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TABLE OF CONTENTS

1.0 SCOPE.........................................................................................................................................2
2.0 REFERENCE DOCUMENTS.......................................................................................................2
3.0 DEFINITIONS...............................................................................................................................3
4.0 RESPONSIBILITIES:...................................................................................................................4
5.0 METHODOLOGY.........................................................................................................................5
6.0 QUALITY CONTROL AND QUALITY ASSURANCE.................................................................6
7.0 MACHINERY AND RESOURCES...............................................................................................6
8.0 SAFETY EQUIPMENTS...............................................................................................................7
9.0 HEALTH, SAFETY AND RISK ASSESSMENT...........................................................................7
10.0 Job Safety Analysis or Risk Assessment..............................................................................9

1.0 SCOPE
This procedure covers Hydrostatic Pressure Testing, Punch listing and Test Package compilation for
Underground Fire Water and Cooling Water system within SEG's scope of Works.

2.0 REFERENCE DOCUMENTS

2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8

JEREF-023 Power Transformer LCC

JERES-A-112 Rev 3 Meteorological and Seismic Design Data
JERES-H-001 Rev 5 Coating Selection & Application Requirements
JERES-P-104 Rev 3 Wiring Methods and Materials
JERES-P-121 Rev 2 Transformers and Reactors
JERES-P-200 Rev 2 Document Management and Final Documentation Requirements
JERES-P-100 Rev 4 Basic Power System Design Criteria
JERES-P-113 Rev 2 Motors and Generators
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2.9 JERES-P-114 Rev 4 Power System and Equipment Protection

2.10JERES-P-119 Rev 3 Onshore Substations
2.11JERES-P-127 Rev 1 Electrical Control Systems
2.12JERMS-P-4531 Rev 2 Power Transformers
2.13JERMS-P-4533 Rev 1 Three-Phase Dry-Type Power Transformers
2.14JERMS-P-5502 Rev 3 Electrical Cables
2.15JERMS-P-6513 Rev 2 Protective Devices
2.16JERSD-P-0008 Low Voltage Switchgear Transformer Incomer
2.17JERSD-P-0015 Rev 1 High Voltage Controlgear Motor Outer with Circuit Breaker
2.18JERSD-P-0017 Rev 3 High Voltage Switchgear Incomer
2.19JERSD-P-0019 High Voltage Switchgear HV HV Transformer
2.20JERSD-P-0025 4.16kV Diesel switchgear Transformer outgoer
2.21JERSD-P-0030 LV LV transformer outgoer
2.22JERITP-P-140200 Pad-mounted transformer
2.23JERITP-P-140300 Dry-Type Power transformer
2.24JERITP-P-140400 Pad-mounted transformer
2.25JERITP-P-140500 Power transformer
2.26JERITP-P-160300 HV MCC
2.27Project Quality Plan
2.28Safety and Medical plan
2.29Schedule D & Sec. 11-14 of JER Contraction Safety Manual
2.30Project Specifications & Standards
2.31All the transformer related IFC drawing
CODES AND STANDARDS
The following, but not limited to, codes and standards shall govern the design, ratings, manufacturing and testing
and installation of the power transformer.
IEC 60034
Rotating electrical machinery
IEC 60044-1
IEC 60044-2

Instrument Transformers : Part 1-Current Transformers

Instrument Transformers : Part 2-Voltage Transformers

IEC 60073 Coding principles for indicators and actuators

IEC 60076
Power Transformers
IEC 60076-1
IEC 60076-3

General
Insulation levels, dielectric tests and external clearances in air

IEC 60076-11 Dry-type transformers

IEC 60137
Bushings for alternating voltages above 1000V
IEC 60214
IEC 60296

On-load tap changers

Mineral Insulating oils for transformers & switchgear

IEC 60445

Basic and safety principles for man-machine interface, marking and identification
identification of equipment terminals and of terminations of certain designated
conductors, including general rules for alphanumeric system
IEC 60446
Basic and safety principles for man-machine interface, marking and identification
Identification of conductors by colours and numerals
IEC 60529
Degrees of protection provided by enclosures (IP Code)
IEC 60664
Insulation co-ordination for equipment within low-voltage systems
IEC 60755

General requirements for residual-current operated protective devices

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 IEC 60947

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Low-voltage switchgear and controlgear

3.0 DEFINITIONS
All the definitions mentioned in the JER Documents have priority over other standards and any deviation of
these standards shall be brought to attention of the COMPANY. It means to the company representative for
resolution.
All terms used in the development of this procedure are defined below:
COMPANY

