Method Statement - 115kV 100 MVA Transformer Installation

CONSTRUCTION OF 380/115/33 kV SUBSATION #3 AND
ASSOCIATED OHTL AT RAS AL KHAIR

CONTRACT NO: 099-C05
METHOD STATEMENT FOR 115kV 100MVA TRANSFORMER
INSTALLATION.
REVISION 00
METHOD STATEMENT
(ALFANAR CO. - RC 099-C05)

CONSTRUCTION OF RIC-3
380/115/33KV S/S & ASSOCIATED 380KV D/C OHTL
IN RAS AL-KHAIR
115kV 100MVA TRANSFORMER INSTALLATION
Method Statement No: Issued
by:
Rev. # Date Description Prepared Checked Approved
00 12-11-2018 115kV 100MVA TRANSFOMER Syed Azmatulla M. Siddique, Ahmed
Quadri Alaa Shahin Abdelhady
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TABLE OF CONTENTS
1. TITLE.
2. SCOPE OF WORK
2.1 General description.
2.2 Plant and equipment.
2.3 Materials.
2.4 Site planning & preparation Work methodology.
2.5 Organization, Responsibilities & Supervision. Work Force.
3. HEALTH & SAFETY
3.1Risk assessments
3.2Jubail ES & H Contractor Requirements Protective & Safety
Equipment.
3.3Contractual Requirements.
3.4Information to personnel.
3.5Emergency Procedures.
3.6Permit Requirements.
4. ENVIRONMENTAL ISSUES
4.1Environmental Impact assessment.
4.2Jubail ES & H Contractor Requirements Contractual Requirements.
4.3Emergency Procedures.
5. QUALITY ASSURANCE
5.1Contractual Requirements.
5.2Critical works.
5.3Inspection & Testing.
5.4 Follow up & Evaluation.
6. APPENDICES
1. TITLE
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Method Statement for 115kV 100MVA TRANSFORMER installation
2. SCOPE OF WORK
2.1 General Description
The purpose of this method statement is to identify the methods,

procedures, resources, and equipment, quality control and safety measures
to be planned, prepared and implemented to ensure proper installation of
380kV GIS Installation as per SEC standard installation practices.
APPLICABLE STANDARD AND REFERENCE:
• Issued for Construction drawings
• SEC Standard 53-TMSS-01

• As per Approved ITP-E-15
• PTS-14EN305
• Approved Material.
2.2 TOOLS, PLANT & EQUIPMENT
• Mobile Crane.
• Step Ladder.
• Scaffolding.
• Boom truck.
• Forklift.
• Oil Filtration Machine
• Chain block, Sling Belts, D-shackle.
• Tools (Will be provided as per requirement by M/S Hyosung)
2.3 MATERIAL STORAGE & HANDLING

Materials handling and storage play an important role in substation construction.
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Proper way of storing and handling of materials promotes efficient and safe
works.
STORAGE AT STORES
i. All transformer parts shall be stacked at the store yard in such a way that the
package do not touch the ground.
ii. Cover the transformer parts using a suitable weather proof/dust proof sheet.
iii. Water shall not be allowed to stagnate in the store yard.
iv. Transformer parts shall be carefully stacked according to erection drawing and
type for easy tracing and vehicle shall approach at selected points for easy
loading and unloading.
v. Store oil at the designated area.
vi. Remove the cover sheet once every week or so in a fine day and dry the
packages.
2.4 SITE PLANNING AND PREPARATION
Alfanar/Hyosung will deploy competent Electrical Engineer/supervisor at site

during the entire Electrical Execution of Work. Alfanar/hyosung will obtain all
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necessary permits and approval as required prior to start of work. Alfanar ES & H
and site management team shall organize effective communication to Alfanar
Workers & sub contractors' personnel (if any) by conducting daily safety tool
box meeting identifying the area of work. Alfanar ES & H and AL FANAR site
management team evaluate the work location prior to start of any work.
2.4.1 Site management plan, access routes, position of plant and equipment.
Alfanar Staff Will work as a team that support site management plan and
Construction of access road.
2.4.2 Co-ordinate works with other Contractors.
Alfanar will held coordination meeting with different contractors and utility
department.
2.4.3 Traffic Management (if applicable)
(Attached)
Plan of routes as per safety routine schedule.
2.4.4 Permits and certificates required, to carry out the works.
Alfanar PTW System and RC PTW applied for any activity at site. All Operators
Certificates available at site as per RC standard requirements.
2.4.5 Communication on site Telephone, radios etc.
Communication on site by means of mobile, telephone or walky-talky etc.
2.5 WORK METHODOLOGY
INSTALLATION PART
PART-A1
PART-A2
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PART – A1
General
Introduction
and
Specification
Painting (Main Tank, Conservator, LV Cable Box)

DESCRIPTION INSIDE OUTSIDE
Type of paint POLY URETHANE
Drying time Min. 5 Hrs 5 Hrs
Prime Coat Between coats Max. 168 Hrs 168 Hrs
Dry film thickness 40μm ↑ 80 m ↑
Color Red Brown Red Brown
Type of paint ACRYL URETHANE
Drying time Min. 8 Hrs
Intermediate coat Between coats Max. N/A 168 Hrs
Dry film thickness 40μm ↑
Color RAL 7038
Type of paint ACRYL URETHANE
Drying time Min. 8 Hrs 8 Hrs
Finish Coat Between coats Max. 168 Hrs 168 Hrs
Dry film thickness 40 μm↑ 40 μm ↑
Color Munsell No. N9.5 RAL 7038
Total film thickness 80 μm ↑ 160 μm ↑
Surface treatment Shot blast(SSPC-SP-10)
NOTE : Inside of tank cover has the same color(RAL 7038) with outside of tank.
Powder coating (Radiators)

DESCRIPTION OUTSIDE
Type of Paint POWLAC PE200
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Specific gravity 1.60 ± 0.05
Curing schedule 10min/200℃(Metal Temperature)
Gel time at 180℃ 200∼250 sec.
Dry film thickness 100 ㎛↑
Color RAL 7038
Surface treatment Shot blast(SSPC-SP-10)
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Application Outdoor
Applicable standards IEC
General Altitude : Max. 1,000 m
Service condition
Ambient temp. : Max. 55
Min. -5
Transformer type Core form
MVA Rating at
80/100 MVA
55℃Rise(ONAN/ONAF), HV & XV
Winding
Phase/Rated frequency 60 Hz
HV winding 115
Rating Rated voltage
XV winding 33
HV winding +8 / -12 steps x 1.25%
Tap Voltage
XV winding N/A
Cooling type ONAN/ONAF
HV winding Delta
Connection
XV winding Wye
Top oil temp. rise 45K
Temp rise
Avg. Winding temp. rise 50K
Limits(℃)
Hot spot Winding temp. rise 63K
B.I.L HV winding 550
(Line/Neutral) XV / XVN winding 170/170
% Impedance (at rated voltage,
between HV-XV, 75℃ reference 22.5% @100MVA base
temp.)
Characteristics
No-Load losses (20℃ reference temp.) 41 kW
Load Losses (Rated Voltage)
435 kW
(500 MVA base, 75℃ reference temp.)
Total Losses (Rated Voltage)
476 kW
(500 MVA base, 75℃ reference temp.)
Auxiliary Losses (at 100 MVA) 9 kW
Sound level (dBA) 79/80 dBA
 Loss tolerances are applied according to IEC 60076-1.
Oil preservation system Conservator

HV Top
Bushing
Location XV Side
Neutral Top
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Construction Overall dimension(L x W x H) 10,950 x 7,200 x 7,170
Shipping dimension(L x W x H) 8,650 x 3,300 x 3,800
Shipping weight (without oil) 74,500 kg
Total weight 126,700 kg
Receiving Transformer and Accessories
Parts can be damaged or lost during shipping. Following the steps in this section will help to identify
any such parts so they can be repaired or replaced as soon as possible. With the exception of impact
recorders or any item specifically marked otherwise, all items delivered become the property of the
owner.
Equipment Required:
 Packing List
 Crowbar, hammer, nails, wrenches and screwdrivers
 Digital camera
 Dew point tester
 500V or 1000V Megger
 Software and connecting cable for impact recorder (if an electronic recorder is used)
Inspection of Main Tank before Off-Loading:

1. Visually inspect the tank and any attached fittings for signs of damage such as dents, stolen or
misaligned parts, paint damage or areas where the tank was welded down and cut free from
transport vehicles. Photograph any suspected damage before off-loading and check off the
appropriate boxes on the Shipment Inspection Report.
2. Check the pressure gauge to verify positive pressure. Photograph the gauge. Record the
results on the Shipment Inspection Report.
In order to read the tank pressure, the normally closed tank valve needs to be opened with
the cylinder valve verified closed. If the pressure is low, the cylinder valve can be opened and
the regulator flow control valve(s) adjusted to re-pressurize the tank to 2 or 3 psi. After re-
pressurizing, the tank valve and cylinder valve should be reclosed. Read the black needle on
the gauge per figure BELOW.
THE TRANSFORMER WILL HAVE SEVERAL WARNING LABELS ATTACHED TO WARN THE WORKERS OF
POTENTIAL SAFETY RISKS AND TRANSFORMER DAMAGE RISKS.THESE WARNING LABELS MUST BE
STRICTLY FOLLOWED.
3. The transformer should be received with positive dry-air pressure inside the main tank.
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Other sections of the transformer, like bushing turrets, may also be pressurized with dry air
or nitrogen gas to protect insulation materials inside. Use caution whenever opening these
parts and obey all warning labels. Reseal and repressurize turrets or other parts with dry air
or nitrogen if they are not going to be installed immediately after opening for inspection.
Black Needle
Gauge showing 2 psi

Typical Shipping Pressure Gauge Configuration
Inspection of Main Tank after Off-Loading:

