METHOD STATEMENT OF EXPANSION OF GMR-HIAL

DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD

INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

METHOD STATEMENT OF DRY TYPE

TRANSFORMERS INSTALLATION, TESTING &
COMMISSIONING WORKS FOR PTB & AIR
SIDE

PROJECT EXPANSION OF PTB & AIRSIDE AT RGIA

CLIENT GHIAL

LARSEN & TOUBRO LIMITED

CONTRACTOR
BUILDINGS & FACTORIES (IC)

NSC ELECTRICAL MICRON ELECTRICALS

DOCUMENT NO. GHIAL/LNT/PTB/E/MS/009/R02

Prepared Accepted Reviewed by

Reviewed by Approved by
by Micron by Micron LTC
LTC QA/QC GHIAL
Electricals Electricals execution

NAME

DATE

SIGNATURE

1
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

INDEX

PAGE NO
SL NO DESCRIPTION
FROM TO

1.0 Scope of work 3 3

2.0 Technical specification references 3 3

3.0 Organization charts 4 4

4.0 Tools & Tackles Required 4 4

5.0 Rools & Responsibilities 4 7

6.0 Work Procedure 7 12

7.0 Environment, Health & Safety 13 13

8.0 Annexures 13 13

8.1 Annexure - A – Organization charts (Micron and L&T) 14 15

8.2 Annexure - B - Hazard Identification & Risk Assessment 16 19

8.2 Annexure – C – Pre-Commissioning checklist 20 20

1.0 SCOPE OF WORK:

2
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

This Method Statement refers to the work procedures contained within Micron Project
Quality Plan & Contract Specifications, which explains and covers the supply,
installation, testing & commissioning of Dry Type Transformer works at PTB & Airside.

2.0 TECHNICAL SPECIFICATION REFERENCES:

I. IS 11171 Technical Specification for Dry type Transformer
II. IEC 60076- Part 11: Dry-type transformers
III. IS 2026 (PART 5) 2011, IS 11171 & IEC 60076-11:2018
IV. IS: 10028 (Part 1)-1985,
IS: 10028 (Part 2 & Part 3) - 1981
-Codes of practice for selection, Installation & Maintenance of transformer
V. IS 2026- For Power Transformer

3.0 ORGANIZATION CHART

3
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

Organization chart is a brief chart indicating the persons responsible for

execution of Transformer SITC works. Please refer attachment Annexure –
A- Organization charts.

4.0 TOOLS AND TACKLES

a. Multi meter,
b. Micro ohm meter,
c. 5KV Megger & 500V megger
d. 20A 3 phase MCB
e. 20A 1 phase auto transformer
f. 2.5 sq.mm wires – 10 Mtrs
g. Screw driver set
h. 10/11 spanner
i. Single phase switch board
j. Crane (220 ton) with boom length 42 Mtrs with operating boom of 23 mtrs
k. Torque Wrench
l. D shackle – 9.5 ton each – 4 Nos
m. Wire rope sling – 12 ton each – 4 Nos
n. MS Wheels – 50 ton – 4 nos each.
o. Mechanical jack – 7.5 ton – 2 nos.
p. Oil jack – 25 ton – 2 nos
q. Railway mechanical jack – 25 ton
r. MS plate – 8mm thickness – 2x5 feet
s. Chain block – 3 ton
t. MS channel – 3.5 Mtrs – 23 Nos
5.0 ROLES & RESPONSIBILITY

5.1. Project Manager:

The Project Manager shall be responsible for arranging necessary

manpower, equipments and materials solves the site technical

4
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

problems and ensuring work progress shall be completed as per

construction schedule.
5.2. Project Engineer :
a. Ensure all required submittals are made and required plant / tools / material
and manpower are available in a timely manner.
b. Ensure execution of all works are carried out according to approvals, contract
specifications, Mock up approvals, approved shop drawings, Project Quality
Plan, Method Statement and that safety measures are implemented.
c. Ensure necessary coordination with GC Management / PMC Representatives
and other Agencies for timely completion of works.
5.3. Site Engineer :
a. Timely provision of complete relevant information, Consultant approved
documents and instructions to site execution / installation team.
b. Proper execution of works as per approved material submittals approved
method-statements, approved construction drawings and adopt all safety
measures as required.
c. The implementation of the procedures mentioned in method statement shall
be ensured by concerned Site Engineer / Site Supervisor.
d. To carryout site work activities with regard to Quality and Safety requirements,
Conducting Tool Box Talks to the site workers and co coordinating with
concerned Quality & Safety Engineer.
5.4. Safety Engineer:
a. Ensure implementation of all safety measures and procedures specific to the
nature and type of execution work being carried out at site.
b. To ensure that project personnel / site execution teams are fully aware of their
responsibilities and have full understanding of the related safety rules,
procedures.
c. To advise the involved personnel about the involved risk at work and necessary
health, safety and environment precautions / measures to minimize it.
d. To keep the site management and Consultant informed about the adopted safety
measures at site and ensuring their adequacy.

