METHOD STATEMENT OF BATTERY

INSTALLATION
KESR MHENDSLK ELEKTRK LTD T.

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Contents
1. Goal..3
2.

Implementation Area...3

3.

Definitions3

4.

Responsibilities........................................................................................................................3
4.1.

Site Manager:....................................................................................................................3

4.2.

Site Engineer:....................................................................................................................4

4.3.

HSE Manager from PPR:..................................................................................................4

4.4.

Supervising Engineer:.......................................................................................................4

5.
Method
..4

5.1. Transport ..5

5.2. Erection Followings are performed at site..5
5.3. Mounting works 5
5.4 Radiators .6
5.5. Conservator.6
5.6. Bushings..6
5.7. Piping6
5.8. Vacuuming..7
5.9. Oil filling7
5.10. Connection protective devices7
5.11 Touch up Paint...8
5.12. Permit to Work Procedure8
5.13 Safety Trainings....8
5.14 PPEs8
5.15 Waste Management on Customer Sites9
5.16 Reporting of Near Misses / Unsafe Acts met on Sites ..9
5.17 Lifting Operations9
KKS No. 440-01-YF-SNO-KSR-004
Page 1 of 18

KESR MHENDSLK ELEKTRK LTD T.

METHOD STATEMENT OF BATTERY

INSTALLATION

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5.18 Machinery and Hand Tools Operating....10

6. Checking The Equipment After Delivery..............................................................................10
6.1. Inspection for Damage..10
6.2. Transportation....11
6.3. Installation works...11
6.4. Evacuation11
6.5. Oil Filling...12
8.Fire prevention and protection...12
9. Emergency response....12
10. Day by Day Schedule..13
List of Personnel who works UAT15
HHIB Manual .15

KKS No. 440-01-YF-SNO-KSR-004

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METHOD STATEMENT OF BATTERY

INSTALLATION
KESR MHENDSLK ELEKTRK LTD T.

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1. Goal
Purpose of this method statement is to define the sequence of Aux.
Transformers installation and safe execution of the job.
2. Scope
The procedure applies for Aux. Transformers transportation, handling, and
installation at all workplaces where these activities will be performed.
3. Definitions
HHIB: HYUNDAI Heavy Industries Bulgaria
Aux.: Auxiliary
PPR : Power Projects
3.1. Risk: The combination of the realization probability of a dangerous situation
and the outcome it will cause.

KKS No. 440-01-YF-SNO-KSR-004

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METHOD STATEMENT OF BATTERY

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4. Responsibilities
4.1. Site Manager:
SM is the first responsible point to follow this procedure,
In cases when the staff do not apply or do not fulfill requirement of this procedure SM
will do required actions such as to inform people who are unaware, to supply right
material, machinery and equipment and/or to ensure specific training to improve teams
ability.
To revise this procedure if it is necessary.
To assign responsible engineers and foremen, to coordinate all activities
To ensure training, informing and updating people who work to apply this procedure
regardless their position,
To coordinate with PPR.
4.2. Site Engineer:
To plan, coordinate and supervise all activities such as storage, lifting, installation.
To apply this procedure in accordance with all standards and specification which are
mentioned in this document,
To implement all protective measures required in accordance with this document,
Site engineer ensure the coordination between other adjacent works are well organized,
Site engineering shall ensure that pre-work checklist is filled,
To perform inspections on daily basis, before each shift and after events that could
increase hazards.
To identify existing and predictable hazards or working conditions that are hazardous,
unsanitary, or dangerous to employees,
To take prompt corrective measures to eliminate or control hazards and conditions.
To coordinate with Supervising Engineer from PPR.
To ensure that the staff involved in the activities has read and understand the method
statement.
To brief the staff involved about the healthy and safe performance of all activities
(toolbox talks).
To receive and/or define all standards including this Method Statement,
To obtain all the necessary standards,
To ensure maintenance compliance with this method statement.
4.3. HSE Manager from PPR:
To define all HSE procedures to be followed,
Overseeing site activities day-to-day,
To follow with corrective actions of all violations of HSE rules.
To organize for health and safety execution of the job,
To provide and cooperate with the site engineers for toolbox talks.
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METHOD STATEMENT OF BATTERY

INSTALLATION
KESR MHENDSLK ELEKTRK LTD T.