1. Review the impact recorder data. Verify that the impact recorder’s battery is still charged
and the unit is functional. Impacts of 3G or less are OK. If an electronic recorder is used,
download the record file. If a chart-type recorder is used deliver the chart paper to the HICO
field engineer or representative as soon as he arrives. Record the recorder serial number
and results on the Shipment Inspection Report.
2. Measure the internal pressure and perform a dew-point test on the dry air inside the
transformer and analyze the results. Record the ambient temperature and measured dew
point on the Shipment Inspection report.
3. Megger test the core and end frame (core-form) or core and T-beam (shell-form) at 500Vdc.
complete list of connections to test. Record the core test results on the Shipment Inspection
Report and record the end frame results separately.
4. Review the results with the customer. E-mail the photos, Shipment Inspection Report and test
results to HICO at the address listed in the Introduction. If any results are unsatisfactory,
contact HICO before proceeding with assembly or oil filling.
5. In cases where a transformer has a permanent nitrogen pressure system installed in place of a
conservator, this system may be used instead of installing a temporary dry air system for
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shipping as above.
Recommended Tests if Shipping Damage is suspected
ELECTRICAL TESTS CAN NEVER BE MADE WHILE THE TRANSFORMER IS UNDER VACUUM DUE TO INCREASED
RISK OF FLASHOVER.
1. Check pressure on unit with pressure-vacuum gauge. If zero reading, purge with dry air and
check for leaks. Note that pressure varies with temperature, and this factor should be
considered.
2. Check percent moisture content in transformer. It should never exceed dew point AS PER BELOW.
3. Perform internal inspection. See section 4.5 for detailed requirements.
WORK INSIDE THE TRANSFORMER REQUIRES A CONFINED SPACE PERMIT AND MUST
BE PERFORMED IN ACCORDANCE WITH OSHA OR APPLICABLE REQUIREMENTS.
SEE THE SAFE WORK PRACTICES SECTION FOR MORE DETAILS
OBSERVE ALL SAFETY LABELS ON THE TRANSFORMER
4. Check de-energized tap changer alignments and contacts with nameplate. Check for shifting of
core and coils, and check for breakage, loose or lost bolts, nuts, etc.
5. Make ratio test on all windings and taps. All windings and taps should check within 0.5%.
6. Check winding continuity and resistance if unit is off ratio.
7. Perform a Megger test on insulation resistance. HV to XV and Ground, XV to HV and Ground,
and HV and XV to Ground. The test voltage should not exceed 500Vdc.
8. If core yoke shows signs of shifting, disconnect core ground bushing and end frame ground
bushing from tank cover and test end frames to core. The test voltage should not exceed
500Vdc. This might happen when unit has been subjected to severe shocks in transit by carrier.
(Minimum acceptable values are 50 mega- ohms.)
Shipment Inspection Report:
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A HICO Shipment Inspection Report form must be filled in and e-mailed to HICO. All sections, lines and
boxes on the form must be filled in completely. Enter N/A if any areas do not apply. Contact HICO if
you do not have a copy of the form.
Dew Point Test

1. Measure internal tank temperature and measure the Dew Point temperature of the air inside
the tank.
2. Use Below pic. for pressure between 0 and 5 PSI.
3. Use upper and left axes for temperatures recorded in Celsius, use the lower and right axes for
temperatures recorded in Fahrenheit.
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Dew Point Limit
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Inventory and Inspection of the Accessories:
1. Verify that all crates, pallets and components listed on the packing list have been received and check
off the appropriate box on the Shipment Inspection Report. Check all crates and pallets for external
damage and evidence of moisture intrusion. Photograph any suspected areas and report on the
Shipment Inspection Report.
2. Open each crate and verify contents against the packing list. Look for water intrusion or
damaged components. Photograph any damaged parts and record missing parts and damaged parts on
the Shipment Inspection Report.
3.Check bushing crates to verify that all internal supports are in place and undamaged. Verify that
crates are roughly level and that all oil filled bushings inside each crate are inclined with the top oil
reservoir elevated. Verify that all bushing stud connectors have been delivered, that porcelain is not
damaged, and that no bushings are leaking oil. Record missing parts and record and photograph any
damaged parts.
4.Check surge arresters to verify that porcelain is not damaged and that all arrester sections and
grading rings have been delivered. Record missing parts and record and photograph any damaged
parts.
5.Check radiators for any signs of damage including dents on plates or edges, paint damage or missing
blanking plates. Record missing parts and record and photograph any damaged parts.
6.Check all piping sections. Record missing parts and record and photograph any damaged parts.
7.Check the main control cabinet and any other cabinets provided on the order. Check to verify that
the cabinet is not damaged and all internal components are in-place and undamaged. Record missing
parts and record and photograph any damaged parts.
8.A claim should be filed immediately with the carrier if any parts are missing or suspected damage is
found.
9.Review the results with the customer. E-mail the Shipment Inspection Report, photos, and other
information on any missing or damaged parts to HICO America.
10.If the transformer is not going to be installed immediately, parts must be stored in accordance with
our recommendations for storage.
Impact Recorder
The HICO standard is to have two impact recorders installed at the factory, one digital recorder and
one paper-analog recorder for each transformer. Additionally, a GPS impact recorder is installed upon
arrival at the North American port. The factory-installed recorders are located under a yellow metal
protection box as shown BELOW.
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Impact recorder
protection box
Note that impacts recorded by the impact recorder are only an indication of possible damage and not
conclusive evidence that shipping damage or even impacts have occurred. Impact recorders may
record impacts if the impact recorder is accidently kicked by a rigger, if rigging comes in contact with
the recorder, or under similar circumstances. The transformer may also withstand impacts well beyond
3G’s without any damage. The determination of damage can only be made following testing and/or an
internal inspection.
 Examination
After the transformer is moved on the pad in the site, its arriving time should be recorded and the
impact recorder data should be examined. HICO America can assist in the review of the data and can
provide a full report from our headquarters in Pittsburgh, PA.
 Notification
The recorder is part of the shipment. If it is missing or damaged, the seal broken, or has been disturbed
in any way, then this information has to be documented and reported to HICO America within a
reasonable amount of time.
 Orientation of Impact Recorder on the Transformer
Most types of impact recorders have axis or direction marks on them that correspond to the axis or
direction as recorded on the strip chart or electronic file. The impact recorder should normally be
mounted on the transformer with the orientation of the impact recorder axes as shown BELOW to
match the axes on the transformer.
Lateral or X-Axis Longitudinal or Y-Axis
Vertical or Z-Axis
Impact Recorder Axes

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It must be noted that in some cases the impact recorder may not be oriented as shown in the photo
above. In these cases, the axes indicated on the strip chart or electronic report will not correspond
to the same axes on the transformer and all impact directions must be adjusted accordingly.
 Analog Paper-Type Impact Recorder
Chatsworth Data (IOG Products) M-2 Type Impact Recorder
Paper Chart Duration: 160 Days Chart Speed: 3 inches per day
Stylus Type Used: 6G
Battery Life: Approximately 180 days
Analog Impact
Recorders
Impacts can be read from the paper chart using the Table BELOW
6G Stylus Table B (Analyze Full

Swing of Arc)
Inches Spaces X Y Z
1/8 1 1G .8 G .8 G
1/4 2 2G 1.6 G 1.5 G
3/8 3 3G 2.4 G 2.2 G
1/2 4 3.9 G 3.2 G 2.9 G
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5/8 5 4.9 G 4.1 G 3.7 G
3/4 6 5.9 G 4.9 G 4.4 G
7/8 7 6.7 G 5.7 G 5.2 G
1 8 7.4 G 6.5 G 5.9 G
1 1/16 8.5 7.8 G 6.9 G 6.3 G
Table 3.1
6G Stylus Table A (Analyze From Centerline)

Inches Spaces X Y Z
1/8 1 1.7 G 1.4 G 1.2G
1/4 2 3.3 G 2.8 G 2.5 G
3/8 3 5.0 G 4.2 G 3.7 G
1/2 4 6.3 G 5.5 G 5.0 G
5/8 5 8.2G 6.9 G 6.2G
Table 3.2
Example of impacts on analog recorder chart
Example: The impacts shown ABOVE would be calculated using the above impact tables. X
Axis = Max impact is 3G. Y Axis = Max impact is 6.5 G. Z Axis = Max impact is 1.2 G
If a new roll of paper must be put into an analog impact recorder, please follow the instructions below
in Figure 3.10 or labels inside the impact recorder itself. Analog Impact Recorder Paper Replacement
Instructions.
 Electronic-Type Impact Recorders
The Shock log RD298 or newer model 298 series impact recorders are battery powered and record
impacts in all three directions. If any significant impacts have occurred during shipment, a blinking red
LED will indicate an alarm or warning condition. The detailed data from the RD298 must be
downloaded with a special data cable onto a PC with Shock log software loaded, but the 298 uses a
standard USB cable. HICO’s field service engineers are equipped with the necessary cables and
software.
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Shock log Impact Recorders RD298
(left) and 298 (right)
Green Blinking Light: Denotes no impact greater than 3G.
“Slow” Red Blinking Light (Warning): Denotes impact greater than 3G
“Fast” Red Blinking Light (Alarm): Denotes impact greater than 4G.
Please note that is it very difficult to determine between an Alarm or Warning. The important
information is whether the indicator light is red or green. HICO can assist with the downloading of
these recorders and a full detailed report can be sent from our Pittsburgh office.
 GPS
The Lat-Lon DPU model impact recorder is solar powered with a battery backup and transmits GPS
location and travel speed and records of any impacts. The data is continuously updated and available
at the Lat-Lon website so no special cables or software are required. The data from these recorders are
monitored daily by the HICO America logistics team.
Note that the X, Y and Z axes are not labeled on the Lat-Lon DPU. See the Figure 3.12 for typical
orientation of the axes as these recorders are typically mounted vertically on the tank wall and not
on top of the unit.
The GPS and communications do not work when the transformer is stored inside an ocean vessel so
these type recorders are only mounted upon arrival at the North American port. The standard is to
have two of these recorders mounted.
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Y-Axis
X-Axis
Z-Axis
Lat-Lon DPU
Impact Recorder
Upon completion of the logistics work scope, HICO America will supply a full report regarding the data
from the GPS recorders.
 Impacts
Shipping impacts recorded are classified into three zones.
o Zone-A
The G-range of this zone is under 3G, including 3G.
The condition of the transportation / shipping in this zone is good.
o Zone-B
The G-range of this zone is between 3G and 6G, including 6G.
Damage may occur in this zone, particularly when impacts greater than 5G have occurred.
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The following checks and tests should be performed.
- Internal visual inspection
- External visual inspection
- Electrical test
 Ratio test
 Insulation resistance test
 Bushing Current Transformer tests
 Functional test for all protective devices
 SFRA test (only if shipping configuration test was performed in the factory)
o Zone-C
The G-range of this zone is greater than 6G.
Damage may occur in this zone. The same checks and tests listed under Zone-B should be
performed.
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PART-A2
Installation Procedures.
1. The tools and equipment listed below are required for HICO for the transformer and must be
supplied by the installation and testing crews.
REQUIRED TOOLS AND EQUIPMENT FOR ASSEMBLY

