POWER TRANSFORMER INSTALLATION

Transcription

1 Project Procedure POWER TRANSFORMER INSTALLATION No.: P /20/2011 PAGE 1 OF PURPOSE The purpose of this procedure is to ensure that power transformer installations are accomplished in compliance with Project specifications, applicable codes, and Contract requirements 2.0 SCOPE The scope of this procedure applies to Pike construction activities. This procedure may also be applied to Subcontractors when invoked by Contract documents. 3.0 REFERENCES 3.1 Project Procedure P-1-4, Quality Control Functions and Responsibilities (Construction Site) 3.2 Project Procedure P-1-5, Quality Control Personnel Assignments (Construction Site) 3.3 Project Procedure P-1-9, Quality Control Interface with Subcontractors 3.4 Underground Electrical Project Procedure P-6.2-1, Direct Buried Cable Project Procedure P-6.2-2, Ductbank Installations Project Procedure P-6.2-3, Grounding Below Grade 3.5 Aboveground Electrical Project Procedure P-6.2-4, Electrical/Instrumentation Raceway and Cable Installation Project Procedure P-6.2-5, Electrical Equipment Installation Project Procedure P-6.2-6, Facility Lighting Systems Installation Project Procedure P-6.2-7, Switchgear Installation Project Procedure P , Lightning Protection

2 PAGE 2 OF Project Procedure P , Electrical Control Panels Project Procedure P , Electric Motor Installation Project Procedure P , Bus Duct Installation 3.6 Project Procedure P , Instrumentation Installation and Checkout 3.7 Specific Vendor installation, checkout, and commissioning instructions 4.0 DEFINITIONS 4.1 Independent Testing Organization (ITO): Any group, other than construction personnel, who performs and documents required electrical testing. 5.0 RESPONSIBILITIES 5.1 The Construction Foreman or Supervisor is responsible for resolution of power transformer installation and test issues with the Project Engineering organization and for retention of required documentation in the Job Site files. 5.2 Other personnel responsibilities are as defined in the procedures Quality Control Functions and Responsibilities (Reference 3.1) and Quality Control Personnel Assignments (Reference 3.2). 6.0 PROCEDURE 6.1 PREREQUISITES Understanding the Requirements The Construction Site Supervisor or the Site Quality Control Manager shall coordinate the following activities: Establish and agree on requirements for inspections and testing (including associated documentation) in accordance with procedure P-1-9, Quality Control Interface with Subcontractors (Reference 3.3), prior to the start of power transformer installation activities. Establish the ITO relationship and define Client contacts Subcontracted Work Prior to the award of a Subcontract, the Construction Site Supervisor and Site Quality Control Manager shall review the applicable engineering documents to determine the extent of the installation and testing work that will be subcontracted. This review shall

3 PAGE 3 OF 6 include selection of the applicable sections of Pike s Quality Program and associated procedures for the Scope of Work for each Subcontract or review and acceptance of the Subcontractor s quality system program for control of the work. 6.2 GENERAL The Construction Foreman or Supervisor or designee, in coordination with the Construction Site Supervisor or Site Quality Control Manager shall verify completion and compliance of power transformer installation and testing activities and indicate acceptance of the work via signature on form QF A, Transformer Installation Checklist (see Form 8.1). ITO forms shall be signed-off as appropriate to indicate acceptance of ITO activities. 6.3 INSPECTION AND VERIFICATION The Site Quality Control Manager or qualified designee shall assure the following meet the requirements of Project drawings and specifications: Verify receiving activities and inspections are complete. Verify equipment preservation program is instituted. Verify equipment conforms to area classification. Verify rating, voltage, and nameplate are in accordance with requirements. Verify location, orientation, and mounting are in accordance with drawings. Verify condition of bushings radiators and tanks, as applicable. If internal connections are to be made, Manufacturer recommendations must be followed regarding dry air, positive pressure, cleanliness, etc. Verify freedom of rotation and lubrication for cooling fans and other accessories. Verify condition of fuses, disconnect switches, and surge arrestors. Check all valves, fittings, and gasket surface for tightness and evidence of oil leakage. Check transformer unit for inclusion of required auxiliary items plus any specified optional equipment. Check transformer secondary terminal box for adequate weatherproofing. Check lubrication and freedom of motion of tap changers. Also, check identification of operating positions. Fill transformer, if required, according to Manufacturer s recommendations.

