1 PURPOSE
2 REFERENCE STANDARDS
3 RESPONSIBILITY
3.1 The Site Manager
3.2 The Quality Control Inspector
3.3 Field Engineer
3.4 Electrical Superintendent..
3.5 HSE Officer
3.6 Vendor Representative
4 MATERIALS AND CONTROL
S QUALITY REQUIREMENTS
6 INSTALLATION
6.1 WORK SITE PREPARATION PRIOR TO INST ALLA TI ON
6.2 INSTALLATION
7 TOOLS AND EQUIPMENT
8 INSPECTION
Emergency Diesel Generators (EDG) Installation Procedure
1 PURPOSE
This procedure covers the Method Statement pertaining to installation of emergency diesel generator to be carried out in Solar Combined Cycle Power Plant Project. This procedure shall be applied to the method and criteria for installation work carried out by the Electrical Department. Field installation personnel must verify the feasibility of this procedure with the approved construction drawing, actual site condition and project specification.
2 REFERENCESTANDARDS
• IEC International Electro-technical Commission
• NEC (NFPA 70) National Electrical Code
• Project and Manufacturer’s Specifications.
• Project Technical Specifications
• Applicable / Approved International Standards
• Approved/lssued for Construction Drawings
3 RESPONSIBILITY
3.1 The Site Manager
Responsible for the Quality Procedure to ensure that construction work is carried out as per Project requirements. His Superintendent/Supervisor shall check that work is ready for inspection and prepare Internal Inspection Request. The Superintendent/Supervisor shall inform all parties concerned for any of inspection and the time schedule.
3.2 The Quality Control Inspector
Responsible for conducting surveillance and inspection duties for work and ensuring quality compliance and efficient recording and reporting of results as required. He shall review all relevant documents, material conformance certificates and non-conformance reports and shall receive all internal requests for inspection from various sections of implementing work and prepare (RSI) Request for Site Inspection as per schedule work priorities and proceeds with the Quality inspection with the client, owner representative as required. He shall also prepare Witness / Hold Point inspection and the corresponding work releases by reviewing records and results as proof that work inspected conforms to contract requirements. He shall also be responsible to ensure that an approved detailed IFC/ AFC or shop drawing is available prior to commencement of the work and all materials to be used are in compliance with the approved project specifications or requirements.
3.3 Field Engineer
Ensure that all related works are carried out in accordance with approved Issued for Construction drawings, specifications, schedule, quality and safety. Check Design and Construction details in reference with the project standard and specification. See to it that the design drawings provide adequate information for purchasing and site construction. Report to Site Manager.
3.4 Electrical Superintendent
Ensure that work once started is carried out as planned and that the applicable standards are complied with. Check working methods and precautions to be taken by the supervisors/foreman before commencing work. In charge of planning and preparation of manpower, materials, tools and equipment together with his supervisors prior to start of any activity. Monitors project completion schedule and the discipline supervisors under him.
3.5 HSE Officer
Supervise the project activities relating to health, safety and environmental compatibility. He
shall carry out regular inspection at site and workplaces whether work is being carried out
according to the given instructions and those personnel are wearing the necessary protective
equipment (PPE). Perform, in co-operation with the Site Supervisors and Foremen regular
Tool Box meetings. Report any adverse condition to health and safety.
3.6 Vendor Representative
Lead testing and commissioning activities for the equipment supplied in accordance to
project specification and contract requirements. He shall ensure that project requirements are
complied, with the necessary test to be performed and results are recorded and acceptable
with the manufacturer’s data, project standards and specifications.
4 MATERIALS AND CONTROL
a. Ensure that materials and equipment are stored and handled in accordance with project and vendor requirements. Material supplied by Vendor shall be stored and handled accordingly
b. Check all supplied materials are in conformance with Purchase Order or Specifications or Drawings. Any discrepancies shall be reported immediately to ABENER.
c. Store generator & other associated components on dust free area and protect them against atmospheric action and dirt.
d. Space heater must be energized during storage period to prevent damage to components due to condensation and negative accumulation.
5 QUALITY REQUIREMENTS
I Generators shall be installed in accordance with specification requirements. QC
Inspector shall verify the area before installation. Generator installed in such
locations shall be totally enclosed and meets the requirements of project standards
and technical specification.
2 QC Inspector shall verify the nameplate data conforms to the specifications and
check exact location in the approved drawings prior to installation. In addition, he
shall check the lubrication and associated devices for any physical defects.
3 The Generator Set concrete foundation will be checked for cleanliness and proper
level.
4 Check the location and alignment of cable feeder to ensure sufficient clearance for
entry and glanding of cables.
5 Check the feeder cable sizes and type in conformance with the design and
specification. Ensure continuity and meggers tests have been done prior to
termination.