Equipment Specs. Task
Crane with slings and rigging See Drawings for weights Transformer assembly
hardware
Manlift General
Ladders General
Hydraulic jacks Installation and general
Rope Lifting and rigging, tag line
Oil processing trailer See Section 5 Vacuum oil processing and filling
Vacuum and oil hoses and fittings
Dry Nitrogen Gas Cylinder or
Air Cylinder w/regulators and hoses
Vacuum gauge to 0.01 Torr
Tygon tubing
Assorted flanges and pipe fittings to 2” – 4”
make up the oil and vacuum
connections
Oxygen meter (O2, CO, CO2, LEL’s) Calibrated and tested Internal inspection or
Dry air (cylinders or generator) <-58°F dew point internal work
Clean plastic sheets and tarps
Anti-seize compound See Section 4.7 Connecting stainless steel
hardware
Oxide removing grease See Section 4.7 Cleaning copper and aluminum
current-carrying surfaces
Torque wrenches Small, medium and large Transformer and component
size assembly
Crow’s foot wrenches Torqueing bushing top terminals
Ratchets 10-30mm General assembly
Open and box-end wrenches 10-46mm
Adjustable wrenches 6,8,10,12 and 15”
Sockets 10-46mm and ¼”-3”
Misc. hand tools, hammers, chisels,
blunt chisels, wedges, screwdrivers,
socket drivers, allen wrenches, torx
wrenches, pliers, tape measures,
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levels, pliers, etc.
Hydraulic crimping tool with dies 4.7/0 (248kCmil) and Connecting ground cables and
6.2/0 (350kCmil) terminals
Silicon grease and rubber cement Installing gaskets
(adhesive)
REQUIRED TOOLS AND EQUIPMENT FOR TESTING

Equipment Specs. Task
Dew Point Tester Dew point test
Variac or variable AC voltage supply to 140VAC Breaker and relay tests
DC power supply 125V Alarm and trip tests
Oil hi-pot tester ASTM D877 or D1816 Oil acceptance tests
Oil moisture tester Doble Domino or Karl
Fischer
Megger 500V and 1000VDC Megger tests
Hand operated air pump Gas accumulation relay test
Multi-meter General
Fused jumpers General
Temperature probe calibration tester Oil and winding gauge calibration
and functional tests
Qualitrol (or equivalent) Rapid Rapid Pressure Rise Relay test
Pressure Rise Relay test kit
Power factor test set Doble M4000 series Power factor, TTR and excitation
Ground cables tests
Mausing wire
Hygrometer
Winding resistance test set Winding resistance tests
DC continuity tester (buzzer) Wiring checks
Manlift Check outline drawing All tests above ground level
Ladders for height requirements
OPTIONAL TOOLS AND EQUIPMENT
Equipment Specs. Task Required if:
Welding machine 200A AC/DC Repairs or Damage occurs or
modification modifications are
s required
SFRA test set Doble M5000 series SFRA tests SFRA test is if required
Leakage reactance Doble M4110
test set
Phase rotation meter 3-phase pump or fan AC supply voltage is 3-phase
rotation checks
Diesel or gas- 120/240/ Fan, pump, Sufficient AC supply voltage
powered 480VAC components and source is not available on-
generator functional tests site
Laptop computer Programming or Transformer is equipped with
with an assortment program editing electronic devices or
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of interconnection monitoring equipment
cables (serial, null- requiring programming
modem, USB, etc.)
Setting the Transformer on the Foundation

Carefully move the transformer into the correct position on the substation pad and make certain that
the base is flat and level. Install shims under the base for leveling if necessary. Exact position on the
pad should be determined beforehand by the end user and communicated with the delivery personnel.
Grounding the Transformer Tank

The transformer tank must be connected to a secure ground before any work is done in or on the
transformer.
Opening and Working Inside the Transformer Tank
THE TRANSFORMER WILL HAVE SEVERAL WARNING LABELS ATTACHED TO WARN THE WORKERS OF
POTENTIAL SAFETY RISKS AND TRANSFORMER DAMAGE RISKS. THESE WARNING LABELS MUST BE STRICTLY
FOLLOWED.
WORK INSIDE THE TRANSFORMER REQUIRES A CONFINED SPACE PERMIT AND MUST BE PERFORMED IN
ACCORDANCE WITH OSHA REQUIREMENTS OR OTHER APPLICABLE REGULATIONS.
SEE THE SAFE WORK PRACTICES SECTION FOR MORE DETAILS.
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BE CERTAIN THE INTERNAL PRESSURE IN THE TRANSFORMER IS AT ZERO(0) GAUGE BEFORE OPENING THE
MANHOLE COVER.
Opening manhole covers

Follow warning labels and never remove the bolts from a manhole cover or other port if there is any
positive pressure inside the tank. Always vent the tank to 0 psi relative pressure before opening
any manhole covers or other ports. Always relieve internal pressure slowly through valves. Failure to
do may result in removed parts becoming flying hazardous objects.
Breaking vacuum
Never break vacuum with atmospheric air, always use dry air or dry nitrogen.
Foreign Material Exclusion (FME) Practices
FOLLOW HICO’S FOREIGN MATERIAL EXCLUSION PRACTICES TO MINIMIZE THE RISK OF TOOLS, PARTS OR
MATERIALS BEING DROPPED INTO THE TRANSFORMER
Tools, nuts, bolts, washers and other materials that might be dropped into a transformer may not be
retrievable, and could cause serious problems affecting the safe operation of the transformer.
Safeguards must be taken to prevent tools or other materials from accidently being introduced into
the transformer. At a minimum, the following steps should be taken whenever the transformer is
opened, or whenever someone works inside the transformer.
Whenever pipes, ports or manholes are open during assembly or maintenance:

 Ensure the tank is at zero pressure by slowly bleeding a valve.
 Only open manholes during favorable weather conditions.
 Clean the area around the openings before they are opened to remove all loose parts,
materials or sources of contamination.
 Only open the pipes, valves, ports or manholes that are necessary to perform the job.
 All workers near any openings should wear clean, dry clothes and clean shoes, empty their
pockets, remove jewelry, secure eyeglasses or other personal items and ensure that they do
not have any items with them that could be dropped into the openings.
 Limit access to the work area to only the people who need to be there and are aware of, and
in compliance with, the FME requirements.
 Keep all tank openings covered whenever practical.
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 Do not have loose tools or parts near any openings.
 If openings are vertical, like an open valve pointing upward, or an open manhole on the
cover, secure tools with a lanyard to the worker’s wrist, or to a rigid point outside the
transformer so they cannot be dropped into the opening. If loose parts that could be
dropped inside are being installed near an opening, place a sheet or similar to catch dropped
parts inside the transformer beneath the work area or dam the pipe or opening so parts
cannot drop inside.
 Be prepared to close all openings quickly if rain or hail start unexpectedly.
Whenever working inside the transformer during assembly or maintenance:

 Keep dry air flow and maintain proper oxygen levels per Section 4.5.2.
 All tools, parts and materials going into the transformer should be logged. Exact quantities
of each part must be recorded (“19 bolts”, for example, not “ a bag of bolts”).
 Clean the area around the manhole or openings before they are opened to remove all
loose parts, materials or sources of contamination.
 All people going inside the transformer should wear clean, dry clothes and clean shoes or
rubber boots, empty their pockets, remove jewelry, secure eyeglasses or other personal items
and ensure that they do not have any items with them that could be dropped before entering
the transformer.
 Keep the tank openings to a minimum and keep temporary covers over openings as much as
possible whenever anyone is not entering or exiting the transformer, as long as the covers do
not interfere with maintaining communication with the workers inside the transformer and
safe confined space procedures.
 Limit the tools and parts to be brought into the transformer to only those tools and parts that
are necessary to perform the job.
 Use a bag or similar container that can be closed securely to carry small parts into and out of
the transformer.
 Lay down a sheet, net or other material below any working area where loose parts must
be installed to catch any parts that might fall.
 Use lanyards to tie off all tools to the worker’s wrist or other secure location.
 Avoid the use of tools or other materials that have parts that can come loose and fall apart
or break into pieces.
 Be prepared to evacuate the transformer and close all openings quickly if rain or hail
start unexpectedly.
 All tools, parts and materials coming back out of the transformer after the work is complete
should be counted and checked against the log to ensure that everything that was brought
in was removed.
If any tools, parts or materials are dropped into the transformer and cannot be completely
Page 25 of 75
retrieved, notify HICO immediately.
Inspecting the Active Part

A preliminary internal inspection is not normally required unless shipping damage is suspected. An
internal inspection should be performed by the HICO Field Service Engineer or HICO’s contractor. If the
customer performs the inspection, the inspection should be performed by an engineer who has been
trained in performing transformer inspections. The Engineer will check for any signs of movement or
damage during shipping.
The internal inspection is a Confined Space entry and must be performed in accordance with OSHA
and all other applicable regulations and requirements. See Section 1 Safe Working Practices .
When you open a transformer, take precautions to prevent moisture, dirt and foreign materials
from entering the transformer or moisture condensing in the transformer.
Do not step on any leads or DETC shafts. Distribute bodyweight to avoid breaking any braces.
Detailed inspection items may be provided by HICO. In general, inspection areas include:
 Top supports of the core assembly

 Side supports to tank wall (if provided)
 Coil compression status
 Coil spacer alignment
 Braces and supports for leads
 Internal busbar connections
 OLTC and tap connections
 DETC contacts and shafts
 Core laminations and core stacking condition
 Bottom centering pin and insulation
 Insulation condition
 Bushing current transformers
Weather
Do not open the transformer or leave it open during rapidly changing weather conditions
unless the opening is completely protected from weather.
Do not attempt to install a transformer if it is raining or snowing.
Do not open the transformer if the relative humidity is greater than 85%.
Do not work inside the transformer if moisture is condensing on the inside of the tank.
Ventilation of Tank
Page 26 of 75
Dry air must be used to ventilate the inside of the tank when it is opened for internal fitting or
for inspection. Please refer to 29 CFR OSHA 1910.146 Permit-Required Confined Spaces.
Additionally, these restrictions must also be followed:
a. The dry air must have a dew point not higher than -58°F (-50℃).
b. Purge all air hoses with dry air to remove all moisture and dirt prior to
use.
c. Use a pressure regulator to control the pressure of the incoming air.
d. Dry air should be blown into the transformer below the working level to
maintain flow of air out through the cover opening. Air hoses may be
taken into the transformer if they are clean, dry and made from an oil-
proof material.
d. The dry air flow rate should be adjusted to maintain continuous airflow
outward through the tank openings. To conserve dry air and prevent the
entrance of dirt and moisture, place a light cover of plywood, hardboard,
or plastic over the manhole opening. The work should be performed in a
sequence such that when accessories such as bushings are being
installed, only one opening other than the manhole will be open at any
time.
e. The transformer must not be opened more than 16 hours at a time and
should be as well sealed as practical whenever working inside the
transformer. Avoid opening more manholes or ports than are absolutely
necessary to protect the dryness of the insulation.
Temporary Sealing of the Transformer between Work Days.
a. Remove all the tools and working material from the transformer.
b. Continue to purge the transformer tank with dry air for 30 minutes after all
the material has been removed.
c. Seal the tank and pressurize it with dry air to 2-3 PSI.
d. If the next work period and re-opening of the transformer will not occur
within three days, we recommend after sealing the tank, that you pull
vacuum on the transformer to an absolute pressure of 2 Torr or less and hold
this level for 4 hours. Break the vacuum with dry air and pressurize the tank
to 3 PSI.
e. During long assembly periods where the tank is opened and resealed
frequently, check the dew point periodically to track moisture control.
Nut and Bolt Assembly
Equipment Required:
 Calibrated torque wrench
 Assorted sockets and crows foot wrenches
 Nickel or nickel/graphite anti-seize compound for stainless steel nuts and bolts such as
Chesterton 725 or Loctite Nickel Anti-Seize with application brush
 Electrical contact oxide removing grease such as Sanchem NO-OX-ID and clean rags
Page 27 of 75
Procedure:
 Nuts and Bolts That Require torqueing with a Calibrated Torque Wrench:
All current carrying connections must be torqued to their required torque values, as listed in the
Tables in Section 4.8, using a calibrated torque wrench. This includes all bottom bushing connection
nuts and bolts, all bushing stud connector hardware, all bushing terminal connector to cable
connections, and all ground cable connection nuts and bolts. This also includes the top terminal of ABB
draw lead bushings and the draw lead jam nut and top terminal of PCore draw lead bushings (or
similar bushing components if required by other bushing manufacturers).
Conservator support structure bolts must also be torqued to their required torque values using
a calibrated torque wrench.
Special Case – Qualitrol Pressure Relief Device: Qualitrol Series 208 Pressure Relief Devices are
supplied with ½” mounting bolts to attach the cast iron base of the device to the transformer. This
may be changed to M12 bolts by HICO. These mounting bolts, whether steel or stainless steel, should
be torqued to 30.4 ft-lbs, and a flat washer must be used between the flange and the bolt head or nut.
Applying torque greater than 30.4 ft-lbs or failure to use a flat washer could cause the cast iron
flange to crack and require the device to be replaced at the installer’s expense.
Special Cases – Bushing and LTC manufacturers specify the torque values for the mounting bolts and
for some current-carrying connections. The manufacturers’ torque values supersede any HICO values
listed in the Tables in Section 4.8.
Note: Any torque values listed in component manufacturers’ bulletins included with this manual supersede the
HICO standard torque values in Section 4.8 for those components.
 Preassembled Nuts and Bolts:

