Method of Statement - Transformer Maintenance - Scanned

WORK METHOD STATEMENT
Customer: MARAFIQ End-user: MARAFIQ

MARAFIQ RFQ No.: N/A Document No.: TCO-MOS-MFTM-19-001
Project Title: MARAFIQ TRANSFORMERS MAINTENANCE WORK
Contents
Introduction .......................................................................................................................................... 5
Reference Documents........................................................................................................................... 5
2.1. Datasheets & Drawings ................................................................................................................. 5
2.2. Reference Standards & Codes....................................................................................................... 5
Responsible Person: .............................................................................................................................. 6
Equipment ............................................................................................................................................. 6
4.1. General Inspection & Testing Equipment: .................................................................................... 6
4.2. Tools Equipment: .......................................................................................................................... 7
4.3. Consumable Tools Equipment: ..................................................................................................... 7
Scope of Work: ...................................................................................................................................... 9
Method of Preparation: ........................................................................................................................ 9
6.1. General steps ................................................................................................................................ 9
6.2. Scaffolding Installation................................................................................................................ 10
Procedures of Visual Inspection & Preventive Maintenance: ............................................................ 10
7.1. Visual Inspection of Transformers: ............................................................................................. 10
7.2. Infrared Temperature Analysis ................................................................................................... 11
7.3. Preventive Maintenances (Plans Based) ..................................................................................... 12
7.3.1. Half Year Preventive Maintenance (HYPM) ........................................................................ 12
7.3.2. 2-Yearly Preventive Maintenance (2YPM) .......................................................................... 13
7.3.3. 4-Yearly Preventive Maintenance (4YPM) .......................................................................... 15
7.3.4. Corrective Maintenances .................................................................................................... 18
7.4. Transformer Replacement General Procedure: .......................................................................... 19
7.4.1. Transformer Dismantling .................................................................................................... 19
7.4.2. Storage and Off-loading ...................................................................................................... 20
7.4.3. Pre-Installation .................................................................................................................... 20
7.4.4. Installation .......................................................................................................................... 20
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This Method of Statement is project specific and shall be dealt as par that. Contains confidential information.

7.4.5. Testing & Commissioning:................................................................................................... 21

7.5. Grounding of the Transformers: ................................................................................................. 22
7.5.1. Testing Procedure - Fall of Potential Measurement Method ................................................. 22
7.5.3. Removal, Re-Installation & Testing of Cables ......................................................................... 25
QA/QC Requirements: ........................................................................................................................ 27
Health & Safety ................................................................................................................................... 28
9.1. General Hazard ........................................................................................................................... 28
9.2. Site Safety ................................................................................................................................... 28
9.3. Manual Handling Risks ................................................................................................................ 28
9.4. Risk of Falling .............................................................................................................................. 28
9.5. Personal Protective Equipment (PPE) ......................................................................................... 28
9.6. General Instructions Safety......................................................................................................... 29
Attachments........................................................................................................................................ 30
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Introduction
This Method Statement covers general standard procedures for the maintenance of Transformers which
include Dry Type, Oil Type & Custom Type Transformers as per following plans basis and as per
international standards mentioned in section 2.2:
 Half Yearly Preventive Maintenance (HYPM)

 2-Yearly Preventive Maintenance (2YPM)
 4-Yearly Preventive Maintenance (4YPM)
 Transformer Corrective Maintenance (CM) activity
 Transformer Replacement Activity
 Infrared Analysis Test
 Dissolve Gas Analysis Test
 Filtration Test
 Grounding and Earth Resistance Measurement.
Reference Documents
2.1. Datasheets & Drawings
 Customer Datasheets (Not provided)
 Transformer Drawings ( To be provided)
2.2. Reference Standards & Codes
 -IEEE-62-1995 Guide for Diagnostic Field Testing of Electric Power Apparatus - Part 1: Oil
Filled Power Transformers, Regulators, and Reactors
 IEEE Standard C57.104™ Guide for the Interpretation of Gases Generated in Oil-Immersed
Transformers
 IEEE C57.104-2008 - IEEE Guide for the Interpretation of Gases Generated in Oil-Immersed
Transformers
 IEC 60183:2015 - Guidance for the selection of high-voltage A.C. cable systems
 IEC 60599:2015 - Mineral oil-filled electrical equipment in service - Guidance on the
interpretation of dissolved and free gases analysis
 ANSI C57.12.01 - Standard General Requirements for Dry-Type Distribution and Power
Transformers Including Those with Solid Cast and/or Resin-Encapsulated Windings
 IEEE C57.12.00-2015 - IEEE Standard for General Requirements for Liquid-Immersed
Distribution, Power, and Regulating Transformers
 IEEE - P62.2/D25 - Approved Draft IEEE Guide for Diagnostic Field Testing of Electric Power
Apparatus- Electrical Machinery
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 C57.146-2005 - IEEE Std C57.146 2005 - Guide for the Interpretation of Gases Generated in
Silicone-Immersed Transformers, Institute of Electrical and Electronic Engineers
 ASTM D-1933-97 - Standard Specification of Nitrogen Gas as an Electrical Insulating Material,
American Society for Testing and Materials
 ASTM) D-3487 - Standard Specification for Mineral Insulating Oil Used in Electrical Apparatus,
American Society for Testing and Materials
 IEC 60502-1 Cables / Low Voltage Cables
 IEC 60947-6-1 Low-voltage switchgear and control gear - Multiple function equipment -
Transfer switching equipment
 M5100 Sweep Frequency Response Analysis (SFRA) Instrument Users Guide
 10.1109/MEI.2014.6701102 : High-voltage testing fundamentals: a cable testing perspective
 IEEE 48-1975 - IEEE Standard Test Procedures and Requirements for High-Voltage Alternating-
Current Cable Terminations
Responsible Person:
 Project Manager
 Site Manager
 Project Engineer (Electrical)
 Project Engineer (Mechanical)
 Testing Electrical Engineer (Transformers)
 Electrical Technician
 Mechanical Technician
 QA/QC Personnel
 HSE Supervisor
 Supervisor/Foreman
 Filtration Machine Supervisor
 Helper
Equipment
4.1. General Inspection & Testing Equipment:
 Freja 300 (three phase secondary injection)
 IR Tester (MEGGER), 500V, 1000V, 2500V, 5000V, 10000V
 ODEN Primary Injection set
 Analogue and Digital Multimeter
 Fluke Clamp Meter
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 AC HIPOT(VLF)
 DC HIPOT
 Micro-ohm meter
 DC Supply (B10)
 CB analyzer-Egil
 IR Camera
 Sverker 760 (single phase secondary injection)
 CT Analyzer
 Transformer Ohmmeter (TRO)
 Three-Phase Transformer Turns ratio
 Oil Test equipment (Breakdown tester 100KV)
 Filtration machine 4000 liter
 Filtration machine 10000 liter
 Tan Delta Test Equipment
4.2. Tools Equipment:

 Set of ordinary wrenches
 Set of toothed wrenches
 Set of Alan Keys
 Set of Alan Key’s bits
 Set of revolver’s bits
 Set of screwdrivers
 Voltammeter
 Sanding box (collection )
 Wires peeler
 Ordinary straight pliers
 Wire shatter
 Measuring tape 5 meters
 Smith hammer
 Plastic hammer
 Tighten hand for bits
 Tighten hand joint
 Full set of short bits
 Torque Wrench
4.3. Consumable Tools Equipment:

 Tool bag
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 Small test wrench

 Big test wrench
 Water scale 30cm
 Concrete liner
 Set of short Alan
 Set of large Alan
 Alan wrench
 French wrench
 Reversible sparks spectacles
 Welder
 Isolated nipper
 Isolated shatter
 Methyl pliers
 Hammer
 Smith hammer
 Smith hammer
 Set of mouse tail filers
 Set of flatted filers
 Set of semi-sphere filers
 Large crossed screwdriver
 Large ordinary screwdriver
 Set of props
 Opening pliers
 Tighten pliers
 Measuring tape
 Set of toothed wrenches
 Sanding pliers
 Doggy pliers
 Estensal wrench
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Scope of Work:
Transformer Maintenance, Inspection, Testing, Gas Analysis, Filtration & Replacement as per
Plans:
 Half Yearly Preventive Maintenance (HYPM) activities for

live transformers,
 2-Yearly Preventive Maintenance (2YPM) activities for
isolated transformers within a period of two days
 4-Yearly Preventive Maintenance (4YPM) activities for
isolated transformers within a period of five days
 Corrective Maintenance (CM) activities for transformers,
 Replacement of Damaged Transformer.
 Infrared Analysis Test
 Filtration Test
 Dissolve Gas Analysis Test
 Grounding and Earth Resistance Measurement.
Method of Preparation:
6.1. General steps
 Work Execution be approved by MARAFIQ.
 Maintenance shall be done according to the approved procedure. Technical query shall
be submitted officially for any amendment from the approved procedure prior to start
any work.
 Master Maintenance Equipment List to be provide to MARAFIQ.
 After approval of Equipment List, Mobilization of Equipment to the Lay down Area of
MARAFIQ.
 The Electrical engineer in coordination Project Manager shall plan and execute the
activities for the Visual Inspection, cleaning, Testing, trouble shooting, and replacement
of the TRANSFORMER in co-ordination with Electrical Team of MARAFIQ.
 Transformers Maintenances are subject to inspection and witness by the client.
 Forms, procedures and sign off sheets for activity shall be prepared and submitted for
review and approval of the client before start of work.
 Necessary clearances shall be taken from other group, (like piping and structural group)
before proceeding with the scheduled works to avoid any overlapping/interference of
work executions.
 The Safety Work Permit shall be prepared based on the schedule of field activities, or in
a daily base activities
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 Ensure that all work/activity are in full compliance with MARAFIQ Standards and
approved Project Specifications.
6.2. Scaffolding Installation

