IRAQ GATES CONTRACTING COMPANY

Method Statement For SS1 Transformer

Replacement (TMM1.1A) Rev: 01R

7100-IGCC-N003-ISGP-G00000-EA-4816-00035 Rev.01R
Doc.No.IGCC-BGC-ELE-MOS-1779 Doc. EXT

IGCC-BGC FRAMEWORK AGREEMENT (KAZ)

Method Statement For Substation 1 Transformer Replacement

TMM1.1A

IGCC BGC FRAMEWORK AGREEMENT

05A 19/07/2022 Issued for approval Haider Hamad G.G.

04A 16/05/2022 Issued for approval Haider Hamad

03A 13/05/2022 Issued for approval Haider Hamad

02A 26/04/2022 Issued for approval Haider Hamad B.N

01R 19/04/2022 Issued for review Haider Hamad B.N

REV DATE DESCRIPTION PREPARED BY REVIEWED BY APPROVED BY

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 IRAQ GATES CONTRACTING COMPANY

Method Statement For SS1 Transformer

Replacement (TMM1.1A) Rev: 01R

7100-IGCC-N003-ISGP-G00000-EA-4816-00035 Rev.01R
Doc.No.IGCC-BGC-ELE-MOS-1779 Doc. EXT

IGCC-BGC FRAMEWORK AGREEMENT (KAZ)

1 Table of Contents
1 Purpose........................................................................................................................................................... 3
2 References...................................................................................................................................................... 3
3 Definitions/Abbreviations.............................................................................................................................. 3
3.1 DEFINITIONS:....................................................................................................................................................... 3
3.2 ABBREVATIONS:.................................................................................................................................................. 3
4 RESPONSIBILITIES........................................................................................................................................ 4
5 Scope of work................................................................................................................................................. 4
6 Major Equipment List..................................................................................................................................... 4
7 DESCRIPTION OF ACTIVITIES....................................................................................................................... 5
7.1 Prior to Start the Work................................................................................................................................... 5
7.2 Pre-Shutdown Activities................................................................................................................................ 5
7.3 Shutdown Activities....................................................................................................................................... 6
8 Personnel and equipment.............................................................................................................................. 8
9 Required Training........................................................................................................................................... 8
10 HSE.................................................................................................................................................................. 9
10.1 HSE Requirements......................................................................................................................................... 9
10.2 Inspection, audit, toolbox, TRIC, etc............................................................................................................. 9
10.3 Permit requirements....................................................................................................................................... 9
10.4 PPE.................................................................................................................................................................. 9
10.5 Welfare Arrangement................................................................................................................................... 10
10.6 Emergency Actions & Equipment............................................................................................................... 10

10.6.1 First Aid................................................................................................................................10

10.6.2 Emergency Actions.............................................................................................................10
11 Attachment.................................................................................................................................................... 10

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 IRAQ GATES CONTRACTING COMPANY

Method Statement For SS1 Transformer

Replacement (TMM1.1A) Rev: 01R

7100-IGCC-N003-ISGP-G00000-EA-4816-00035 Rev.01R
Doc.No.IGCC-BGC-ELE-MOS-1779 Doc. EXT

IGCC-BGC FRAMEWORK AGREEMENT (KAZ)

1 Purpose

To mitigate the issue of voltage variation and power demand in future, it is proposed to destruct the
existing 4 x 12MVA incoming transformers, TMM 1.1 A/B and TMM 1.2 A/B and install replacement 4 x
15MVA transformers complete with on load automatic tap changer and all ancillary equipment.

2 References

 IGCC Quality Assurance & Quality Control Procedures.

 IGCC Safety Procedures
 ISO 9001:2015 - Quality Management System – Requirements.
 ISO 14001 Environmental Management System
 Destruct Workpack for TMM1.1A & TMM1.2A (9500-WGEL-N003-ISGP-G00000-BA-5794-12101)
 Destruct Workpack for TMM1.1B & TMM1.2B (9500-WGEL-N003-ISGP-G00000-BA-5794-12102)
 Installation and Hook Up Workpack for TMM1.1A & TMM 1.2A (9500-WGEL-N003-ISGP-G00000-BA-
5794-12103)
 Installation and Hook Up Workpack for TMM1.1B & TMM 1.2B (9500-WGEL-N003-ISGP-G0000-BA-
5794-12104)
 BGC WMPs 2, 7, 11, 19, 20, 24, 25, 26 - CSE, Tools, Hazard Recognition, Lifting & Hoisting,
Isolations, EPTW, PTW, PPE & Safety Signs and Barricades – a specific EPTW is required when
working on TMM1.1A 33kV, a normal PTW will be used for installing RTCCs etc.