All preassembled nuts and bolts should be checked during assembly as they could become loose
during shipping.
 Cleaning:
All current-carrying surfaces must be cleaned and coated with electrical contact grease to remove
all oxides from the surfaces and protect the surfaces from future oxidation before they are bolted
and connected together.
 Thread Lubricants:
All galvanized steel, bronze or brass threaded connections must be made without any thread lubrication.
Page 28 of 75
All external stainless steel threaded connections must be made using a nickel/graphite anti-seize
compound on the threads to prevent galling. All stainless steel threaded connections inside the
transformer and under oil must be made without any anti-seize compound or other lubrication. Table
4.7 lists the torque values for internal stainless steel hardware without anti-seize compound or
lubrication.
Nut, Bolt and Washer Configurations
 Spring/Belleville Washer Connections:
When connecting flanges or other joints with Spring/Belleville washers, the connection should a flat
washer must be provided under the bolt head. The Spring/Belleville washer must have a flat washer
between the Spring/Belleville washer and the flange or other surface to protect the surface from
damage. In cases using double nuts, the connection should be made as shown in Figure 4.2. The lower
nut must have a Spring/Belleville washer between the lower nut and the flange or other surface. The
bolt length must be long enough to provide at least one full thread beyond the outer end of the nut.
Single Nut Spring/Belleville Washer Configuration
Page 29 of 75
Double Nut Spring/Belleville Washer Configuration
Page 30 of 75
Required Torque Values
Table 4.1 applies to galvanized steel, SAE Grade 5 and Stainless Steel Type 304 nuts and bolts through
an un-threaded hole in Steel, Stainless Steel, Copper or Aluminum base material. See Table
4.7 for internal stainless steel hardware torque values.
Table 4.1
Galvanized SAE Grade 5 and Stainless Steel Type 304 Hardware Unthreaded
Steel. Stainless Steel, Copper or Aluminum Base Material Torque in FT-LBS
IN-LB values listed in parenthesis for FT-LB values <20
Stainless Steel
Galvanized
Type 304
Steel SAE
Bolt Material w/Anti-Seize
Grade 5
Compound
Non-Lubricated
(External Only)
Bolt Size Torque in FT-LBS (IN_LBS)
M6 4 (48) 3 (36)
M8 10 (120) 7 (84)
M10 20 14 (168)
M12 35 24
M14 57 39
M16 108 61
M18 152 83
M20 217 116
M22 297 159
M24 376 203
M27 550 300
M30 745 409
M33 1020 553
M36 1309 712
M39 1693 922
M42 2098 1143
M45 2618 1425
M48 3146 1718
M52 4072 2221
M56 5063 2759
M60 6307 3443
M64 7624 4159
M68 9251 5045
Page 31 of 75
Table 4.2 applies to Silicon-Bronze and Brass nuts and bolts through an un-threaded hole in Steel,
Stainless Steel, Copper or Aluminum base material.
Table 4.2
Brass and Silicon-Bronze Hardware
Unthreaded Steel, Stainless Steel, Copper of Aluminum Base Material
Torque in FT-LBS
Bolt Material Brass Silicon Bronze

Bolt Size Torque in FT-LBS (IN-LBS)
M6 2 (24) 2 (24)
M8 4 (48) 6 (72)
M10 7 (84) 12 (144)
M12 13 (156) 21
M12 13 (156) 21
M14 20 33
M16 32 52
M18 43 72
M20 61 101
M24 105 174
M30 213 347
M39 485 788
M42 597 973
M48 901 1465
Page 32 of 75
Table 4.3 applies to Brass and Silicon-Bronze nuts and bolts through threaded copper or aluminum
base material.
Table 4.3
Brass and Silicon-Bronze Hardware Threaded
Copper or Aluminum Base Material Torque in
FT-LBS
Copper Aluminum
Base Material (With Threaded (With Threaded
hole) hole)
Bolt Size Torque in FT-LBS (IN-LBS)
M6 1 (12) 0.4 (4.8)
M8 2 (24) 1 (12)
M10 5 (60) 2 (24)
M12 8 (96) 4 (48)
M12 8 (96) 4 (48)
M14 13 (156) 6 (72)
M16 21 9 (108)
M18 29 12 (144)
M20 41 17 (204)
M24 71 30
M30 141 59
M39 318 130
M42 394 163
M48 593 246
Page 33 of 75
Applies to galvanized steel, SAE Grade 5 and Stainless Steel Type 304 nuts and bolts through an un-
threaded hole in Steel, Stainless Steel, and Copper or Aluminum base material.
Galvanized SAE Grade 5 and Stainless Steel Type 304 Hardware

Unthreaded Steel. Stainless Steel, Copper or Aluminum Base Material
Torque in N-m and kgf-cm
Stainless Steel
Galvanized Steel
Bolt Type 304 w/Anti-
SAE Grade 5
Materia Seize Compound
Non-Lubricated (External Only)
l
Torque Torque
Bolt Size N-m kgf-cm N-m kgf-cm
M6 6 59 4 40
M8 14 140 9 95
M10 27 280 19 190
M12 48 490 33 335
M14 77 790 53 540
M16 147 1500 82 840
M18 206 2100 113 1150
M20 294 3000 157 1600
M22 402 4100 216 2200
M24 510 5200 274 2800
M27 745 7600 407 4150
M30 1009 10300 554 5650
M33 1382 14100 750 7650
M36 1774 18100 965 9850
M39 2293 23400 1250 12750
M42 2842 29000 1548 15800
M45 3548 36200 1931 19700
M48 4263 43500 2328 23750
M52 5517 56300 3009 30700
M56 6860 70000 3739 38150
M60 8546 87200 4665 47600
M64 10329 105400 5635 57500
M68 12534 127900 6836 69750
Page 34 of 75
Applies to Silicon-Bronze and Brass nuts and bolts through an un-threaded hole in Steel, Stainless
Steel, Copper or Aluminum base material.
Brass and Silicon-Bronze Hardware

Unthreaded Steel, Stainless Steel, Copper of Aluminum Base Material
Torque in N-m and kgf-cm
Brass Silicon Bronze

Bolt Material Non-Lubricated Non-Lubricated
Torque Torque
M6 2 21 3 34
M8 5 50 8 80
M10 10 100 16 165
M12 17 175 28 290
M12 17 175 28 290
M14 27 280 45 460
M16 43 440 71 720
M18 59 600 97 990
M20 83 850 137 1400
M24 142 1450 235 2400
M30 289 2950 470 4800
M39 657 6700 1068 10900
M42 809 8250 1318 13450
M48 1220 12450 1985 20250
Page 35 of 75
Applies to Brass and Silicon-Bronze nuts and bolts through threaded copper or aluminum base
material.
Brass and Silicon Bronze Hardware Threaded

Copper or Aluminum Base Material Torque in
N-m and kgf-cm
Copper Aluminum
Base Material (With Threaded hole) (With Threaded hole)
Non-Lubricated Non-Lubricated
Torque Torque
M6 1 14 0 5
M8 3 34 1 14
M10 6 65 3 28
M12 11 115 5 49
M12 11 115 5 49
M14 18 185 8 78
M16 28 290 12 120
M18 39 400 16 165
M20 56 570 23 235
M24 96 980 40 410
M30 191 1950 79 810
M39 431 4400 176 1800
M42 534 5450 221 2250
M48 804 8200 333 3400
Page 36 of 75
Applies to unlubricated stainless steel nuts and bolts through unthreaded copper or aluminum base
material or threaded stainless steel base material – for internal transformer connections only.
Internal Stainless Steel Hardware

Unthreaded Copper or Aluminum or Threaded Stainless Steel Base Material
Torque in ft-lbs, in-lbs, N-m and kgf-cm
Stainless Steel Type 304

Base Material without Anti-Seize Compound or Lubrication
(Internal Connections)
Torque
Bolt Size
M10 22 264 30 297
M12 42 504 57 574
M14 70 840 97 965
M16 99 1188 137 1369
Table 4.8 applied to black iron nuts and bolts used in internal transformer connections only.
Internal Black Iron Hardware

Torque in ft-lbs, in-lbs, N-m and kgf-cm
Bolt Size FT-LBS IN-LBS Torque N-m kgf-cm
M10 34 408 46 470

