Transformer - SOP INSTALASI DAN KOMISIONING RADIATOR R1

AFTER SALES SERVICE PROCEDURE
Joint Venture Company of

RADIATOR REPLACEMENT OF THE
GE and PT. PLN (Persero) TRANSFORMER AT SITE
Document No : Issued Date : October 09, 2018

Revision No : 02 Page : 1 of 18
Original QA Copy Distribution List
√ B.O.D HRD MM Fin. IT MT Svc.
PD ENG QC Test Comm. Project A.S

UTR – Power Transformer √
PD ENG QC Test Comm. Project A.S
UTR – Traction Transformer
Incoming W.H All dept.
Name Function Sign. Date

ORIGINATOR
THEMY AFTER SALES
ISDIANTO ENGINEER
CHECKED HARIO HEAD OF

BRAHMIARSO AFTER SALES
SERVICE
DEPARTMENT


DOCUMENT HISTORY
Revision Effective Date Nature of Release

No Date
00 18-09-2015 September 2015 New Initial
01 23-09-2015 September 2015
02 25-07-2017 July 2017
03 08-10-2018 October 2018 Revised and Modify


1. SCOPE
This resume of works made as the guideline for radiator replacement, which installed on
the transformer at site.
2. QUALITY, EHS & REFERENCE

2.1 Quality
All documentation (reports) related to the quality process must be recorded in a
folder and always available on site (during assembly and site test), and reported to
the After Sales Manager.
If there is a discrepancy in the process, should be noted and reported to the After
Sales Manager.
The Transformer should be installed (assembled) according to the UNINDO
drawings and carried out by suitably qualified and experienced persons.
Attention:
- The groove is located on one side of the assembly and the gasket shape can be
“O” Ring or flat.
- The compression of the gasket is limited to the depth of the groove or limiter.
- The tightening of the bolts must be carefully achieved according to the operating
instruction Torque value.
- Before positioning the gasket in place and assembling the parts, the surface of
the groove and mating faces must be clean, smooth, without scratch and free of
weld spatter or paint runs.
- O-ring dimensions must correspond to the size of the groove (refer to the detailed
drawings).
- Carefully position the gasket into its groove.
- Fit the flange of the radiator and hold it in place while hand tightening the nuts or
screws.


- During this operation verify that the gasket doesn’t come out the groove and
become trapped or broken.
2.2 EHS
EHS instruction PTR-E&C-OI-10.000 and local EHS regulations must be read and
strictly applied.
- Use appropriate personal protective equipment (PPE).
- Safety helmet, safety shoes, safety gloves, safety goggle and high visibility
clothes/vest must be permanently worn by the workers.
- Safety harness must be used when working at height above 1.8 meters.
- Make sure always work on a safe distance from the energized line-voltage and
equipment/machinery.
- Kindly please pay attention to avoid any oil spilled.
2.3. REFERENCE
1) IEC 60076
2) Transformer General Arrangement / Transformer Outline Drawing
3) PTR-E&C-OI-40.010-EN-A - Gaskets and seals
4) PTR-E&C-OI-30.020-EN-A – Installation of The Cooling System
5) PTR-E&C-OI-40.000-EN-A - Assembly of bolts, screws, nuts and studs. Torque
value
6) PTR-E&C-OI-30.090-EN-A – Transformer Oil Filling
7) PTR-E&C-OI-30.100-EN-A – Oil Recycling
8) IH-1-MPT-4-200 Radiators Assembly


PPE (PERSONNAL PROTECTIVE EQUIPMENT)
Helmet Safety Shoes Safety Glasses
Body Hardness Safety Gloves

