Document Title:

Method Statement of
Rectification of Defect No. E398

Project:

Provision of
Electrical & Instrument Rectification Service
(KPC1901-0000-PRC-TP-027)

Document No.: KPC027-MST-KPS1-037-01

Purpose:
☐ For Information ☐ For Review ☒For Approval ☐For Construction ☐As-Built

00 Based on KPC comments 20/07/2020 A. Hamad A. A. Hussein M.Ibrahim

00 First issue 27/06/2020 A. Hamad A. A. Hussein M.Ibrahim

Revision Description Date Drafted Reviewed Approved

Client:

KURDISTAN PIPELINE COMPANY

Contractor:

UNI-TECH EPC SOLUTIONS

KPC027-MST-KPS1-037-00 Page 1 of 13
 Project Title: Provision of Electrical & Instrument Rectification Services Revision: 01
Contract No: KPC1901-0000-PRC-TP-027
Document Title Method Statements for Defect Item No. E398
Document No.: KPC027-MST-KPS1-037-01 Page 2 of 13

1 Introduction ........................................................................................................................... 3
2 The Purpose of the Defect Rectification................................................................................. 3
3 Definitions ............................................................................................................................. 3
4 Abbreviations......................................................................................................................... 4
5 Scope of Work ....................................................................................................................... 4
6 Reference Documents ........................................................................................................... 4
7 HSE Requirements ................................................................................................................ 5
8 Planning & Preparation .......................................................................................................... 5
9 Engineering ........................................................................................................................... 6
9.1 Philosophy of connection: ........................................................................................ 6
9.2 Latched annunciator specification:........................................................................... 7
9.3 Expanding a trip signal ............................................................................................ 7
9.4 Proper installation location on the panel door: ......................................................... 8
9.5 Wiring inside the switchgear cubicle: ....................................................................... 9
10 Procurement .......................................................................................................................... 9
11 Execution ............................................................................................................................ 10
12 Testing and Commissioning ................................................................................................ 11
13 Requirements ...................................................................................................................... 12
13.1 Tools and Equipment:............................................................................................ 12
13.2 Documents: ........................................................................................................... 12
14 Manpower ........................................................................................................................... 12
14.1 Engineering team .................................................................................................. 12
14.2 Execution team...................................................................................................... 12
14.3 Testing team ......................................................................................................... 12
15 Material take-off................................................................................................................... 13
16 Demobilization ..................................................................................................................... 13

KPC027-MST-KPS1-037-01 Page 2 of 13
 Project Title: Provision of Electrical & Instrument Rectification Services Revision: 01
Contract No: KPC1901-0000-PRC-TP-027
Document Title Method Statements for Defect Item No. E398
Document No.: KPC027-MST-KPS1-037-01 Page 3 of 13

1 Introduction
This Method Statement is to describe required engineering, procurement, execution, and
test activities for rectifying the defect with the following detail:

Defect Equipment Tag Recommendations

Area Defect Description Equipment
ID no No. for repair works
E398 KPS1 Trip and alarm signals of KPS1-PWE-DTT-005 Power The signals must be
Buchholz, winding Transformer sent individually.
temperature and pressure Annunciators must be
relief valve are merged and installed in related
sent as a trip signal to the cubicles.
circuit breaker.

2 The Purpose of the Defect Rectification

Any transformer has many mechanical protections and electrical protections. For accurate
and easier maintenance, we need to know which kind of protection caused the trip or we
can identify a problem before happening from its alarm for this purpose, we use a latch
annunciator.
According to the schematic drawing of transformer feeder cubicle as shown in site survey
report UNTI1801-KPS1-ELC-RE-0000-2 the alarms and trips are mixed and both cases
the circuit makes trip while the transformer can continue to operate during alarm until the
alarm condition is maintained.
For defect E398 firstly we will separate the alarms and trips and then connecting each
signal and trip to a dedicated channel of latch annunciator.

