PAGE

1 of 14

INSTALLATION PROCEDURE
FOR
POWER TRANSFORMER
3X330 MW POWER PLANT PROJECT
INDRAMAYU- WEST JAVA.
 DOCUMENT NO. :
P-T3109-EI-004
INSTALLATION PROCEDURE ISSUED DATE :
FOR 11-03-2008
POWER TRANSFORMER
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 2 of 13 00

ORIGINATED BY REVIEWED BY APPROVED BY DISTRIBUTION

- SDCC : Original
- CNEEC : Copy
- All Dept. : Copy

Rifyan T M. Arifin Iman P Agus S

ISSUED EFFECTIVE
REV. NO BRIEF OF REVISION
DATE DATE
00 21/03/08 21/03/08 Original Issue

W-QC-A-001.E4

TABLE OF CONTENT

No. Descriptions Page

COVER 1 of 13
1 TITLE 3 of 13
2 SCOPE 3 of 13
3 OBJECTIVE 3 of 13
4 REFERENCE 3 of 13
5 DESCRIPTION PROCEDURE
3 of 13
5.1 GENERAL 3 of 13
5.2 DELIVERY 3 of 13
5.3 INSPECTION UPON ARRIVAL ON SITE 5 of 13
5.4 UNLOADING 5 of 13
5.5 STORAGE
6 of 13
5.6 INSPECTION OF THE LOCATION
6 of 13
5.7 DISPLACEMENT AND INSTALLATION OF THE
6 of 13
EQUIPMENT
5.8
 DOCUMENT NO. :
P-T3109-EI-004
INSTALLATION PROCEDURE ISSUED DATE :
FOR 11-03-2008
POWER TRANSFORMER
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 3 of 13 00

5.9 MEASUREMENT OF THE TANK-EARTHING

INSULATION 6 of 13
5.10 INSPECTION OF THE EQUIPMENT 6 of 13
5.11 OIL TREATMENT BEFORE ASSEMBLY 7 of 13
5.12 CONSERVATOR FITTING-OUT / ASSEMBLY 8 of 13
5.13 ASSEMBLY OF HV BUSHINGS, LV BUSHING AND
ACCESSORIES 9 of 13
5.14 PARTIAL OIL FILLING UNDER VACUUM 10 of 13
5.15 OILTOPPING-UP UNDER VACUUM FOR
CONSERVATOR WITH RUBBER-POCKET 11 of 13

5.16 WIRING 12 of 13
5.17 EQUIPMENT AND TOOLS 13 of 13

1. TITLE

Installation Procedure For Power Transformer

2. SCOPE

This procedure is to describe the minimum requirements for installation

Power Transformer during receiving of materials, storing, and installation
work.

3. OBJECTIVE

This is to assure that the requirements of installation Power Transformer are

meets the codes requirements and contract specifications. To make sure,
the works are carried out in acceptable workmanship and follow the
requirements in the quality manual.

4. REFERENCE

4.1 T.J.E. Quality Manual , M-01 rev.0

4.2 Applicable Manufacturers Manuals/standards
4.3 Contract Specifications and Construction Drawing – CT 3109-703
 DOCUMENT NO. :
P-T3109-EI-004
INSTALLATION PROCEDURE ISSUED DATE :
FOR 11-03-2008
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4.4 Standards, codes and recommended practices – GB 50052-95

5. PROCEDURE

5.1 GENERAL

The work shall be done according to good workmanship and by using

the suitable tools and material as stated in the construction drawings,
approved documents, and procedures and it shall be studied before
installation.

5.2 DELIVERY

Transformers do not usually need packing for delivery except for

some protection to the few accessories, which are not considered
necessary to remove for transport. Fragile or bulky accessories that
are removed for transport are packed in numbered crates. Details of
crate contents appear on the delivery advice.

The condition in which the transformers are prepared for transport is

partially dismantled and part of dielectric removed (because
expansion of the dielectric caused by temperature changes means
that some spare volume capacity is required) and filled with N2 with
pressure ± 0.2 bars as well as manufacturer standard.