Saudi Aramco Total Refining and Petrochemical Company

CONTRACTOR

Sinopec Engineering Group Saudi Ltd

4.0 RESPONSIBILITIES:
4.1The project manager shall ensure that all operations related to transformer installation work have been risk
assessed and necessary control measures have been implemented to carry out the task in a safely
manner.
4.1 The construction or site manager shall manage and control overall responsibility for site, QA/QC and
provide management commitment to the site quality plan.
4.2 The QA/QC manager shall ensure that all works is in compliance with project procedures and ITP
requirements. Also to ensure the project quality management systems documentation is prepared for the
project. Reviewing test plans if necessary to ensure adequate assurance is provided for implementation of
activities affecting quality. Ensure all documentations reported are audited to ensure compliance with
SATORP requirements. He is responsible for developing and maintaining the authorized QC signatories
list.
4.3 Contractors construction engineer shall review and confirm that all transformer installation sequence of
work being implemented are as per the activities stated in the method statement and in compliance with
the (SATORP) codes, standards and project specification.
4.4 Contactors supervisor shall supervise all Installation activities as required by the project drawings and
specifications. He shall prepare all the necessary permits in advance and get it approved from the
companys designated representative for the execution.
4.5 Contractors site supervisor shall conduct regular toolbox meetings and explain the requirements of PPE
and other special needs to create a safe working environment. He is responsible for achieving the target
and the project milestones.
4.6 Contractors QA/QC Inspector shall closely monitor and assure all installation activities are carried out as
per (SATORP) QA/QC requirements and conduct frequent inspections and maintain all records as
required by project QA/QC Program.
4.7 Contractors Safety inspector shall closely monitor and assure that all works are carried out in highly safe
manner. Gearing the workers with full strength of safety protective equipment, preparation of safety
barricading and dust control screening wherever applicable in safe manner, safe workability of equipment
to be used and fulfilling any other additional safety needs as required during work executions. He shall
also check and ensure that only qualified personals are carrying out the equipment and machinery related
works.
4.8 Contractor shall appoint their own safety manager and he shall conduct safety routine inspection around
the site in weekly basis. He shall prepare and submit a report to the company any accidents occurrence.

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5.0 METHODOLOGY
5.1 GENERAL
Ensure that all relevant site condition and working practices are observed.
Check and ensure Cold and Hot Work permits are obtained.
Ensure that the materials are in accordance with the project specifications.
Verify and prepare all tools and equipment required for safe execution of work is available.
5.2 SEQUENCE OF WORK
Review and finalized the installation documents on listed below together with the clients representative.
Power transformers construction details drawing, transformer power and control cables schedule layout/termination drawings, Material Requisition Form, Material Receiving and Inspection Report, Material
Receiving, Storage and Issue Checklist, Installation Work Permit, JSA , Risk Assessment and Lifting /
Transport Permit.
Transformers foundation base final inspection.
Foundation base installation, orientation, wheel mounting rail or mounting rail, elevation, center, alignment,
squareness and plumpness shall comply with construction approved drawing. This drawing shall show
recommended clearances for safe operation and future maintenance of the transformer installation.
Prior to Lifting, Work permit to be produced for Lifting & Road Closure. Ensure that all relevant site condition
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and safety work practices are observed prior to work execution. Barricade range of work area to assure
safety work environment with safety barricade tape and warning signs.
Prior to transformers mobilization and upon equipment receipt, inspection shall be done to verify if the
transformers technical specification from the nameplate details complies with the equipments PR,
manufacturers equipment MSDS and Vendors Declaration of Conformity documents.
Mobilization of materials, equipments and machineries to the designated area by using manpower, trolley and
forklift.
The crane (refer to attached mobile crane data sheet for reference) shall be parked at the parking area and
the outriggers shall be fully extended to secure firm parking.
After Crane has been parked Barricades & Safety signals to be placed for road closure & lifting in progress
board to be provided
Lifting team including rigger, signalman and lifting supervisor shall implement and execute the lifting and
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installation operation with the guidance of the construction engineer for the final setting down positioning of
the transformer. For each lifting, the boom length shall be extended within safety range in order to lift the
Transformer secure and safely.
Transformer will be pulled out from Truck by using crane using lifting Chains and swung to its foundation
plinth.
The transformer should be mobilized and installed in an upright position, swung to its foundation plinth and
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then be slowly lowered down for positioning. Stopper will be used to fix its position.
For the remaining assembly body parts will be done by transformer vendor.
Proper identification and labeling shall be implemented from the transformers switchgear panel/ OLTC control
panel/local control panels NAMEPLATE, electrical and instrument control relays, contactors, devices,
sensors, power/control cables and motors.
Clear all the barricading tape and close-up once work completion to resume normal traffic flow.
To do housekeeping after works to ensure work place has been always remain tidy and safe.
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6.0 QUALITY CONTROL AND QUALITY ASSURANCE