 Survey the area to make sure there are no obstacles in the area that will interfere
with scaffolding erection.
 Inspection of all scaffolding components by competent installer should be done prior
to erection
 Scaffolding shall be erected on level ground with suitable sole plates/screw jack to
support and spread the load.
 Scaffolding shall be erected with adequately supported diagonal bracing, longitudinal
bracing and zigzag bracing.
 Scaffolding shall be erected with adequately supported working platform with guard
rails and toe boards
 Scaffolding shall be inspected by authorized End User/Client personnel and tagged
prior to cable pulling activities.
Procedures of Visual Inspection & Preventive Maintenance:

7.1. Visual Inspection of Transformers:
(a) Oil Leak Checks
7.1.1. Check the entire transformer for oil leaks
7.1.2. Verify the location of flanges and verify oil leaks in that locations.
7.1.3. If the flanges are leaking, note down the reason of leaking due to worn out gaskets as an initial
inspection.
7.1.4. Check the flange body and make sure the leak is not due to the damaged body.
7.1.5. Check around the tank, if there is dust, clean it with solvent to make sure that there is no cavity or
defect.
7.1.6. Check the welds for any leakage, if there is leak note down in the inspection report.
7.1.7. Check Oil leaks/gasket integrity Top-Cover, Radiators, Conservator, Cable Box, Inspection ports
, Valves.
(b) Oil Pumps (if applicable)

7.1.8. Check the flow indicators and pump isolation valves to ensure that oil is circulating properly
7.1.9. To ensure motors are turning in the proper direction, use an ammeter to check the motor current
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7.1.10. Compare results with the full-load-current indicated on the motor nameplate. If the motor is
reversed, the current will be much less than the nameplate full-load-current
7.1.11. Check oil pumps with a if they develop unusual noises. Mention in report if any.
7.1.12. Inspect the bearings for any wear and tear.
(c) Fans and Radiators
7.1.13. Inspect all isolation valves at the tops and bottoms of radiators to ensure they are open.
7.1.14. Inspect cooling fans and radiators for cleanliness and fans for proper rotation.
7.1.15. Check for dirty or damaged fan blades or partially blocked radiators.
7.1.16. Check to see if fans are reversed electrically (i.e., pulling air first through the radiators and then
through the fan blades). This means that the blades are rotating in warm air after it passes through
the radiator, which is much less efficient.
7.1.17. Place a hand on the radiator opposite the fans; air should be coming out of the radiator against
your hand. Watch the blades as they rotate slowly when they are starting or stopping to determine
which way they should be rotating and correct the rotation if necessary
7.2. Infrared Temperature Analysis

7.2.1. Infrared analysis should be conducted annually while equipment is energized and under full load,
if possible
7.2.2. Analysis should also be conducted after any maintenance or testing to see if connections that
were broken were re-made properly.
7.2.3. Also, if IR is performed during factory heat run, the results can be used as a baseline for later
comparison.
(a) For Tanks
7.2.4. Make sure the person is IR experienced staff. Ask for the previous scan records if available.
7.2.5. Perform the IR analysis of Tanks and make sure there is no usual high temperature pattern on the
tanks.
7.2.6. Thermal patterns of transformer tanks and radiators should be cooler at the bottom and gradually
warmer ascending to the top
7.2.7. If there is unusual pattern, then it is due to low oil level, circulating stray currents, blocked
cooling, loose shields, tap changer problems mention it in the report. If it is not the case inform
the plant staff.
7.2.8. Compare the scans and make sure there is no much deviation.
(b) For Surge Arresters
7.2.9. Check the unusual thermal patterns on the surface of lightning arresters.
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7.2.10. Check for hotspot along the surge arresters.

7.2.11. If any bright spot is noted, note it down.
7.2.12. If the spot is yellow, then refer to immediate de-energization and replacement.
(c) For Bushings
7.2.13. Check the IR scans of bushings to verify the oil levels.
7.2.14. If the oil level is low, check the seal in the bushing bottom which probably has been failed.
7.2.15. Check that oil is not leaking back into the transformer.
7.2.16. Check the top seal based on the IR readings of the bushing.
(d) For Radiators and Cooling Systems
7.2.17. IR scan all cooling systems, including heat exchangers, fans, pumps, motors, etc
7.2.18. Check inside control panels for overloaded wiring, loose connections, and overheated relays.
7.2.19. Look for unusual thermal patterns and compare similar equipment
(e) Corona Scope Scan
7.2.20. With the transformer energized, scan the bushings and surge arresters and all high-voltage
connections for unusual corona patterns
7.2.21. Corona should be visible only at the top of bushings and arresters, and corona at connections
should be similar to sister connections.
7.2.22. Check for bushing deterioration due to physical defects, the corona pattern will grow
progressively larger.
7.2.23. The corona scope will reveal this problem long before a flashover.
7.3. Preventive Maintenances (Plans Based)

7.3.1. Half Year Preventive Maintenance (HYPM)
7.3.1.1. All necessary work permits shall be secured before any activities on site.
7.3.1.2. All drawings and documents to be used shall be issued by the Plant Operator.
7.3.1.3. Make sure the scaffold being used is inspected and is tagged green.
7.3.1.4. For visual inspection refer to section 7.1
7.3.1.5. Now check the Tap Counter and record the Tap Position in the Datasheet.
7.3.1.6. Check for excessive corrosion and oil leaks. Pay special attention to flanges and gaskets
(bushings, valves, and radiators) and the lower section of the main tank.
7.3.1.7. Report oil leaks to maintenance, and pay special attention to the oil level indicator if leaks are
found
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7.3.1.8. Check the top oil transformers temperature. If temperature, pressure, or oil level gauges never
change, even with seasonal temperature and loading changes, something is wrong, Note the
comments for replacement.
7.3.1.9. For the gauges, make sure that the gauge is not stuck, or data sheets may have been filled in
incorrectly
7.3.1.10. Check the extra pointer, which normally red, indicates maximum temperature since the last
time the indicator was reset. This red pointer rises with the main pointer but will not decrease
unless manually reset; thus, it always indicates the highest
7.3.1.11. Now record the temperature of the windings through the thermometer dedicated for it on the
transformer.
7.3.1.12. If either dial indicator is more than 5 ºC different than the mercury thermometer, it should be
replaced with a spare.
7.3.1.13. Now carefully inspect the temperature and oil level data sheets.
7.3.1.14. Examine the DGA (Dissolve Gas Analysis) Report for evidence of leaks or other problems.
(bushings, valves, and radiators) and the lower section of the main tank
found
7.3.1.17. Severely corroded spots should be wire brushed and painted with a rust inhibitor
7.3.2. 2-Yearly Preventive Maintenance (2YPM)