High power transformers and reactor are generally transported by

specialized companies. The transporter is responsible for providing
the suitable means required for monitoring during road, rail or sea
transportation; this monitoring specially concerns check of the
nitrogen pressure in the equipment, which is transported without oil
and for which a nitrogen supply system is provided

5.3 INSPECTION UPON ARRIVAL ON SITE

a) In any case, as soon as the equipment arrives on site, a detailed

inspection is required: Shock traces, scratches, detective
wedging, and nitrogen pressure, condition of accessories crates.
b) For equipment delivered full of oil, check for conditions and oil
leakage at the bushings, ferrules, flanges, valves, etc…
If leakage is detected, check the tightening of the hardware
(screws, bolts) and the torques, especially on the bushings
c) If, for equipment delivered pressure – inflated with nitrogen, the
pressure is droop too low, make sure that the equipment is still
pressurized; otherwise, restore pressure. If the pressure is equal
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P-T3109-EI-004
INSTALLATION PROCEDURE ISSUED DATE :
FOR 11-03-2008
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to atmospherically pressure, specific provisions shall be taken

according to the situation in order to eliminate any possible water
ingress. Then locate leaks using soapy water. After leaks
detection, comply with the bolts tightening torques.

NOTE: Storage of the equipment under the nitrogen pressure must be

limited

5.4 UNLOADING

a) If handling means are not available for unloading of the

transformer (over head traveling bridge, crane), use hydraulic
jacks, metal girders, dry and hard wedging wood such as oak or
colonial timber.
During unloading, each handling operation requires a specific
study in order to define the equipment dimensions, the metal
girders wedging wood and jacks required, considering the type of
equipment, the height of the trailer or of the wagon; the height of
the extension of the jack, the height of the rollers.
The last handling step, before installation of the rollers any other
supporting device, consists in wedging the equipment at the
required height, plus two or three centimeters to facilitate
positioning of the supporting devices (girders, insulators, rollers,
etc) under the equipment.

b) Unloading using overhead traveling bridge or crane requires strict

monitoring of the lifting equipment (slings, lifting beams, etc).
These slings shall not present any cuts strand, traces or sock or
rust.

Compliant strictly with the maximum angle of slings: 60°.

(Refer to Manufacturer Manual Instruction)
c) Position the rollers before handling the equipment in order to
minimize the handling equipment loading time. Strictly comply
with the various slinging points, which are generally indicated on
transformer. Any case, refer to the corresponding instruction
manual.

5.5 STORAGE

If the transformer is to be stored for any length of time, it is preferable

to prepare the partial erection. It means that the conservator must be
installed to the transformer with its breather and the treated oil must be
filled in to the transformer up to the same level of conservator. Since
 DOCUMENT NO. :
P-T3109-EI-004
INSTALLATION PROCEDURE ISSUED DATE :
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the breather is filled with silicagel, the color of the silicagel in the drier
must be in controlled periodically.

It is dangerous to store a transformer without it fully filled with

dielectric, except if it is delivered with a filling of nitrogen which
pressure can be monitored periodically to keep pressure in positive
position.

During the storage period, it is essential that the protective items be

maintained in proper condition for normal operation. Then, the
transformer cabinet & motor drive OLTC cabinet which have the
heater, need to be supplied with the electricity to keep such
temperature in it to avoid the corrosion and humidity.
The requirements of the specification for the dielectric used are
applicable from the time the transformer is assembled.

5.6 INSPECTION OF THE LOCATION

Before installation of the equipment, check the cell dimension:

sleepers, rails. Check the retention pit; check the ballast, the chassis
or conservator support blocks

NOTE: If the equipment is installed in building with natural ventilation,

check the air vents. If forced ventilation is used, checks
presence of the exhausters.

5.7 DISPLACEMENT AND INSTALLATION OF THE EQUIPMENT

a) Move the equipment using a hoist or hand jack (tirfore) to its final
location.
b) Once the equipment is in place check the alignment in relation to
the cell axes, specified in the overall dimension and approved lay
out drawing.

5.8 MEASUREMENT OF THE TANK-EARTHING INSULATION

The value of the equipment tank insulation resistance in relation to

earth must be follow to manufacturer standard under 500 VDC.

5.9 INSPECTION OF THE EQUIPMENT

 DOCUMENT NO. :
P-T3109-EI-004
INSTALLATION PROCEDURE ISSUED DATE :
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All equipment components, whether delivered in bulk or in crane, are

submitted to the following checks:
a) quantity
b) compliance with drawings and specifications.

5.10 OIL TREATMENT BEFORE ASSEMBLY

5.10.1 PURPOSE

To condition oil before filling of transformer.

