformers

 Employees shall maintain a safe distance from the people during removing
packing.
 All protruding nails shall be removed or hammered down.
 The dismantled materials to be stacked properly (don’t stack to height) and to be
barricaded.
 Keep stripped materials stacked neat and orderly. Properly place feet for support
when prying forms loose.

6.4 Marking/drilling/chipping on floor/wall for bolting of Transformers.

 Firefighting equipment’s must be available with carry out the hot work activities.
 Certified Fire Watch must be present during and after hot work.
 Don’t operate power tools in damp/wet conditions.
 Ensure tools are fitted with dead man’s switch.
 Double insulated tools must be used.
 All equipment’s, power tools and electrical cords shall be inspected by a
competent personal, colour coded and validated prior to start the job.
 All power cords, including extension cords must be maintained in a serviceable
condition to comply safety policy.
 Avoid loose connection and multiple connections in one socket.
 Ensure competent personnel are provided to operating the Equipment’s.
 Auxiliary handle and safe guards must be with respective Power tools.
 Sharp edges shall be shaped by file in a safe manner.
 Good cable management must be ensured while using on ruff surface.
 Electrical cords must be protected from damage while crossing access.
 Hand placement shall be in safe positioning to avoid pinch points/ crushing injuries
 Appropriate hand protection to be provided to those who involved in the activity
 Suitable ear protection to be worn in noisy areas.
 Dust mask must be worn during drilling and chipping.

6.5 INSTALLATION

 Installation instructions as detailed in manufacturer’s manual shall be checked

before starting the works and all necessary equipment and tool shall be prepared.
 The equipment shall be installed as per the location given in the equipment layout.
If due to practical reasons it is not possible, the responsible person of the
 installation team has to inform the electrical or instrument superior in order to find
an alternative location.
 Scaffolding and other improvised implements shall not be used to move panels as
they cause damage to the underside and paint work of the panel. Hydraulic Jacks
will be used to lift and move panels.
 Before installation of the equipment, the base must be flat; the position of the
equipment shall be marked on the floor, anchors bolts shall be installed in
accordance with the dimensional drawing of the equipment, as appropriate.
 The unpacked equipment shall be placed on a suitable pallet trolley, moved slowly
to the correct location, lifted with hydraulic jacks and fixed onto its position.
 The equipment will be fixed to the base by tightening the anchor bolts. Align the
equipment with respect to the other side by equipment.
 Cables will be terminated as detailed in the approved drawings.
 All packing materials will be removed from the work area.

1. WORK PROCEDURE

1.1 HANDLING AND STORAGE

On receipt of the transformer and accessories at site, necessary precautions shall be taken for
unloading, moving & storage as follows:
 Material shall be stored in a covered / dry space at all time.
 All materials received at site shall be inspected and ensure that the materials are as per
approved material submittal.
 Any discrepancies, damage etc. found will be noticed and reported for further action.
 The site engineer has to ensure that all equipment used at site is free from any damage
or deformity of any kind. Any minor damage observed shall be repaired suitably and in
case if the repairs could not be done correctly, the equipment are to be removed from
site.
 All material deliveries shall have certificates documents such as certificate of origin, etc.

1.2 GENERAL INSTALLATION PROCEDURE

 Installation activities for Transformer below mentioned procedure are recommended to
follow-up step by step in sequential manner.
 Pre delivery inspection shall be performed by the system manufacturer’s local dealers at
dealer’s facilities to ensure no damage as occurred in transmit to all transformer
components.
 Site Engineer prior to start the installation, shall be ensure that approved shop drawings
related to the installation area are referred to and that required materials are available at
site as per approved submittals.
 Site engineer has to ensure that all the materials are received as site as per approval
material submittals.
 The nameplate will be check against equipment date sheet to confirm conformity with the
approval, then material inspection request should be raise for material verification upon
delivery at site.
 Ensure all civil works are complete for the areas including floor paint, to carry out the
installation ensure clearance is obtained from respective authorities to proceed further.
 Installation procedures are to be followed as per manufacturer’s recommendations.
 Installation works shall be carried out only with respect to approved shop drawings of
latest revision.
 Transformer will be off loaded to the place nearest to the installation and protected
correctly from dust & environment, etc.
 Prior to installation, the foundation will be checked for cleanliness and ensure that the
area is in level.
 Ensure that the installation of transformer is carried out in accordance with
manufacturer’s installation recommendations and requirements of applicable standards
and in accordance with recognized industrial practices and specified in project
specification to ensure that installation complies with requirements.
 Transformer neutral terminal & body shall be connected with earth as per approved
drawing.
 Cable connection shall be done as per project specification and approved drawing.
 Pre & post installation and commissioning at site using available site load shall be
performed in coordination with vendor and in the presence of consultant representative as
appropriate.
 After inspection of transformer, suitable action will be taken to protect the unit from dust
by suitable covering, and shall further be released for the testing work.
INSPECTION AND TESTING
Work execution and test shall be monitored, witnessed and recorded according to the
inspection list and QC Forms given by the applicable ITP. Ensure that all relevant
manufacturers’ testing and certificate are available and verified in accordance to client
specification.
The Contractor, and through him, his consultants, subcontractors and suppliers
engaged in supplying, manufacturing, construction, installation, commissioning and
testing or any other service connected with the Works, shall maintain Inspection and
Test Plans (ITP) appropriate for the services they provide that are accepted by the
Employer’s Representative. These accepted ITPs will stipulate the necessary level
and frequency of tests and inspections for each aspect of the Works, and also
stipulate, without limitation:
a) The personnel responsible and/or involvement of various parties for undertaking
and certifying the inspection and/or testing;
b) The procedure or instructions for the inspection and/or testing;
c) The test method or a reference to the relevant standard of testing;
d) The inspection and/or testing required prior to commencement of an activity;
e) The inspection and/or testing during an activity and its frequency;
f) The inspection and/or testing required for the completion of an activity;
g) All Quality “Hold Points” (H), “Witness Points” (W) and “Observation Points”
(o) shall be identified by the Contractor for his Quality Department to inspect and verify
its acceptance; The Employer’s Representative can place additional Quality “Hold
Points” (H), “Witness Points” (W) and “Observation Points” (O) for the
Contractor‘s quality department on a case-by-case basi; and
i) Employer’s Representative may designate additional Quality “Hold Points” for his
inspection on a case-by-case basis.
The Contractor shall conduct inspections and tests in accordance with his detailed
plans as stipulated in the ITP. Records shall be kept of the completion of the
inspections and tests that identify the record of the results which shall be made
available for review during Employer’s Representative audit.

