Method Statement

A) Transformer Dismantling at PMU Mersing

B) Installation , processing and testing at
PMU Masjid Tanah

Transformer 45 MVA 132/33 kV, ET10506/1

Table of contents
1. Dismantling procedures
2. Installation procedures
3. Leak Test
4. Airbag Normalizing
5. Checklist
6. Safety Procedures

Mar 14, 2016

Prepared by:

Mohammad Hafiz
Head - Services

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 Dismantling procedures at PMU Mersing

1) Before proceeding for dismantling, make sure all packagings available to pack
the material , also clean oil drums / skid tank available for transferring the oil.
All blanking plates should be readily available.
2) Close all the cooler valves top and bottom to the transformer.
3) Drain the oil from the bottom header to empty the oil from radiator and headers
and also drain the oil from the main tank until half oil level gauge on the tank to
empty the oil from conservator , turrets, pipings and approx. 100 mm below the
cover level. The oil to be drained into the clean drums/ clean oil tanks and their
opening to be sealed air tight.
4) Disconnect all the wiring to the instruments and pack it nicely to avoid water
entry. All the conduits used for joining to be separated out. The instrument
openings to be sealed air tight.
5) Disconnect the fan wiring and dismantle the fans along with its supports.
6) Dismantle the radiator ties and pack it properly.
7) Dismantle the radiators and headers (top and bottom) and close all the openings
with the gasket and blanking plate. Pack them in the wooden case with
sufficient dampers to take care of the vibration/impact during the transport.
8) Dismantle the conservator and its support and secure the conservator on the
steel support. Close all the openings and blank them air tight. MOG to be
installed with guard to avoid transit damage.
9) Dismantle the cable box and disconnecting chamber and mount them on the
steel supports.
10) Disconnect the bushings for HV, LV, TV and neutral and pack them properly
from inside as well as outside to avoid water entry and also in a manner to avoid
damage during transit.
11) Dismantle the HV turret for all the 3 phases , blank them and secure them on the
steel plate for transportation. Mark them for easy identification.
12) PRD to be separated from the drain pipe to avoid any damage during transit.
13) All the pipings for conservator , OLTC, Buchholz relay to be packed in wooden
case with all the openings sealed properly. Mark them for easy identification
14) All the valves to be fitted with valve guards.
15) OLTC DM to be covered with protection hood and OLTC on the cover also to
be protected with the hood. LCP to be covered with the enclosure for protection
16) All the supports for cable box, conservator to be packed properly. Mark them
for easy identification
17) All the fasteners to be packed in separate polythene packings and kept inside the
pipe case.
18) Instruments such as fans, buchholz relay to be packed in a separate case taking
care of the fragile nature of the instrument.
19) All the openings on the transformer to be blanked off, dry air/ nitrogen to be
filled at 0.2 bar and pressure monitored for 48 hrs with no leakage.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 20) Shock recorder to be installed and core frame IR readings to be taken before
transporting the transformer.
21) Transformer height to be measured and it should be slinged properly onto the
trailer. All care to be taken for transport height to avoid hitting underbridges etc.

Installation , processing and testing procedures at PMU

Masjid Tanah
22) After the transformer is positioned on the plinth, before carrying out any
installation, conduct the following checks and tests
a) Measure dew point of the gas to determine the insulation dryness in case the
transformer is dispatched completely gas filled. – CG will conduct with PTIS
providing the manpower
b) Measure Insulation Resistance for core and frame at 1000 volts – CG will
conduct with PTIS providing the manpower
c) Download the shock recorder readings to check the shocks received while
transportation from factory to site. Check the level of shocks in X , Y and Z
direction – CG will conduct with PTIS providing the manpower
.
23) All the accessories along with the transformer main tank to be verified based on
the detailed packing list.