3 Definitions/Abbreviations

3.1 DEFINITIONS:

CONTRACTOR (IGCC) - Iraq Gates Contracting Company

COMPANY – BASRA GAS COMPANY (BGC)

PROJECT – IGCC BGC FRAMEWORK AGREEMENT (DP130 Transformer Replacement)

3.2 ABBREVATIONS:

ITP : Inspection and Test Plan.

QA : Quality Assurance
QC : Quality Control
QMS : Quality Management System
EMS : Environmental Management System

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 IRAQ GATES CONTRACTING COMPANY

Method Statement For SS1 Transformer

Replacement (TMM1.1A) Rev: 01R

7100-IGCC-N003-ISGP-G00000-EA-4816-00035 Rev.01R
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IGCC-BGC FRAMEWORK AGREEMENT (KAZ)

4 RESPONSIBILITIES

Electrical engineer
Overall vision for the work and coordination with all departments and client to check the work are
executed according to SOW, client specifications by applying of all HSE and quality requirements.

Overall vision for the work and coordination with all department and client to check the work are
executed according to SOW, client specifications by applying of all HSE and quality requirements.

Site Supervisor
Follow-up execution of work activities in daily base by coordination with HSE supervisor, logistic
team and QC inspector.
Preparation & reviewing of Method Statement and JHA/ Risk Assessment with HSE Advisor.
Reporting to mechanical engineer.

HSE Advisor
Preparation & reviewing of Method Statement and JHA/ Risk Assessment with Mechanical
Supervisor.
Coordinate with HSE supervisor for providing of all HSE requirements as per site conditions.
Follow-up with client.
Reporting to Mechanical engineer.

Workers
Performing of all activities as per approved method statement and according to HSE and Quality
requirements.
Reporting to site supervisor.

5 Scope of work

 Destruct Work for existing transformer, TMM1.1A

 Installation and Hook Up Work for new transformer, TMM1.1A
 MV cable installation and termination between new MS1.1B Incomer and old MS1.1A incomer
 LV Cable Migration for MS1.1A
 Installation of new 63A, 4P MCCB in ASP1.1 – for supplying ACDB-1

6 Major Equipment List

 Existing 33kV Distribution Board, HS1

 Existing 12MVA Transformer, TMM1.1A
 Replacement 15MVA Transformer, TMM1.1A
 Remote Tap Changer Panels, RTCC 1.1A, RTCC 1.1B, RTCC 1.2A and RTCC 1.2B
 Distribution Boards, ACDB-1 and DCDB-1
 Existing ASP1.1 (Power Supply to ACDB-1)
 Existing DCP1.1 (Power Supply to DCDB-1)
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 IRAQ GATES CONTRACTING COMPANY

Method Statement For SS1 Transformer

Replacement (TMM1.1A) Rev: 01R

7100-IGCC-N003-ISGP-G00000-EA-4816-00035 Rev.01R
Doc.No.IGCC-BGC-ELE-MOS-1779 Doc. EXT

IGCC-BGC FRAMEWORK AGREEMENT (KAZ)

7 DESCRIPTION OF ACTIVITIES

7.1 Prior to Start the Work

Following WMP guidelines contained in:

WMP# 24 Permit to work
WMP# 26 Safety Signs & Barricades
WMP# 2 Confined space entry
WMP# 19 Isolations
WMP# 20 Lifting & Hoisting
WMP# 7 Hand & Power Tools
WMP# 11 Hazard Recognition
WMP# 25 PPE
a. Obtain a valid EPTW and/or PTW with attachment of approved method statement, JHA.

b. Equipment’s shall be tested and calibrated, for each device should have valid BGC inspection
certificate.

c. Mobilization of all materials to site

d. Area Barricaded with all HSE signs.

e. Prepare the work according the HSE WMP.

f. Print and fill all the applicable CSSS for this task before and during the execution of the work.

7.2 Pre-Shutdown Activities

Following WMP guidelines contained in:

WMP# 2 Confined space entry
WMP# 24 Permit to work
WMP# 20 Lifting & Hoisting
WMP# 7 Hand & Power Tools
WMP# 26 Safety Signs & Barricades
WMP# 11 Hazard Recognition
WMP# 25 PPE
1. Civil work preparation
 Leveling the lifting area for crane settlement by using JCB
 Compacting the area suitable for crane
2. Assembling of transformer wheels of TMM1.1A
 Mechanical technicians shall execute the work
 In case of welding required, certified welder shall execute the work
3. Installation of 4 x RTCC and 2 x DB panels
 Pre-fabrication of panel frames/plinths at IGCC workshop for RTCC panels
 In case of Floor slab cut outs being required for cable entry, we will utilize core cutting equipment.
 Modify metal floor plate for Supply cable entry to ACDB-1 and DCDB-1
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Method Statement For SS1 Transformer