7.3.2.5. Record Nitrogen Pressure / Oil Temp and write down in the sheet, compare it with the standard
requirements and mark the comments.
found
change, even with seasonal temperature and loading changes, something is wrong
7.3.2.10. The gauge may be stuck, or data sheets may have been filled in incorrectly. Verify the gauge
has proper moving pointer.
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7.3.2.11. An extra pointer, normally red, indicates maximum temperature since the last time the indicator
was reset. This red pointer rises with the main pointer but will not decrease unless manually
reset; thus, it always indicates the highest. Check this extra pointer functionality.
transformer on the inspection sheet and time for check.
7.3.2.14. Inspect pressure devices to see if they have been operating properly.
7.3.2.15. This must be done from a high-lift bucket if the transformer is energized.
7.3.2.16. Look at each pressure relief device to see if the yellow (or blue) button is visible. If the device
has operated, about 2 inches of the colored rod will be visible. Make sure to re-set the device as
per the instructions of plant operator.
7.3.2.17. Test the alarm circuits by operating the switch by hand and making sure the correct annunciator
point is activated.
7.3.2.18. If the relief device operates during operation, do not re-energize the transformer; Frequency
Measurement Equipment and other testing may be required before re-energizing, and an oil
sample should be sent for analysis.
7.3.2.19. While the transformer is de-energized, functionally test the Buchhholz relay by pumping a
small amount of air into the top chamber with a squeeze-bulb hand pump
7.3.2.20. Check to make sure the correct alarm point has been activated. Open the bleed valve and vent
air from the chamber.
7.3.2.21. On some relays, a rod is provided so that you can test both bottom and top sections by pushing
the floats down until the trip points are activated.
7.3.2.22. If possible, verify that the breaker will trip with this operation.
7.3.2.23. Use DMM to check the switches. If these contacts activate during operation, it means that the
oil level is very low, a pressure wave has activated (bottom contacts), or the transformer is
gassing (top contacts).
7.3.2.24. If this relay operates, do not re-energize the transformer until you have determined the exact
cause.
7.3.2.25. If a small amount of gas is found in this relay when the transformer is new (a few months after
startup), it is probably just air that has been trapped in the transformer structure and is now
escaping; there is little cause for concern.
7.3.2.26. If the transformer has been online for some time (service aged), and gas is found in the
Buchholz, oil samples must be sent to the lab for DGA and extensive testing.
7.3.2.27. Consult with the Plant Electrical Team and definite cause of the gas bubbles must be
determined and corrected before re-energization of the transformer.
7.3.2.28. Careful measurement of winding resistance can detect broken conductor strands, loose
connections, and bad contacts in the tap changer (de-energized tap changer [DETC] or LTC).
7.3.2.29. Results from these measurements may indicate the need for an internal inspection
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7.3.2.30. A bypass device is sometimes used across tap changers to ensure power flow in case of contact
failure. This prevents failure of the transformer in case excessive voltage appears across faulty
contacts. Check the bypass device.
7.3.3. 4-Yearly Preventive Maintenance (4YPM)

7.3.3.5. Recording of Nitrogen Pressure / Oil Temp and write down in the sheet, compare it with the
standard requirement and mark the comments.
found
change, even with seasonal temperature and loading changes, something is wrong
7.3.3.10. The gauge may be stuck, or data sheets may have been filled in incorrectly
7.3.3.11. An extra pointer, normally red, indicates maximum temperature since the last time the indicator
was reset. This red pointer rises with the main pointer but will not decrease unless manually
reset; thus, it always indicates the highest
transformer.
7.3.3.14. Inspect pressure devices to see if they have operated
7.3.3.15. This must be done from a high-lift bucket if the transformer is energized
7.3.3.16. Look at each pressure relief device to see if the yellow (or blue) button is visible
7.3.3.17. If the device has operated, about 2 inches of the colored rod will be visible.
7.3.3.18. Test the alarm circuits by operating the switch by hand and making sure the correct annunciator
point is activated.
7.3.3.19. If the relief device operates during operation, do not re-energize the transformer; Frequency
Measurement Equipment and other testing may be required before re-energizing, and an oil
sample should be sent for analysis
7.3.3.20. While the transformer is de-energized, functionally test the Buchhholz relay by pumping a
small amount of air into the top chamber with a squeeze-bulb hand pump
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7.3.3.21. Check to make sure the correct alarm point has been activated. Open the bleed valve and vent
air from the chamber.
7.3.3.22. On some relays, a rod is provided so test both bottom and top sections by pushing the floats
down until the trip points are activated.
7.3.3.23. If possible, verify that the breaker will trip with this operation.
7.3.3.24. Use DMM to check the switches. If these contacts activate during operation, it means that the
oil level is very low, a pressure wave has activated (bottom contacts), or the transformer is
gassing (top contacts).
7.3.3.25. If this relay operates, do not re-energize the transformer until you have determined the exact
cause.
7.3.3.26. If a small amount of gas is found in this relay when the transformer is new (a few months after
startup), it is probably just air that has been trapped in the transformer structure and is now
escaping; there is little cause for concern.
7.3.3.27. If the transformer has been online for some time (service aged), and gas is found in the
Buchholz, oil samples must be sent to the lab for DGA and extensive testing.
7.3.3.28. Consult with the Plant Electrical Team. A definite cause of the gas bubbles must be determined
and corrected before re-energization of the transformer.
7.3.3.29. Do Careful measurement of winding resistance which can detect broken conductor strands,
loose connections, and bad contacts in the tap changer (de-energized tap changer [DETC] or
LTC).
7.3.3.30. Results from these measurements may indicate the need for an internal inspection if needed.
7.3.3.31. A bypass device is sometimes used across tap changers to ensure power flow in case of contact
failure. This prevents failure of the transformer in case excessive voltage appears across faulty
contacts. Check the Bypass device functionality.
7.3.3.32. Do core insulation resistance and core ground test if an unintentional core ground is suspected;
this may be indicated by the DGA. Refer to next section for testing & commissioning. This test
is only necessary if the winding resistance test shows all connections and tap changer contacts
in good condition. Some oil may have to be drained to accomplish this and bring core grounds
outside through insulated bushings and are easily accessed.
7.3.3.33. Attach DC Megger® (1,000-volt Megger® is recommended) between the core ground lead (or
the top of the core itself and the tank [ground]) and check the resoatnce.
7.3.3.34. Apply a DC voltage between these points, and measure the resistance. A new transformer
should read greater than 1,000 mega-ohms. A service-aged transformer should read greater than
100 mega-ohms. Ten to one-hundred mega-ohms is indicative of deteriorating insulation
between the core and ground. Less than 10 mega-ohms is sufficient to cause destructive
circulating currents and must be further investigated [20]. A solid, unintentional core ground
may read zero ohms; this, of course, causes destructive circulating currents and must be
corrected before energization.
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7.3.3.35. Frequency Measurement Equipment test set is used along with accompanying software. The
software automatically performs analysis of test results and responds with a four letter code: G
= Good, I = Investigate, D = Deteriorated, and B = Bad.
7.3.3.36. If a “D” or “B” code is encountered, the insulation should be re-tested, carefully investigated,
and the problem explained before re-energizing
7.3.3.37. internal inspection should be considered before the unit is re-energized
7.3.3.38. If the problem is severe, the unit may have to be taken out of service.
7.3.3.39. The purpose of this test is to determine the state of dryness of the windings and insulation
system and to determine a power factor for the overall insulation, including bushings, oil, and
windings
7.3.3.40. The power factor should not exceed 0.5% at 20 EC. Temperature correction of test results can
be performed automatically on the Frequency Measurement Equipment test set.
7.3.3.41. The power factor should not exceed 0.5% at 20 EC. Temperature correction of test results can
be performed automatically on the Frequency Measurement Equipment test set.
7.3.3.42. Measures and records the capacitance (including bushings) between the high and low-voltage
windings, between the high-voltage winding and the tank (ground), and between the low-
voltage winding
and the tank (ground)
7.3.3.43. Perform the excitation test before any dc tests. Excitation current tests should never be
conducted after a dc test has been performed on the transformer
7.3.3.44. Detect short-circuited turns, poor electrical connections, core de-laminations, core lamination
shorts, tap changer problems, and other possible core and winding problems.
7.3.3.45. On three-phase transformers, results are also compared between phases. This test measures
current needed to magnetize the core and generate the magnetic field in the windings.
7.3.3.46. Frequency Measurement Equipment software only gives two indications on this test: “G” for
good and “Q” for questionable. On a three-phase, wye/delta or delta/wye transformer test, the
excitation current pattern will be two phases higher than the remaining phase
7.3.3.47. Compare the two higher currents only. If the excitation current is less than 50 milliamps (mA),
the difference between the two higher currents should be less than 10%
7.3.3.48. If the excitation current is more than 50 mA, the difference should be less than 5%. In general,
if there is an internal problem, these differences will be greater
7.3.3.49. For bushings that have a potential tap, both the capacitance between the top of the bushing and
the bottom tap (normally called C1), and the capacitance between the tap and ground (normally
called C2) are measured.
7.3.3.50. To determine bushing losses, power factor tests are also performed. C2 capacitance is much
greater than C1. Bushings without a potential tap are normally tested from the bushing top
conductor to ground.
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7.3.3.51. Compare test results with factory tests and/or prior tests to determine deterioration. About 90%
of bushing failures may be attributed to moisture ingress, evidenced by an increasing power
factor from Frequency Measurement Equipment testing on a scheduled basis.
7.3.3.52. For a delta/wye transformer, a test voltage of variable frequency (normally 20 hertz [Hz] to 2
megahertz [MHz]) is placed across each phase of the high-voltage winding. With this set of
tests, low-voltage windings are isolated with no connections on any of the bushings.
7.3.3.53. An additional set of tests is performed by short circuiting all the low voltage windings and
again placing the test voltage on each phase of the high-voltage winding.
7.3.3.54. A third set of tests is made by isolating the high-voltage winding and placing the test voltage
across each low voltage winding.
7.3.3.55. Although other tests could have revealed this problem, SFRA showed the problem was with
“A” phase and, therefore, where to concentrate the internal inspection.
7.3.4. Corrective Maintenances