5.10.2 ASSEMBLY PROCEDURE

a) Place the oil treatment tank near the transformer; install the oil
tank or tanks and the pipes. The capacity of the tank or tanks of
defined according to the amount of oil to be treated.

b) Take a sample on the delivery side in order to perform the

specified checks according IEC 60422 table before conditioning
the oil.

c) Make the connections according to the attached sketch 1.

d) Fill the tank with the oil treatment apparatus or the means
available on site (sketch 1) and carry out closed – circuit
treatment in the tank by means of the treatment equipment of a
type operating in vacuum and temperature (sketch 2)

During the operation, periodically check parameters defining the

conditions (flow rate, vacuum, duration, etc….)

After12 hours (for approximately 25 m3), take a sample of the oil

to determine dielectric strength.

Several type of the equipment may be used to determine the

dielectric strength of the oil.
Refer to the manufacturer’s manual for the use of the appropriate
equipment
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P-T3109-EI-004
INSTALLATION PROCEDURE ISSUED DATE :
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5.11 COOLING SYSTEM FITTING-OUT/ASSEMBLY

5.11.1 RADIATOR

a) Open the red flange on the pipe of radiator

b) Make sure the butterfly valve is in closed position, with remark
bottom of valve.
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P-T3109-EI-004
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c) Clean the valve, if there are any dusts on the valve, and then install
the gasket
d) Install cooling radiators, radiator support, upper and lower holder of
radiator.
e) Open the butterfly valve.
f) Install fan on lower side of radiator (refer to manufacturer drawing)
open the flange of the pipe that will connect the main tank to the
radiator Lift one-piece radiator

5.12 CONSERVATOR FITTING-OUT / ASSEMBLY

5.12.1 SECURE THE CONSERVATOR

On the equipment or on the device provided for this purpose if the

conservator is not attached to the equipment.

5.12.2 INSTALL THE CONSERVATOR ON ITS SUPPORTS

a) Install horizontal support conservator on the up-cover of the main

tank.
b) Lift the conservator with crane to the horizontal support conservator.

c) Install conservator on its support and OLTC conservator with oil level
indicator.
d) Set carefully the conservator then tighten the bolt/nuts and make sure
all supports have already installed.
e) Install piping, valve and breather for conservator.
f) Install Buchholz, air release device and its piping
g) Install Protection Device, valve and piping for OLTC.
h) Connect the earthing cable.

5.13 ASSEMBLY OF HV BUSHINGS, LV BUSHING AND ACCESSORIES

5.13.1 ASSEMBLY OF HV BUSHING

a) Open the flange on the HV tubular
b) Install the HV Bushing on the top of HV Tubular
c) Make sure the positions of lead from winding in the center of the
bushings hole
d) Take the rod and tighten lead at winding
e) Install the insulator
f) Make sure that the position of the bushing have already in the
center of the flange of the tubular
g) Install gasket, nut and flag.
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P-T3109-EI-004
INSTALLATION PROCEDURE ISSUED DATE :
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5.13.2. ASSEMBLY OF LV BUHINGS AND NEUTRAL LV BUSHING

a) Open the flange on the LV tubular

b) Install the LV Bushing on the LV Tubular
c) Install the Neutral LV Bushing on the LV Tubular
d) Make sure the positions of lead from winding in the center of the
bushings hole
e) Take the rod and tighten lead at winding -Install the insulator
f) Install gasket, nut and flag

5.13.3 ASSEMBLY OF ACESSORIES

a) Install pressure relief device and sudden pressure relay

b) Make cable connection on Pressure Relief Device.

5.14 PARTIAL OIL FILLING UNDER VACUUM

a) Disassembled the protecting covers used for shipment.

Secure on the tank the valves, which are not installed for
transportation, especially the valves located on the bottom of the
tank. Refer to the equipment drawings and manufacturer manuals

b) Prepare a special elbow pipe, 50 mm dia, with 2 taps for

connection of vacuum meter and a transparent polyvinyl chloride
pipe to be used as a level indicator.

c) In case of an apparatus fitted a partition for on – load tap changer,

link the two partition trough flanges or draining / filtration valves
provided on the tank:
 At the upper part : to create a vacuum
 At the lower part : to fill with oil
d) Connect the vacuum pump to the special pipe disk valve. Install the
polyvinyl chloride between the drain valve and the nipple provide
on the special pipe. Since the pipe will be used as a level indicator
during vacuum filling. Check for tightness.

e) Start the vacuum pump until obtaining in the tank a residual

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P-T3109-EI-004
INSTALLATION PROCEDURE ISSUED DATE :
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pressure under 3 torrs as well as manufacturer standard. Wait for

about 2 hours before filling.