M12 55 660 75 765
Page 37 of 75
Approximate Equivalent Metric and Inch Bolt Sizes Metric Inches
M6 1/4
M8 5/16
M10 3/8
M12 1/2
M14 9/16
M16 5/8
M18 11/16
M20 3/4
M22 7/8
M24 1
M27 1-1/16
M30 1-3/16
M33 1-1/4
M36 1-1/2
M39 1-1/2
M42 1-5/8
M45 1-3/4
M48 1-7/8
M52 2
Page 38 of 75
Standard Bolt Dimensions
Dimension(mm)
Standard
Bolt &
Hex-Bolt Hex-Nut
Nut
A B C A B
M6 11.5 10 6 11.5 10
M8 15 13 8 15 13
M10 19.6 17 10 19.6 17
M12 21.9 19 12 21.9 19
M14 25.4 22 14 25.4 22
M16 27.7 24 16 27.7 24
M18 31.2 27 18 31.2 27
M20 34.6 30 20 34.6 30
M22 37 32 22 37 32
M24 41.6 36 24 41.6 36
M27 47.3 41 27 47.3 41
M30 53.1 46 30 53.1 46
M33 57.7 50 33 57.7 50
M36 63.5 55 36 63.5 55
M39 69.3 60 39 69.3 60
M42 75 65 42 75 65
M45 80.8 70 45 80.8 70
M48 86.5 75 48 86.5 75
M52 92.4 80 52 92.4 80
M56 98.1 85 56 98.1 85
M60 104 90 60 104 90
M64 110 95 64 110 95
M68 115 100 68 115 100
Page 39 of 75
Tightening Sequence for Nuts and Bolts
Using ratchets, torque wrenches, and spanners, tighten bolts in a diagonal pattern in several steps. The
first time around, tighten to around 60-70% of full torque value, the second time to nearly 100%, and
the third time to reconfirm full torque value.
The general tightening sequence of nuts and bolts is as follows:
Tightening Pattern
Page 40 of 75
Recommended Assembly Order and Quality Checks
This procedure applies to the on-site assembly of all new oil-filled transformers. Many of the tasks
listed below are covered in detail in various HICO procedures and all work must be done in
conformance with those procedures. This procedure only covers the recommended order for
performing the tasks.
After the transformer tank has been placed on the foundation in the final location and all parts have
been inventoried, inspected and verified as clean and dry, the transformer assembly should be
performed in the following general order. The exact order of assembly should always be determined
by the installation crew leader, and can be modified as long as safety is not compromised, equipment
is not at risk and test results will not be adversely affected.
Grounding:
The tank ground should be connected to the site’s ground grid or other secure ground point as soon as
possible after the transformer is placed on the foundation. This is a safety issue and must be done
before any other work is done on the transformer.
Preliminary Tests:
It is recommended that the CT’s be pre-tested before the transformer is assembled and filled with oil. A full
series of ratio, polarity, insulation resistance and excitation tests on each CT will ensure that the correct CT is
installed in the turret properly and that no shipping damage has occurred.
It is also recommended that any bushings showing any signs of shipping damage such as crate
damage or shifted porcelain be tested before the transformer is filled with oil.
Performing these tests before the transformer is filled with oil will minimize the cost and impact of
any problem.
Assembly:
The optimal order of assembly for the major components varies by transformer design and should be
evaluated by the HICO field service engineer or supervisor on the assembly crew considering all of the
following issues:
If the transformer was shipped by barge or exposed to salt spray or other corrosive contaminants
during shipping, the transformer tank and all conduits and parts that were exposed must be washed
with a pressure washer before assembly can start. If the site is an energized substation, it may be
necessary to perform this pressure washing before bringing the transformer into the station if the
work cannot be performed safely. Any crates with components found to have moisture intrusion
Page 41 of 75
during shipping must also be pressure washed to remove any corrosive contaminants.
The conservator support structure must be installed and all bolts torqued before the conservator or
conservator piping can be attached. The conservator should be loosely bolted to the conservator
support structure before the conservator piping (including the Buchholz relay, if equipped) is installed
and the conservator position must be adjusted using the slotted holes to align the piping, if the mis-
alignment is greater than 1/8” in any direction, before bolting the piping together and torqueing the
bolts that hold the conservator in place.
The turrets must be installed before the bushings or gas collection piping can be installed.
If any gas collection piping, conduits or any LTC operating shafts are designed to be routed over any
manhole or handhole covers, all internal work through these manholes or handholes should be
performed before the piping, conduits or operating shafts are installed, to avoid later partial
disassembly.
All cabinets or conduits that were removed for shipping and are located behind radiators must
be installed before the radiators.
All bushings that are bottom-connected through handholes on the tank wall behind radiators must
be installed and connected internally before the radiators are installed.
Any bushings that require lower corona shields should be measured and evaluated before assembly to
verify whether the bushing can be installed from the top of the turret with the shield attached or
whether the shield must be connected internally after the bushing is mounted in the turret. Bushing
shields must be placed around the conductor or mounted to the bushing bottom before connecting
the bushing.
All bushings that require the draw-lead nut or top terminal to be torqued to manufacturers’ specified
values must be torque before installing any bushing stud connectors or neutral ground bus connections,
or before testing.
The installation of all radiator or heat exchanger support structures and cooling piping and pumps (if
equipped) must be coordinated with the installation of the radiators or heat exchangers to prevent
radiator piping and components from being exposed to excessive mechanical stresses during or after
assembly. If a complicated support system is provided, consult with HICO America before starting the
assembly if a HICO field service engineer is not on site.
All arrester support structures must be installed after the radiators or heat exchangers if they
are mounted directly above the radiators or heat exchangers.
Bus or cable connections to neutral bushings should be measured and placed in the proper position,
but final connection to the bushing can be delayed until after commissioning tests are completed.
All accessories such as relays, pressure relief devices, gauges and temperature controllers should be
installed after the risk of damage from installing other components has passed. All wiring to these
components should be tested for insulation strength at 500Vdc before the wiring is terminated at the
devices.
All internal and external cabinet grounds and surge arrester grounds must be connected before
testing the accessories or wiring.
If the transformer is equipped with pumps, the pumps must not be energized before the
Page 42 of 75
transformer and oil piping is filled with oil.
If the transformer is equipped with an LTC, the LTC must be manually operated over the full range of
taps to verify correct position indication and correct operation of limit switches before operating
power can be connected to the LTC. The LTC cannot be operated electrically before all manual tests
are completed and correct operation is verified, and the LTC cannot be operated electrically or
tested before the transformer and LTC are filled with oil.
If the transformer is equipped with an LTC with an oil filtration system, the filtration system operation
must be thoroughly tested and the filter tank and piping must be filled with oil before any electrical
testing is performed on the filter system or LTC.
The transformer must be filled with oil only after all major components and accessories that cannot
be installed or replaced without removing the oil have been installed.
All bolted connections requiring torques with a calibrated torque wrench must be torqued to
the required value when the connection is first made and again as a final torque before
releasing the transformer for service.
Some plastic zip ties degrade from exposure to sunlight. Use only UV-rated zip ties for cable tying or
metal if allowed by the site.
Dry air cylinders and gauges used for shipping should be removed prior to oil filling.
Blanking plates and transportation covers are part of the transformer unless otherwise stated. They
should be stored properly in case the transformer is relocated in the future.
Testing, Supplied Power and Final Connections and Checks:
Final commissioning tests must only be performed after the transformer has been filled with oil and
the oil temperature has cooled to less than 40°C. For more information, refer to Section 6
Commissioning Tests.
 Power factor and capacitance on the transformer and bushings
 Oil Quality and DGA
 Ratio and single phase excitation. Excitation tests must be performed before any DC
tests.
 SFRA (if required)
 Winding resistance (after the excitation tests)
 Insulation resistance – core, end frame and windings (after the excitation tests)
 Test current transformers from the control cabinet terminals for ratio, polarity,
insulation resistance and plot the excitation curve.
 Functional test of the AC power circuit and components: automatic transfer switch (if
equipped), cooling controls, pumps (if equipped), fans, cabinet heaters and lights.
Verification of correct 3-phase power rotation if designed for 3-phase supply power,
and marking the rotation direction at the main terminal connections if the power
supply is not permanent.
 LTC electrical functional tests
Page 43 of 75
 Calibration or check of temperature gauges
 Functional test on all protective relays and alarms
 Programming and functional test all electronic components or monitoring devices
Bushing stud connectors must be installed after all tests are completed. All connections must be
torqued after installation.
The transformer must be thoroughly checked for oil leaks after testing is complete.
The transformer and work area must be cleaned and all debris disposed of properly.
Clean-Up and Release for Service:
All nicks, scuffs and scratches must be repaired with abrasive tools and the touch-up paint that is
provided per Section 4.22. This must be the last step in the assembly process before any safety
grounds are removed and the transformer is released for service.
If any issues are encountered during assembly, or if the drawings, procedures or equipment can be
improved to facilitate the assembly and ensure high quality, please notify HICO America. We place
a high value on your constructive feedback.
Gasketing
HICO’s standard gasketing system uses flat or round O-ring type gaskets and flanges equipped with
machined gasket grooves.
All gaskets, gasket grooves and sealing surfaces must be closely examined during assembly to ensure
that the gaskets are clean and in good condition and that the gasket grooves and sealing surfaces are
clean and undamaged to ensure that the joints will not leak.
The proper size gaskets must be installed for each joint to ensure leak-free service. If properly
designed gaskets from HICO are not available, the following general guidelines should be considered if
making new gaskets:
Page 44 of 75
X = Gasket groove width
a Y = Gasket groove depth
Gasket groove area = (X x
b
Y Y) d A
Y
X X
a = Gasket width
d = Gasket thickness (Diameter)
b = Gasket height
A = Gasket area
Gasket area = (a x b)
Gasket area A = Π(d/2)2
(a x b) should be 85-96% Gasket area should be
of (X x Y) and b should approximately 85-96% x (X x Y)
be approximately 1.3- and d should be 1.3-15 x
1.5 x Y
Page 45 of 75
Gasket Dimensions
Note that the center of the gasket should be approximately in the center of the of the gasket groove.
There must be some practical tolerance for these dimensions, but for flat O-ring gaskets the cross-
sectional area of the gasket (a x b) or (d/2)2 should be 85-96% of the groove area (X x Y). The gasket
height (b) or (d) should be 1.3-1.5 times the groove height (Y).
Gaskets are normally buna-n material, or nitrile with a 70 Durometer value. Viton gaskets may also
be used in higher temperature areas. Before assembling, check the gasket exterior and assure it’s
free from scratches or dust. If the gasket has any damage, it must not be used. Gaskets should be
wiped clean with alcohol and coated lightly with Vaseline or a similar product before installing.
Gaskets on vertical flange faces may require a small amount of glue to secure them during assembly.
Installing Bushings
Before installing any radiators or coolers, check the requirements for making the bottom bushing
connections. It may be necessary to connect some bottom-connected bushings through handholes on
the tank wall and this may not be possible once radiators or coolers are installed.
Bushings may be draw-lead or bottom-connected types. Review the bushing supplier’s
documentation and instructions for lifting and rigging instructions and installation procedures. Note
that bushing manufacturers have critical torque requirements for draw-lead nut and top terminals.
Always verify that all bushing top terminal gaskets are in place. If any are missing, contact HICO for
new gaskets. Refer to the bushing manufacturer’s manuals or instructions.
Verify oil levels are visible in all bushings and compare the levels between bushings of the same type.
All current carrying connections must be torqued using a calibrated torque wrench to the torque
values listed in the manufacturer’s instructions. Bottom terminals must be torqued to the values listed
in the appropriate Table for hardware and base material
Bushing manufacturers may have unique torque requirements for current-carrying connections. If
the torque values are not included in the manufacturer’s instruction leaflet or manual, contact HICO
for guidance.
Failure to properly torque current-carrying parts on bushings can lead to equipment damage,
outages and can void the warranty.
Orientation of the Bushing Oil Level Gauge
Always review the bushing manufacturer’s manuals and the transformer drawings to determine how
the bushings should be oriented. The bushing manufacturer’s instructions supercede any general
instructions in this manual.
Bushings with glass bowl oil level gauges do not require any special mounting orientation, unless the
customer has a preference for the locations of the test taps.
Page 46 of 75
Bushings that are mounted horizontally and equipped with an oil level gauge should have the bushing
oriented to facilitate viewing of the gauge from ground level. Horizontally mounted bushings with an
oil expansion chamber should have the chamber oriented to the top of the bushing.
ABB bushings rated 500kV and greater with magnetic oil level gauges that are mounted on an angle
should be oriented with the magnetic oil level gauge facing downwards as shown in the sketch
below. Other manufacturers and lower voltage bushings may have different requirements.
Magnetic
Oil Level
Gauge
Facing
Downwards
Magnetic Oil Level Orientation