The quality of the works shall be in line with the SATORP standards. Required tests shall be performed on each
stage of concrete works and the report shall be prepared and submitted to the company representative for prior
approval.
6.1

INSPECTION AND TESTING PROCEDURE

Transformer installation, inspection and testing shall be carried out in accordance with approved for
construction drawings, specifications and details, JERES-P-104 Wiring Methods and Material Selection, Field
Installation and Testing of Electrical Equipment IEC Standard.
Field Installation and Testing of Electrical Equipment as per SATORP Code, and Project Specification.
The required inspection shall be carried out based on, ITP for Transformer Installation.
Inspection results shall be recorded and documented.

7.0 MACHINERY AND RESOURCES

Basic Electrical Hand Tools
Measuring tape
Walkie Talkie
Lifting gears / shackles (certified)
Ladders
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Mobile Hydraulic Crane
Scaffolding
QA/QC Inspector
Construction(Electrical and Mechanical) Engineer
HSE Officer
Lifting Supervisor with complete Lifting Crew.

8.0 SAFETY EQUIPMENTS

Safety shoes
Safety helmet
Safety glass
Safety harness (for working at height more than 2 meters)
Approved body wear/uniform
Hand gloves

9.0 HEALTH, SAFETY AND RISK ASSESSMENT

The health and safety shall perform a splendid role in all construction activities to ensure that all the works are
carried out in a safe manner and creating a healthy environment. The individuals especially in related with health
and safety and complying with the SATORP safety standards shall perform the duties. Appropriate work permit
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shall be applied in accordance to the requirements of Schedule D and Section II-14 of the JER Construction
Safety Manual.
9.1 A safety officer or a safety coordinator shall be present at site full time during the execution of works and
also to clarify the safety related issues.
9.2 Daily toolbox meetings shall be conducted as mandatory requirements to describe and discuss the safety
related issues.
9.3 The works shall be risk assessed and proper guidance should be managed before implementation of
every individual activities.
9.4 Following safety requirements shall be fulfilled.
9.4.1 Safety barricade shall be provided wherever necessary.
9.4.2 The Lifting Supervisor shall examine the equipments, lifting gears, tag lines, surrounding and its
environment to ensure the operation can be safely executed.
9.4.3 Throughout the operation, the lifting team shall ensure their presence. Lifting Supervisor and the
Signalman shall be within the visible distance of the crane operator throughout the whole operation.
9.4.4 Necessary safety signboards shall be provided at work places as required by safety Standards.
9.4.5 All workers shall be provided with job specific Personal Protective Equipment.
9.4.6 Safety flickering lights shall be provided for vehicles working on long-time hours especially on night
hours.
9.4.7 The approving authority shall inspect all equipment checklists for machineries related to the activities
prior before commencing the works.
9.4.8 Working equipment shall be equipped with amber lights, horns, safety guards, etc. as required and
mentioned in safety manuals.
9.4.9 Any incident at site shall be immediately reported to company and recorded.
9.4.10 Weekly safety statistics reports and safety performance reports etc. shall be repaired and recorded.
9.4.11 Daily safety task assignment shall be prepared.
9.4.12 Man shelters shall be provided to protect the workers from adverse climatic condition, i.e. sand storm,
high temperature.
9.4.13 Potable water source shall be provided for adequate numbers for workers.
9.4.14 Work place to be tidied before leaving as to ensure safely work environment always has been remain.

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10.0 Job Safety Analysis or Risk Assessment.

No

Work
Activity

Hazard

Possible
accident/
Health
Person
at Risk

Lifting,

Strike by

Serious injury or

Transport
and lowering

swinging boom.

death.

to
transformers
base
foundation.

Pin down or

Serious injury or

striken by lifted
load.

death.

Power or Dry
Transformer
s
Installation

Knifecuts during
power
and
control

and

Serious injury.

Existing risk

Additional Risk

control(if any)

Control

Lifting watchman
or
supervisor proper
safety watch.

Safety work

Lifting watchman
or
supervisor proper
safety watch.

Safety work

Proper wearing of
PPE and use of

Safety work
practice.

practice for crane

liftworks.

practice for crane

liftworks.

cable installs.

tools.

Accidental bruise
and muscle
dislocation.

Serious injury.

Proper wearing of
PPE and use of
tools.

Safety work
practice.

Serious injury or
may cause
Blind ness.

Proper wearing of
appropriate
safety glass.

Safety work
practice.

Serious injury

Proper wearing of
PPE and use of
tools.

Safety work
practice.

Accidental eye
injury.
Accidental burn
from exothermal
weld.