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To ensure that the equipment, tools, PPEs meet the site requirements,
To ensure supervision and compliance with the health and safety provisions of this
document.

4.4. Supervising Engineer from PPR:

To supervise the activities and to ensure that the job is implemented in accordance with
the design and the provisions of this document,
To provide assistance for the protective measures required in accordance with this
document,
To perform inspections on daily basis,
To identify existing and predictable hazards or working conditions that are hazardous,
unsanitary, or dangerous to employees,

To take prompt corrective measures to eliminate or control hazards and conditions.

5. Method
5.1. Transport
In general, the transformers are transported without bushings, conservator, radiators, fans, pipes,
and some of protective devices dismantled.
The transformer is oil filled up to 200 mm below the cover and the empty space above in the
tank is filled with dried nitrogen. The drained oil is transported with barrels or special oil tracks
KKS No. 440-01-YF-SNO-KSR-004
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METHOD STATEMENT OF BATTERY

INSTALLATION
KESR MHENDSLK ELEKTRK LTD T.

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to the site.
The accessories and insulating materials should be protected from moisture until the
commencement of mounting works.
5.2. Erection Steps are performed at site.

The transformer is rolled to the place of erection and the main body is adjusted to be
parallel to the ground.

Inspection of the transformers has to be done before starting the erection

The impact recorded which mounted on transformer have to be checked by HHIB

Supervisor and site manager and will be submitted to PPR.

5.3. Mounting works

In this section re-erection of the spare parts that were dismantled for transport shall be
mentioned. After the re-erection touch-up the damaged parts of paint according to its
specification.

Attention !

Bushings must be mounted during the daylight only.

If, generally weather conditions are unfavorable, mounting of the bushing turrets and LV
bushings can have the priority in mounting procedure during short time fair weather

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METHOD STATEMENT OF BATTERY

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periods.

During mounting active part should avoid contacting air much as possible.

5.4. Radiators

Unpack and clean the radiators.

Remove the blind flanges from the throttle valves and tighten the fixing bolds.

Change the O-ring

Mount the radiators

5.5. Conservator

Mount the consoles of conservator.

Mount the conservator regarding to dimensional drawing.

5.6. Bushings

Unpack the bushings and clean them.

Remove the blind flanges from the turret

Clean the flange surfaces put the new O-ring on mounting flange and mount the
bushings.

Particular care should be taken not to allow anything to enter in the transformer tank
during mounting works.

KKS No. 440-01-YF-SNO-KSR-004

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METHOD STATEMENT OF BATTERY

INSTALLATION
KESR MHENDSLK ELEKTRK LTD T.

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5.7. Piping

Unpack the pipes, remove the covers and check inside of pipes to ensure there is nothing
inside the pipes.

Put new gaskets

Mount the pipes regarding to dimensional drawing.

5.8. Vacuuming

Valve positions must be checked according to valve diagram.

Vacuum hose must be connected to the appropriate flange then vacuuming can be started

After vacuum value drops under 1 mbar, transformer should be kept under the vacuum
before oil filling.

Vacuum must be continued until top up the transformer with oil

5.9. Oil filling

After the vacuuming time is finished, oil filling starts

Oil is taken to a separate oil circulation tank . After treatment fill the transformer with oil.

Take an oil sample and test it. The oil must have a dielectric strength according to
transformer manual. If this condition is not fulfilled, it is necessary to dry and degas the

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METHOD STATEMENT OF BATTERY

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oil in the transformer.

If there is humidity in the transformer, the active part should be dried.

The oil draining, handling and filling should be made through an oil treatment machine
with all necessary equipment, only with the appropriate flanges and hoses.

The power supply for the treatment shall be inspected by responsible electrician.

Precautions against injuries, swallowing and oil spillages shall be taken.

Before commencing the work oil absorbing materials should be present as well as
securing all possible points of a leak-pump connections etc.

Fire extinguishers and a person present as a fire-watchman will be necessary.

