1 PURPOSE.
2 REFERENCES.
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.
5 GENERAL REQUIREMENTS.
6 INSTALLATION.
6.1 WORK.SITE PREPARATION PRIOR TO INSTALLATION.
6.2 LV SWITCHGEAR I MCC INSTALLATION.
7 TOOLS AND EQUIPMENT.
8 INSPECTION.
1 LV Switchgear and Motor Control Centres (MCC) Installation Procedure
This procedure covers the Method Statement pertaining to installation of low voltage switchgears and motor control centers to be carried out in 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.
Low Voltage (LV) switchgear and Motor Control Centers (MCC) shall mean electrical apparatus intended for switching circuits of voltages less than 600V for isolation, protection or control of the circuits.
2 REFERENCES
- NEMA National Electrical Manufacturer’s Association
- NEC (NFPA 70) National Electrical Code
- Project and Manufacturer’s Specifications.
- Project Technical Specifications
- Approved/Issued 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 I Hold Point inspection and the corresponding work releases by reviewing records and results as proof that work inspected confonns 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 infonnation 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.
b. Check all supplied materials are in conformance with Purchase Order or Specifications or Drawings. Any discrepancies shall be reported immediately to ABENE
c. Store switchgear & other associated components on dust free area and protect them against atmospheric action and dirt preferably in air conditioned room to prevent damages of electronic components part.
d. Coordinate with contractor for space heater needs to be energized during storage period to prevent damage to components due to condensation and negative accumulation.
5 GENERAL REQUIREMENTS
1 LV Switchgears and MCC’s shall be installed in an indoor, as per project specifications and approved drawings.
2 Base plate, floor fixing, wall fixing etc. shall be checked for level and location and fixing points checked against their position on the respective sections. Cable sleeves and ducts shall be inspected to ensure correct line and location.
3 Before installing in position, cabinet sections shall be opened up and inspected for cleanliness and ensure no foreign bodies are present. Dust shall be removed using a vacuum cleaner or with rags as appropriate.
4 Sections will be inspected for mechanical damage and megger checked to ensure it has no direct connection to earth.
5 Installation shall be witnessed to ensure the equipment is vertical and fixing bolts tightened. Where equipment consists of a number of sections, the assembly shall commence from the control section. Section on either side of the center shall be alternated, levelled and shimmed as necessary.
6 The joints between sections shall be neat and inconspicuous and each cabinet section shall be flush with those adjacent to it.
7 The joints between each section shall be neat and inconspicuous and each cabinet shall be flush with those adjacent to it.
8 All enclosures will be provided with an earth terminal of no less than 12 mm in diameter to which all internal apparatus, screens and supporting material will be connected.
9 Switchboard earth bars shall be connected to the main earthing grid at each end of the equipment.
10 Wires shall not be jointed or teed between terminations. All wires shall be clearly identified at each end. The same identifier shall not be used on wires in different circuits on the same section.
11 Stranded conductors shall be terminated accordingly; larger conductors shall use an approved crimped terminations lug.
12 All exposed terminals and cable terminations will be shrouded with non-flammable material to prevent accidental contact.
6 LV Switchgear and Motor Control Centres (MCC) Installation
6.1 WORK SITE PREPARATION PRIOR TO INSTALLATION
a) Check manufacturer’s instructions for transporting, loading and unloading activity for LV switchgear and MCC.
b) Sequence of installation and general assembly must be considered when transporting the equipmen Check the equipment’s identification tag to detennine equipment or parts need to be transported first.
c) When transporting the equipment to work site, ensure that equipment is finally secured on the trailer/truck.
d) Loading and unloading of switchgear and control gear must be performed by a competent rigging crew and performed in accordance with the company’s safety requirements.
e) Dimension and weight of the equipment shall be considered in selecting the lifting equipment needed for the activity. All lifting equipment especially crane which is usually used for lifting activity must follow the safety requirements of the project.
f) Equipment will be lifted through the lifting members that are usually bolted to the top of packaging group.
g) Lifting activity must not be done during bad weather condition. All lifting activity must follow the safety requirement initiated by HSE department.
h) Check that loading and unloading area has enough space for the activity.
i) Respective sections and compartments of the equipment will be unloaded in front of the substation or where it will be more accessible and easier to transport inside the building location. Crane lifts it to the point where a pallet jack can bring it to the specified location.
j) It is advised that packaging should be opened only in front of the substation. During unpacking and removal of wooden boxes, physical and visual inspection shall be conducted to check for damages, dent and paint finishes.