Replacement (TMM1.1A) Rev: 01R

7100-IGCC-N003-ISGP-G00000-EA-4816-00035 Rev.01R
Doc.No.IGCC-BGC-ELE-MOS-1779 Doc. EXT

IGCC-BGC FRAMEWORK AGREEMENT (KAZ)

 Use of Hiab for transportation of panels to SS1
 Use of Hydraulic trolley to install the panels inside SS1
4. Installing cable tray inside SS cellar room and transformer yard
 Pre-fabrication for tray support at IGCC workshop
 Using power and hand tools for fixing of cable tray
 All the sharp edge shall be deburred, painted, and protected by rubber edging to avoid damaging
the cable
5. Installation of power and control cables between RTCC 1.1A/B, RTCC1.2A/B, DBs, TMM1.1A, new MS1.1,
old MS1.1, new MS1.1, ASP1.1 and DCP1.1
 Cable pulling will be done manually by electrical technicians
 All the technicians working inside cellar room shall have confined space entry training
 Hand tools and power tools are required for glanding and termination activities and ensuring
correct gland size for each cable and correct cable ferrules.
 Upon completion of cable pulling, dressing of cables is required for neat finishing. Cable ties shall
be used for dressing and according to BGC specification

7.3 Shutdown Activities

Following WMP guidelines contained in:

WMP# 24 Permit to work

WMP# 19 Isolations
WMP# 20 Lifting & Hoisting
WMP# 2 Confined space entry
WMP# 7 Hand & Power Tools
WMP# 26 Safety Signs & Barricades
WMP# 11 Hazard Recognition
WMP# 25 PPE

1. Coordinate with Operations & Electrical Maintenance team to perform isolation for TMM1.1A feeder and
incomer and ensure LOTO system is applied, all primary and secondary cables to be proved DEAD
before works begin – EPTW must be issued prior to any work on TMM1.1A being carried out.

2. Dismantling and re-installing of TMM1.1A transformer shade

 Installing scaffolding by certified scaffolder – Erection of scaffold around the transformer TMM1.1A
to allow the disconnection of cables both 33kV and 3.3kV. Erect a protection scaffold cover to
protect it from falling materials during removal of transformer shade. Remove scaffold to allow
removal of the transformer.
 Dismantling and re-installing of transformer shade by mechanical technician – Scaffold protection
will be erected to protect new transformer. Shelter will then be reinstated. Scaffold will then be
removed.
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Method Statement For SS1 Transformer

Replacement (TMM1.1A) Rev: 01R

7100-IGCC-N003-ISGP-G00000-EA-4816-00035 Rev.01R
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IGCC-BGC FRAMEWORK AGREEMENT (KAZ)

 Using crane to dismantle and re-install the structure of the shade – shade materials will be laid in a
free space near SS-1 and storing by using hard barrier.

3. Disconnecting and destructing of cables by using hand tools

 Disconnecting of 3.3KV and 33KV power cables from transformer TMM1.1A and existing SWGRs
(HS1, MS1.1A) sides

 Disconnecting of control cables between transformer TMM1.1A and MS 1.1, HS 1 BUS A

 Disconnection of existing NER cable

 Disconnecting of existing transformer and NER earthing cables

4. Destruction of existing transformer and installation of new one

 Transformer lifting method statement will be detailed and submitted separately by lifting team

 Relocation of dismantled transformer shall be decided by BGC

 Ensure orientation of 33kV and 3.3kV terminations for new transformer as per approved layout

5. Destruction of existing transformer NER and installation of new one

 Lifting plan shall be prepared for destructing and installation of NERs – to be submitted separately

 Relocation of dismantled NER shall be decided by BGC

6. Cable glanding and termination

 Cable glanding and termination for LV power and control cables at transformer, DBs, new/old
MS1.1A and HS1 using power and hand tools
 Cable glanding and termination for 3.3kV cables from transformer, NER and SWGR side by using
power and hand tools and MV certified and approved Cable Jointers
 Cable glanding and termination for 33kV cables from transformer and SWGR side by using power
and hand tools and MV certified and approved Cable Jointers
 Reconnect of earthing cables
 Cable Jointer Certificates to be attached to Method Statement

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 IRAQ GATES CONTRACTING COMPANY

Method Statement For SS1 Transformer

Replacement (TMM1.1A) Rev: 01R

7100-IGCC-N003-ISGP-G00000-EA-4816-00035 Rev.01R
Doc.No.IGCC-BGC-ELE-MOS-1779 Doc. EXT

IGCC-BGC FRAMEWORK AGREEMENT (KAZ)