24) If transformer is dispatched gas filled then vacuuming has to be done and after
that oil filling under vacuum to be done, all the accessories on the main tank to
be installed after oil filling, installation of other accessories which does not
involve the releasing of the gas can be done parallely

25) Check the oil sample from the drums/bulk oil as per TNB specn for 8 tests (
1 sample only) as per clause 2A.2.1 at TNBR /other accredited laboratory
as approved by TNB – Already done at PMU Mersing

Item No.5 – If required due to damage seen in shock recorder.

26) This inspection is required if there are heavy shocks observed as seen in the
shock recorder report.
Check the locating post on the cover to see if any movement of the core coil
assembly has actually taken.
Open the manhole inspection for doing the internal inspection if required or felt
necessary, The internal inspection is possible, if proper space available
otherwise inspection to be carried out from outside. During internal inspection,
make a list of things taken inside and while coming out should verify the same.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 Note : All the precautions required for confined space working should be taken.
Also no covers should be opened during rainy weather/ bad weather/ heavy
wind blowing.

27) Before installing the main tank conservator , check the conservator at
ground level by opening the manhole inspection cover to verify the air bag
& float arm position of magnetic oil gauge. Also verify the MOG for OLTC
as well as main tank by moving the float up and down. Do not move the
pointer as it may get damaged.

28) Before any installation activity to be conducted or any cover to be opened on the
main tank, make sure the oil is filled until the core coil assembly level. Since the
transformer is gas filled dispatch hence fill up the oil after processing into
transformer under vacuum.

29) Install the HV turret followed by HV bushings. Check the IR value of the HV
bushings before installation.

30) Similarly install the LV turret and LV phase and neutral bushings . Check the IR
value of the bushings before installation.

31) Similarly install the TV bushings . Check the IR value of the bushings before
installation.

32) Install the HV neutral also check the IR value, followed by header supports,
headers , cooler pipes, radiators, conservator support, conservator, Buccholz
relay piping, radiators, conservator piping, OLTC piping and breather piping.

33) Install the LV DC and cable box. Verify the surge arrester installation inside the
cable box.

34) For internal connection for LV , TV and neutral bushings to connect the flexible
jumpers/leads from the winding , make sure the oil level is below the inspection
cover, open the cover during dry weather.

35) Connect all the conduit wiring to the instruments installed on the transformer

36) Check the lead lag for OLTC drive mechanism.

37) Immediately after inspection, close all the covers and check the tightness of all
flange openings, inspection covers, valves and all the joints to the
recommended torque with the torque wrench. Refer the torque table as below.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 38) Pull vacuum for 4-6 hrs and after that start filling filtered oil under vacuum (oil
to be filtered inside skid tank and BDV and ppm to be more than 60 kV and less
than 15 ppm respectively) Two cycle filteration to avoid contamination from the
oil container to go inside the transformer.

39) Raise the oil up to the conservator level and check for any leakage by applying
pressure up to 0.2 bar and monitor it for 4-6 hrs during which time the pressure
should be maintained (ambient temperature may cause the pressure to

increase/decrease), This is blanking pressure test and is very important to be

carried out . If not done and any leak is there then during the vacuuming it is
very difficult to detect and it will end up sucking in moist air.

40) If no leak observed , lower the oil from the transformer till the cover level.
Also after the blanking pressure test done , release the excess pressure and
then close the equalizing valve between main tank and OLTC.

41) Heat the oil through the filteration machine till the temperature reaches 60 deg
celcius. Heat it for a minimum of 24 hrs for 30 kl oil.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 42) After the above temp is achieved, drain out the complete oil into the skid tank
and pull vacuum till it reaches 70mbar. Draining out oil should be as fast as
possible to avoid the winding to cool down, if possible use two hose pipes to
drain the oil, one using natural gravity and other through the filter machine.
Draining of oil should be under the influence of nitrogen gas/dry air or use of
breather.
During vacuuming , make sure to equalize the air bag with the conservator and
OLTC with the main tank with the equalization arrangement already provided.
Refer the figure above for the vacuuming arrangement. This is schematic
representation and conservator breather valve will be used for vacuuming and
connection of vacuum gauge.