3 Definitions
COMPANY KPC (Kurdistan Pipeline Company)

PROJECT Provision of Electrical & Instrument Rectification Service

CONTRACTOR UniTech-EPC Solutions

SITE KPS1

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 Project Title: Provision of Electrical & Instrument Rectification Services Revision: 01
Contract No: KPC1901-0000-PRC-TP-027
Document Title Method Statements for Defect Item No. E398
Document No.: KPC027-MST-KPS1-037-01 Page 4 of 13

4 Abbreviations
Abbreviation Definition

SOW Scope of Work

KPC Kurdistan Pipeline Company

MS Method Statement

TBT Toolbox Talking

ITP Inspection Test Plan

RFI Request for Inspection

JRA Job Risk Assessment

5 Scope of Work

- Select proper material

- Purchase proper materials
- Install the annunciator on the feeder’s cubicle door according to the attached
document: Panel layout of transformer feeder’s cubicle (Modified)
- Connecting the annunciator at the transformer feeder’s cubicle and modifying the
control circuit according to the attached document: Schematic drawing of the
transformer signal (Modified)
- Testing and commissioning the system
- Startup the transformer safely

6 Reference Documents
- Project HSE Plan.
- The survey report UNTI1801-KPS1-ELC-RE-0000-2 (only related part): Schematic
diagram of transformer signal (Existing)
- Panel layout of transformer feeder’s cubicle (Modified)
- Schematic diagram of the transformer signal (Modified)

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 Project Title: Provision of Electrical & Instrument Rectification Services Revision: 01
Contract No: KPC1901-0000-PRC-TP-027
Document Title Method Statements for Defect Item No. E398
Document No.: KPC027-MST-KPS1-037-01 Page 5 of 13

7 HSE Requirements
- Site Induction.
- TBT before start work by contractor HSE supervisor and Team leader. All of the
team including technicians and labors will attend.
- Risk Assessment & PTW, including approved Method of Statements.
- Ensure that all electrical equipment is inspected by a competent person.
- PPE Required for the activity:
Foot protection Eye protection Hand protection Head protection Protective clothing Face protection

- Use suitable barriers, barricades and warning signs around the workplace.
- Before start arrange with the electrical department to apply LOTO.
- During rectifying this defect power tools will be used and using the proper
protection is necessary.
- Housekeeping.

8 Planning & Preparation

Below items need to be prepared before starting activities:
- Arrange with KPC regarding execution starting date, duration, and required
permissions.
- Apply for Gate pass permission for all the team.
- Apply for PTW.
- Mobilize equipment and tools.
- HSE survey according to section 7 (HSE Requirements)
- Prepare the proper power supply.
- TBT before start work by contractor HSE supervisor and Team leader. All of the
team including technicians and labors must attend.
- Area Barricaded with warning signs.
- Prepare a hardcopy of approved documents including MS, ITP, RFI, JRA.
- Assess parallel activities and coordinate with their team leader to avoid any
interference.

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 Project Title: Provision of Electrical & Instrument Rectification Services Revision: 01
Contract No: KPC1901-0000-PRC-TP-027
Document Title Method Statements for Defect Item No. E398
Document No.: KPC027-MST-KPS1-037-01 Page 6 of 13

9 Engineering
9.1 Philosophy of connection:
According to the site survey report, the available signals of the transformer KPS1-PWE-
DTT-005 are as the following:

- Oil level alarm low

- Oil level alarm high
- Oil temperature alarm
- Oil temperature trip
- Pressure relieve trip
- Buchholz alarm
- Buchholz trip
At the existing connection, all of the signals mixed and sent to protection device as
“Transformer trip”. but we decide that:
- separate the trips and alarms.
- use separated signal lamps for each trip or alarm.
The annunciator connection map is as shown in Figure 1:

Transformer signals Annunciator channels and labels

Oil level alarm low Channel-1 Oil level alarm low

Oil level alarm high Channel-2 Oil level alarm high

Oil temperature alarm Channel-3 Oil temperature alarm

Oil temperature trip Channel-4 Oil temperature trip

Pressure relieve trip Channel-5 Pressure relieve trip

Buchholz alarm Channel-6 Spare

Buchholz trip Channel-7 Buchholz alarm

Channel-8 Buchholz trip

Protection device Channel-9 Spare

Tag: F31
Siemens 7S1602
Channel-16 Spare

Figure 1-Annunciator connection mapping

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 Project Title: Provision of Electrical & Instrument Rectification Services Revision: 01
Contract No: KPC1901-0000-PRC-TP-027
Document Title Method Statements for Defect Item No. E398
Document No.: KPC027-MST-KPS1-037-01 Page 7 of 13

9.2 Latched annunciator specification:

We use a 16-channel annunciator. it has more than double of channels required that will
be served as spare channels. The specification table is as below:

Table 1- Latched annunciator

Sample Figure Name Specifications Material
Latched annunciator 16-Channel -
110V AC/DC
Size:
Height 137mm,
Width 137mm,
Depth 58mm

9.3 Expanding a trip signal

The trip signal coming from the transformer is only one wire (for each signal) but we want to
distribute it to the annunciator and protection circuit and this cleared in Figure 1 with the red lines.
For this purpose, the auxiliary control relays must be used in Figure 2 describing how signals will
be expanded and multiplexed to one signal for protection device. Table-2 identifying the auxiliary
relays specifications.

Figure 2-Expanding and multiplexing of trip signals

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 Project Title: Provision of Electrical & Instrument Rectification Services Revision: 01
Contract No: KPC1901-0000-PRC-TP-027
Document Title Method Statements for Defect Item No. E398
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Table 2- Auxiliary relay specifications

Sample Figure Name Specifications Material
Miniature plug-in 110VDC Schneider/Zelio relay
relay 4 O/C contacts, 6A family

Relay socket Ue<250V Schneider/Zelio relay

Mixed contact type family

9.4 Proper installation location on the panel door:

The annunciator must be installed on the door of the panel in such location that:
- Easy to see
- Wiring not interfered with other equipment
- During opening and closing, the panel door annunciator not touched the panel
Notice that the annunciator previously installed on the panel during the shutdown.

Figure 3-Annunciator installation location on the panel door

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 Project Title: Provision of Electrical & Instrument Rectification Services Revision: 01
Contract No: KPC1901-0000-PRC-TP-027
Document Title Method Statements for Defect Item No. E398
Document No.: KPC027-MST-KPS1-037-01 Page 9 of 13

9.5 Wiring inside the switchgear cubicle:

Normally for the internal wiring, the 1.5mm2 or 2.5mm2 wires used. for better performance, we
choose the 2.5mm2. Wire and other wiring materials mentioned in table 3:

Table 3-Wiring and termination materials

Sample Figure Name Specifications Material
Wire 2.5mm2, black, green Copper alloy
and yellow (for
equipment earthing),
1KV PVC insulated

Wire tag φ6mm2 PVC

Bootlace 2.5mm2 Standard type

Cable tie 2.5x200 mm Nylon

10 Procurement
The annunciator, auxiliary relay set and other wiring and termination materials purchased
based on approved EMS documents from certified manufacturers or agents.
The proposed material specification at the engineering section (section 9) will be
reflected in the EMS in detail.

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 Project Title: Provision of Electrical & Instrument Rectification Services Revision: 01
Contract No: KPC1901-0000-PRC-TP-027
Document Title Method Statements for Defect Item No. E398
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11 Execution
The execution can proceed as the following steps as in the following chart:

Start

Make a proper opening on the front

door of panel according to layout
drawing

Cleaning and painting of the cut sharp

edges

Installation of annunciator

Remove the existing wrong connection

Connect the annunciator to the panel

circuitry according to schematic drawing

Testing and commissioning

End

Chart 1-Annunciator installation chart

- Applying LOTO procedure and turning the load off (this step will be performed by
KPC operation team or by Unitech according to site operation instructions).
- Turning the AC supply and DC supply of control circuit for related switchgear cubicle
(this step will be performed by KPC operation team or by Unitech according to site
operation instructions).
- Choosing the proper location, it will be aligned with protection device and 1 inch far
from it.
- Define the limits of cutting.
- Isolating of existing circuitry by using thick fabric cover to prevent the falling the hot
filings inside the terminals and other parts.
- Make 4 holes at corners of cutting limit (inside of limit).

