3/7/2014 Quality Control procedure for Power Transformer | jasteen

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Quality Control procedure for Power Transformer

Posted on January 11, 2011

1.0 PURPOSE

The purpose of this procedure is to describe the system of control for all activities and define the sequence of
work for installation of Power Transformer. This procedure also includes the interface, and responsibilities
relating to Power Transformer Installation & Testing activities, in compliance with project specifications and
IFC drawings.

2.0 SCOPE

The scope of this procedure covers the activities of Power Transformer and related inspection activities to
meet project specification & shell standards.

3.0 REFERENCES

3.1 CUSTOMER / COMPANY DOCUMENTS:

DEP 33.65.40.31- Gen – Power Transformers

DEP 33.64.10.10- Gen – Electrical Engineering Guidelines
- Power Transformers
DEP 82.00.10.10 Gen – Project Quality Assurance
– Material Identification & Traceability Procedure
– Material Receipt Inspection Procedure
– Preservation of Project Equipment & Material.
– Engineering Specification for Concrete works.
– Power & Auxiliary Transformers, Water Injection Cluster.
– Specification for Neutral Earthing Resistor.
– Hazardous Area Equipment & Electrical Bulk Materials.
– Electrical Engineering Design.

3.2 DOCUMENTS:

3.2.1QA/QC Documents:

- Project Quality Plan

- Inspection and Test Plan for Electrical Installation.

- Quality Control Procedure for Material Identification and Traceability

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3.2.2 HSE Document:
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4.0 ABBREVIATIONS Enter your email address

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4.1 Company :
4.2 Contractor : Pow ered by WordPress.com

4.3 Sub Contractor :

4.7 ITP : Inspection and Test Plan
4.9 QA : Quality Assurance
4.10 QC : Quality Control
4.11 RFI : Request for Inspection
4.13 NCR : Non Conformance Report
4.14 PQP : Project Quality Plan
4.10 HSE : Health Safety & Environment.

5.0 ROLES AND RESPONSIBILITIES

Following are the roles and responsibilities of personnel involved in this scope of procedure.

5.1 PROJECT MANAGER:

Project Manager shall report to the Project Director

Shall be responsible for the execution of the project in line with the contractual requirements.

5.2 QA/QC MANAGER:

QAQC Manager shall report to the Project Manager.

Shall be responsible for ensuring the Project Quality requirements and shall monitor all the Quality related
issues throughout the project.

5.3 HSE MANAGER:

HSE Manager shall report to the Project Manager

Shall be responsible for ensuring the Project HSE requirements and shall monitor all the HSE related issues
throughout the project.

5.4 PROJECT DOCUMENT CONTROLLER:

Document controller shall report to the Project Manager.

Shall be responsible for controlling & issuing all the Project related documents throughout the Project. He
shall be key point to receive and transmit documents from the CONTRACTOR and to the CONTRACTOR. He
shall maintain the status of documents like revisions, approvals etc.

5.5 CONSTRUCTION MANAGER:

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Construction manager shall report to the Project Manager

Shall be responsible for arranging necessary equipment, man power, consumables, areas for storage,
erection, preservation and ensuring that the procedure is implemented and complied with all specifications
and HSE requirements.

5.6. PLANNING ENGINEER:

Planning Engineer shall report to the Project Manager.

Shall be responsible for monitoring the equipment receipt and erection activities in line with the schedule /
targets given by the CONTRACTOR’s Project controls department. He shall be responsible for planning the
field erection activities including but not limited to the materials, machinery and manpower.

5.7 CONSTRUCTION ENGINEER:

Shall report to the Construction Manager.

Shall coordinate and interface with Contractor’s construction engineer to ensure the work front availability
at site. He shall be responsible for arranging the tools & tackles, issue of drawings for erection, monitoring the
drawing revisions and modifications if any to meet the progress target set by the Project controls.
Shall ensure the preparation of daily reports.

5.8 STORE KEEPER:

Shall report to Material controller.

Shall be responsible for proper storage and issue of special tools, gaskets, bolts & nuts and other accessories
received with equipments, as per the manufacture’s recommendations.

5.9 QA/QC ENGINEER:

.
Shall report to the QC Manager
Shall be responsible to ensure that works carried out at site are complied with project quality requirements,
to identify and intimate the CONTRACTOR for the hold, witness and review points as described in the
inspection and test plan for Electrical Installation. He shall interface and coordinate with the CONTRACTOR’S
Lead QC Manager to resolve the issues related to quality and shall monitor the Implementation of procedure at
site.

5.10 QC INSPECTOR E & I:

Shall report to the QC Engineer.

Shall inspect the incoming equipment and verify the materials received are confirming to the AFC
Drawings.

6.0 CONSTRUCTION EQUIPMENTS

Cranes, Fork Lifts, lifting belts, slings and other necessary tools and tackles for rigging & material handling
operation shall be calibrated & colour coded as per HSE requirement.