k) Sections are lifted through the lifting bolt. When not provided, slinging through the pallet using stand-off protection at the top corners to space the slings correctly and prevent chafing of paintworks during lifting
Caution: Cubicles may easily tip over, when transported with pallet jack, observe safe allowable distance between pallet and the ground
6.2 LV SWITCHGEAR and MCC INSTALLATION
a) Area must be prepared; install warning sign and barricade the area. Unauthorized person must not be allowed at the activity area.
b) Inside substation, safe practices for shifting and lowering of sections from pallet jack shall be observed. Avoid using metallic levers to protect paint finishes.
c) Remove barrier bags and loose items of equipment’s sections. Check for cleanliness and ensure that no foreign bodies are present inside.
d) Assemble the sections side by side. Set them in the position called for on the drawing of the base plan. It shall be coupled and aligned as describe in the GA lay-ou
e) Set sections into its installation position. Use a spirit level to make sure sections are level both across its width and along its length. Plumb using a plumb line.
f) Successively move the sections into positions. Line-up the bolt holes in the steel channels in the foundation. As sections are maneuvered into place, keep front of each section parallel to the base line.
g) Assemble/reconnect bus bar as per manufacturer/vendor detailed drawings. All bus bar bolts will be torque tested (see manufacturer’s manual torque settings)
h) Reconnect all auxiliary wirings and accessories removed during shipmen i) Bolt the equipment’s sections together through the tie bolt holes.
j) Bolt the entire sections of the equipment to the channels in the foundation. Check the system again to make sure it is level and plumb.
k) Remove all the shipping blocks or braces. Examine all the meters, relays, etc. and remove any shipping blocks or braces.
All transparent flashover shields and compartment covers should be fitted and doors left closed. Temporary protection should be provided to protect equipment from other construction works.
m) Install and exercise all breakers, starters, and miscellaneous devices and assure that the equipment is suitable for electrical energization.
n) The draw-out circuit breakers and controllers shall be properly installed in their housings, with any rails adjusted as required for smooth trave
o) Main and secondary contacts on the removable and stationary sides shall be checked for tightness and adjusted if loose. Covers or enclosures shall be securely bolted in place.
p) After completing the installation and assembly of switchgear and control gear, energize the space heater when needed.
7 TOOLS AND EQUIPMENT
- Electrician’s standard tool box (pliers, spanners, screw drivers )
- Crane of sufficient capacity, with complete lifting accessories
- Forklift
- Pallet Jack
- Hydraulic Jack
- Measuring tape
- Spirit level and plumb line
- Calibrated Torque Wrench
- Chain block
- Warning sign and barricade tape
- Electrical drill and drill bits
- Vendor supplied tools
8 LV Switchgear and Motor Control Centres Inspection
Quality Control personnel verify that assembly and installation of switchgear conforms to the approved engineering drawing, manual instructions and specifications of the project. RSI shall be prepared according to the approved Inspection and Test Plan to notify Client’s inspection representative and concern person regarding scheduled dates of inspection. Once inspection is done and accepted, checklist must be signed and records are properly kept.
Step by Step Guide LV Switchgear and Motor Control Centres (MCC) Installation
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. Mobilization of equipment
D. Transport of materials loading & Unloading
E. LV Switchgear and MCC Assembly and Installation
A. Transport of materials loading & Unloading (Get approval for access follow site speed limits follow proper traffic signs & signals, turn on hazards ligh 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. Preparation of materials (Ensure permit to work must be obtain, prior to start the activi 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. a) Area must be prepared; install warning sign and barricade the area. Unauthorized person must not be allowed at the activity area )
C. LV Switchgear and MCC / Loading and Unloading (Ensure all lifting activity will be controlled and supervised by a competent Supervisor and Rigger, Never exceed the SW Operator, rigger and equipment third party certification)
D. Opening of LV Switchgear and MCC Wooden Box (The required PPE must be provided like hand gloves and clear glass inside the building. Workers must wear safety harness and shall be inspected daily prior to use by the user or if using an A-Type Ladder one man only will be allowed on the ladder and another will be holding to prevent ladder form falling).
E. Shifting & Installation of LV Switchgears and MCC (Proper Manual Handling Safety Awareness, Practice proper lifting techniques at all times. As much as possible avoid lifting alone. Ensure people are capable for the task. All persons to observe careful in manual handling who are required to carry out manual handling tasks. All Personnel given and wear appropriate gloves. Proper manual lifting techniqu Maintain good housekeeping / material & tools arrangement on the work area. Mechanical Handling (Using of Lifting Pallet Jack & Chain Block) (Practice proper lifting techniques at all limes. As much as possible avoid lifting alone. Ensure people are capable for the task. All persons to be trained in manual handling who arc required to carry out manual handling tasks. All Personnel given and wear appropriate gloves.)
F. Dally 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 )