6 INSTALLATION
6.1 WORK SITE PREPARATION PRIOR TO INSTALLATION
a) Check availability of the latest approved engineering drawing, general arrangement drawing and manufacturer’s manual. It must be readily available prior to installation
works. Installation of EOG with its skid, its tanks, exhaust, piping, its enclosures, auxiliaries, components shall be in accordance with the Vendor’s and ABENER’s
instructions, recommendations and IFC Drawings.
b) Prepare tools and materials to be used. Broken or damaged tools must not be used. Pallet jack and hydraulic jack must be available for the activity.
c) Acquire work permit. All work personnel must wear complete PPE (hard hat, safety shoes, hand gloves etc.).
d) Conduct toolbox meeting for all working personnel prior to start of work. Discuss the sequence of work to be done and safe practices to be made.
e) Ensure that foundation and area is cleared by civil for installation works. Check that area is also clear for access; check any obstruction and foreign materials are removed.
f) Verify arrangement of the equipment to plan for the sequence of loading/unloading, placing and installation of generator
6.2 INSTALLATION
a) Area must be prepared; install warning sign and barricade the area. Unauthorized person must not be allowed at the activity area.
b) The location of the generator must with all local regulation. The location of the generator must also comply with all special industrial regulations. Locate the generator in an area that meets the following requirements.
I) Clean
2) Dry
3) Well Ventilated
4) Easily accessible for inspection and maintenance.
c) The installation of this generator sets, see the appropriate application and installation guide.
d) Inside substation, safe practices for shifting and lowering of sections from pallet jack shall be observed. Paint finishing of the generator should be protected.
e) Each diesel engine generator is to be mounted on a substantial combined under base or bedplate, through anti-vibration mountings of an approved type in reference with
the Vendor instructions. Equipment such as the control panels and any other item likely to be affected shall be protected from vibrations transmitted through the floor
or supporting structure.
I) The Generator set should then be erected and checked for the position and alignment. Any discrepancies shall be reported to the Client Representative for resolution.
g) Check the levels and positions of the generator and the other equipment to be connected with the dimensions given upon the general arrangement drawings.
h) Mounting elevation and clearances are in accordance with the approved drawings. Anchorage and bolts shall be properly tightened with respect to the torque requirements specified by the Vendor. QC Inspector shall verify and check the installations.
i) Assemble/reconnect bus bar as per manufacturer/vendor detailed drawings. All bus bar bolts will be torque tested (see manufacturer’s manual torque settings).
j) Connection to the earthing grid is to be done and equipment grounding connections shall be connected.
k) Ensure that all related works are done and completed as specified on approved drawings and specifications.
1) After completion of installation works, surface damages caused by handling and installation works should be repainted as specified by the Client. The generator set
must be cleaned of any oil and dirt stains.
7 TOOLS AND EQUIPMENT
a. Electrician’s standard tool box (pliers, spanners, screw drivers etc.)
b. Crane of sufficient capacity, with complete lifting accessories
c. Forklif/Pallet Jack
d. Hydraulic Jack
e. Measuring tape/Spirit level and plumb line
f. Calibrated Torque Wrench
g. Chain block
h. Warning sign and barricade tape
i. Electrical drill and drill bits
8 INSPECTION
All inspections shall be coordinated by QA/QC Inspector, who will implement the inspection
program and notify all parties involved in advance of the scheduled dates of inspection to enable
them to participate. Relevant records shall be signed by all the required parties and originals kept by
Site QA/QC Department. Final erection checks shall be carried out in accordance with approved ITP.
Inspections shall be done per level, area or drawings.
Inspection of Generator installation shall be carried out in accordance with the Inspection Checklists.
Records must be maintained for each test.
Step by Step Guide of the work plan
Explain in detail the steps that must be taken to ensure that the task is carried out safely (include drawing and sketches where required, include pre commencement of work activities and the work itself in a chronological manner).
A. Verify IFC drawings availability
B. Verify Documents for QC material receiving inspection
C. Transport of materials loading & Unloading
D. Generator Installation and Assembly
E. Fuel Day tank installation
A. Transport of materials loading & Unloading (Get approval to the security for access follow site speed limits follow proper traffic signs & signals, tum on hazards light. only competent and certified rigger and operator should do the lifting, ensure one flag man for traffic control during activity. Provide barricade with signage’s)
B. Installation and Assembly of Generator (Ensure permit to work must be obtain, prior to start the activity. Conduct
toolbox talk prior lo the task to be done. And wearing of PPE to all personnel. All tools and equipment is in good
condition. Competent person to perform the task. Manufacturer’s instruction is understood and followed. Proper handling
technique is observed Third party calibration certificate for testing equipment. )
C. Installation and placing of fuel day tank (Ensure permit to work must be obtain, prior to start the activity. Conduct
toolbox talk prior to the task to be done. And wearing of PPE to all personnel. All tools and equipment is in good
condition. Competent person to perform the task. Manufacturer’s instruction is understood and followed. Proper handling
technique is observed. Third party calibration certificate for testing equipment)
D. Daily housekeeping (Full supervision on the area remind personnel for safe working and good housekeeping on the area should be done before and after the work )
Isolated Phase Bus Installation Procedure | Method of Statement
Uninterruptible Power Supply (UPS) and DC Systems Installation Procedure
Excitation and Isolation Transformers Installation Procedure