Document Number PEC-QU-GDE-X-10866

Revision 0
Applicability All

Document Type Guideline

QUALITY CONTROL PROCEDURE

INSTALLATION OF POWER TRANSFORMERS

(GUIDELINE)

REVISION / APPROVAL HISTORY

0 Issued For Client Review

Rev. Date Description of Change Developer Reviewer Approver

Documented Information of approvals are retained in QMS

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CONTENTS
1.0 PURPOSE ................................................................................................................................... 3
2.0 SCOPE ........................................................................................................................................ 3
3.0 DEFINITIONS / ABBREVIATIONS............................................................................................. 3
4.0 REFERENCES ............................................................................................................................ 3
5.0 RESPONSIBILITY & AUTHORITY............................................................................................. 3
6.0 DESCRIPTION OF ACTIVITIES ................................................................................................. 4
6.1 General Requirements ............................................................................................................ 4
6.2 Material Inspection Prior to Installation ................................................................................... 4
6.3 Equipment Inspection .............................................................................................................. 4
6.4 Installation Inspection .............................................................................................................. 4
6.5 Transformer Oil ....................................................................................................................... 5
6.6 Transformer Windings ............................................................................................................. 6
7.0 DOCUMENTED INFORMATION TO BE RETAINED (RECORDS) ........................................... 7
7.1 List of Verifying Documents (ITRs) ......................................................................................... 7
8.0 APPENDICES ............................................................................................................................. 7

Notes:

This document and referenced ITRs shall be applied to Construction/Inspection & Test activities
carried out on E&C Project Sites.

This document is based on widely used international codes, standards and good engineering practice
that is applied in Oil & Gas Projects and is intended to highlight the minimum tests and inspections
that ensure quality requirements are fulfilled within the scope of the document.

This document and referenced ITRs are generated to provide guidelines to Petrofac E&C Project
teams including their sub-contractors during preparation of project specific QCPs/ITRs and shall be
customized to meet specific requirements based on applicable project specifications and/or other
statutory and regulatory requirements. It may also be utilized at bidding/proposals stage.

In case of any conflict between this document and the Project specification, drawings and applicable
codes, the project specification shall take precedence over this QCP and applicable ITRs.

The referenced Inspection and Test Records (ITRs) are controlled independently. Therefore, the
latest revision of these ITRs, at the time of initiation, shall be utilized.

ITR number suffixed with letter “X” are classified as in-process Site/Field Quality Records and will not
be part of the Turnover System Process where as ITR number suffixed with letter “A” are part of the
Turnover Process and Turnover Records.

When filling ITRs do not leave any blanks. If an item/activity is not applicable, denote as N/A.

Use of Blanco, Tipp-ex etc. on ITR is forbidden.

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1.0 PURPOSE
1.1 The purpose of this procedure is to define the inspection and testing method, acceptance
criteria for the installation of power transformers and the responsibility of construction and
Quality Control personnel with regard to this procedure.

2.0 SCOPE
2.1 Quality Control Procedure defines the Quality Control activities and the inspections & tests
pertaining to the Installation of Power Transformers.

2.2 This procedure covers work up to and including mechanical completion.

3.0 DEFINITIONS / ABBREVIATIONS

Company : Vedanta/Cairn Limited
PEC, E&C or Contractor : Petrofac Engineering & Construction
SC or Subcontractor : EDAC Engineering Limited
Project : Integrated Gas Facilities For RDG Fields
QCP : Quality Control Procedure
ITP : Inspection & Test Plan
ITR : Inspection & Test Record
QC : Quality Control
PPE : Personal Protective Equipment
RFI : Request for Inspection
V : Volts
KV : Kilo Volts
DC : Direct Current
HSSE : Health, Safety, Security and Environment
CMP : Construction Management Procedure
4.0 REFERENCES
EDAC-PIC-E-ITP-002 : ITP-Installation of Electrical Power & Control Cables
EDAC-PIC-E-ITP-004 : ITP- Installation of Power Transformers
EDAC-PIC-E-ITP-003 : ITP-Installation of Switchgear, Motor Control Centers
and Bus Ducts
EDAC-PIC-E-ITP-008 : ITP-Installation of Earthing and Lightning Protection
System
IEC 60156 : Insulating Liquids–Test Method
5.0 RESPONSIBILITY & AUTHORITY
5.1 The SC Site Electrical Engineer/Supervisor shall be responsible for ensuring that Power
Transformers are installed to an acceptable standard of workmanship and in accordance
with applicable drawings and specifications as well as making request for inspection (RFI)
to Quality Department at each stage of work as per the applicable ITP requirements.