43) After having reached 70 mbar check the leak rate as per manual.

44) After leak rate is achieved, continue vacuuming to the full vacuum (less than 1.3
mbar or 1 torr) as per the manual , once 1 torr is achieved continue vacuuming
for 36 hrs for 132 kV transformers. Extended cycle of vacuum to be done since
the transformer was stored for long time under gas.

45) During the vacuuming, filter the oil in the skid tank for two cycles at a
temperature of about 55-60 degree Celcius and keep the oil prepared to be filled
back into the main tank under vacuum.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 46) Once vacuum is finished , fill the oil into the transformer under vacuum till the
oil reaches 30 – 40 deg celcius level in oil level indicator on the conservator ,
now break the vacuum using the nitrogen gas. Refer the drawing below for
schematic representation and understanding.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 47) Filter the main tank for 3 cycles or 24hrs , if 30 kl oil and filter m/c capacity is
6 kl/hr , then the total no. of hours should be around 24 hours for 3
cycles(consider filter m/c efficiency to be 80%).
After the main tank filtration is complete filter the cooler bank separately for 3
cycles. Filter the conservator separately for 2 hrs.
Suck out the oil from the OLTC using oil suction pipe on OLTC and then
fill fresh oil after filteration. Finally, filter the OLTC compartment for 2
hrs with the small filter m/c or by adjusting the valve to reduce the flow of
oil.

48) After the filteration is complete, Check the oil parameters for the acceptance
criteria.

49) Allow settling time for oil, do leak test with nitrogen gas at 5 psi or 0.3 bar and
check all the gasketted joints for any oil spills, leaks or seepage. The PRD
should be locked or oil level in the conservator to be lowered otherwise PRD
may operate. Refer the procedure as below.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 METHOD STATEMENT - OIL LEAK TEST

Introduction
The purpose of this test is to prove that no oil leaks exist on the Transformer tank, cooler
bank and all other oil compartment. The Test shall be carried out upon completion of the
erection work, whereby all fittings, i.e. conservator, radiators etc are in place and all
valve open/close as required in the service.
The additional test pressure of 0.35 bar as per FAT requirement shall be measured at the
base of the tank and this pressure will be in addition to the normal static head pressure.

Pressure measured at bottom = Normal static head pressure at bottom +

0.35 bar
The pressure will be applied either to the conservator tank or to the airbag inside the
conservator by introducing Nitrogen (N2) gas / Dry air.
One pressure gauge to be connected to the inlet side and another pressure gauge should
be used at the bottom of the tank. The pressure to be monitored by taking initial
readings(without application of gas pressure) and to these readings the additional pressure
of 0.35 bar (5.15 psi approx ) to be applied. The final reading with the gas pressure
obtained should be monitored for 24 hours.