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Hand tools & calibrated Testing Equipments suitable for Transformer installation & testing
The Supervisor / Foreman shall ensure that the equipment & accessories used are suitable for the job and
are in good working condition. Electrical Connections made to complete the electrical work shall be as per
good engineering practices.

7.0 DRAWING RECEIPT & ISSUE OF EQUIPMENT

The Engineering Department will issue to construction department the Issued for Construction Drawings
provided with Material Traceability List complete with information such as identified profile and description
to corresponding material items.

After receiving the Issued for Construction Drawings, the Construction Department will request the equipment
from the Store. The Store will issue the Material issue Slip with equipment stated.

8.0 CALIBRATION CONTROL

The measuring instruments like Insulation Tester, Low resistance meter(Ductor), Multimeter, Clamp meter,
Primary & Secondary Current injection Testing Kit. and surveying instruments, spirit level, measuring tape
etc. deployed in erection activities shall be calibrated periodically once in six months at certified laboratory
and the certificates may be submitted for review. The certificates are to be made available at site during
various stages of inspection.

9.0 QUALITY CONTROL

9.1 Receiving Inspection:

9.1.1 Check the availability of “IFC” drawings, vendor manuals and instructions etc.

9.1.2 Equipment received will be stored according to the installation schedule

and manufacturer’s instruction.

9.1.3 All Material Receiving Inspection to be completed before installation in position and if any discrepancy
found, item will be entered in the punch list and maintain a record.

9.1.4 Proper protection will be provided against wind, dust, rain corrosion etc.

9.2 Inspection Prior to Installation:

9.2.1 Foundation release note shall be received from civil department prior to installation work.

9.2.2 Prior to installation of the equipment foundation shall be inspected in order to

Confirm AFC drawing requirements for dimension, center line coordinate,
elevation and layout.

9.2.3 Check that the orientation marks are provided prior to installation.

9.2.4 Test certificates for the lifting cranes, tools & tackles shall be made available &

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accepted by HSE person.

9.2.5 All the tools and tackles used for installation works shall be of good quality.

9.2.6 Lifting space availability shall be verified.

9.2.7 Temporary platform or scaffolding required shall be fixed prior to lifting the
equipment.

9.2.8 Safety personnel shall be informed about all the heavy lifts well in advance.

9.3 The erection area shall be cordoned off and proper signboards shall be provided.

Preservation & protection shall be followed by the vendor instruction manual /

Preservation of project equipment

9.4 Assembly:

9.4.1 Contractor shall ensure site assistance of the equipments Vendor support
specialized person present & supervise during assembly of the transformer.

9.4.2 RFI shall be raised 24 hours before the actual schedule for Inspection as per
the approved ITP.

9.4.3 Extreme care shall be taken against any entry of foreign contaminants into the Transformer tank during
assembly or internal inspection.

9.4.4 No blank plate or access disk shall be opened or removed from the
transformer assembly if there is slightest possibility of disturbed environmental
changes (sand storm, dust cloud, rain or heavy humidity)

9.4.5 Any open earthworks or grading operation within the local vicinity of the
transformer erection / installation shall be suspended until the transformer
installation & oil circulation actions are completed.

9.4.6 The number of tools used inside the Transformer shall be counted before and
after work, in order to ensure that non left inside.

9.4.7 Tightening of the gaskets shall be as per Vendor manual instruction.

9.4.8 Examine the bushing for dirt deposit and clean them as per Vendor Manual

9.4.9 Check the oil level in the oil cup and ensure that air passages are free in the
breather.

9.4.10 Check the OTI and WTI pockets and replenish oil if required.

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9.4.11 Do not leave secondary terminals of CT open.

9.4.12 Do not mix OLTC oil with main tank oil during circulation.

9.4.13 Fire fighting equipment shall be available near the oil treatment equipment as
well as the work site adjacent to the transformer.

9.4.14 All installation shall be carried out as per Vendor Manual.

9.5 INSTALLATION PROCEDURE

9.5.1 Transformer Position & Levelling.

9.5.1.1 Transformer shall be installed at a level floor strong enough to support the
weight and prevent accumulation of water.

9.5.1.2 The Transformer foundation shall be provided with adequate oil soak pit and
drains.

9.5.1.3 The Transformer foundation shall be prepared at a location such that the
Transformer shall get enough air circulation to cool the Transformer.

9.5.1.4 The Transformer shall be moved into position on the substation pad and base
shall be leveled. Install shims under the base for levelling if necessary.

9.5.1.5 The Transformer Installation shall be such that there is easy accessibility for
inspection.

9.5.1.6 The Transformer position shall be such that the breather, oil level indicator,
name plate, dial thermometer etc can be examined with the Transformer
energized.