5.2 The Electrical QC Inspector/Site Supervisor shall be responsible as indicated on the ITP
for verifying that work carried out is complete, correct and meets the specified
requirements.

5.3 The QC Engineer or his designee shall be responsible for ensuring that all inspections
and tests are witnessed based on approved ITP, recorded on applicable ITR listed in 7.1
and signed off.

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5.4 The Site Electrician under the supervision of Electrical Supervisor shall conduct all tests
and the test shall be witnessed as per applicable ITP and results recorded by SC
Electrical QC Inspector.

6.0 DESCRIPTION OF ACTIVITIES

6.1 General Requirements

6.1.1 All material received at site shall be inspected upon receipt in accordance with
Construction Management Procedure for Material Receiving.

6.1.2 The test shall be recorded as defined herein and witnessed by Subcontractor, PEC
and Company as indicated in applicable ITP. Prior to issuing the report forms, the
inspection items shall be signed off by the concerned inspection personnel as
indicated on the ITP No. EDAC-PIC-E-ITP-004.
6.2 Material Inspection Prior to Installation

6.2.1 Prior to removal to site, power transformer and accessories shall be inspected by
Material Controller for physical damage and oil leakage etc.

6.2.2 Where damage is observed, this shall be recorded and reported based on Material
Receiving procedure.
6.3 Equipment Inspection

6.3.1 The nameplate shall be checked against the transformer data sheet to establish
conformity.

6.3.2 Where transformer auxiliaries are shipped loose, these shall be identified and
checked against the equipment MRR (Material Receiving Report).
6.3.3 Where oil immersed transformers are delivered oil filled, the oil level shall be checked
to ensure no leakage from flanges and/or welded joints.

6.3.4 Where an oil conservator with air breather is installed, the silica gel in the breather
shall be checked to ensure no ingress of moisture.

6.3.5 Check that all internal spaces are filled with oil (by means of the vents) and that the
air has been completely vented out.

6.3.6 Where shock recorder fitted, recorder events should be downloaded and analyzed
upon arrival at site.

6.3.7 Inspection results shall be recorded on ITR-E-0301A.

6.4 Installation Inspection

6.4.1 The transformer installation shall be carried out by the Mechanical Erection Group.

6.4.2 Prior to installation, the transformer foundations shall be checked for cleanliness level
and lay-out field orientation and also ensure that foundation has been accepted by
Civil QC.

6.4.3 The location, alignment and orientation of transformer with bus duct/cable ducts shall
be checked to ensure sufficient clearance for entry and glanding of cables and
connection with bus ducts.

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6.4.4 Support for bus ducts shall be checked to ensure that no undue pull or loading is
exerted on the transformer.

6.4.5 The installation of the transformers shall be inspected to ensure correct orientation
and alignment for cabling.

6.4.6 The transformers shall be inspected for mechanical damage. All accessories shall
be checked against the Equipment Data Sheet and recorded on ITR-E-301A.

6.4.7 Earthing shall be checked to ensure that it is as per the detail drawings. Particular
attention shall be paid to “Neutral Earth” connections.