5.10. Connection protective devices

Connect the wiring cables on the protective devices according to the wiring scheme for
protective devices.
5.11 Touch up Paint
After erection all damaged points on paint of transformer have to touch up without delay.
5.12. Permit to Work Procedure:
5 LOTO steps are implemented which include the followings:
1 SEPARATION of equipment from all possible voltages sources (bring switching devices
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METHOD STATEMENT OF BATTERY

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in an open position by disconnecting from bus-bars, consumers, etc.)

2 ISOLATION process to be completed by a process of signs; Locked out do not move.
(informing all concerned that the device has been isolated and must not be moved)
3 VERIFICATION of absence of voltage (VAV) to be done (Is the equipment which checks
the existence of energy, verified whether it runs properly or not)
4 EARTHING and SHORT-CIRCUITING, the point of work and ALL points of supply;
Each one of the three phases (L1, L2 and L3) are connected to earth or first make
connection of one phase to earth and then short-circuit the 3 phases.
5

ADJACENT LIVE equipment to be adequately screened and the work area to be marked
off. The supervisor starts to work.

5.13 Safety Trainings:

Safety trainings will be given
1. Personal Protection
2. Handling materials and safety
3. Control of substance hazardous to health regulation

5.14 Personal Protective Equipments:

Mandatory PPEs:

Safety Shoes

KKS No. 440-01-YF-SNO-KSR-004

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METHOD STATEMENT OF BATTERY

INSTALLATION
KESR MHENDSLK ELEKTRK LTD T.

Safety clothing

Safety helmet (the colour depends on customer request)

Parachute style safety harness (while working at height)

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No specific PPE for the electrical testing is required as setup will be done with equipment
isolated. Test measurements are only to be done by trained and competent persons.

Safety glasses and gloves.

5.15 Waste Management:

If the waste is domestic or hazardous, none of them will be on workplace, pedestrian walkways.
Any scattered material, equipment tool or any other residues will not be leave on workplace,
pedestrian walkways, forklift ways etc.
5.16 Reporting of Near Misses / Unsafe Acts met on Sites
Every near miss or unsafe act will be reported immediately to the Site Manager and HSE
Manager by phone or by filling near miss reporting form to help taking related corrective actions.
5.17. Lifting Operations
Execution of the lifting operations will comply with the provisions of the Project HSE Manual.
Cranes will be set on even flat ground. Pads will be used under the outriggers feet where
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METHOD STATEMENT OF BATTERY

INSTALLATION
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necessary. When work is close to excavation the lifting equipment will be positioned away from
the excavation edge according to the soil type and the weather conditions, in order to prevent
earth collapse. Working limits of the lifting equipment stipulated by the manufacturer will not be
exceeded. All lifting equipment will be stored in closed area away from wet and direct sunlight.
Lifting of the stacks of cable trays will be carried out only with fabric slings with the proper safe
working load limit. Fabric slings shall be protected for sharp edges on the trays. The slings will
be inspected and color-coded. Lifting operation shall be segregated from other persons on site.
All personnel and third parties will be kept out of any area where they might be struck or crushed
by a load or lifting equipment if it swings, shifts or falls. Operators of lifting equipment will be
able to see the full path of the load or have a signaler with an appropriate means of
communication to guide them. Operator will obey an emergency stop signal at all times, no
matter who gives it. The operator will not leave the operating controls while the load is
suspended. Taglines will be used all time, it refers to load to be guided and controlled. Lifting
equipment will not be used in the open air where weather conditions could affect the integrity of
the equipment or expose persons to danger. All lifting equipment shall be stored in closed area
away from wet and direct sunlight.
5.18. Machinery and Hand Tools Operating
All machinery, equipment and tools will be maintained in good working order; will be inspected
regularly and color coded; and will be operated by competent persons. All necessary measures
will be in place in order to prevent environmental pollution. Guards will be in place to protect
workers from moving parts. Electrical tools will be double insulated and grounded connected to
ground fault circuit interrupters (GFCI).
All vehicles will have backing warning device. Banks man will guide vehicles in narrow work
places and when reversing. Vehicles will not pass, will not be positioned or parked close to
excavation edges. Where manual handling cannot be avoided tasks will be designed to minimize
the weight, range of motion, and frequency of the activity. During manual handling all workers
have to wear safety gloves and make sure they are protective against trip hazards and sharp
edges. The distance between the person and the object being handled will be as small as possible.
Employees will use good manual handling techniques for lifting, pulling or pushing. Material
handling equipment will be easy to move, with handles that can be easily grasped in an upright
posture. Heavy objects will be stored at waist level. Manual handling training will be delivered.
6. Checking the Equipment after Delivery
6.1. Inspection for Damage
KKS No. 440-01-YF-SNO-KSR-004
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METHOD STATEMENT OF BATTERY