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 Project Title: Provision of Electrical & Instrument Rectification Services Revision: 01
Contract No: KPC1901-0000-PRC-TP-027
Document Title Method Statements for Defect Item No. E398
Document No.: KPC027-MST-KPS1-037-01 Page 11 of 13

- Cutting the panel door with a small Dremel tool or jigsaw according to attachment
Panel layout of transformer feeder’s cubicle (Modified).
- Removing sharp edges of metal by using metallic file.
- Cleaning and painting the cut edges.
- Coat the cut edges at least two times by using paint marker pen.
- Installation of annunciator without damage.
- Removing the existing connection according to attachment Schematic diagram of
transformer signal (Existing).
- Make new wiring according to attachment Schematic drawing of transformer
signal (Modified).
- Check the labels and connections.
- Starting the test and commissioning according to section 12.

12 Testing and Commissioning

Testing of installed annunciator and its commissioning as the following items:

- Visual inspection of installed materials (annunciator, auxiliary relays, and wiring) and
checking if material installed in healthy condition without any damage.
- Cold loop-check and continuity test for switchgear: testing of continuity for modified wiring
and labels.
- Cold loop-check and continuity test for interconnection: testing of continuity of
interconnection between transformer and switchgear cubicle according to as-built
drawing.
- Simulation the alarm and trip signals and check the annunciator and protection device’s
reactions respect to all signals one by one (hot loop check) as the following steps:
• Energize control circuit.
• Keep the circuit breaker at “draw out” position.
• Using a wire jumper short a transformer signal.
• Check the annunciator and protection device for trip or alarm.
• Repeat these steps for all of the transformer signals.
- Insert the circuit breaker to the test position and simulate any one of the trips because in
last step we checked all signals individually and we got the trip signal in for each signal.
- If all tests and inspections are satisfying then the transformer is ready to energize.

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 Project Title: Provision of Electrical & Instrument Rectification Services Revision: 01
Contract No: KPC1901-0000-PRC-TP-027
Document Title Method Statements for Defect Item No. E398
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13 Requirements
13.1 Tools and Equipment:
- Hand Tools
- Power tools (Dremel or jigsaw and heat gun)
- Multimeter
- Fire extinguisher

13.2 Documents:
- MST
- RFI
- ITP
- PTW
- JRA
- Datasheet of annunciator and auxiliary relay
- Panel layout of transformer feeder’s cubicle (Modified)
- Schematic diagram of the transformer signal (Existing)
- Schematic diagram of the transformer signal (Modified)

14 Manpower
14.1 Engineering team
- An electrical Engineer
- An HSE supervisor
- A QA/QC Engineer.

14.2 Execution team

- An electrical Engineer
- A QA/QC Engineer.
- An HSE supervisor
- One Technicians
- One helper

14.3 Testing team

- An electrical Engineer
- An HSE supervisor
- A QA/QC Engineer.
- One Technicians

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 Project Title: Provision of Electrical & Instrument Rectification Services Revision: 01
Contract No: KPC1901-0000-PRC-TP-027
Document Title Method Statements for Defect Item No. E398
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15 Material take-off

- Latched annunciator,16-Channel, 110V AC/DC, Size: Height 137mm,Width

137mm,Depth 58mm.
- Miniature plug-in relay, 110VDC, 4 O/C contacts, 6A Schneider/Zelio relay family.
- Relay socket, Ue<250V, Mixed contact type, Schneider/Zelio relay family
- Wire, 2.5mm2, black or green and yellow (for equipment earthing), 1KV PVC
insulated, Copper alloy
- Wire tag, φ6mm2, PVC
- Bootlace, 2.5mm2, Standard type
- Cable tie, 2.5x200 mm, Nylon

16 Demobilization
- Close the PTW.
- Housekeeping.

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