4 PAGE 4 OF 6 Inspect for leaks around tank and radiator (liquid filled transformers). Check transformer oil level indicator for proper oil level. Verify transformer liquid temperature indicator and transformer pressure-vacuum gauge as appropriate. Verify ground connection to transformer ground pad, ground bus, and transformer secondary neutral, if applicable. Assure space heaters are connected and operable. Assure test instruments are calibrated. Assure final inspection is complete and all punch list items are cleared. Verify instruments, indication lamps, and interlocks are correct. Verify MCCB, contactors, fuses, and CTs are correctly sized and identified. Verify the oil level correct. Verify unit is internally/externally clean and covers are securely fastened with all screws. Verify all spare entries are blanked/plugged with correct fittings. Check all connections are correctly tightened to correct torque settings. Verify that equipment tag is installed and visible. Verify warning labels/placards are installed and visible. Verify touch-up paint is complete. Take oil sample and send for analysis, according to American Society for Testing and Materials (ASTM) procedure. 6.4 ITO TEST PERFORMANCE The following transformer tests are generally beyond the scope of normal construction practice, and, therefore, are usually performed and documented by an ITO. Oil samples are obtained from transformers and tested as required (dielectric strength, acidity, interfacial tension, specific gravity, color, moisture content, PCB content, and labeling). Test insulation resistance of transformer windings in accordance with Project specifications. Test each transformer using AC Power Factor Test, as required.

5 PAGE 5 OF 6 Function-check operation of interlock system, as required. Set transformer taps to give desired secondary voltage based on expected primary voltage for normal operating conditions. Verify Insulation Power Factor (Dolby Test) DC resistance of windings, as required. Calibrate each relay with approved Project relay settings. Test CT secondary windings and verify proper operation of applicable relays and associated devices. Short unused CTs. Test PT secondary circuit and verify proper operation of all applicable relays. Test operation of space heater units, including switching devices. Test ground resistance for switchgear ground bus in accordance with Project specifications. Verify ITO has completed and documented all tests. 6.5 SUBCONTRACTED WORK During power transformer installation and testing activities, the Construction Foreman or Supervisor or designee shall monitor and verify the Subcontractor s work for compliance with engineering requirements and applicable procedures. As a minimum, this shall include the following: When Subcontractors are working to the Quality Control Project Procedures, compliance shall be maintained to the applicable sections of these procedures, as required by the Contract. When Subcontractors implement their own program for control of the work, the Site Quality Control Manager or designee shall verify compliance with that program. Installation, verification, and testing activities shall be documented in accordance with Pike s Quality Program or the Subcontractor s own program for control of the work as required by Contract. 6.6 IMPLEMENTATION OF PROGRAM The Site Quality Control Manager shall assure the implementation of this program is consistent with the engineering design and the Contract. 7.0 ATTACHMENTS None

6 PAGE 6 OF FORMS 8.1 Quality Form QF A, Transformer Installation Checklist 9.0 REVISIONS AND APPROVALS Revision Level Revision Date Revision Description Department Head (Approver) 0 9/10/2010 Original Issue David Bartlett 1 07/20/2011 Updated logo and company name N/A

7 FORM 8.1 PAGE 1 OF 2 TRANSFORMER INSTALLATION CHECKLIST Project: Tag No.: Description: Sub System: Sub System Description: Manufacturer: PO Number: No. Items to be Checked Job Number: Client: Data Sheet: Location: Drawing: Date: Model No: Serial or Mark No: 1 Check equipment and nameplate details with datasheet. Check and record primary winding insulation a resistance [2500VDC (690V)] 2 Temp. MΩ Check and record secondary winding insulation b resistance [1000VDC (415V)] Temp. MΩ 3 Check for mechanical damage. 4 Verify equipment is mounted/anchored according to drawings and Manufacturer s instructions. 5 Verify equipment is grounded according to drawings and Manufacturer s instructions. 6 Verify all shipping stops, bracing, and packing are removed. 7 Verify all internal cabling and wiring are neat, correct, and undamaged. 8 Verify unit trimmed out according to drawings and Manufacturer s instructions. 9 Verify instruments, indication lamps, and interlocks are correct. 10 Verify MCCB, contactors, fuses, and CTs are correctly sized and identified. 11 Verify no fluid leaks. 12 Verify oil level is correct. 13 Verify unit is internally/externally clean and covers are securely fastened with all screws. Attribute Required Date Completed/ Initials Verified by Quality Form QF A, Rev. 1 Last Revised: 07/20/2011 Project Number: Project Procedure P Page 1 of 2

8 FORM 8.1 PAGE 2 OF 2 TRANSFORMER INSTALLATION CHECKLIST Project: Tag No.: Description: Sub System: Sub System Description: Manufacturer: PO Number: No. Items to be Checked Job Number: Client: Data Sheet: Location: Drawing: Date: Model No: Serial or Mark No: Attribute Required Date Completed/ Initials Verified by 14 Verify all spare entries are blanked/plugged with correct fittings. 15 Check all connections are correctly tightened to correct torque settings. 16 Verify equipment nameplate is installed and visible. 17 Verify warning labels/placards are installed and visible. 18 Verify touch-up paint is complete. 19 Take oil sample and send for analysis according to ASTM procedure. Make (Test Equipment) Model Serial No. Calibration Expiration Date 20 Remarks: Description Foreman Supervisor Site QC Manager Signature Print Name Date Quality Form QF A, Rev. 1 Last Revised: 07/20/2011 Project Number: Project Procedure P Page 2 of 2