MATERIAL HANDLING & STORAGE

General: Contract specification and manufacturer's recommendation shall be the

master reference for the material handling, storage and transport.
EQUIPMENT & TOOLS

 PPE’s : Coverall, gloves, hard hat, safety glass, safety shoes

 Tools/ Equipment : One set roller pads, round steel bars, reinforcing bars,
step ladder, drill machine, torque wrench, water level,
open spanners, screw drivers, hand tools, marking pens/
markers, Cable Winch, Cable Drum Jacks, Cable Rollers,
Survey Equipment, and Cable Drum Trailer, Tool Kit,
Leveling Instrument, Drill Machine, Welding Set,
Generator, Hand Tools, Rope, Scaffoldings and
Hydraulic Jack

 Heavy Equipment : Hydra, Crane, JCB, Man lift

TESTING EQUIPMENTS

 PPE’s : Coverall, gloves, hard hat, safety glass, safety shoes

 Tools/ Equipment :, Testing Kit, Megger, Earth Tester, Multimeter.


MATERIAL REQUIREMENTS

 Wood planks
 Fasteners
 Sealants
 Rivets
 Brush
 Approved Paint

QUALITY
 Quality system shall be in accordance with the quality manual and inspection test plan (ITP)
together with all related / referenced procedures.
 QC Engineer shall establish a proper coordination with the representative of the
CONTRACTOR/COMPANY regarding Quality and keep records of all inspections related to
the works.
 Quality system shall be in accordance with the approved Project Quality Plan, ITP’s, Quality
Control Procedures together with approved drawings and specifications.
 Construction team shall always ensure compliance with the quality requirements.
  QC Engineer shall establish a proper coordination with the representative of the
CONTRACTOR/COMPANY regarding Quality and keep records of all inspections related to
the works.

HSE TEAM
 Subcontractor HSE team comprises Site HSE manager, HSE engineers, safety officers and
safety assistants and are responsible for ensuring compliance with HSE standards and
procedures during execution of the works.
 A team of Construction engineer, Field engineer & HSE Engineer shall be responsible for
carrying out complete job safety analysis (JSA) and mitigation proposal and HSE Engineer
shall coordinate with COMPANY/CONTRACTOR HSE team and getting their approval for the
same.
 Safety is everybody’s responsibility, foremen, construction site engineers, construction
manager shall ensure implementation of safety requirements and Site HSE manager and HSE
team holds the responsibility to ensuring that all safety requirements mentioned in project
standards & HSE policy including those mentioned in this procedure & JSA are followed
entirely and strictly during the execution.

HSE
 Health, Safety and Environmental consideration is of foremost importance.
SUBCONTRACTOR is firmly committed to full compliance with all applicable HSE industry
standards and local laws.
 SUBCONTRACTOR shall be responsible to implement these policies fully within the project.
 SUBCONTRACTOR shall be responsible for monitoring the activities of the site operations and
for coordinating with COMPANY Site HSE Manager for any support or emergency response
that is required. He shall be responsible for ensuring all personnel on the project are suitably
trained and that all safety certifications, documentation for the equipment are available.
 All personnel shall obtain necessary safety induction training and required passes prior to
mobilization to island and SUBCONTRACTOR construction & HSE team shall ensure that all
works shall be carried out in accordance with approved HSE plan / risk assessments(RA)
 CONTRACTOR / SUB CONTRACTOR shall follow all safety requirements and PTW system
set by COMPANY.

REFERENCE DOCUMENTS
 SOP- MOWP process- Version 1.2 2.
 QAQC plan
 BIAL - Projects Construction EHS Regulations
 SITE ACCESS-STP
 ATTACHMENTS
 Risk Assessment (RA)
 STP Project team Emergency Contacts