*** (Transformer Manual to be followed for this activity) ***
7.3.4.1. Transformer oil replacement: Oil replacement will be followed with one of the drying method
as described in Transformer Provided Manual (Transformer on-line oil dehydration) below;
additional to, scrapping of the old (removed) oil.
7.3.4.2. Shut down power to the transformer and ground all of the metal equipment that will be
involved in changing the transformer oil. Check the manufacturer's procedures to make sure all
safety precautions are followed.
7.3.4.3. Test the transformer insulation and look for signs of shorts or damaged windings. If everything
checks out, drain the transformer oil. Once the oil is drained, proceed with flushing out the
inside of the transformer. The objective is to get as much of the old oil out as possible.
7.3.4.4. Replace the transformer drain plug and refill the unit with fire retardant oil. Wait four to five
hours and then retest the transformer insulation. After the second insulation test, allow the unit
to sit overnight.
7.3.4.5. Check for leaks the next morning. If no leaks are detected, energize the unit with out a load. Let
it sit energized for at least three hours and then add the load. Recheck the unit the next day
looking for leaks, pressure and temperature deviations.
7.3.4.6. Transformer oil reclamation (on-line & off-line): The transformer oil reclamation shall be as
per the approved method as per IEEE standard 637. The activity will include
mobilization/demobilization of manpower / scaffolding / all related equipment. In addition to,
any related oil testing activity in terms of oil parameters measurement (DBDS, BDV, moisture,
acid no, color no, oil power factor, IFT etc), DGA monitoring for a limited period.
7.3.4.7. Transformer oil dehydration (on-line & off-line) : The transformer dehydration shall include oil
removal in a separate tank, oil heating, filtering through OTP, applying vacuum to transformer
tank if required, filling back to the transformer tank. The activity will include
18

mobilization/demobilization of manpower / scaffolding / all related equipment. In addition to,

any related oil testing activity in terms of oil parameters measurement (DBDS, BDV, moisture,
acid no, color no, oil power factor, IFT etc), DGA monitoring for a limited period.
7.3.4.8. Transformer winding drying will include one of the following methods.
a. Circulation of hot dry oil: Circulation of dry oil through the tank and extraction &
absorption of moisture in vacuum de-gasifier.
b. Heat / vacuum cycle: This will include following procedure

 Heat core and coil with hot oil circulation
 Drain the oil
 Vacuum treatment
 Cycle repetition if necessary.
 Attend to oil leaks if any as a result of the heat / vacuum cycle process
c. Hot oil spray: This will include following procedure

 Bring oil level to bottom part of core
 Oil spraying under vacuum
 Increase vacuum level after spray is stopped to ensure final dry out.
 Attend to oil leaks if any as a result of the heat / vacuum cycle process
d. Combined oil spray / hot air / vacuum / oil circulation/ cycles process : This will involve
the following,
(i) Pre-starting procedure :
 drain the oil,
 vacuum pre-dry the tank, core and coil
 bring oil level to the bottom part of core with dry, clean, stable, well soluble oil
(ii) Heating process
 Oil spray through spreading pipes installed above the winding under vacuum
7.4. Transformer Replacement General Procedure:

7.4.1. Transformer Dismantling
7.4.1.1. Removal and fixing back of all transformer access obstructions as necessary for successful
completion of stated tests and maintenance activities such as but not limited to Sunshade
Canopy, Steel Structure, Screen wall, Bus Duct, Firefighting System, and Power Cables.
19

7.4.1.2. On site testing, test as specified in the scope, including the removal/re-installation of HV/LV
links and other obstructions as maybe required to conduct the tests.
7.4.1.3. Handling of transformer oil activities i.e. oil treatment, regeneration and replacement.
7.4.1.4. Transformer commissioning after different type of activities.
7.4.1.5. Preparation of the report detailing the complete condition assessment of the transformers
Detailed recommendation for the transformers against the findings.
7.4.2. Storage and Off-loading

7.4.2.1. Use Fork Lifts or Mobile Crane to off-load the transformers. Make sure that the capacity of the
fork lifts or mobile crane can carry the weight of the transformers.
7.4.2.2. Off load the transformer on the designated off-loading area. Proper care must be observed during
offloading to prevent unnecessary damage or dents on the transformers.
7.4.2.3. Ensure that the transformers are properly protected and covered with tarpaulin.
7.4.3. Pre-Installation
7.4.3.1. All materials and documentation relevant to this particular section of works shall be checked by
the Construction Department prior to the commencement of works ensuring that these are correct
and approved type.
7.4.3.2. Before any permanent works will continue, pre-inspection on all materials, tools and access for
installation to be carried out.
7.4.4. Installation
7.4.4.1. It has been presumed that all related civil works has been completed prior to transformer
installation.
7.4.4.2. Before the transformer will be delivered to site, ensure that the transformer railing is fixed as per
approved drawings and comply on municipality requirement.
7.4.4.3. Move the transformers from the designated off-loading area or storage area using fork lift and set
them in position near to the transformer room. Make sure that the orientation of the transformer
with regards to the position of cable entries is correct.
7.4.4.4. Push in the transformers inside the transformer room. Set the transformer on their final positions
and make sure that they are properly secured and protected.
7.4.4.5. Raise Request for Inspection for Transformer Installation.
7.4.4.6. Conduct on site test for the transformer. Test shall include winding insulation resistance test and
shall conform to manufacturer’s recommendation and specification. All tests must be recorded
and conducted in the presence of Consultant by manufacturer testing engineer.
7.4.4.7. Dress and terminate the incoming and outgoing cables on the transformers. Ensure that the cables
were supported properly. Cable glands, lugs and termination kits shall be approved type.
7.4.4.8. After termination works has been completed, clean the transformer cable box and ensure that it
is free from foreign materials and excess openings must be sealed off and ensure that all the
connections are properly tight and torque.
20

7.4.4.9. Raise Request for Inspection for the cable terminations and dressing.
7.4.4.10. Cover the cable boxes. Bolts and nuts must be tightened properly. Make sure that the
transformer room is clean and free from foreign materials.
7.4.5. Testing & Commissioning:

7.4.5.1. Ensure only trained persons shall operate the power tools.
7.4.5.2. Ensure all concerned personals shall use PPE and all other items as required.
7.4.5.3. Ensure adequate lighting is provided in the working area at night time.
7.4.5.4. Ensure service area/work area openings are provided with barricade, tape, and safety nets
7.4.5.5. Prior to the commencement of any permanent works, areas and access will be inspected to
confirm that they are in a condition for permanent works to commence ensuring the
environment is clean and dry. Testing will commence only after the equipment is completely
installed as per approved method statement for the installation of the Transformer and released
for testing commissioning.
7.4.5.6. All materials and relevant documentation to this testing works shall be checked by the
responsible personnel prior to the commencement of testing activities.
7.4.5.7. Before any Item of equipment is accepted for testing a visual inspection will be carried out on
that equipment. Where defective equipment is found it will be reported to Consultant for further
action.
7.4.5.8. The testing Electrical Engineer/Supervisor should confirm the availability of necessary Three
Phase AC power supply and Single phase for testing activities.
7.4.5.9. The testing Electrical Engineer/Supervisor should confirm the availability of proper access to
the site area in which the equipment have to be tested.
7.4.5.10. When a satisfactory pre-testing inspection has been carried out, the testing work will
commence.
7.4.5.11. The testing Engineer will instruct the supervisor regarding the testing works and will arrange
for all necessary schematic drawings, data sheets and test formats to be available at the testing
area.
7.4.5.12. The supervisor will check that all the necessary tools and equipment’s to be used for testing are
available in the testing area.
7.4.5.13. After the testing work is completed the supervisor checks all the testing equipment and returns
to the storage cabin.
7.4.5.14. While carrying out the testing work the Testing Engineer will fill all the necessary test formats.
After completion of testing work the Testing Engineer will obtain the signature of relevant
officials: Consultant
21