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Immediately after delivery to site or when first off-loading, all equipment must be
examined for possible transport damage.
If any damage or oil leakage is discovered the site management, the transportation
company, the transport insurers, the appropriate representative or the main factory must be
informed immediately.
A record of the damage, where apparent must be prepared in conjunction with the other
participants. Minor damage which may appear unimportant should also be included. Late claims
cause difficulty in the negotiations with the insurance companies.
Accessory equipment packed in boxes or crates should not be stored outdoors until it is
required for use.
6.2. Transportation
Aux. transformers equipments will be transported by crane. Transportation of aux.
transformers accessories is made when the site is ready. Crane will be used and all necessary
precaution matures will be taken. Providing pickup to transportation of aux. transformers
accessories from lay down area to the field. Equipments stay suitable place, so it prevents to
work and workers work safely.
6.3. Installation works
Internal sections of the pipes shall be checked prior to installation to ensure that they are
free of dirt and moisture. Before the radiator is installed, the radiator butterfly valve blind flanges
on the tank must be removed and the mounting studs must be retightened. All components of the
transformer defined on the dimensional drawing must be installed according to the plan. The
conservator must be removed from its package, checked and cleaned as required. The pipe
connections, the Buchholz relay, valves etc. must be removed from their packages, checked and
installed after being cleaned, as required. Bushings must be removed from the packages and
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METHOD STATEMENT OF BATTERY

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cleaned. The blind flanges on the bushing must be removed and the bushing must be installed
carefully in accordance with the installation instructions; all measures required to avoid any
foreign object from falling inside the tank during this work, must be taken fastidiously.
6.4. Evacuation
We recommend that a two-stage vacuum pump set and an obtainable vacuum within
transformer tank is used for evacuation. If the specified vacuum cannot be achieved, all the
equipment used for this process should be checked for leakage.

6.5. Oil Filling

Preparation for oil filling should be made during evacuation. If required, the oil must be
degassed and dried by circulating. When the oil meets the specified requirements and the
evacuation time is over, oil is filled into the transformer tank from the storage tank through the
treatment plant. The filling speed should be adjusted to ensure that the vacuum in the transformer
tank is maintained.
Spillage: Waste mineral oils ecotoxic features cause permanent ecological damage to
nature is thrown at random. Water, soil and air pollution causing damage to the environment and
human health. Oil spills from contaminating the environment sand, earth or other materials
avoided. Directly from the spilled oil or by using appropriate absorbers should be made. Oil
gator application can be done for oil leakage. The sample will be taken from contaminated soil
before and after oil gator application to prove the effectiveness of oil gator. All oil changes must
be applied under controlled conditions, absorbent materials or chemical spillage must be kept for
oil leaks, continuity of the application, and disposal of oil contaminated waste. While the aux.
transformers will be erected, we will use bin for leaking oils.
7. Fire prevention and protection
All the necessary fire prevention measures (while welding will be made, flammable materials
will be got rid of area.) will be taken in accordance with the contract provisions and project
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METHOD STATEMENT OF BATTERY

INSTALLATION
KESR MHENDSLK ELEKTRK LTD T.

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procedures. The measures will be communicated with the staff involved in the job. Fire
extinguishers and fire watchmen will be there where personnel will work.
8. Emergency response
In order to minimize the consequences and to provide adequate response in case of emergency
the involved staff will receive training in accordance with the Procedure for emergencies.
Contact persons in case of emergency:
In case of emergency call: 0530 568 11 70
0530 568 11 66
Site Manager: 0530 237 08 54
HSE: 0507 762 69 64
Fire brigade: 0542 215 10 55
Site Medical Center: 0530 884 54 48
List of attachments:
1. Day by day schedule
2. Risk Assessment ( See RA in the attachment )
3. List of the staff involved in the job
4. HHIB Manual
5. Toolbox attendance sheet

Attachment 1: Day by day schedule

KKS No. 440-01-YF-SNO-KSR-004
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METHOD STATEMENT OF BATTERY

INSTALLATION
KESR MHENDSLK ELEKTRK LTD T.