Oil Spill Equipment


3. TOOLS
3.1 Tools sets for mechanical
3.2 Tools sets for electrical wiring
3.3 Multimeter (AVO)
3.4 Calibrated torque wrench
3.5 Oil treatment plant complete with accessories (adaptor flange, hose, etc.)
Note:
For radiator replacement, we can use oil treatment machine with capacity
minimum 1000 - 2000 liters / hours.
3.6 Temporary tank as a temporary storage of oil from radiator prior to dismantling
process.
Note:
Oil volume for one-piece radiator around 200 – 300 liters.
Please provide temporary oil storage tank which can accommodated to the oil
volume of all radiators.
3.7 Mobile crane; with minimum capacity 5 ton.
Depend on location and position of the object to reach (radiator unit) with safe
condition.
3.8 Ambient monitoring equipment (humidity meter)
3.9 Bucket with capacity 10 Liters.
3.10 Clothes for cleaning.
3.11 New radiator with quality control checked.
3.12 New gasket with correct spec and size.
3.13 Oil Break Down Voltage Test
3.14 Water Content Equipment Test


4. PROCEDURE
4.1 Oil Testing before Start the Work
1. Check the oil breakdown voltage in the transformer.
2. Check the water content in oil of the transformer.
4.2 Reducing Oil

1. Prepare oil treatment machine to transfer the oil from radiator to the temporary
tank.


Air Vent
Oil Draining of Radiator
Fig 1. Valve plate of the Transformer
2. Close the top and bottom radiator valves (800) tightly.

3. Connect hose from the oil draining of the radiator to the inlet of oil pump.
4. And connect the other hose from the outlet of oil machine to the oil storage
tank.
5. Start transferring the oil and open slowly air vent bolt on the top of the radiator
(refer to Fig 1.).
6. Ensure the oil from radiator is completely transferred to the oil storage.
7. Remove the hose from radiator.


Fig. 3 Illustration of the transformer
4.3 Dismantling the Radiator

1. Disconnect, unwire and dismantle the cooling fans (if applicable).
Cooling fans and it support should be dismantle if they connected directly with
the radiator or have possibility to disturb the process.
Please check drawing and actual condition at site.
2. Dismantle the radiator support on bottom and top side which is disturb the
radiator replacement.


3. Preparing and put web sling on lifting point of radiator unit.

Note:
Prior to dismantle radiator from main tank, the radiator shall be hang up by the
crane.
4. Unscrew all the nuts on radiator valve.
5. Put a plastic bucket under radiator valve to avoid residual oil drop to the ground.
6. Slowly move the radiator and lift it up.
Note:
Once the radiator free; temporary close the radiator valve with blank flange.
7. Put radiator safely on clean and flat surface.
Note: During lifting the radiators; kindly please avoid any oil spill. Hang the bucket if
needed.
4.4 Installing the Radiator

1. Prepare the new radiators to be installed.
2. Make sure cleanliness and there’s nothing blocked the radiator pipes.
Note:
The inlet and outlet pipes of radiator must be in sealed condition and filled with
nitrogen or dry air during transportation. If you find the open/broken inlet/outlet
sealed flange, cleaning the possible debris or moisture inside radiator must be
taken care.


Fig 4. Unpack the radiators
Fig 5. Removing the pipes protection
3. Remove the blanking flanges from the valves which the radiator will attach to.
Note:
Open the flange one by one, based on the radiator which want to be installed.
4. Remove the gasket in place, clean the flange and replace with a new gasket.
Make sure the gasket is fit with the groove.
5. Place the rubber mat or wood at the bottom of radiator to be lifted.


This is to avoid the radiator fins touching directly to the ground which may broke
the fins during stand up process.
Fig 6. Rubber mat or wood
6. Stand up the radiator.

7. Prepare the new radiator gasket and press softly around with the finger.
Fig 7. Put the radiator gasket
8. With the help of the crane, carefully position the radiator on the upper and lower
flanges located on the transformer.


Please make sure that no damage is caused to the bolts.
Fig 8. Fitting of the radiator
9. When the radiator is in place maintain it with the crane and screw
simultaneously the new nuts on the studs at the upper and lower flanges.
10. Tightened all the nuts properly.
11. Proceed with the assembly of the other radiators according to the same
procedure until the last one is mounted.
12. Install the diagonal radiators support, lower (908) and upper holder of radiator
(905).
Fig 9. Upper and lower support
13. Re-install the cooling fans unit on radiators (if applicable).