Test Procedure

o Ensure complete erection of the Transformer accessories, all bolt joints

connection tightened with the recommendation torque value and oil is completely
filled in the main tank, radiators, OLTC Chamber, OLTC conservator and
sufficient oil level at the main conservator tank. All the operation followed strictly
in line with the manufacturer’s recommendation in operation and maintenance
manual.
o All the thread joints should be covered with Teflon tape to ensure no leaks.
o Ensure all valves are in normal service position, i.e. OPEN position for radiators,
piping system and conservator tank. OLTC Chamber bypass valve should be also
in OPEN position in order to equalize the pressure.
o Final checking for all joints is free from any oil stain or dirt. If any oil stains
found should be cleaned with soap water and surface made dry.
o Nitrogen (N2) gas cylinder / Dry air cylinder /generator shall be located near to
the Breather for Main Conservator.
o Shut the Main Breather Pipe valve and dismantle the Breather. Connect the gas
pipe to the the Main Breather pipe flange connection if the pressure is applied
through the airbag.
o Clamp both the PRD’s to avoid it from operating.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 o In case pressure is applied to the conservator tank then open the equalizing valve
for air bag and main conservator in order to avoid excessive pressure being
applied to the bag.
o If the PRD’s not clamped, then make the main tank conservator oil level to
around 10 deg celsius to avoid PRD from operating.
o Record the initial pressure reading at the pressure gauge connected to the bottom
of the main tank.
o Introduce N2 gas/ Dry air into the transformer either from the air bag or through
the conservator tank until the pressure at the bottom reads normal static head
pressure + 0.35 bar.
o Record these final pressure reading at the bottom of the main tank. Maintain these
pressure for 24 hours. If any increase / decrease taking place due to ambient
temperature it should be ignored.
o Tight shut the N2 / dry air gas pipe valve and monitor the pressure trend for 1 to 2
hours, to stabilize the pressure.
o Hourly log the pressure readings along with the oil temperaturel/ambient
temperature for 24 hrs.
o Hourly monitoring of the flange joints and oil seal joints continuously for the
initial 3-4 hrs followed by again monitoring for the final 3-4 hrs.
o Any indication of pressure drop due to the leakage detected on the main tank /
assembly through out the test duration, the Oil Leak Test shall be considered
failed.
o Check for any leakage at all inspection covers , gasketted joints and weld section.
No oil spill, leak or drip should occur.
o It shall be deemed that the Transformer has passed this test if the transformer
main tank, radiators, conservator and all flanges, joints, weld, valves and fittings;
all is oil tight and free from leaks.
o After the leak test successful, release the gas and connect back the breather.

Note :
1) Since there is considerable variations of ambient temperature throughout the
day , its very important to take into account the pressure increase / drop
because of the same. The pressure at the start and at final stage after 24
hours should be approximately same if the ambient is almost the same.
2) Pressure should be checked only at the flange opening of PRD and not at the
spring side.

50) After leak test found to be ok, do air venting & nitrogen processing for Air bag.
Refer the procedure below.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 METHOD STATEMENT - Airbag Normalizing

Airbag processing without vacuum

Proceed as follows:
- Inflate airbag to 0.1 maximum bar, letting the air vent on the conservator open.
-Maintain the device at a constant temperature and verify if exist a loss of pressure for a
period of 24 hours. If there is no loss of pressure, then you can considered that the air bag
and the conservator have been perfectly mounted. (This step may be done if airbag found
leaking)
- Inject oil at low pressure by the lower part of the conservator until it escapes through the
airvent plugs in the upper part.
- Close the air vent plugs and fill the oil in the conservator through the lower part, while
letting the air bag deflated progressively.
- Conclude with the fill up when the oil reaches the level of operation temperature.

Airbag processing under vacuum

Proceed as follows:
-Open equalizing valve and Create vacuum inside the airbag as well as conservator.
-Open the valve at the lower part to fill oil. Due to vacuum in the conservator, the oil
level will rise automatically. Stop filling oil once the volume required in the conservator
is reached
-Maintain conservator under vacuum, but let dry air or nitrogen enter airbag, then this
will inflate by itself and will take all the free space because the conservator was not
completely full. Inflate the airbag to a maximum pressure of 0.1 bar
-Check that in the air venting plugs appear oil, guaranteeing that the conservator does not
have anymore air.
-Close the air venting plugs and if it is necessary adjust the level.

IMPORTANT: CAUTIONS
When the device is ready and working, never open the valve/vent plugs in the upper part.
Such opening would create an air current in the upper part of the device creating a drop
in the oil level that is compensated by a drop in the volume of the airbag.
If you think that air has entered the conservator, first, you must inflate the airbag
below 0.1 bar and after that open the venting plugs to bleed oil.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 51) Conduct the guard test ( all alarm and trip contacts for devices installed such as
pressure relief device, buccholz relay, OLTC surge relay, oil level gauge to be
checked either by simulation/ actual operation.