5
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

e. To ensure continuous inspection/surveillance of site activities, implementation of

HSE policies, advising, training site staff / work men regarding EHS
Implementation. Ensure to take work permits and make sure that HIRA to be
approved before starting the work.
f. Ensure work area to be Barricaded & necessary Tools Box Talk before starting
the Works.
g. Ensure that Experience person to be engaged with all job specific PPE’s
h. Ensure Hydra /Mobile Crane shall be operated by authorized personnel with
Rigger/Signal Man. Display TPI & Operator details Ensure tool & tackles are
TPC[Third Party Certificate]
i. Ensure good supervision ,unauthorized entry prohibited ,good communication,
j. Certified Electrician /Engineer shall perform the electrical job pertaining to HT
Panels
k. Ensure no work force stand under lantern while taking up or bring down
l. Ensure implementation of all safety measures and procedures specific to the
nature and type of execution work being carried out at site.
m. To ensure that project personnel / site execution teams are fully aware of their
responsibilities and have full understanding of the related safety rules,
procedures.
n. To advise the involved personnel about the associated risk at work and
necessary health, safety and environment precautions /mitigation measures to
minimize it.
o. To keep the site management and Consultant informed about the adopted safety
measures at site and ensuring their adequacy.
p. To ensure continuous inspection/surveillance of site activities, implementation of
HSE policies, advising, training site staff / work men regarding EHS
Implementation.

5.5. Quality Engineer:

a. Preparing the Method Statement, ITP, and check list.
b. Calling the client/PMC for inspections.
c. Ensure approved materials are used in the site.
6
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

d. Checking, quality aspects of material, tools and equipment are used at site.
e. Ensure works are performing as per the approved shop drawings.
f. Verify the quality of tools and tackles, their certificates, suitability and
working conditions and keep a record.
g. Completion and verification of installation

6.0 WORK PROCEDURE

Receiving, unloading, shifting and storage:
Transformer shifting proposed routing plan

6.1 . Receiving:
6.1.1 When the transformer is received at site, the following points should be
checked.
6.1.2 The characteristics of the transformer, indicated on the Name Plate,
should coincide with those that appear on the Test Record Sheet and
these, at the same time, should match the order specifications.
6.1.3 Check that the transformer has all relevant safety warnings.

7
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

6.1.4 Check the general state of the Transformer. There should be no dents
6.1.5 - The state of the paint: check that there is no flaking, scratches, etc. on the
enclosure (if the transformer is of this type) or on metallic parts.
6.1.6 Check all of the transformer’s accessories (wheels & Accessories etc.) If any
damage is observed, or if any of these have been lost during transport, the
transport company and manufacturer should be informed immediately to
determine who is responsible and to calculate the cost involved.
6.1.7 Before unpacking the transformer, the difference in temperature between indoors
and outdoors is considerable, a prudential period of time should be waited (2
hour) so that the transformer’s temperature can stabilize. This is to prevent
undesired condensation on the transformer surface.
6.1.8 During transport the transformer should not be moved by pushing on coils or
connections directly.
6.1.9 Cables for dragging can be attached. If the transformer has to be pushed, then
this can be carried out by pushing on the flanges that hold the magnetic circuit in
place.
6.1.10 The top flanges have 4 lifting lugs or holes and hoisting can be carried out by
attaching slings that form an angle of 50-70º to the lifting lugs or to the
transformer enclosure roof.
6.1.11 The total weight of the transformer 9 tonn. Taking weight of the transformer , 220
tonn / suitable Crane has been considered to lift and place at the locations
6.1.12 The attachment holes or lifting lugs has a minimum diameter of 40 mm,
considering this D- Shackels 9.5 tonn capacity and sling to be used
6.1.13 The base and cooling elements (in case of fans) are designed to ensure that the
transformer can be moved using a lever and do not impede handling; however,
care must be taken not to push on the encapsulated phases. If levers are used,
we recommend using wooden stops to protect those elements.
Before starting the unload of transformers – below points to be checked at site
 Position of crane to be leveled and barricading to be done
 HT trench to be strengthened by giving the Jack support

8
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

 The Trench openings to be closed with the help of C channel placed on that
8mm thick MS plate to be laid
 Unlevel soil to be leveled and ramming to be done
 Electrical room should be ready to receive the transformers

6.2 Unloading of transformer:

a. 220 ton crane is selected based on the site survey considering the weight
of transformer on secured position without blockage of access
b. Ensure crane outrigger is secured and good condition ,fully extended
c. Use four D-shackle of each 9.5 ton capacity with wire rope sling of each 12
ton capacity for the lifting of Transformer.
d. Provide two tag line to maintain load gravity
e. Lift load up to 150 mm to ensure load secured for lifting
f. Secured and clear any obstruction of unload area

g. Unload transformer on railway jack.