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Day by day schedule

The present schedule covers the procedures regarding the erection of 2x32 M
19+/-8x1.25%/6.3kV
Responsible supervisor:
Da
y

Activities

1. General meeting
2. Inspection of the trrs
2.1 Visual inspection
2.2 Equipment
inspection
3. Impact recorders
4. Preparations for
erection

1. Assembling of
radiators

2. Preparation for
draining

3.Preparation of
conservator
3

1.Draining of oil
2. Bushing assembling
3. Oil filling

Nescessary
Equipment

Vladimir Simeonov
Details

Clarifying all questions regarding the erection

transformers

Packing list
Hand tools
See
Attachment 1
See
Attachment 1
Oil vessel with
volume approx.
3000 liters.Oil
pump with
applicable
flanges and
hoses.Power
supply for the
pump
See
Attachment 1
See day2 point
2
See
Attachment 1
See day2 point
2

4
KKS No. 440-01-YF-SNO-KSR-004
Page 16 of 18

Inspection of all boxes in accordance with the

list
Collecting the data from the impact record
Moving and unpacking the equipment, crane po
e t.c. (TR1)

Draining of oil is nescessary in order to reduce

level inside - from 200 to - 650. The quantity of
drained - 3000liters.

Preparations as:Inspection and assembling of

indicators
Draining of approx. 3000 liters of oil.
Assembling of LV side bushings

Filling back the drained quantity of oil

METHOD STATEMENT OF BATTERY

INSTALLATION
KESR MHENDSLK ELEKTRK LTD T.

1. Assembling of
conservator
2. Starting Vaccuum

1.Assembly of cooling
fans
2. Oil filling

3. Start of circulation

See
Attachment 1
Vaccuum
machine, power
supply, hoses
and flanges
See
Attachment 1
Vaccuum
filtering
machine, power
supply
Vaccuum
filtering
machine, power
supply

-17/16

Assembling of the conservator and all pipes

transformer
The vaccuum will be made for 16 hours+ the
bushing installation

Assembly of cooling fans and radiator groun

Filling of the transformer, starting with the tap

Circulation should be done with oil treatment m

heaters at 55'C For 24 hours

See
Attachment 1

Finishing all cable connections on the transfo

1. Air releasing of TC

See
Attachment 1

Complete air releasing of the tap change

4. Functional check

Switching off the machine, disconnectin

See
Attachment 1
See
Attachment 1

1. Leak test stop and

inspection

1. Tr-r 1 is ready for site

tests

See
Attachment 1

Erection unit 2
1. Tr-r 2 is ready for site
tests

See
Attachment 1
See
Attachment 1

12

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4. Cable connections

2. Stop of circulation
3. Air releasing of the
tr-r

7.12.

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Complete air releasing of the transforme

Functional check of the transformer protec

Visual inspection of the transformer for leak

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Time schedule for site tests should be provided

responsible
laboratory. (approx. 1 day per transformer)

In this period - all procedures from day 2 to day

Time schedule for site tests should be provided
responsible
laboratory (approx. 1 Day per transformer)

METHOD STATEMENT OF BATTERY

INSTALLATION
KESR MHENDSLK ELEKTRK LTD T.

1314
15

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List of Personnel who work UAT.

1. Responsible Supervisor: Vladimir Simeonov
2. Responsible Foremen: Ali Sarkaya, Hseyin elik
3. Electrician workers: Emrah Davul, Metin elik, Murat Sarkaya

Attachment 4: HHIB Manual

-18/16

See Attachment
1. Site tests
1
1 Final visual check of
tr-rs
Inspection and touchpaint correction (if nescess
Remark: Nescessary manpower for the erection: 4 technicians

Attachment 3: List of Personnel

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See complete HHIB erection manual in the attachment.

KKS No. 440-01-YF-SNO-KSR-004

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