7.5. Grounding of the Transformers:

7.5.1. Testing Procedure - Fall of Potential Measurement Method
****** (Refer to Figure: 01 while using this procedure) *****
7.5.1.1. Check the condition of the soil & ground. Make sure the ground is not too moist which will
affect the testing of Grounding and select parameters as per that. Refer to Table: 01
7.5.1.2. Clear the area from the persons for effecting testing & safety.
7.5.1.3. Wear the necessary PPEs and Gloves.
Figure:01 - (Earth Electrode & Two Stakes Connection)
7.5.1.4. First, the earth electrode of interest must be disconnected from its connection to the site. Caution
should be taken while disconnecting and make sure the system from which this grounding is
coming is not energized.
7.5.1.5. Second, connect the tester to the earth electrode.
7.5.1.6. For the 3-pole Fall-of-Potential test, two earth stakes are placed in the soil in
a direct line—away from the earth electrode.
7.5.1.7. Make sure the spacing of 20 meters (65 feet) is there. Refer to Table:02 below for further
spacing requirements.
7.5.1.8. Connect the ground tester as shown in the Figure:02.
7.5.1.9. Press START and read out the RE (resistance) value
7.5.1.10. This is the actual value of the ground electrode under test. If this ground electrode is in parallel
or series with other ground rods, the RE value is the total value of all resistances.
7.5.1.11. Make sure the probe is placed outside the sphere of influence of the ground electrode under test
and the auxiliary earth.
22

7.5.1.12. If you do not get outside the sphere of influence, the effective areas of resistance will overlap
and invalidate any measurements that you are taking.
7.5.1.13. The Table:01 is a guide for appropriately setting the probe (inner stake) and auxiliary ground
(outer stake).
7.5.1.14. To test the accuracy of the results and to ensure that the ground stakes are outside the spheres of
influence, reposition the inner stake (probe) 1 meter (3 feet) in either direction and take a fresh
measurement. If there is a significant change in the reading (30 %), you need to increase the
distance between the ground rod under test, the inner stake (probe) and the outer stake (auxiliary
ground) until the measured values remain fairly constant when repositioning the inner stake
(probe)
7.5.1.15. Record all the readings on the Test Data Sheets and Mark as tested.
Table:01 – Positioning Requirements
7.5.2. Testing Procedure – Stake-less Method for Online System
****** (Refer to Figure: 02 while using this procedure)*****
7.5.2.1. Check the condition of the soil & ground. Make sure the ground is not too moist which will
affect the testing of Grounding. Refer to Table:01
7.5.2.2. Clear the area from the persons for effecting testing & safety.
7.5.2.3. Wear the necessary PPEs and Gloves.
7.5.2.4. Testing Engineer to make sure that selective testing is feasible; the earth electrode of interest
does not need to be disconnected from its connection to the site. The technician does not have
to endanger himself by disconnecting ground, nor endanger other personnel or electrical
equipment inside a non-grounded structure
7.5.2.5. The tester is then connected to the earth electrode of interest, with the advantage that the
connection to the site doesn’t need to be disconnected.
****** (Refer to next page for Figure: 02) *****
23

Figure: 02 - (Clamping & 2 Stakes Connections

7.5.2.6. Place a special clamp is placed around the earth electrode, which eliminates the effects of
parallel resistances in a grounded system, so only the earth electrode of interest is measured.
7.5.2.7. Place two earth stakes are placed in the soil in a direct line—away from the earth electrode.
7.5.2.8. Normally, spacing of 20 meters (65 feet) is sufficient or refer to Table:01 for positioning
requirements.
7.5.2.9. Connect the ground tester device as shown in the picture. Press START and read out the RE
(resistance) value.
7.5.2.10. A known current is generated by the between the outer stake (auxiliary earth stake) and the earth
electrode while the drop in voltage potential is measured
between the inner earth stake and the earth electrode.
7.5.2.11. Measure the current flowing through the earth electrode of interest is measured using the clamp.
7.5.2.12. This is the actual value of the ground electrode under test. If this ground electrode is in parallel
or series with other ground rods, the RE value is the total value of all resistances.
7.5.2.13. Make sure the probe is placed outside the sphere of influence of the ground electrode under test
and the auxiliary earth.
7.5.2.14. If you do not get outside the sphere of influence, the effective areas of resistance will overlap
and invalidate any measurements that you are taking.
7.5.2.15. The Table: 01 is a guide for appropriately setting the probe (inner stake) and auxiliary ground
(outer stake).
7.5.2.16. To test the accuracy of the results and to ensure that the ground stakes are outside the spheres of
influence, reposition the inner stake (probe) 1 meter (3 feet) in either direction and take a fresh
measurement. If there is a significant change in the reading (30 %), you need to increase the
distance between the ground rod under test, the inner stake (probe) and the outer stake (auxiliary
ground) until the measured values remain fairly constant when repositioning the inner stake
(probe)
7.5.2.17. Record all the readings on the Test Data Sheets and Mark as tested.
24

7.5.3. Removal, Re-Installation & Testing of Cables
a. Removal of Cable:
 All necessary work permits shall be secured before any activities on site.
 All drawings and documents to be used shall be issued by the Plant Operator.
 Instrument & Valves to be physically checked and verified with the datasheets check that supply
voltage details on the nameplate are correct for the instrument and ensure with the Client Plant
Operator that there is no power system in connection with it.
 Remove the terminal cover safely.
 Checked the power on terminal through Multimeter to ensure there is no power.
 Access to terminals for cable disconnection and after disconnection use insulation tape on each
cable line/core.
 Remove the gland and keep the cable safe.
 Cover the instrument/valve terminal cover with all screw/bolts.
 Keep the cable safely to avoid any damages.
b. Re-connection cable.
 All drawings and documents to be used shall be issued by the Plant Operator.
 Instrument & Valves to be physically checked and verified with the datasheets
 Prior to re-connection the cable with instrument/valves, check the power in the cables through
Multimeter.
 Inspect the terminal block physically to notice any damages.
 Insert the cable through gland, and terminate cable and tight the screw at termination points.
 Make sure the tags are properly secured on the cables.
 Attach the terminal cover and properly tighten the screws to close the valve access assembly.
c. Cable Testing
 A continuity test shall be carried out to confirm the cable continuity and cable tag
numbers.
 All cables are to be tested before and after termination according to rated voltage or as
per project specifications by using insulation tester (Megger).
d. Cable Tray & Conduit Installations:

General
25

 All drawings and documents to be used shall be signed & stamped as ”Issued for
Construction”.
 Material to be physically checked and verified with the approved Bill of Material.
 Material to be unpacked in front of the Client’s/End User’s representative and any
damages/missing material to be noted and forwarded to the client.
 If scaffolding is required then please follow the instructions mentioned in scaffolding section.
e. Conduit Installation:
 Verify the proposed Conduit routing.
 Check the material received is as per the BOM and is practically acceptable to be
installed at the site.
 Conduits, which are more than slightly damaged, shall be rejected.
 Conduits can be installed on a uni-structural channel or angle supports. Conduits can directly
installed on to the wall/floor with supporting C clamps.
 If Conduits are to be installed under the false flooring then barricade the area and provide
appropriate sign boards before removing any false flooring tiles.
 Conduits in floors/walls shall be routed and installed so as to avoid the fixings of floor standing
equipment or other third party equipment.
 Similarly for overhead Conduits, barricade the area and provide appropriate signboard.
 Drilling works should be carefully done.
 Screwed connections between conduits and accessories shall be screwed up tight.
 Conduits run on the surface shall be secured with galvanized saddles spaced not mores than 2
meters apart.
 Conduits shall not be run closer than 150mm to any steam or hot water pipes and shall be run
underneath such pipes rather than over them
 Appropriate Elbows, LB’s, LR’s, pull boxes, TEE’s etc should be used wherever required.
 The conduit should be firmly fixed with the C clamp.
 Wherever the Conduits have to be cut from the original length proper cutting tools to be used.
 Threading of the conduit should be done in a professional manner and should be free from
damages.
 Where conduits are left "open ended" prior to wiring, caps or plugs to prevent the ingress of
building materials shall be used.
 All conduits runs must be designed to permit wiring to be readily installed after the complete
erection of the conduits though the available draw-in, accessory and luminary suspension boxes.
 No wiring or draw-in wires, cables or wire of any description are to be drawn into the conduits
until the section of the conduit system involved is complete.
26

QA/QC Requirements:
 The Quality Control Program shall be as per MARAFIQ Project Procedure in conjunction with
the Engineering Standard. The detailed inspection stages and methods shall be as per the
Approved Inspection and Test Plan.
 Prior to commencing the Inspection Work, the Transformer shall be inspected visually for any
damages during and after Maintenance Activity.
 All installed Transformers shall be inspected for elevation as per the IFC drawings.
 Inspection and test plan must be submitted ahead of time for PMT & MARAFIQ approval.
 All RFI’s shall be submitted 24 hours ahead of scheduled date of inspection.
 All relevant attachments including IFC Drawing must be attached on all submitted RFI’s.
 Work execution, material approval and testing shall be monitored witnessed and recorded on
documents in accordance to the inspection list, QC form given by applicable ITP field installation
and its support.
 Transformer Engineer shall carefully check against IFC drawing for the following items:
a.) Check for correct elevation
b.) Check the correct size and materials.
c.) Check for proper grounding.
d.) Check for correct mounting
e.) Check for adequacy of supports.
f.) Check for adequate sunshade installation.
g.) Check for the correct polarity of the instrument supply.
 For calibration procedures to be approved before by the MARAFIQ.

