PROCEDURE FOR INSTALLATION, TESTING & COMMISSIONING

OF DRY TYPE DISTRIBUTION TRANSFORMER

VOPAK TERMINAL KANDLA
VTKN CAPEX UP GRADATION PROJECT
Doc. No. : VTKN/9001/TE/004

DATE
05.12.2014

DETAILS OF REVISION

Rev No. : 00

REV
00

Issued for Review & Approval

Page 1 of 7

PROCEDURE FOR INSTALLATION, TESTING & COMMISSIONING

OF DRY TYPE DISTRIBUTION TRANSFORMER
VOPAK TERMINAL KANDLA
VTKN CAPEX UP GRADATION PROJECT
Doc. No. : VTKN/9001/TE/004

TABLE OF CONTENTS

1.0

SCOPE

2.0

PURPOSE

3.0

REFERENCE DOCUMENTS

4.0

RESPONSIBILITIES

5.0

PROCEDURE

6.0

FORMATS

7.0

DOCUMENTATION

8.0

GENERAL

9.0

SAFETY

Page 2 of 7

Rev No. : 00

PROCEDURE FOR INSTALLATION, TESTING & COMMISSIONING

OF DRY TYPE DISTRIBUTION TRANSFORMER
VOPAK TERMINAL KANDLA
VTKN CAPEX UP GRADATION PROJECT
Doc. No. : VTKN/9001/TE/004

Rev No. : 00

1.0 SCOPE
This Procedure describes guidelines for Installation & Testing of Dry Type Distribution Transformer included
in ELECTRICAL WORKS for VTKN CapEx up gradation Project, at Vopak, CRL Terminal Pvt. Ltd., Old
Kandla.

2.0 PURPOSE
The purpose of this procedure is to provide guidelines for Installation, Testing and Commissioning of Dry
Type Distribution Transformer at Vopak, CRL Terminal Pvt. Ltd. Old Kandla.

3.0 REFERENCE DOCUNENTS

i.

Approved SOR.

ii.

Latest AFC Drawing.

iii. Approved Vendor Drawing.

iv. Tender Documents.
v.

OEM Erection Manuals

vi. TCE Specifications

If there is any contradiction between contract specifications and this procedure, the Tender Documents
shall prevail.

4.0 RESPOSIBILITIES
The responsibilities of implementation of this procedure lie with Project Manager, AFCONS A/c VTKN
CAPEX UP GRADATION PROJECT

5.0 PROCEDURE
5.1

MATERIALS
After receipt of material at site, IMIR shall be made & material shall be inspected as per approved ITP.

5.2

PRE INSTALLATION CHECKS

i.

Ensure the received material is as per approved vendor drawings / documents.

ii.

Check foundation its level, centrelines, anchor bolts / insert plates. In case of rail mounted type checks
centre line & level of rails. Check Transformer to be placed on foundation as per approved AFC GA drawing
for Dry Type Distribution Transformer.

iii. Check the Serial no. and Rating of Transformer as per specification / AFC drawing.
iv. Inspect for availability of all accessories.
v.

Inspect any physical damages, missing or short supplied items for insurance claim.

vi. Check completion of Civil works, get the clearance from Civil and cleanliness of area.

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PROCEDURE FOR INSTALLATION, TESTING & COMMISSIONING

OF DRY TYPE DISTRIBUTION TRANSFORMER
VOPAK TERMINAL KANDLA
VTKN CAPEX UP GRADATION PROJECT
Doc. No. : VTKN/9001/TE/004

Rev No. : 00

vii. Availability of Tested, Calibrated & Standard Tools & Tackles, skilled manpower for Shifting & Lifting of
equipment.
viii. Check the size of terminal box suitable for Incoming Cables.
5.3

INSTALLATION METHODOLOGY
5.3.1 INSTALLATION CHECKS OF DRY TYPE DISTRIBUTION TRANSFORMER.
i.

Check sequence of installation as per installation flow chart / Erection Manual.

ii.

Check bushing cracks, chips or presence of paint or dirt. Bushing should be cleaned as per vendors
instruction.

iii. Phasing & Orientation of Transformer to be checked as per AFC drawings.

iv. Install of Cable boxes / Bus-duct as per approved drawings.
v.

Install foundation bolts / Stoppers

vi. Install / Grout the anti-earthquake plate as mentioned in the specifications & approved drawings.
vii. Check healthiness of all accessories of transformer.
viii. Install all accessories of transformers as per approved GA / Installation manual.
ix. Install marshalling box as per approved GA and fix the all control cables routes to Marshalling box.
x.

Ensure cable connection at the cable & box, their colour coding & tightness (if required use of spring and flat
washers on the appropriate faces to be confirmed) and cleanliness of lapping surfaces. For multiple cable
connection, check for correctness of phasing.

xi. Check the connection of Space heaters & Thermostat in Marshalling box & Control Cabinet.
xii. Dressing of all power and control cables to be checked.
xiii. Ensure the construction of earth pits and earth grid for Transformer Body & Neutral is as per AFC drawing,
xiv. Ensure the earthing connection of Transformer body, Marshalling panel, HV Cable Box. LV terminal box,
Transformer neutral is as per AFC drawing.
xv. The equipment earthling connections tightness and earth resistance value to be checked.
xvi. If required or specified, Dry-out of Transformer to be done.
xvii. Ensure the tightness of cables at HV & LV sides and control cables in Marshalling panels.
xviii. Installation completion certificate and hand over for Testing & Commissioning.
5.3.2
i.