9
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

6.3 Shifting of transformer

 Provide MS channel beams on utility trench slab for increase its bearing
capacity. Check trench load bearing capacity with CMPC department
before unloading transformer.
 Unload the transformer on MS wheel on trench.
 Push the transformer with the help of chain block to its final location.
6.4 Storage
The dry-type transformer is for indoor installation. Do not store in places where it
is exposed to effects of the weather.
If the transformer is not going to be put into operation immediately then it should
be stored bearing in mind the following recommendations:

10
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

6.4.1 The temperature in the storage place cannot be below than –25ºC (C1 and C2
type). When C1 type transformers storage will be lengthy with temperatures
lower than –25ºC it must be consult with the manufacturer.
6.4.2 The place will be dry, clean and good ventilated. When is stored, this type of
transformer should remain inside its plastic packaging cover. In particularly damp
places, bags with humidity absorbing products.
6.4.3. Do not pressure on encapsulated phases, connections or terminals. Do not
damage paintwork.
6.4.4 If the transformer is equipped with plug-in terminals, these should all have cone
protectors to ensure that the terminal contacts remain clean and undamaged.

Ratings of Transformer
I. 2500 kVA Dry Type -11 No’s

6.5. Termination / Testing:

After installation of transformer connect the Body Earth and Neutral Earth Strips as
per approved drawing mentioned sizes.
I. After Megger and Hi Pot tests, terminate the Incoming cable on transformer
II. Incoming cable termination to be done with client approved termination kit.
III. Outgoing Busduct connections shall be done as per approved drawings.
IV. All transformers testing and commissioning is to be done as per relevant
IS/IEC standards.
V. Conduct the simulated site tests and Record the readings in the Test Formats
and get the Approval of the concerned Engineers
VI. Check for correct operation of all protection devices and alarms :
Excessive winding temperature.
VII. Check for the adequate protection on the electric circuit supplying the
accessories
VIII. Check the resistance of all windings on all steps of the tap changer.
IX. Conduct & measure the following tests:
(i) IR test by using megger.
11
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

(ii) Voltage ratio by using multi meter.

(iii) Magnetic core balance & vector group test etc.
(iv) Back feed test by using clamp meter
X. Check for cleanliness of the transformer and the surroundings
XI. Continuously observe the transformer operation at no load for 24 hours.
XII. Gradually put the transformer on load, check and measure increase in
temperature in relation the load and check the operation with respect to
temperature rise and noise level etc.
XIII. Shall prepare a comprehensive commissioning report including all
commissioning test results and forward to Employer for future record.
Routine testing of 2500 kVA:
i) Measurement of voltage ratio at all tap positions
ii. Vector group test at normal tap
iii. Measurement of winding resistance at all tap positions
iv. Measurement of impedance voltage on all taps
vii. Measurement of insulation resistance at 2500 V, DC
xi. Magnetic balance test at normal tap
The entire test as per standard IS-11171 shall be conducted, on
completed transformer assembly. The acceptable values shall be in
accordance with the relevant standard.

12
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

7.0 ENVIRONMENTS, HEALTH & SAFETY:

1. ENVIRONMENTS
 Stop the activity if the climate is rainy, cyclone, and storm.
 Clean the work area from packing cartoons, waste, and other materials etc.
after Completion work
 Ensure no waste, cartoon, papers and other materials shall be flying in air.

2. EHS & SAFETY

 Before start work take WTP(permit to work) with Approved RA
 Work carried out according to RA (Risk Assessment)
 Give PEP Talk/TBT to the workers involved Before starting Work
 to be perform job experience person with all job specific PPE’s
 Hydra Crane operates by authorized operator with Rigger. Display TPI &
Operator details Ensure tool & tackles are TPI [Third Party Inspection]
 Good communication in between mobile crane operator & Rigger/signal man
 Good supervision and good communication with other crew members
 No one should be stand under suspended load while unloading of
Transformers
 Certified & competent electrician perform electrical task
 Use green scaf tag mobile scaffold & locked coaster wheel while work on -
 Use safety harness working at 1.8 meter above height
 If small cable drum follow manual handling method as per EHS plan
 Welding & grinding work follow method as per Site EHS plan.
 Certified testing engineer perform testing & commissioning i.e earth test, etc
task

8.0 Annexures 14 14

8.1 Annexure - A – Organization charts (Micron and L&T) 15 16

8.2 Annexure - B - Hazard Identification & Risk Assessment 17 20

8.2 Annexure – C – Pre-Commissioning checklist 21 21

13
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

8.1 Annexure - A – Organization chart (MICRON

ELECTRICALS)

14
 METHOD STATEMENT OF EXPANSION OF GMR-HIAL
DRY TYPE TRANSFORMERS AIRPORT, HYDERABAD
INSTALLATION, TESTING &
GHIAL/LNT/PTB/E/MS/009/R02
COMMISSIONING

Organization chart (L & T)

15