 The Calibration to be witnessed by the MARAFIQ Representative and the test reports to be
signed by the witness.
 Client representative to verify and witness the instruments traceability.
 Work execution, material approval and testing shall be monitored witnessed and recorded on
documents in accordance to the inspection list, QC form given by applicable ITP cable installation
and support installation.
 Transformer inspector shall carefully check against IFC drawing and workmanship for the
following items:
a.) Check for correct routing.
b.) Check the correct cable size and materials specification.
c.) Check for proper cable pulling procedures.
27

d.) Check for Cable Scheduling.

e.) Check for cable twisting and cable outer sheath.
f.) Check for cable dressing.
g.) Check for cable ID/marking or identification tag for references.
 Transformer Engineer shall verify, the manufacturer’s Transformer certificate and that the cables
complies with the company standard.
 All the forms and procedures to be followed as per MARAFIQ Methodology. Complete test reports
to be submitted at the end.
Health & Safety

9.1. General Hazard
It is the intentions of SASSCO Tamimi that all work activities are carried out in a safe manner in
accordance with End User/Client Safety Standards.
9.2. Site Safety

There can be a lot of hazards associated with working on site and End User/Client Life
Saving Compliance procedures shall be followed.
9.3. Manual Handling Risks

Care should be taken when lifting heavy equipment or items manually. It is preferable
to reduce any risk by avoiding manual lifting but if it is unavoidable, correct lifting
procedures should be used.
9.4. Risk of Falling

Most work are on overhead cable tray so all personnel shall be equipped with fall
protection equipment.
9.5. Personal Protective Equipment (PPE)

The minimum equipment shall be as follows:
 Approved safety helmet

 Approved earplugs
 Approved electrical protection & impact protection safety shoes and dielectric boots
 Approved eye protection (safety glass and goggles)
 Approved gloves
 Approved fall protection equipment (Full Body Safety Harness)
 Approved fire resistant overall.
28

9.6. General Instructions Safety

 Safe work permit requirement is mandatory. All personnel involved in the activities shall wear
complete personal protective equipment (PPE) in accordance with the safe work requirements.
 Conduct job safety tool box before starting the work, and issue daily JSA. And the safety officer
shall verify that all the necessary and applicable documents, related to the safest operation are in
possession before commencing the job.
 Place barricade and warning sign boards in applicable locations. Restrict Personnel/equipment
entering the work area.
 Check adequacy and availability of all tools, before commencement of installation activity.
 If the weather conditions turns bad, (like sand storms, wind storms raining or hailstorms) shall
immediately coordinate to safety officer and all works shall be stopped.
 Safety procedures shall be followed at all times.
 Ensure that everyone involved in the work is competent
 Follow LOTO procedure
 Toolbox talk must be deliver to all personnel working on the activity
 Insulated PPE shall be in use,
 Insulated tools shell be used for all live operations
 Ensure the proper earthing shall be provided
 .Safe means of access shall be provided;
 All live electrical operation must be done only by competent persons,
 Ensure the proper earthing shall be provided,
 PTW should be followed
 Full time coverage of safety officer shall be maintained until the completion of activity
 Don’t expose the machine to rain or wet conditions,
 Circuit breaker ELCB / RCCB / GFCI shall be in use,
 Workplace/passage ways must be free from obstructions.
 Proper Housekeeping is maintained all around the workplace.
 All the electrical cables must be raised or buried
 All employees must aware of emergency contact no/nearest assembly area/telephone booth
 Communicate to control room or security section in case of emergency.
29

Attachments
Attachment: 01 - Datasheets
30
Client :
Consultant:
Contractor:
Form No. TS-PT01
Date: Rev:0 Page 2 of 21
Location: Serial No.:
SITE TEST REPORT
1. NAME PLATE DETAILS
Manufacture Cooling Method
Vector Group Rated Capacity
Rated Frequency 60 Hz Rated Voltage
Rated Power Current (A)

MVA HV LV1 POS.1/HV POS.15/HV POS.25/HV LV1/LV2
ONAN 146
ONAF1 183 380 18
ONAF2 220
Short Circuit Impedence % base 110MVA Max Ambient Temp.

Pos POS.1/HV POS.15/HV POS.25/HV Winding Temp Rise
HV/LV1 Oil Temp Rise
HV/LV2 NA NA NA Hot spot Temperatur Rise
HV/LV1+LV2 NA NA NA On Load Tap Changer MR
LV1-LV2 NA NA NA Type :
Current Transformer Data
Description Burden VA Terminal Ratio Class
2. MECHANICAL CHECKS AND VISUAL INSPECTION

a Check name Plate data for correctness in accordance with approved drawings
b Check all components are installed
c Check for any damages, oil leakage, defectives
d Check all groundings are securely connected “at least two points
e Check that piping for Buchholz relay has proper slope and direction towards the conservator
f Check that Inlet &Outlet valves of Buchholz relay are OPEN
g Check that the valves for Protective relay of OLTC are OPEN
h Check all valves between main tank and radiator are OPEN
i Check the colour and quantity of Silica gel in the breather and oil pot level
j Check labelling of both High & Low Voltage Bushings
k Check labelling of all Aux. Devices in accordance with drawings
l Check proper Installation of all Aux. Devices
m Check Oil level in the conservator and Bushings.
n Check tightness of all wiring
o Check installation of Gas Monitoring Unit “CALISTO” , sample valves are open
p Check installation of On Load Tap Changer
q Check installation of Hydraulic Plate (showing valve status : filling & vacuum)
Company Tested By
Name
Signature
Date
Client :
Consultant:
Contractor:
Form No. TS-PT01
XFMR TAG: Location: Serial No.:

Ambient Temp: Humidity Oil Temperature:
SITE TEST REPORT
3. MEASUREMENT OF VOLTAGE RATIO
A. HV to LV1
MEASURED RATIO
Tap Tap Voltage (kV) R-Phase Y-Phase B-Phase Rated
No 1U-1N / 2U-2V 1V-1N / 2V-2W 1W-1N / 2W-2U Ratio
HV LV1 Ratio Error % Ratio Error % Ratio Error %
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Test Equipment Model Cal Due Date Test Equipment Model Cal Due Date
Company Tested By
Name
Signature
Date
Client :
Consultant:
Contractor:
Form No. TS-PT01

SITE TEST REPORT
3. MEASUREMENT OF VOLTAGE RATIO
B. HV to LV2
MEASURED RATIO
Tap Tap Voltage (kV) R-Phase Y-Phase B-Phase Rated
No 1U-1N / 3U-3V 1V-1N / 3V-3W 1W-1N / 3W-3U Ratio
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Company Tested By
Name
Signature
Date
Client :
Consul :
Contractor:
Form No. TS-PT01

4. MEASUREMENT OF WINDING RESISTANCE
A. HV WINDING
R - Phase ( 1U - 1N ) Ω Y - Phase ( 1V - 1N) Ω B - Phase ( 1W - 1N ) Ω
Tap
Measured OIL Cal Resist Measured OIL Cal Resist Measured OIL Cal Resist
No 0 0 0
Resistance Temp 75 C Resistance Temp 75 C Resistance Temp 75 C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
B. LV 1 WINDING
R - Phase ( 2U - 2V ) Ω Y - Phase ( 2V - 2W ) Ω B - Phase ( 2W - 2U ) Ω
Tap
No 0 0 0
13
C. LV 2 WINDING
R - Phase ( 3U - 3V ) Ω Y - Phase ( 3V - 3W ) Ω B - Phase ( 3W - 3U ) Ω
Tap
No 0 0 0
13
Company Tested By
Name
Signature
Date
Client :
Consultant:
Contractor:
Form No. TS-PT01

5. MEASUREMENT OF MAGNETIZING CURRENT
A. AT HIGH VOLATGE SIDE
Voltage MAGNATIZING CURRENT
Tap
Frequency R-Phase Y-Phase B-Phase Remarks
No
(Hz) Voltage mA Voltage mA Voltage mA
1
2
3
4
5
6
7
8
9
10
11
12
13 60 Hz
14
15
16
17
18
19
20
21
22
23
24
25
1U 2u
A
~ V 2w
1N
Power Source 2v
60 HZ 380 V
1W 1V
Company Tested By
Name
Signature
Date
Client :
Consultant:
Contractor:
Form No. TS-PT01
SITE TEST REPORT