In general, bushings that are mounted on an angle and equipped with a sight glass in the head of the
bushing should normally have the bushing oriented in the preferred orientation so the oil level gauge
will provide the correct reading and the high and low normal oil levels will be within the range of the
sight glass, but this may not be practical if the bushing bottom terminals are not aligned in this
orientation. In this case, bushings should be oriented to meet the bottom terminal requirements with
the minimal effect on the site glass performance. In some cases it may be possible to rotate the bottom
bushing terminal to better align the bottom terminal and sight glass. Bushings with oil level gauges
should be mounted similarly, but the oil level may read slightly high or low when mounted on an angle.
There are several types of bushing designs, some with two sight glasses to provide monitoring of oil
levels over a wider range. Consult the bushing manufacturer’s documentation for direction on
orientation in special cases like these.
Page 47 of 75
Oil Level
High
Reads
Level
Low
Reads
Level
Oil Level
Bushings mounted on compound angles will require slightly different orientation to properly locate
the oil level gauge. A level placed on the face of the gauge should read plumb when the bushing is
rotated to the correct mounting position.
Preferred and Incorrect Sight Glass Orientations
Bushing Bottom Shield Installation
Inspect bushing bottom shields for scratches, nicks, or other damage such as peeling paint. Inspect for
any dust or debris on the exterior and wipe with an ammonia-based cleaner and clean, dry cotton
cloth.
The bushing shield should only be set down in an upright position and never on its side. Lay down a
soft cloth so that it is never sitting directly on the ground.
Page 48 of 75
Some shields will lock into place with a clicking sound when rotated clockwise into the proper
position. Twist the shield from side-to-side to verify it’s locked in place and not able to move freely.
Refer to the bushing literature for further information.
Installing Radiators and Cooling Equipment
Radiators are easily damaged if they are not lifted properly. Never lift a HICO radiator from any part
except the factory installed lifting eyes on the upper and lower headers. Cooler fins are very delicate
and may be easily damaged during handling. Work should be done with the highest level of attention
to avoid fin damage. Coolers should be moved as slowly as possible during crane transport. Ensure
there are no other structures in the moving routes. If the side of the cooler’s fins have a protective
plate attached, carefully detach it after completing the assembly.
HICO radiators are equipped with lifting eyes on the upper and lower header pipes. These lifting eyes
are the only points where rigging can be attached for lifting the radiators.
To remove the radiators from their crates, there are two possible methods:
1. If two cranes are available, connect slings for one crane to the lower header lifting eyes and
the other crane’s slings to the upper header lifting eyes. Slowly lift both sides simultaneously,
keeping the radiators approximately horizontal.
2. If only one crane is available, connect slings to the upper header lifting eyes and slowly lift the
radiator, up righting it before lifting it from the crate. The bottom of radiator should be
supported by a board to protect the drain plug from damage during lifting.
Radiators should be set on boards on the ground if they will not be installed immediately after lifting
from the crates.
Radiators are gasketed and sealed at the factory. Open the flange cover plates and inspect the internal
part of the radiators to ensure that they are clean and dry before mounting them.
Remove only the temporary sealing covers for connecting the radiators. Swan neck type radiators
will have a permanent sealing cover on the topmost header which should not be removed.
Page 49 of 75
Temporary and permanent sealing covers for radiator installation
When installing radiators, great care must be taken to ensure that none of the gaskets fall from the
gasket groove and become pinched when the flanges are bolted together. If the gasket is not
lubricated and a light amount of Vaseline used in the gasket groove is not sufficient to hold the gasket
in place, it may be necessary to use a very small amount of glue in the gasket grooves on vertically
oriented flange faces.
Butterfly valves 6 inches or larger will have a disk that projects slightly from the flange when
closed. This projecting disk side should always be installed on the side toward the tank wall. This is
so that blanking plates will seal properly if the equipment has to be removed and blanked off in the
future.
HICO’s standard 3” butterfly valves do not have a disk that projects when closed, but the assembly
sequence must be followed. The stud bolts should be installed through the valve body into the tank
wall piping before installing the radiator onto the stud bolts.
If radiator valve operation is checked prior to installing radiators, ensure slight positive pressure on
the tank prior to opening. All valves should be opened after installation and prior to beginning the
vacuum and oil filling process.
Page 50 of 75
Butterfly Valve Assembly
Page 51 of 75
If Cedaspe 3” butterfly valves are used, the bolts are installed from the tank wall side of the flange
into the valve body as shown
Cedaspe 3” Butterfly Valve Assembly
Install radiators per the below procedure:

1. Hoist the radiator from the ground paying special attention not to damage any other radiators.
2. Remove the blanking plates and gaskets
3. Tilt the radiator to drain any residual oil if needed and inspect the inside of radiators visually.
The practice of putting rags or “diapers” in the headers temporarily to prevent oil dripping
while moving the radiator is greatly discouraged.
4. Remove the blanking plate and gasket on the radiator valve on the transformer.
5. Clean the flange surfaces.
6. Hoist the radiator by crane and guide the radiator by hand.
7. Install gasket and line up the upper and lower flanges
8. Mate up the flanges and tighten the nuts in a diagonal pattern
9. Continue the same process with all radiators.
Do not run pumps without oil or with the valves closed to avoid damage to the pumps.
Page 52 of 75
Fan motors must be checked to ensure that drain plugs are properly installed.
Fans may be equipped with directional plugs that must all be oriented to prevent moisture intrusion in
the mounted position. Horizontally mounted Krenz-Vent fans may have L-shaped plugs that must be
oriented correctly Refer to the fan tags or literature for exact orientation information.
Horizontal Krenz-Vent Plug Orientation
California Turbo fans should have the vent plugs oriented
Page 53 of 75
California Turbo Plug Orientation
For other fan manufacturers, consult the fan information in Section 9 or contact HICO America.
Conservators, pipes, radiators and heat exchangers should all be checked before installation to ensure
that any bags of silica gel or other items that may have been placed inside for shipping are removed
before installation.
Installing Pressure Relief Devices
The transformer may be furnished with more than one pressure relief device. In general, one device
should be provided for every 10,000 gallons of total oil volume. If removed for shipping, the pressure
relief devices need to be re-installed using new gaskets. Inspect the gasket and groove for damage or
debris. The gasket fits upward into the groove, so great care must be taken to line the gasket up
properly. Vaseline or gasket glue may be needed to hold the gasket in place during assembly. If a
semaphore is used, check that it’s centered over the pin and there is no damage to the semaphore
arm or stopper pin. The pressure relief devices are rated for vacuum and do not need to be removed
during vacuum processing.
Note that the cast base of the Qualitrol Pressure Relief Device can be easily broken if the mounting
bolts are over torqued. The ½” or M12 mounting bolts must be torqued to 30.4 FT-LBS and no higher.
The Qualitrol or ANSI style connectors for the alarm wiring should be hand tightened only.
Overtightening can twist and break off the pins inside.
Check and retighten the bolts on the terminal box for alarm wiring if needed.
steps listed below for installation of the semaphore on Qualitrol PRD’s.
Pressure Relief Device