9.5.1.7 The sampling valve, drain valve etc shall be at convenient locations.

9.5.2 Turret Installation

Remove the blank plate on the turret and on the transformer tank. Drain if any
oil present in the turret. Clean properly and placed them on the tank in correct
orientation as per the drawing, tighten all nuts over the stud.

9.5.3 Bushing Installation

9.5.3.1 Before starting the bushing installation check for any damage or oil leakage and clean the Bushing as
per vendor Manual Instruction

9.5.3.2 Lift the bushing to inclined position with respect to vertical, the angle of
inclination shall match with the angle of position to which the bushing to be

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erected.

9.5.3.3 Care shall be taken to avoid dragging the bushing on the floor while lifting from
its horizontal position to vertical inclination.

9.5.3.4 Open the blank plate of the turrets and take out the winding leads.

9.5.3.5 Slowly insert the bushing through the turret, which is bolted with the winding
leads. Finally the lead reaches the top of the bushing and the bushing sits
over the turret.

9.5.4 Radiator Installation

9.5.4.1 Radiator panels and flange mating surface shall be inspected for any damage
during transportation.

9.5.4.2 Check all valves on tank flanges are closed and remove all blank plates

9.5.4.3 Remove blank plates on radiator flanges and inspect for moisture or any type
of contamination inside radiator headers. If radiators are contaminated,
flushing is required.

9.5.4.4 Lift the radiator by means of single lifting eye at the top and install radiators.
Bolts shall be drawn up evenly, alternating across the corners, top and
bottom, until spring washers are fully compressed.

9.5.4.5 Follow the vendor manual Procedure for Transformer oil filling

9.5.5 Installation of Cable Box & Termination

Bushing insulation of cable box shall be checked for damage.

9.5.6 Temperature Indicator

Oil & winding temperature indicators shall be calibrated & fixed on the top of
the main tank

9.5.7 On Load Tap Changer Assembly

Check the tap couple with the driving mechanism

9.5.8 Neutral Earthing Resistor

9.5.8.1 Open and check for any physical damage.

9.5.8.2 Align the NER panel as per the manufacturer’s drawing.

9.5.8.3 Earthing connection of the Transformer shall be done as per AFC drawing.
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9.5.9 Buchloz Relay

The Buchloz relay shall be installed between the transformer tank and oil conservator.

9.5.10 All Cable support, Cable Connection shall be completed as per AFC drawing &
Specification.

10.0 TESTING

Following electrical test shall be completed before energizing the transformer

• Transformer oil dielectric Test (BDV Test)

• Winding Insulation Resistance Test

• Primary Winding Resistance Test.

• Secondary Winding Resistance Test

• Vector Group Test

• All CT Test (Polarity Ratio & Magnetization Test if required)

• Protection Device Functional Test

• Tap Changer Setting / Ratio Test in all Taps

• If any other Test recommended by Vendor shall be done.

11.0 HEALTTH AND SAFETY REQUIREMENTS

Prior to commencement of any activity, all personnel involved on the job shall attend the project HSE
Induction training.
The site management, supervisors and safety officers will closely supervise and monitor all phases of
activities in connection with the compliance of safe working models.
Personnel shall use protective gears and clothing in accordance with the project general safety guidelines.
All personnel working in this project shall wear proper personal protective equipment (PPE) such as safety
helmets, safety glasses, safety shoes, hand gloves etc. as required.
All equipment like Cranes, Fork lifts, Chain pulley blocks, lifting belts, slings and other necessary tools and
tackles for rigging & material handling operation, electrical equipment etc. shall be inspected by competent
personnel prior to use at site. Equipment will be regularly checked and inspected by the safety officer.
Any accident / Injury / near miss shall be reported immediately to appropriate authorities. Work shall stop
and area secured
The Construction Engineer / Supervisor shall be responsible for presenting all employees with a Pre-work
briefing / Tool box talk using the risk assessment before work starts.
The Construction Engineer / Supervisor shall immediately correct any hazards observed or reported to him.

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In the case of major hazards, work shall be stopped and appropriate and satisfactory permanent action to
remove the hazards shall be taken.
Good housekeeping shall be maintained at all times

12.0 DOCUMENTATION & RECORDS

– Material Receiving Inspection Check sheet

– Storage Handling & preservation Check sheet
– Inspection of Power Transformer Installation
– Power Transformer Insulation Resistance / Dielectric Absorption / Polarization Index Test Record.
– Power Transformer Oil Dielectric Strength Test
– Grounding Transformer / Neutral Earthing Resistor
– Installation of Neutral Earth Resistor
– Test Record for Neutral Earthing

NOTE: Sample copies of above are as attachments of this procedure.

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About jasteen
Working as Sr. QA/QC Inspector (Electrical) for Galfar Engineering & Cont. Emirates, UAE.
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