f) Supply the tank via the upper filtering valve, with the oil from the
storage vessel or tank, treated using the vacuum and temperature
operating type oil treatment equipment. Treatment is carried out
under vacuum at a oil temperature between 50°Cand 60°C. For the
oil treatment equipment heating line, refer to the specific
instructions of the equipment used.

g) Fill the tank at about 10 cm under the upper section of the cover.

h) Stop the filling and shut the upper filtering valve.

i) Maintain vacuum during about 1 hour.

j) Gradually break the vacuum in the tank by opening the special pipe
valve.

k) Disconnect the vacuum, the polyvinyl chloride used as level

indicator after closing the drain valve: remove the special pipe.

l) The inspection results obtained during partial oil filing under –

vacuum will be recorded:
 In the standard table, established for check of the oil treatment
or under vacuum filling operations.
 In the inspection data sheets, for the values of parameters
checked at the end of the each main step of partial oil filling
under vacuum.

5.15 OILTOPPING-UP UNDER VACUUM FOR CONSERVATOR WITH

RUBBER-POCKET
a) Close all the conservator valves
b) Remove the dryer of the OLTC compartment
c) Block the link with the tap changer compartment dryer (if
necessary)
d) Open the following valves:
 Tank conservator link
 Tap changer compartment / conservator link (if necessary)
 Pocket conservator link

CAUTION:
If the equipment is provided with an retaining valve, kept in the open
position.
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To do this, refer to the equipment manual.

 Connect the vacuum pump to the transformer dryer pipe
 Apply vacuum to the unit to reach a residual pressure of 3 torrs
and maintain it for at least 2 hours
 While maintaining the vacuum, feed the appliance slowly via the
upper filling valve with hot oil, treated by oil treatment equipment
operating under vacuum and at the temperature
 Monitor the level of the oil as indicated by the oil level indicator of
the conservator, and if necessary, by the auxiliary compartment.
When the indication corresponds to the oil temperature, stop
filling
 Close the pocket conservator link valve
 Turn of the vacuum pump
 For a conservator with an auxiliary compartment interconnecting
valve
 Gradually release the vacuum in the pocket
 Fill the pocket to a maximum of 50 with nitrogen
 Purge the conservator with the pugs screws located in the upper
part
 Bring the pocket atmospheric pressure

After return to t ambient temperature, it may be necessary to adjust

the oil level so that the level indications correspond to the oil
temperature.
 Bring the valves to the operational position and consult the valve
plate
 Close the main conservator / tap changer compartment link (in
case)
 Open the dryer / tap changer compartment (in case)
 Fit the dryer of the OLTC compartment (in case)
 Fit the dryer of the transformer if the conservator is equipped
with diaphragm (as seen in the picture ), fill the diaphragm with
N2 first

5.16 WIRING

The circuits shall be corresponding with the diagram requirements

If required, the manufacturer may provide for distribution of the
equipment and connections in several cabinets or boxes.
In general:
 A box, at tank potential is reversed for transformer protections and
signaling
 One or several cabinets are electrically insulated from the tanks and
reserved for cooling system power supply and monitoring
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INSTALLATION PROCEDURE ISSUED DATE :
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The switchgear, the motor and the cabinets are wired by the
manufacturer in compliance with the state of the art.
Cables providing for connections between cabinets, boxes and
switchgear shall comply with the standard specified on the order.
They shall be secured on cable pathways provided on the equipment
tank.

The wiring is dimensioned according to the plant used. The various

cable leads are connected to the terminal so that, in case of damage,
they can be easily replaced without upsetting the internal wiring of
cabinets or boxes.
Connections to the terminal shall be achieved using lugs, crimped on
the cable using adequate tongs.

Compliance with the diagram is checked by “wire-to-wire” inspection.

Welding of the bonding braids shall be tested for strength by manually
pulling these braids.
The dielectric tests shall be carried out during the assembly
completion checks.

5.17 EQUIPMENT AND TOOLS

These equipments and tools should be available before starting

works/assembly.

DESCRIPTION QUANTITY REMARK

Crane 10 ton 1 unit Lifting and
assembling

Sling wire for crane 10 ton 1 set

Oil filtering/purely and vacuum 1 unit Filling & treatment oil

machine 1500 - 3000 lt./hours if necessary
equipment with horse
Torque wrench 1 set

Spanner : 8mm, 13mm, 22mm, 1 set

30mm etc

Adjustable wrench 1 set

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Screw driver (plus & minus) 1 set

Multi tester 1 unit

Megger 1 unit
Oil tester 1 unit