The following steps shall be completed in order.
1. Remove one cover mounting screw (Item #11)
Page 54 of 75
NOTE: Do not remove more than one cover mounting screw.The cover is under spring Pressure and could be
released.
2. Locate the mounting hole of the semaphore assembly (Item #15) over the location of
the removed screw and reconnect the mounting screw – do not fully tighten the screw
yet.
3. Align the tip of the semaphore directly above the indicating pin (Item #8) in the center of
the pressure relief device cover.
4. Tighten the mounting screw.
5. Check the semaphore for free movement from horizontal to vertical position.
6. Set the semaphore in a horizontal position (as shown) with the top of the semaphore
directly over the indicating pin.
Installing the Gas Accumulation Indicator
The transformer may be equipped with a Buchholz relay that performs this function. If so, follow
the procedures in Section 4.17 Installing the Buchholz Relay.
Mount the relay in the designated location.
The tubing connecting the relay to the valve on the transformer gas collection piping must be properly
configured or the relay will not work properly. The tubing must have a continuous upward slope from
the main valve toward the relay and should be as short as possible. Any sharp bends or downward
sloping areas will trap any gas bubbles and block the tube, preventing correct operation of the relay.
The connection to the relay is oil-tight so the gasket must be checked for damage or debris prior to
connection. Following the diagonal pattern per Figure 4.6.
Connect the tubing and sample valve and close the sample valve. Check the sampling device for any
shipping damage prior to installing the tubing. Tubing should be cut to size by a pipe cutter. Make sure
there are several inches of straight, smooth tubing at each end prior to installing and tightening the
compression fittings.
The relay can withstand vacuum, but the valve to the relay should be closed during oil filling.
Page 55 of 75
After filling is complete, install a drain bucket under the sample valve then open the main valve and
sample valve and observe the gauge drop to 0cc. Let enough oil drain from the sample valve to ensure
that no air remains in the relay or tubing. If the gauge does not start to drop after a 10-15 seconds,
check the tubing between the main valve and the relay.
Installing the Buchholz Relay
Check the Buccholz Relay, test button, and sampling connection for damage. Install the Buchholz
Relay in the designated location in the conservator oil piping. The relay must be installed in the
upwardly sloping horizontal section of the oil piping.
Connect the gas collection tubing and sample valve and close the sample valve. Check the sampling
device for any shipping damage prior to installing the tubing. Tubing should be cut to size by a pipe
cutter. Make sure there are several inches of straight, smooth tubing at each end prior to installing
and tightening the compression fittings.
After oil filling, open the sample valve and bleed off any air in the sample tubing. Do not close the
valve to the sampling device while it is oil-filled.
Installing Oil and Winding Temperature Gauges
Mount the gauges on the locations shown on the detailed outline drawing. Check or set the
temperature settings for each contact. Check and program electronic temperature controllers as
required. Install the temperature probes after testing is complete.
Care should be taken not to twist or kink the capillary during installation. Excess capillary tube length
should be coiled around a fixed rod on the thermometer protection cover. Do not coil excess tube
onto the damper structure on the back of the thermometer. The Qualitrol or ANSI style connectors for
the alarm wiring should be hand tightened only. Overtightening can twist and break off the pins
inside.
If test kit is available, we recommend to test any fiber optic probes prior to oil filling.
Installing Rapid Pressure Rise Relay
If the Rapid Pressure Rise Relay (RPRR) is removed for shipment and must be remounted, first check
that the gasket and groove are not damaged and are free from debris. Tighten per the tightening
sequence in Figure 4.6.
The vent should be orientated upward
Page 56 of 75
Vent must face upwards
RPRR Vent Orientation
The valve for the RPRR should be closed during vacuuming operations.
Page 57 of 75
METHOD OF STATEMENT FOR 380kV 502MVA
TRANSFORMER INSTALLATION
REVISION 00
Installing Oil Level Gauge
Typically the oil level gauge will come preassembled to the conservator. If it must be reassembled on
site, first check that the gasket and groove are not damaged and are free from debris. Tighten per the
tightening sequence in Figure 4.6. Check there is no damage to the inside components, needle, or
window.
Do not move the needle of the oil level gauge by hand. For most models, you can remove the gauge
from the internal mechanism and use a magnet being the gauge to move the needle for testing.
For Qualitrol 039 remote indicators, check that the serial numbers of the oil level gauge and remote
indicator match. If the float is attached, only move the float to change the reading and verify the gauge
and remote indicator readings match. If the float is disconnected, you can move the bezel to change the
reading and verify both readings match.
Installing Oil Flow Indicators
Typically oil flow indicators will come preassembled to the oil piping. If they must be reassembled on
site, first check that the gasket and groove are not damaged and are free from debris. Inspect the
internal components and sight window for damage. Tighten per the tightening sequence in Figure 4.6.
Touch-Up Painting
After all assembly and inspections are complete, the final step of assembly is to touch-up paint on any
nicks or scratches caused during transportation and assembly.
If using the HICO-supplied touch-up paint, follow these procedures:
1. Using sandpaper or steel wire brush to remove any rust or peeling paint from the surface.
2. All surfaces to be painted should be cleaned with cloths and compressed air.
3. Allow any wet surface to dry. Any surface damp from dew must not be painted.
4. Mix the paint by the ratio of 5 parts base to 1 part hardener by volume. If using an airbrush,
thinner may be added.
5. Several thin coatings are more effective than one thick coating. At least two coatings are
Page 58 of 75
REVISION 00
recommended, allowing the first to dry completely before applying the second.
Installing Bellows
Some transformers may have flexible sections of piping called bellows. To properly install these bellows,
follow the steps below:
1. If the bellows needs adjustment prior to mating up the pipe sections, loosen or tighten the nuts
accordingly to shorten or lengthen the bellows.
2. Once sized properly and before assembling, tighten all the nuts on the inside and outside.
Torque value is 217 ft-lbs (294 N-m).
3. Assemble the pipes with bellows.
4. After vacuum and oil filling is completed, loosen the inside nuts on each side of the stud to leave
a 5mm gap.
Bellows Final Configuration
Each size of bellows is designed for limited displacement between pipe sections. If it appears the
bellows will be extended beyond these values, please check all the surrounding pipe connections.
Page 59 of 75
REVISION 00
Diameter Bellows Dimensions Max Axial Displacement Max Lateral Displacement

3” 80mm x 200mm -20 / + 10 mm ± 7 mm
6” 150mm x 300mm ± 30 mm ± 25 mm
8” 200mm x 300mm ± 15 mm ± 15 mm
10” 250mm x 300mm ± 15 mm ± 15 mm
12” 300mm x 300mm ± 15 mm ± 15 mm
Maximum Bellows Displacement
2.6 ORGANIZATION, RESPONSIBILITY & SUPERVISION MANAGEMENT
1. RESPONSIBILITY & SUPERVISION MANAGEMENT

Management will provide adequate controls to provide a safe workplace, and will provide
adequate resources and training to its employees to encourage fire prevention and the safest
possible response in the event of an emergency.
PROJECT MANAGER
Project Manager will be responsible for:-
 Overall implementation and monitoring of all the activities.
 TO arrange Material and resources.

CONSTRUCTION MANAGER
1.
Site Manager will be responsible for:-
 Over-all direction.
 Planning and Monitoring.
 Coordination.
QA/QC MANAGER/ENGINEER
QA/QC Manager /Engineer will be responsible for:-
 Monitoring the work is carried out as per the approved ITP .
 To ensure all materials to be used is approved by Client.
 Check each and every activity before and after the completion of the work.
Page 60 of 75
REVISION 00
ES&H MANAGER
• Is knowledgeable of specific client regulations and enforce them.
• Knows the requirement of contract document and relevant subject of Govt. Workman's
regulations.
• Control emergency situation.
• Ensure that accident reports are prepared, reviewed and distributed.
• Maintains discipline at site.
• Assist Project Manager in communicating safety status & accident report etc., to client.
• Maintain close liaison with client representatives.
• Recommends ideas for safety improvement.
• Ensure work as per standard with minimum risk.
• Gives proper instructions to Foreman/Workmen regarding safer working.
ENGINEERS (ELEC., CIVIL & MECH)
• Ensures work as per IFC drawing.
• Ensures maintenance of instruments in proper condition.
• Gives proper instructions to Foreman/ Electrician/ Workmen regarding good quality and
safe work.
• Motivates also testing team to work safely.
• Takes necessary precautions before commencing any activity.
• Maintain close liaison with Safety Officer, QC Engineer.
SAFETY OFFICER
• Implements all the safety aspects.
• Coordinates with ES & H Manager.
Page 61 of 75
REVISION 00
• Conducts daily safety inspection and motivates work force to work safely.
• Conducts periodic inspection of tools, equipment and ensures right tools are used for
specific jobs.
 Checks availability of First Aid Kit, Fire Extinguishers and safety equipment's.
• Checks that proper clearances are maintained while working below or near power lines.
• Ensures that work permit procedures are followed in restricted areas is familiar with RC/
SEC-EOA work permit procedure.
• Gives feedback for safety improvement.
• Ensures workers wearing safety gears like safety belts, safety gloves, safety shoes,
hard hats etc.
• Displays Emergency telephone numbers at appropriate places.
• Checks for provision of all the warning signs and warning tapes at the construction
site.
• Investigates all accidents immediately within his area of responsibility and submit an
accident report immediately to SEC EOA/ RC/Project Manager.
Nurse or First Aider
• The Nurse or first aider should be well experienced in first aid practices and RC/ SEC-
EOA safety rules.
• Will be responsible for fast treatment of any burns, injuries or any type of accidents.
• Conduct periodically inspections of all employees and check any signs of illness.
• Ensures the availability of first aid kits in good conditions.
• Informs any injury or accident to the Safety officer and write a report about the injured
employee.
Foreman (Electrical/Civil/Mechanical)
• Ensure Safety policy.
Page 62 of 75
REVISION 00
• Maintains discipline.
• Directly deals with emergencies.
• Attends weekly safety and fire prevention meetings.
• Continuous monitoring of the work site.
• Maintains liaison with Engineer/ Foreman and Safety Officer in resolving safety issues.
• Investigate accidents & near misses.
• Report on safety violation conditions to supervisors and allows corrective actions
through instruction given to violators.
• Render disciplinary action where appropriate.
All Employees
• Comply with Client and company policies.
• Report hazards.
• Report injuries.
• Report accidents/ near misses.
• Be physically fit and mentally alert.
• Operate or repair equipment only when authorized.
• Follow personnel safety and conduct rules at all times.
Page 63 of 75
REVISION 00
2.6.1 ORGANISATION CHART
2.7 Work Force
2.7.1 Qualified Personnel Required

 Site Engineers
 QA/QC Engineer
 QC Inspectors
 Surveyor
 Safety Officer
 Equipment Operators
Page 64 of 75
REVISION 00
 Foremen
 Carpenters
 Steel fixers
 Helpers
 Crane Operator
 Rigger
2.7.2 Histogram of the workforce to be involved with the works
Page 65 of 75
REVISION 00
3 HEALTH AND SAFETY.
3.1 Risk Assessment
 (Risk Assessment format attached with the M/S)

- ES&H Department must be informed of every activity on site in advance.
- Risk assessment should be implemented to all manpower at the site.
- First Aid and Nearest Hospital contact must be made available with the site.
- Possible risk assessment shall be made and necessary action shall be followed for all the
work. In addition below given activity/item shall be given due importance.
 Main Risk Assessment issues:

- Working at Height: Control Measures
 Properly Planned
 Appropriately Supervised
 Not carried out if weather condition jeopardize health and safety

- Manual Handling: Control Measures
 Assessment for Heavy or awkward lift loads
 Use of mechanical devices where possible to move the load
 Loads within the individual handling
 If carrying the load check that walk away is clear
 Operatives to be trained in Kinetic lifting

- Noise: Control Measures
 Assessment for specific working task
 Hearing protection where required
 Information/Training/Tool box talk to be given to all on the effects of noise
 Signage to be erected in mandatory hearing protection zone

- Power tools for woodwork: Control Measured
 Ensure protective guard is in position, inspected for damage before use
 Only trained and competent person to operate equipment

Page 66 of 75
REVISION 00
 Good housekeeping must be maintained
 Ensure adequate ventilation and vacuum fitted to the machine
 Wear PPE.
 GFCI equipped tools/ battery operated tools only be used.

- Housekeeping/Site Tidiness: Control Measures
 Implement ‘Clear as you create’ policy
 All access and agrees routed must be kept clear and free from obstruction
 When sweeping, apply water to the floor to prevent dust becoming airborne
 Where possible all waste generated must be disposed in to a suitable skip immediately.
However temporary stack dumps may be implemented in designated location.
- Cutting Timber and Plywood: Control Measures
 Good hygiene
 Adequate ventilation inside carpentry workshop.
 Separate cutting areas where necessary
 Noise assessment where necessary
 Guard must be in place and well maintained when using tools
 GFCI/RCD protected power supply to prevent any shock.
 Good housekeeping to be maintained
 Wear suitable PPEs
 Fire Extinguisher mounted suitable type (ABC 10 kg).