52) All the tests on the transformer for site acceptance will be done.

These tests to be conducted by TNB CMU

a) Frequency response analysis
b) Insulation power factor test for bushings and windings at 10 kV.
c) Excitation current test at 10 kV.
d) Voltage ratio test.
e) Vector group test.
f) Magnetic balance test.
g) Impedance test
h) Winding resistance test.
i) Insulation resistance & polarization index for windings & core frame.
j) Dirana test.

Contractor Checks / Tests: (OEM Test)

a) Physical Inspection

b) Insulation Resistance test

The test shall be performed using a 5 kV insulation tester.
The following measurement must be recorded: -
1) Between Primary and Earth
2) Between Secondary and Earth
3) Between Primary and Secondary
4) Between Tertiary and Earth
Limits : All values must exceed 1 G

c) Transformer insulation oil tests

1) Moisture content (ppm)
2) Neutralization Value
3) Interfacial Tension
4) Oil Colour index
5) Carbon test
6) Density test
7) Inhibitor Content
8) Viscosity at 40 deg C
9) Dielectric Breakdown test (kV) at 2.5mm gap
10) Oil Power factor

d) Mechanical (oil leak test)

e) Local operation tests

PMU Mersing / PMU Masjid Tanah
ET10506/1 , 45 MVA , 132 / 33 /11 kV
Note :

1) During the filter processing it is very important to have the breathers fitted on
transformer , skid tank, vacuum break should be done preferably with nitrogen
gas or dry air.

2) Right vacuum guage (Mcleod guage or Pirani Guage) to read fine

vacuum i.e 1.0 torr and below and different hose pipes for vacuum and oil
filteration to be used. The length of hose pipe for vacuum as well as location
of vacuum pump should be near to the transformer. The vacuum gauge to be
installed on transformer.

3) Also make sure the skid tank is clean from the inside, the filter cartridge is
clean.

4) Filter machine if used for filteration of refurbished /repaired transformers or

filtration of OLTC should be flushed properly with clean oil.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
PMU Mersing / PMU Masjid Tanah
ET10506/1 , 45 MVA , 132 / 33 /11 kV
PMU Mersing / PMU Masjid Tanah
ET10506/1 , 45 MVA , 132 / 33 /11 kV
PMU Mersing / PMU Masjid Tanah
ET10506/1 , 45 MVA , 132 / 33 /11 kV
PMU Mersing / PMU Masjid Tanah
ET10506/1 , 45 MVA , 132 / 33 /11 kV
PMU Mersing / PMU Masjid Tanah
ET10506/1 , 45 MVA , 132 / 33 /11 kV
PMU Mersing / PMU Masjid Tanah
ET10506/1 , 45 MVA , 132 / 33 /11 kV
 SAFETY PROCEDURE

1. INTRODUCTION

This method of statement is meant for the installation of power transformer in general.

1. GENERAL SAFETY PRECAUTION

 All workers shall wear minimum PPE during the whole work duration.
 While working in a live substation, barricading the work area with a suitable
means (red/ white tape, plastic chain, etc) and put necessary and sufficient
warning sign. Ensure that the work is restricted inside the confined area.
 If crane usage is required, ensure that the crane is properly parked and secured.
Ensure clear communication between the driver and the team supervisor to avoid
miscommunication. Inspect all lifting units are in good condition.
 All machines and tools that going to be used must be in good working condition.
Carefully check for any damaged or broken parts.
 When working with filteration machines, ensure all hoses having no leaks,
properly connected and sealed. Should there any oil leak, immediate action to
clean up must be taken to avoid any accident due to slippage.
 When working at height, ensure that the area below is clear. Carefully not to drop
any tools/ items that may hit others.
 When lifting part/ accessories, ensure that the item is properly secured. Do not
stand directly below the item being lifted.
 All lifting equipment e.g sling wires, shackles shall be visually inspected prior to
any lifting works being carried out.
 For any lifting work, the instruction to commence lifting originates from the
supervisor/signal man after getting acceptance from project site supervisor.

