Transformer Loading & Unloading: Method Statement

Introduction

This Method Statement describes the safe sequence of work for loading and unloading power transformers at stores and EHV substation sites. Power transformers are high-value, precision-engineered items — improper handling can cause winding damage or bushing breakage that may not be immediately visible but can result in failure once energised.

All operations must be carried out under the continuous supervision of an experienced Site Engineer and Safety Engineer. Only authorised personnel are permitted inside the work area during any lift.

Sequence of Activities

All transformer loading and unloading operations follow this sequence without exception:

Material & T&P Required

All lifting equipment must carry valid third-party test certificates, which must be available at site before work commences.

Loading Procedure

• Position the crane adjacent to the transformer at the store. Confirm ground is suitable for crane outrigger loads.
• Block all wheels of the crane and trailer — both front and rear — with wooden sleepers before any lifting begins.
• Place crane jacks on firm ground and extend to working position.
• Tie all four sides of the transformer with rope to allow controlled guiding during the lift.
• Attach slings to the transformer lifting hooks using D-Shackles, following the manufacturer's rigging arrangement.
• Lift the transformer slowly and steadily onto the trailer. A qualified Rigger and Banksman must guide the crane operator throughout — no sudden movements at any stage.
• Load transformer accessories onto a separate trailer and secure with chain or rope.
• Secure the transformer on the trailer using chain or rope — verify all lashings are tight before the vehicle moves.

Transportation to Site

• Before departure, verify the approved transport route for height restrictions, bridge load limits and road width constraints.
• Maintain low, constant speed throughout the journey. Avoid sharp braking, acceleration and tight turns.
• Check all lashings on arrival at site before commencing unloading.

Unloading Procedure — Site

• Position crane and trailer at the designated unloading area adjacent to the transformer foundation. Confirm the ground is level and stable for crane outriggers.
• Block all crane and trailer wheels with wooden sleepers — front and rear.
• Place crane jacks and extend to working position.
• Tie all four sides of the transformer with rope before lifting begins.
• Barricade the entire unloading area with warning tape. No unauthorised personnel are permitted inside the barricade at any time.
• Use the same T&P as used for loading — confirm all test certificates remain valid.
• Lift the transformer clear of the trailer and lower slowly onto the prepared foundation.
• Fix transformer wheels / anchor bolts to the foundation as required.
• Unload accessories from the second trailer and place as directed by the Site Engineer.
• Site Engineer and Safety Engineer must monitor all operations continuously throughout loading and unloading.

Safety Requirements