Cooling fans may be installed on a cooling fans support, depend on the design of
the transformer.
Please refer to drawing “General Arrangement” in the Instruction Manual of the
transformer.
14. Open slowly the air vent valve on top radiator to let the air escape from the
radiator during oil filling.
15. Open the top radiator valve (800).
Let the oil from main tank filled the radiator.
16. Closed immediately the air vent valve once the oil bleed.
17. Open the bottom radiator valve (800).
18. Repeat the process no. 11 – 14 for other radiators.

4.5 Oil Filling and Treatment

1. The oil filling of the transformer must be carried out under vacuum through an
oil treatment plant with hot oil which has been previously treated.
Note:
As the oil filling is carried out under vacuum, all of the compartments inside
the transformer must be connected so that the vacuum is equalized in the
transformer.
2. Before filling the transformer, the oil must have been proceeding and
achieved the value below:
- BDV ≥ 70 kV/2,5mm
- Water content ≤ 10 ppm at Temperature 20oC
3. Record the results of the testing of the oil in a form that has been provided.
4. The oil filling must be made through an oil treatment plant with treated and
vacuum oil heated 60 – 70 °C.


5. Connect the pipes between the oil storage tank and the input of the oil
treatment plant.
6. Connect the outlet of oil treatment plant to the draining pipe of main
conservator (807).
Please see Fig 1. Valve plate of the transformer.
7. Fill the transformer through the draining pipe of main conservator.
8. Check the levels of oil on Oil Level Indicator appropriate with the oil
temperature at the time.
9. Ensure the air vent (air release) the transformer done properly for main tank,
conservator, all radiators, all HV – LV bushing.
10. Dismantle the hoses and cleaning the transformer.
11. Check valve position before energizing.


THE GUIDANCE VALVE POSITION BEFORE ENERGIZE THE TRANSFORMER



HIGH LIGHT FOR SAFETY



DON’T SPILL OIL ON THE GROUND SOIL OR FLOOR ARROUND WORK AREA

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AFTER SALES SERVICE PROCEDURE

Joint Venture Company of

Document No : Issued Date : October 09, 2018

Original QA Copy Distribution List

√ B.O.D HRD MM Fin. IT MT Svc.

PD ENG QC Test Comm. Project A.S

Name Function Sign. Date

CHECKED HARIO HEAD OF

Joint Venture Company of

Document No : Issued Date : October 09, 2018

Revision Effective Date Nature of Release

Joint Venture Company of

Document No : Issued Date : October 09, 2018

2. QUALITY, EHS & REFERENCE

Joint Venture Company of

Document No : Issued Date : October 09, 2018

Joint Venture Company of

Document No : Issued Date : October 09, 2018

PPE (PERSONNAL PROTECTIVE EQUIPMENT)

Helmet Safety Shoes Safety Glasses

Body Hardness Safety Gloves

Joint Venture Company of

Document No : Issued Date : October 09, 2018

Joint Venture Company of

Document No : Issued Date : October 09, 2018

4.2 Reducing Oil

Joint Venture Company of

Document No : Issued Date : October 09, 2018

Oil Draining of Radiator

Fig 1. Valve plate of the Transformer

2. Close the top and bottom radiator valves (800) tightly.

Joint Venture Company of

Document No : Issued Date : October 09, 2018

Fig. 3 Illustration of the transformer

4.3 Dismantling the Radiator

Joint Venture Company of

Document No : Issued Date : October 09, 2018

3. Preparing and put web sling on lifting point of radiator unit.

4.4 Installing the Radiator

Joint Venture Company of

Document No : Issued Date : October 09, 2018

Fig 4. Unpack the radiators

Fig 5. Removing the pipes protection

Joint Venture Company of

Document No : Issued Date : October 09, 2018

Fig 6. Rubber mat or wood

6. Stand up the radiator.

Fig 7. Put the radiator gasket

Joint Venture Company of

Document No : Issued Date : October 09, 2018

Please make sure that no damage is caused to the bolts.

Fig 8. Fitting of the radiator

Fig 9. Upper and lower support

13. Re-install the cooling fans unit on radiators (if applicable).

Joint Venture Company of

Document No : Issued Date : October 09, 2018

Joint Venture Company of

Document No : Issued Date : October 09, 2018