1.1 DO’S and DON’TS for safety Measures/Precautions :

 Safety measures/precautions should be given the due importance during inspection/

erection/maintenance work. Any mishap during the process will result in delay in
erection, endangering human life, endangering equipment life.

DO’S :

1. IMP. : Insulating oil and insulation for windings and connections are inflammable.
Watch for fire hazards.
2. Replace Nitrogen gas completely with air if it was filled in main unit for
transport/storage.
3. Make sure that nothing is kept inside the pockets before one enters inside main unit.
Also take off the wrist watches and shoes.
4. List up all the tools and material to be taken inside and check it after coming out to
make it sure that no tools is left inside.
5. There must be a protective guard for lamp to be taken inside.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 6. Keep inspection covers open for supply of fresh air, when working inside.
7. When one person is working inside, second must be outside for emergency.
8. Use fix spanners, tie them to wrist of person or somewhere outside the tank.
9. Be careful during connections where bolted joints (jumper connection) are involved.
So that, nuts/washers etc., are not dropped inside the tank.
10. Attach the caution tags “DO NOT OPERATE THE SWITCHES” while working on
energized unit.
11. Make sure that the fire-fighting equipment are available at the oil- treatment
equipment as well as work place and adjacent to the transformer.
12. Transformer tank as well as oil treatment equipment shall be connected with
permanent earthing system of the station.
13. Check air cell in conservator
14. Attend the leakages on the bushing.
15. Examine the bushings for dirt deposits and coats, and clean them periodically.
16. Check the oil in transformer for di-electric strength and moisture content and take
suitable action for restoring the quality.
17. Check the oil level in oil cup and ensure air passages are free in the breather. If oil
is less, make up the oil.
18. If inspection covers are opened or any gasket joint is to be tightened, then tighten the
bolts evenly to avoid uneven pressure.
19. Check and clean the relay and alarm contacts. Check also their operation, and accuracy
and if required change the setting.
20. Check the pointers of all gauges for their free movement.
21. Clean the oil conservator thoroughly before erecting.
22. Check the OTI and WTI pockets and replenish the oil, if required.
23. Fill oil in transformer at earliest opportunity at site &follow storage instructions.
24. Check the door seals of Thermojunction Box. Change rubber lining if required.
25. Ensure proper tightness of top terminal cap of condenser bushings to avoid rain water
entry.
26. Check oil level in condenser bushing, any discrepancy should be reported to
Manufacturer.

DON’TS :

1. Do not take any fibrous material such as cotton waste inside while repairing.
2. Do not drop any tools/materials inside.
3. Do not stand on leads/cleats.
4. Do not weld, braze or solder inside the tank.
5. Do not weld anything to tank wall from outside.
6. Do not weld anything to conservator vessel if bag is inside.
7. Do not Smoke on or near the transformer.
8. Do not use Fibrous cleaning material, as it can deteriorate oil if mixed with it.
9. Do not leave off circuit tap switch handle unlocked.
10. Do not use low capacity lifting jacks on transformer for jacking.
11. Do not change the settings of WTI and OTI alarm and trip frequently. The setting
should be done as per the site condition.
12. Do not leave any connection loose.
13. Do not meddle with the protection circuits.
14. Do not leave Thermojunction box/M.Box doors open, they must be locked.

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV
 15. Do not switch off the heater in TJ Box/Marshalling box except to be periodically
cleaned.
16. Do not leave ladder unlocked, when transformer is ‘ON’, in case it is provided.
17. Do not store transformer for long after reaching site. It must be erected and
commissioned at the earliest.

Prepared By

Mohammad Hafiz Shaikh

Head - Services
Crompton Greaves Limited

PMU Mersing / PMU Masjid Tanah

ET10506/1 , 45 MVA , 132 / 33 /11 kV