TESTING OF DRY TYPE DISTRIBUTION TRANSFORMER

Measure winding resistance at each tap. Test Vector group, polarity, magnetizing current, magnetic
balancing.

ii.

Test Insulation Resistance & PI.

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PROCEDURE FOR INSTALLATION, TESTING & COMMISSIONING

OF DRY TYPE DISTRIBUTION TRANSFORMER
VOPAK TERMINAL KANDLA
VTKN CAPEX UP GRADATION PROJECT
Doc. No. : VTKN/9001/TE/004

Rev No. : 00

iii. Test Transformation Ratio at each tap points.

iv. Check WTI, Thermostat settings.
v.

Simulation test of thermostats, WTI for alarm and trip signals.

vi. Check tightness of wire connection at NCT terminals and marshalling terminals.
vii. Simulation test for all external interface connection alarms, annunciation and trip circuits checking.
viii. Check Tap Changer Control Operation without Energizing Transformer.
ix. Check the CT Ratio & Polarity. Ensure all earthing connections.
x.

Check the knee point voltage of CL PS C.T. (if any)

xi. Check the Door switch operation.

xii. Ensure the tightness of Transformer body & Neutral earthing connections.
xiii. Adopt relay settings as per Relay Setting diagram & Test Transformer Relay Protection as per approved
scheme.
5.3.3

MEGGAR TEST
The Transformer & its cable shall be check for insulation resistance by using suitable rating of Meggar.

Suitable rating of Meggar as per Equipment Voltage

5.3.4

Equipment
Voltage (AC)

Minimum Test Voltage (DC)

230-500V

500V

6600V

5000V

POST INSTALLATION AND TESTING CHECKS

i.

Transformer & Relay testing results to be reviewed prior to commissioning.

ii.

Check & attend all points mentioned in the commissioning checklist.

iii. Check the IR / PI and keep record for energisation.

iv. Check mechanical operation of Tap-changer including indicator.
v.

HT, LT & Bus duct connections to be checked for tightness & phasing.

vi. Tightness of winding lead connection to Bushing terminals.

vii. Connection & Tightness of all Jumpers / Bus-bar at HV & LV side.

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PROCEDURE FOR INSTALLATION, TESTING & COMMISSIONING

OF DRY TYPE DISTRIBUTION TRANSFORMER
VOPAK TERMINAL KANDLA
VTKN CAPEX UP GRADATION PROJECT
Doc. No. : VTKN/9001/TE/004

Rev No. : 00

viii. Water tightness of all covers of Transformer, Bus ducts, Marshalling Panel etc.
ix. All control wires tightness to be checked.
x.

Relay settings to be checked as per approved settings.

xi. Preparation of Marked up drawings.

xii. Installation completion certificate and handing over to commissioning.
5.3.5

POST ENERGISATION CHECKS

i.

The inrush magnetizing current and No Load Current

ii.

Alarm, if any relay flag operated

iii. Voltage and current of all three phases.

iv. Note the Winding Temperature
v.

Transformer humming sounds and vibrations.

vi. Cable box for heating and any abnormal sounds.

GENERAL CHECKS
i.

Fire Alarm, Sand bucket & Fire Extinguisher shall be provided as specified near Transformer.

ii.

Sand filling shall be done in the cable trench as per the drawing. Cable trench shall be covered after the
cable laying is carried out in accordance with the specifications.

iii. Cable trays shall be covered, where ever required, as per the project specifications.
iv. Unused holes should plugged with suitable plug.
v.

After testing the J/B shall be properly closed to avoid any unauthorized changes.

vi. Proper sealing shall be provided at the cable entry into the control room, cable room.
5.3.6

INSPECTION AND TEST PLAN

Inspection and test plan for Installation / Erection & Testing of Dry type Distribution Transformer for
Electrical Work

6.0 FORMATS
i.

Installation / Erection & Testing of Transformer Testing & Meggar readings test Record.

ii. Installation / Erection & Testing of Transformer Check list.

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PROCEDURE FOR INSTALLATION, TESTING & COMMISSIONING

OF DRY TYPE DISTRIBUTION TRANSFORMER
VOPAK TERMINAL KANDLA
VTKN CAPEX UP GRADATION PROJECT
Doc. No. : VTKN/9001/TE/004

Rev No. : 00

7.0 DOCUMENTATION
i.

Documents shall be prepared in approved formats at all stages of Installation / Inspection as per approved
ITP and maintained, duly signed by AFCONS / TCE.

ii.

As Built Drawings.

iii. OEM Drawings / Manuals

iv. Test Reports

8.0 GENERAL
i.

All inspection shall be carried out as per approved ITP.

ii.

House keeping shall be carried out everyday after completion of work.

iii. Scaffolding shall be erected wherever required.

9.0 SAFETY
i.

All safety precautions shall be taken as per SHE requirements of the project.

ii.

Related JSA shall be prepared and to be approved from PMC before starting any activity.

iii. Tool box meeting shall be conducted before starting any job.
iv. Full care and precaution shall be taken by the field management for the safety and sanitation of workmen in
the field to prevent accidents during the execution of works
v.

During execution, the electrical equipment shall be placed so as to give no obstruction for traffic and proper
measures shall be taken to prevent damage due to falling bodies etc. and decrease in insulation
performance due to water penetration etc.

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