7. Cable Migration for MS1.1A as per below approved SLD

8. Testing and ITRs completion

8 Personnel and equipment

Personnel
 Electrical Engineer 1
 HSE Advisor 2
 Permit Applicant/ Holder 2
 Electrical technician 12
 Skilled labor 4
 Civil technician 6
 Mechanical technician 3
 Lifting supervisor 1
 Certified / Approved 33kV Cable Jointers

EQUIPMENT
 Electrical Hand tools
 Power tools
 Crane
 Hiab

9 Required Training
 CSE training
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 IRAQ GATES CONTRACTING COMPANY

Method Statement For SS1 Transformer

Replacement (TMM1.1A) Rev: 01R

7100-IGCC-N003-ISGP-G00000-EA-4816-00035 Rev.01R
Doc.No.IGCC-BGC-ELE-MOS-1779 Doc. EXT

IGCC-BGC FRAMEWORK AGREEMENT (KAZ)

 MV cable joint training up to 33KV

10 HSE
10.1 HSE Requirements
1- Continuous gas test monitoring is required for CSE work.
2- EPTW and/or PTW need to be in pace along with all required documents (JHA,
MOS, Gas Test certificate, TBT sheet, hot work checklist, etc.)
3- Ensure sufficient supervision on the activities.
4- Equipment and tools need to be inspected and tagged as required and in good
condition.
5- Personnel will comply with all PPE requirements.
6- Ensure using the appropriate tools.
7- Barricade each activity area c/w Safety Signs.
8- Housekeeping.

10.2 Inspection, audit, toolbox, TRIC, etc.

CSSS Inspections will be carried out using the CSSS Check sheets. Check sheets used will
be relevant to the tasks being conducted and will be decided by the HSE Site Supervisor.
Completed check sheets to be filed by the KAZ HSE Lead.

Task Risk Identification Cards will be completed as part of the Permit to Work. These will be
used to drive and record the toolbox talks.

10.3 Permit requirements

- BGC Electrical Permit to Work, EPTW
- BGC Permit to Work, PTW
- BGC Isolation Certificate(s), ICC
- BGC Gas Test Certificate
- BGC Confined Space Entry Permit
- Approved Method Statement
- Approved JHA

10.4 PPE
All personnel are required to wear standard PPE at all times on the worksite which will
consist of:

• Flame Retardant Coveralls

• Safety Boots
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Method Statement For SS1 Transformer

Replacement (TMM1.1A) Rev: 01R

7100-IGCC-N003-ISGP-G00000-EA-4816-00035 Rev.01R
Doc.No.IGCC-BGC-ELE-MOS-1779 Doc. EXT

IGCC-BGC FRAMEWORK AGREEMENT (KAZ)

• Safety Helmet
• Safety Glasses
• Gloves

Personnel will also wear necessary PPE as identified by the JHA or changing site conditions.
PPE must be inspected by the users prior to every use and discarded if found to be
unserviceable. Additional stocks of PPE will be maintained at the KAZ IGCC Camp and may
be obtained through the KAZ HSE Lead.

10.5 Welfare Arrangement

Site welfare arrangements will consist of:

• Provision of coolers and ice,

• Fresh drinking water,

10.6 Emergency Actions & Equipment

10.6.1 First Aid

Site first aid will be provided by the Site HSE Supervisor. A first aid kit will be positioned in
the working area, this will be visibly signed. In case of any injury or illness incident the first
aider will assess and escalate as required. Should more than simple first aid be required
the first aider will call the KAZ emergency number 07809 213 970 and request ambulance
support.

All incidents requiring treatment will be reported to the KAZ HSE Lead for investigation and
reporting through the appropriate procedures.
First aider will check the contents of the first aid kit on a weekly basis and record the check on
the enclosed check sheet.

10.6.2 Emergency Actions

Upon hearing the plant alarm all personnel are to evacuate to the safest KAZ Plant
Emergency Muster point and assemble for a headcount.

Fire on the worksite – Raise the alarm by calling EROC on 07809 213 970, attempt to fight
the fire if trained and comfortable, if the fire is too large and intense muster at the worksite
muster point for a head count then evacuate to the safest KAZ Plant Emergency Muster Point.

All personnel are to be made aware of the emergency arrangements upon initial arrival at

site. Emergency drills will be conducted at the worksite as scheduled by the KAZ HSE Lead.

Records of drills will be maintained.

11 Attachment

JHA for Construction Works related with above

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 IRAQ GATES CONTRACTING COMPANY

Method Statement For SS1 Transformer

Replacement (TMM1.1A) Rev: 01R

7100-IGCC-N003-ISGP-G00000-EA-4816-00035 Rev.01R
Doc.No.IGCC-BGC-ELE-MOS-1779 Doc. EXT

IGCC-BGC FRAMEWORK AGREEMENT (KAZ)

Cable Jointer Authorisation Certificates

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