- Deliveries to Site: Control Measures
 Mechanical lifting where necessary
 All operative and personnel to be briefed and trained
 Carry out ground survey, check for service ducts/covers etc.
 Select suitable size machines
 Provide steel rod plates to spread loads over service ducts as required.
 Provide suitable access and egress routed for vehicles.
 Designated areas to be kept clear of materials
 Sufficient lights to be provided

Page 67 of 75
REVISION 00
 Where visibility is restricted, movement of plant or pedestrians will be under direct

control of a competent and trained banksman/slinger.
 Updated traffic management plan will be followed segregated (pedestrian/ vehicle
movement).
 Planned sequence of unloading
 Exclude persons not involved in the work of machines from delivery area.
 No lifting over people other dangerous items/equipment
 Site fire plan
 Suspend work during uncontrolled environment
 Remove keys from vehicle when driver is not in the room
 Inspect work areas daily, repair or replace any damage barrier

- Abrasive wheels: Control Measures
 Planned preventive maintenance of equipment
 Only trained personnel may change abrasive wheels
 Suitable storage facility for equipment
 Personnel noise assessment
 GFCI/ Battery operated tools only be used.

- Mobile Crane Lifting Operations: Control Measures
 Trained Crane and Slinger operator
 Weight of loads to be ascertained
 Wear PPEs
 Crane shut down when maximum wind speed reached (32 km/hr.)
 No overhead electric wires
 Aviation light at top
 Proper maintenance of crane
 Do not exceed safe working loads

- Hazardous Substances: Control Measures
 Any substance or material hazardous to health requires a COSHH assessment to be
carried out
Page 68 of 75
REVISION 00
 The control measurements thus established must be implemented and monitored
 Operatives to be briefed in assessment findings and controls
3.2 Jubail Environmental Safety & Health Contractor Requirements

 Wear at all the time suitable protective clothing, gloves and eye protection, dust masks
should be used all the time; the wet adhesive may cause irritation by skin contact.
 All Environmental and Health shall be taken care.
 Execute periodic cleaning to keep site.
 Adjacent properties free of accumulations of waste materials, concrete, debris,

rubbish, and windblown debris resulting from construction operations.
 Store volatile wastes in covered metal container remove from premises daily.
 Prevent accumulation of waste which creates hazardous condition.
 Conduct cleaning and disposal operation to comply with local environmental laws.
 Provide plastic cover over electrical and electronic components to reduce dust
accumulation in interior parts.
3.3 Protective & Safety Equipment
 All person at all time when on the site have to wear a protective helmet.
 Safety shoes/boots shall be issued to all personnel on the site.
 Appropriate glasses and eye protection to be issued to workman as required.
 In places where high slopes workers shall be equipped with a safety full body harness
with retrieval line securely anchored to the structure.
 All workers as a requirement will use protective hand gloves to protect against sharp or
rough edges, chemicals, and hot or cold surface accordingly.
 Lifting equipment and carriers shall not use its full capacity to handle a load.
3.4 Contractual Requirements
All safety and health which are required to fulfill by the contractor will be takencare in
accordance with the International EH & S Standards in conjunction with client’s
Specification, Standards, and Instructions.
3.5 Information to Personnel
Safety and Environmental education and information and awareness to be disseminated
to all the employees in shape of training, seminars, safety tool box meetings and safety
Page 69 of 75
REVISION 00
refresher courses, like project safety induction, Redman Green man training, Defensive
driving, Work at height, hot work, firefighting, and RC life critical requirements.
3.6 Emergency Procedures
 First aid clinic is available at site in the hour of need.
 Emergency Telephone numbers are posted and displayed on site on appropriate

locations.
 Rescue aids will be in place such as retrieval lines, safety harness, etc.
 In the event of heat stress and strokes a fully equipped ambulance is available to
transport the victim to the nearest hospital for treatment.
 Eye wash bays to be provided on site.
 Walking passages shall be clear from obstacles
 Assembly point shall be located on clearly visible area.
 Transportation will be ensured all time during working hours at site for any emergency
situation.
3.7 Permitting Requirements
 Work at height permit.
 Hot work permit.
 Lifting permit.
4 ENVIRONMENTAL ISSUES:
4.1 Environmental Impact Assessment
None
4.2 Jubail Environmental Safety & Health Contractor Requirements
Same as addressed in above section
Please see the Section above
4.4 Emergency Procedures
Please see the Section above
Page 70 of 75
REVISION 00
5 QUALITY ASSURANCE
• IFC drawings
• ITP - Inspection and test plan
• PTS – Project Technical Specification for substation and OHTL
5.2 Critical Works
1. Offloading of Transformer.
2. Installation of accessories at height.
5.3 Inspection & Testing (ITP)
• All inspection shall be done as per approved ITP and accordingly RFI’S shall be raised
for inspections.
5.4 Follow up & Evaluation
• Follow up shall be in order to check and evaluate the works as per standards and
Project specifications during the construction phases.
6 APPENDICES
Page 71 of 75
REVISION 00
Acknowledgement Signatures:
The personnel listed below confirm receipt of the method statement and have had the contents
Explained to them, understand it and are aware of the site ES&H requirements.
Name Employer Date Signature
Note to FE, CS & FCS – Any significant change from this method statement requires it to be revised and
resubmitted to RC before work can commence.
Page 72 of 75
REVISION 00
SAFE SEQUENCE OF WORK
ACTION DETAILS
Description of 1. 380kV 502MVA TRANSFORMER INSTALLATION
the work
PREPARATION 380kV 502MVA TRANSFORMER INSTALLATION
TBT ,and START UP, card shall perform before the task
1. Offloading of Transformer
2. Unpacking of Transformer materials as per the requirement.
3. Required Tools and Equipment
4. Setting the Transformer on the Foundation
5. Grounding the Transformer Tank
6. Opening and Working Inside the Transformer
7. Inspecting the Active Part
8. Temporary Sealing of the Transformer Between Work Days
9. Bolt & Nut Assembly
Sequence of 10. Required Torque Values
work and how 11. Standard Bolt Dimensions
operations are 12. Tightening Sequence for Nuts and Bolts
controlled 13. Recommended Assembly Order and Quality Checks
14. Gasketing
15. Installing Bushings
16. Installing Radiators and Cooling Equipment
17. Installing Pressure Relief Devices
18. Installing the Gas Accumulation Indicator
19. Installing the Buchholz Relay
20. Installing Oil and Winding Temperature Gauges
21. Installing Rapid Pressure Rise Relay
22. Installing Oil Level Gauge
23. Installing Oil Flow Indicators
24. Touch-Up Painting
25. Installing Bellows
Individual 1. ES&H manager

responsible for 2. Site safety officers
Page 73 of 75
REVISION 00
3. Site manager
4. Construction manager
controls and
5. Project manager
monitoring
6. Site supervisors
7. Site foremen
 Mobile Crane.
 Step Ladder.
 Scaffolding.
 Boom truck.
Plant and
equipment’s to  Forklift.
be used
 Oil Filtration Machine
 Chain block, Sling Belts, D-shackle.
 Tools (Will be provided as per requirement by M/S Hyosung)
1. Boom truck
2. Forklift
Operator training 3. Mobile Crane
requirements 4. Oil Filtration Machine
5. Scaffolding.
Risk assessment Enclosed

applicable
Safety control 1. Mobile Crane

measures for 3'd 2. Oil Filtration Machine
parties
Environmental Enclosed ,for details please section 4

control 1. Hazardous waste management program
2. Waste control
3. Waste management
4. Waste management disposal
5. Dangerous goods and hazardous materials storages
Page 74 of 75
REVISION 00
First aid & PPE Male Nurse & 2 Certified First Aiders with all occupied clinic shall provide at
site
Emergency  Fire Station #998
procedures
 Traffic Accident #993
 Ambulance #997
 Police #999
 AI Fanar Safety Manager-----------------------------#0599794224
 Al Fanar Project Manager ---------------------------#0550220627
 AI Fanar Construction Manager------------------ #0580133020
 AI Fanar First Aider --------------------#0564007808
 Eye wash bays to be provide on-site walking passages shall be

located on clearly visible area.
 Assembly point shall be located on clearly visible area.
 Transportation will be ensured all time during working hours at site
for any emergency situation.
Page 75 of 75

Method Statement - 115kV 100 MVA Transformer Installation

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Method Statement - 115kV 100 MVA Transformer Installation

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CONSTRUCTION OF 380/115/33 kV SUBSATION #3 AND

ASSOCIATED OHTL AT RAS AL KHAIR

(ALFANAR CO. - RC 099-C05)

115kV 100MVA TRANSFORMER INSTALLATION

Method Statement No: Issued

2.1 General Description

The purpose of this method statement is to identify the methods,

• SEC Standard 53-TMSS-01

2.3 MATERIAL STORAGE & HANDLING

2.4 SITE PLANNING AND PREPARATION

Alfanar/Hyosung will deploy competent Electrical Engineer/supervisor at site

2.5 WORK METHODOLOGY

Painting (Main Tank, Conservator, LV Cable Box)

Powder coating (Radiators)

Type of Paint POWLAC PE200

Surface treatment Shot blast(SSPC-SP-10)

Auxiliary Losses (at 100 MVA) 9 kW

Sound level (dBA) 79/80 dBA

 Loss tolerances are applied according to IEC 60076-1.

Oil preservation system Conservator

Receiving Transformer and Accessories

Inspection of Main Tank before Off-Loading:

Gauge showing 2 psi

Inspection of Main Tank after Off-Loading:

Recommended Tests if Shipping Damage is suspected

SEE THE SAFE WORK PRACTICES SECTION FOR MORE DETAILS

OBSERVE ALL SAFETY LABELS ON THE TRANSFORMER

Dew Point Test

Lateral or X-Axis Longitudinal or Y-Axis

Impact Recorder Axes

 Analog Paper-Type Impact Recorder

Chatsworth Data (IOG Products) M-2 Type Impact Recorder

Stylus Type Used: 6G

Battery Life: Approximately 180 days

6G Stylus Table B (Analyze Full

6G Stylus Table A (Analyze From Centerline)

Example of impacts on analog recorder chart

REQUIRED TOOLS AND EQUIPMENT FOR ASSEMBLY

REQUIRED TOOLS AND EQUIPMENT FOR TESTING

Setting the Transformer on the Foundation

Grounding the Transformer Tank

Opening and Working Inside the Transformer Tank

SEE THE SAFE WORK PRACTICES SECTION FOR MORE DETAILS.

Opening manhole covers

Foreign Material Exclusion (FME) Practices

Whenever pipes, ports or manholes are open during assembly or maintenance:

Whenever working inside the transformer during assembly or maintenance:

Inspecting the Active Part

 Top supports of the core assembly

 Preassembled Nuts and Bolts:

 Spring/Belleville Washer Connections:

Single Nut Spring/Belleville Washer Configuration

Bolt Material Brass Silicon Bronze

Galvanized SAE Grade 5 and Stainless Steel Type 304 Hardware

Brass and Silicon-Bronze Hardware

Brass Silicon Bronze

Brass and Silicon Bronze Hardware Threaded

Internal Stainless Steel Hardware

Stainless Steel Type 304

Internal Black Iron Hardware

M10 34 408 46 470

Magnetic Oil Level Orientation