6.4.8 Check the valves open and close freely. “Check that the butterfly valves of radiators
are open.

6.4.9 Check the thermometer and the correct position of the auxiliary contacts for alarm
and trip.

6.4.10 Check the correct position of the tap changer and padlock, if padlocking facility is
provided.

6.4.11 Inspection results shall be recorded on ITR-E-0301A.

6.5 Transformer Oil

6.5.1 Transformer insulating oil shall be tested using a Foster Type OTS60 (AUTO) or
equivalent dielectric test set and witnessed by Electrical QC Inspector.

6.5.2 Where the transformer has been supplied pre-filled with oil, a sample shall be taken
from the lowest possible point in the tank.

6.5.3 Where the insulating oil is supplied separately, samples shall be taken from each
container prior to filling.

6.5.4 The tests shall be carried out as per the Equipment Operating Instructions for the
particular standard applicable to the project. The tests shall be carried out with a
2.5mm gap between electrodes and as per the Equipment Operating Instructions for
IEC 60156 standard or any other international standard recommended by vendor. The
Arithmetic mean of the Breakdown Voltage shall not be less than value recommended
by the manufacturer.

6.5.5 If the results are lower than the value specified by manufacturer’s standard, the
transformer oil shall be treated.

6.5.6 Testing of insulating oil for sealed transformer is not considered necessary.

6.5.7 The oil shall be filled under vacuum only using "Stream line filters” or equivalent. After
oil filling is complete, the following points shall be checked/inspected.

a) The final level shall be checked.

b) Temperature, level and pressure surge devices checked for completeness.

c) Confirm valves are open for radiator and trap air vented to atmosphere,
conservators, air dryers, insulating bushings and flanges shall be checked.

d) The whole system shall be inspected to ensure no oil leakage.

6.5.8 The oil shall be retested as in 6.5.1 after a suitable settling period.

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6.5.9 Inspection results shall be recorded on ITR-E-0303A.

6.6 Transformer Windings

6.6.1 Prior to connection of the power and control cables, checks shall be carried out on
the transformer windings and protective devices.

6.6.2 Continuity and resistance of both primary and secondary windings shall be
measured and recorded.

6.6.3 The windings insulation resistance shall be tested as follows:

a) The tests shall be conducted between the primary and secondary windings to
earth and between the two windings.

b) Windings not under test shall be earthed.

c) Dielectric absorption value and Polarization Index shall be calculated and

compared against manufacturer’s recommended values. A dielectric absorption
test shall be made winding to winding and winding to earth.

d) A sixty-second test shall be made, unless the transformer is larger than 1500
KVA or if the windings are rated above 15 KV, in which case a ten-minute test
shall be run.

e) The Dielectric Absorption test shall be computed as the ratio of the sixty-second
to the thirty-second reading, or Polarization Index test should be conducted as a
ratio of ten-minute to the one-minute reading, as appropriate.

6.6.4 Test voltage and minimum insulation resistance shall be as per as per
manufacturer’s published data or below table.

Transformer Insulation Resistance/Test Voltage

Minimum Test Min. IR Value-MΩ

Transformer Coil Rating
Voltage Oil filled Dry

Up to 600V 1000 Volts DC 100 500

Above 600V and up to 5KV 2500 Volts DC 1000 5000

Above 5KV and up to 15KV 5000 Volts DC 5000 25000

Above 15KV and up to 35KV 5000 Volts DC 10000 25000

6.6.5 Current Transformers (C.T) which is located in neutral boxes should be inspected for
mounting arrangement, polarity and verified against vendor drawings to make sure
they are as specified.
6.6.6 Inspection results shall be recorded on ITR-E-0301A as applicable.

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7.0 DOCUMENTED INFORMATION TO BE RETAINED (RECORDS)

7.1 List of Verifying Documents (ITRs)

No. ITR No. Description QMS Reference No.

1 ITR-E-0301A Installation of Power Transformers

Nil
Power Transformer Oil Dielectric Strength
2 ITR-E-0303A
Test

8.0 APPENDICES
Nil

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