6. CHECK OF PHASE DISPLACEMENT
Tap Voltage Applied
Connection Measured Voltage (V) Result
(kV) Winding Voltage
1U-1V= 1V-2W 1V-2V 1W-2V 1W-2W
HV 1U - 2 U
467.8
1U-1V= 1V-3W 1V-3V 1W-3V 1W-3W
HV 1U - 3U
466.8
Sl no Vector Relation (Subtractive) Result Vector Relation (Subtractive) Result

1V 1V
2V 1V - 2W > 1V - 2V = YNd1 3V 1V - 3 > 1V - 3V = YNd1

1
1U 1W - 2V = 1W - 2W 1U 1W - 3V = 1W - 3W
1W 1W
2U 2W 3U 3W
7. MAGNETIC BALANCE TEST

SINGLE PHASE INJECTION
Taped Single phase voltage Measured Voltage
1U-1N 1V-1N 1W-1N 2U-2V 2V-2W 2W-2V
15
25
1U
v2
~ V1
1V 2W 2V
Power Source 1N
60 HZ 380 V V2
V2
Company Tested By
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Consultant:
Contractor:
Form No. TS-PT01

SITE TEST REPORT
8. INSULATION RESISTANCE TEST:
Insutation Resistance in …….. GΩ

15 Sec 60 Sec 600 Sec
Test
Measurment IR @20 IR @20 IR @20
Voltage Oil Oil Oil
IR O IR O IR O
Temp C Temp C Temp C
HV-TANK 5KV
LV1-TANK 5KV
LV2-TANK 5KV
HV-LV1 5KV
HV-LV2 5KV
LV1-LV2 5KV
CORE-TANK 1KV
CORE CLAMP-TANK 1KV
Company Tested By
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Consultant:
Contractor:
Form No. TS-PT01

SITE TEST REPORT
9. SHORT CIRCUIT IMPEDANCE MEASURMENT @ 180MVA BASE
a. HV -LV1 Winding at Tap 1 LV1 Winding Factory tested
Tap. 1 Phase Injected Voltage current (A) Impedance shorted Impedance @
433.2 KV R-N 2U,2V
146.6 A Y-N 2V,2W
B-N 2W,2U
b. HV -LV1 Winding at Tap 15 LV1 Winding Factory tested

380 KV R-N 2U,2V
167.15 A Y-N 2V,2W
B-N 2W,2U
c. HV -LV1 Winding at Tap 25 LV1 Winding Factory tested

342 KV R-N 2U,2V
185.7 A Y-N 2V,2W
B-N 2W,2U
1U 2U
A1
V1
1V
2W 2V
Power Souce
60 Hz 380 V 1W
1U 2U
1V
V2 2W 2V
Power Souce 1W
A3
60 Hz 380 V
1V
V3 2W 2V
A3
Power Souce 1W
60 Hz 380 V
Company Tested By
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Contractor:
Form No. TS-PT01

SITE TEST REPORT
9. SHORT CIRCUIT IMPEDANCE MEASURMENT @ BASE
a. HV -LV2 Winding at Tap 1 LV1 Winding Factory tested
433.2 KV R-N 2U,2V
146.6 A Y-N 2V,2W
B-N 2W,2U
b. HV -LV2 Winding at Tap 15 LV1 Winding Factory tested

380 KV R-N 2U,2V
167.15 A Y-N 2V,2W
B-N 2W,2U
c. HV -LV2 Winding at Tap 25 LV1 Winding Factory tested

342 KV R-N 2U,2V
185.7 A Y-N 2V,2W
B-N 2W,2U
1U 3U
A1
V1
1V
3W 3V
Power Souce
60 Hz 380 V 1W
1U 3U
1V
V2 3W 3V
Power Souce 1W
A3
60 Hz 380 V 3U
1V
V3 3W 3V
A3
Power Souce 1W
60 Hz 380 V
Company Tested By
Name
Signature
Date
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Consultant:
Contractor:
Form No. TS-PT01
SITE TEST REPORT
9. SHORT CIRCUIT IMPEDANCE MEASURMENT @ 180MVA BASE
g. HV -LV1& LV2 Winding at Tap 1 LV Winding Factory tested
433.2 KV R-N 2U,2V
146.6 A Y-N 2V,2W
B-N 2W,2U
h. HV -LV1& LV2 Winding at Tap 15 LV Winding Factory tested

380 KV R-N 2U,2V
167.15 A Y-N 2V,2W
B-N 2W,2U
i. HV -LV1& LV2 Winding at Tap 25 LV Winding Factory tested

342 KV R-N 2U,2V
185.7 A Y-N 2V,2W
B-N 2W,2U
j. LV1-LV2 Winding at Tap 13 LV Winding Factory tested

R-N 2U,2V
Y-N 2V,2W
B-N 2W,2U
Impedance Voltage = ( H.V Rated Tap. Current x Average Voltage) ÷ Average Current
= V
Percentage Impedance = ( Impedance Voltage ÷ H.V Rated Tap. Voltage ) x 100
Z = %
Company Tested By
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Consultant:
Contractor:
Form No. TS-PT01

SITE TEST REPORT
10. ZERO SEQUENCE IMPDANCE MEASURMENT
10. 1. Open circuit Zero Sequence impedance Factory tested
LV Winding Open
Phase Injected Voltage current (A) Impedance Impedance @
1
13 2U,2V,2W
25
1U 2U
A1
V1
1V
2W 2V
Power Souce 1W
60 HZ 220 V 3U
3W 3V
10. 1. Short circuit Zero Sequence impedance LV Winding Factory tested

Phase Injected Voltage current (A) Impedance Shorted Impedance @
1
13 2U,2V,2W
25
1U 2U
A1
V1
1V
2W 2V
Power Souce 1W
60 HZ 220 V
3U
1 Correction Zero Sequence Impedance Voltage(V)
= (Measured Voltage X Rated Current X )/ Suuply Currrent
3W
2 Zero Sequence Impdance% 3V
= 300 X { [Measured Voltagae X 1.732/Rated Volatge] X (Rated Current/supply current)}
3 Ohm/Phase
=3 X Measured Voltage/ Supply Cuurent
Company Tested By
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Client :
Consultant:
Contractor: Form No. TS-PT01

Page 13 of 21
Date: 13/02/09 Rev:0

SITE TEST REPORT
11.INSULATION POERFACTOR/TAN DELTA MEASURMENT
connection Measurment
Sl. A. Tandelta and capacitance
Test Measurment for winding Test Cap
Ambient Temp: D.F %
Capacitance
No. ENG GND GAR Ma Watt (Pf) D.F% 0
(H-G)
Mode Volts @ 20 C
C(H-G)+C(HV-LV1)
1 GST H.V LV1 LV2 10KV
LV1,LV
C
2 GST H.V 10KV
2
C(H-LV1)
3 UST H.V 10KV
C(LV1-G)+C(LV1-LV2)
4 GST LV1 LV2 HV 10KV
C(LV1-G)
5 GST LV1 HV,LV2 10KV
C(LV1-LV2)
6 UST LV1 10KV
C(LV2-G)+C(LV2-H)
7 GST LV2 HV LV1 10KV
C(LV2-G)
8 GST LV2 HV,LV1 10KV
C(LV2-H)
9 UST LV2 10KV
B. Tandelta and capacitance Measurment for Bushing

Measurment Ambient Temp:
Sl. Test Test Cap D.F %
Bushing
No. Ma Watt (Pf) D.F% 0
Mode Volts @ 20 C
1 1U UST 10KV
2 1V UST 10KV
3 1W UST 10KV
4 1N UST 10KV
Company Tested By
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Consultant:
Contractor:
Form No. TS-PT01

SITE TEST REPORT
12.CALIBERATION OF WINDING TEMPERATUR INDCATORS BY CURRENT INJECTION
Winding temp. Indicator

Manufacture : MR
Type MT-ST 160 WR
Test procedure
Adjust the variable resistance according to manufacture settings
Make sure that the oil bulb is partially filled with oil
Inject full-load secondary current
Record the temp. As indicated in WTI every 5 min. For 45 min.
HV CT Ratio Resistance N.A Current Ref Grad

LV1 CT Ratio Resistance N.A Current Ref Grad
LV2 CT Ratio Resistance N.A Current Ref Grad
HV Winding Indicator LV1 Winding Indicator LV2 Winding Indicator

Time
Heating Oil Wind Deviatio Heating Oil Wind Deviatio Heating Oil Wind Deviatio
Inter
Current Temp Temp n Current Temp Temp n Current Temp Temp n
0 Min
5 Min
10 Min
15 Min
20 Min
25 Min
30 Min
35 Min
40 Min
45 Min
Company Tested By
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Consultant:
Contractor:
Form No. TS-PT01

SITE TEST REPORT

13.CALIBERATION OF WINDING AND OIL TEMPERATUR INDCATORS
Ref 0
Measurement C
Temp
0 OIL Tolerance H
Tolerance LV1 Tolerance LV2 Tolerance
C V
Temp temp temp
t
40 e
m
50 p
60
70
80
90
100
110
120
Company Tested By
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Contractor:
Form No. TS-PT01
Date: 13/02/09 Rev:0 Page 16 of 21

SITE TEST REPORT
14. TEST OF PROTECTION DEVICES AND AUXILARY CIRCUITS:
A. INSULATION AND CONTINUITY CHECK
Subject Check Result
No. Remarks
Device & Equipment Terminal Continuity Insulation
0
Fan control (60 C)
Temprature Relay Fan control (65 0C)
1
for oil(CT031) Alarm to DCS (90 0C)
0
Trip (506.7) (100 C)
0
Fan control (70 C)
2
for HV Wdg. (CT 033) Alarm to DCS (105 0C)
0
Trip (115 C)
0
Fan control (70 C)
3
for LV1 Wdg.(CT034) Alarm to DCS (105 0C)
0
Trip (115 C)
0
Fan control (70 C)
4
0
Trip (115 C)
Oil level indicator Min. (Alarm to DCS)
5
for TR Max
6
for OLTC Max
Pressure Relief for Trip
7
Transformer (81) Trip indication (Alarm to DCS)
8
9
Pressure Relief Trip
10
device-1 for OLTC Trip indication (Alarm to DCS)
Alarm to DCS
11 Buchholz Relay
Trip
Signal Relay for Alarm to DCS
12
rubber bag
OLTC Protective Trip
13
device
Buchholz Relay for Alarm to DCS
14
H.V Turrets (H3) Trip
15
16
17
L.V.2 Turrets Trip
18
L.V.1 Turrets Trip
Company Tested By
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Signature
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Client :
Consultant:
Contractor:
Form No. TS-PT01
SITE TEST REPORT
15. CHECK LIST FOR COOLER CONTROL SYSTEM OPERATION CHECK
Operation Confirmed Resualt
A. Cooler control fan operation check
1. Manual operation All cooling fans operationl.
Group 1 and Group 2
2. Automatic operation
Start Fan Group 1 - Operation
Oil temp. 60 0C Odd Number Fans 1-11
HV wdg temp. 70 0C Odd Number Fans 1-11
LV1 wdg temp. 70 0C Odd Number Fans 1-11
LV2 wdg temp. 70 0C Odd Number Fans 1-11
Start Fan Group 2- Operation
Oil temp. 65 0C Even Number Fans 2-12
HV wdg temp. 75 0C Even Number Fans 2-12
LV wdg temp. 75 0C Even Number Fans 2-12
LV wdg temp. 75 0C Even Number Fans 2-12
B. Lamp & Heater operation check
1. Lamp
Door switch both
ON Lamp - ON
OFF Lamp - OFF
C. Heater
Thermostat Setting value change more
than ambient Temp. Heater - ON
Thermostat Setting value change less
than ambient Temp. Heater - OFF
D. Alarm circuit check
1 Fan Group 1 Running (K1)

2 Fan Group 2 Running (K2)
3 Fan Group 1Fault (K05)
4 Fan Group 2Fault (K06)
5 Fan Group 1 MCB Trip(F1)
5 Fan Group 2 MCB Trip(F2)
6 Control Volatge MCB Ttip(F01)
7 Heater MCB trip (F02)
8 Socket outlet MCB Trip(F03)
9 Calisto MCB Trip(F04)
10 Source-1 distrubed(K101)
11 Source-2 distrubed (K201)
E. Gas Monitoring Unit "CALISTO"
1 Water Transducer output (4-20 mA)
2 Hydrogen Transducer output (4-20 mA)
3 Hydrogen Alarm #1 (250 ppm)
4 Hydrogen Alarm #2 (500 ppm)
5 Water Alarm (30 )ppm
Company Tested By
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Signature
Date
Client :
Consultant:
Contractor:
Form No. TS-PT01
SITE TEST REPORT
16. PROTECTION DEVICES FUNCTIONAL CHECK
Subject
Sl No
Device & Equipment Terminal Remarks
Fan control (60 0C)
1
for oil(CT031) Alarm to DCS (90 0C)
0
Trip (506.7) (100 C)
0
Fan control (70 C)
2
for HV Wdg. (CT 033) Alarm to DCS (105 0C)
0
Trip (115 C)
Fan control (70 0C)
3
0
Trip (115 C)
0
Fan control (70 C)
4
0
Trip (115 C)
5
for TR Max
6
for OLTC Max
7
8
9
Pressure Relief Trip
10
device-1 for OLTC Trip indication (Alarm to DCS)
Alarm to DCS
11 Buchholz Relay
Trip
Signal Relay for Alarm to DCS
12
rubber bag
OLTC Protective Trip
13
device
14
15
16
17
L.V.2 Turrets Trip
18
L.V.1 Turrets Trip
Company Tested By
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Signature
Date
Client :
Consultant:
Contractor:
Form No. TS-PT01

SITE TEST REPORT
17. TAP POSITION ON INDICATION CONTACTS CHECK
S38M S39M S40M U5 (mA)

Tap
Resistance Resistance X1
position Term Term Term Contact
Actual Measured Actual Measured 211-212
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Company Tested By
Name
Signature
Date

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WORK METHOD STATEMENT

Customer: MARAFIQ End-user: MARAFIQ

Customer: MARAFIQ End-user: MARAFIQ

7.4.5. Testing & Commissioning:................................................................................................... 21

Customer: MARAFIQ End-user: MARAFIQ

(This page is intentionally left blank)

Customer: MARAFIQ End-user: MARAFIQ

 Half Yearly Preventive Maintenance (HYPM)

Customer: MARAFIQ End-user: MARAFIQ

Customer: MARAFIQ End-user: MARAFIQ

4.2. Tools Equipment:

4.3. Consumable Tools Equipment:

Customer: MARAFIQ End-user: MARAFIQ

 Small test wrench

Customer: MARAFIQ End-user: MARAFIQ

 Half Yearly Preventive Maintenance (HYPM) activities for

Customer: MARAFIQ End-user: MARAFIQ

6.2. Scaffolding Installation

Procedures of Visual Inspection & Preventive Maintenance:

(b) Oil Pumps (if applicable)

Customer: MARAFIQ End-user: MARAFIQ

7.2. Infrared Temperature Analysis

Customer: MARAFIQ End-user: MARAFIQ

7.2.10. Check for hotspot along the surge arresters.

7.3. Preventive Maintenances (Plans Based)

Customer: MARAFIQ End-user: MARAFIQ

7.3.2. 2-Yearly Preventive Maintenance (2YPM)

Customer: MARAFIQ End-user: MARAFIQ

Customer: MARAFIQ End-user: MARAFIQ

7.3.3. 4-Yearly Preventive Maintenance (4YPM)

Customer: MARAFIQ End-user: MARAFIQ

Customer: MARAFIQ End-user: MARAFIQ

Customer: MARAFIQ End-user: MARAFIQ

7.3.4. Corrective Maintenances

Customer: MARAFIQ End-user: MARAFIQ

mobilization/demobilization of manpower / scaffolding / all related equipment. In addition to,

b. Heat / vacuum cycle: This will include following procedure

c. Hot oil spray: This will include following procedure

7.4. Transformer Replacement General Procedure:

Customer: MARAFIQ End-user: MARAFIQ

7.4.2. Storage and Off-loading

Customer: MARAFIQ End-user: MARAFIQ

7.4.5. Testing & Commissioning:

Customer: MARAFIQ End-user: MARAFIQ

7.5. Grounding of the Transformers:

Figure:01 - (Earth Electrode & Two Stakes Connection)

Customer: MARAFIQ End-user: MARAFIQ

Table:01 – Positioning Requirements

7.5.2. Testing Procedure – Stake-less Method for Online System

****** (Refer to Figure: 02 while using this procedure)*****

****** (Refer to next page for Figure: 02) *****

Customer: MARAFIQ End-user: MARAFIQ

Figure: 02 - (Clamping & 2 Stakes Connections

Customer: MARAFIQ End-user: MARAFIQ

7.5.3. Removal, Re-Installation & Testing of Cables

d. Cable Tray & Conduit Installations:

Customer: MARAFIQ End-user: MARAFIQ

Customer: MARAFIQ End-user: MARAFIQ

 For calibration procedures to be approved before by the MARAFIQ.

Customer: MARAFIQ End-user: MARAFIQ

d.) Check for Cable Scheduling.

Health & Safety

9.2. Site Safety

9.3. Manual Handling Risks

** (Refer to Figure: 02 while using this procedure)*

** (Refer to next page for Figure: 02) *