1 SCOPE
2 REFERENCE DOCUMENTS.
3 AUTHORITIES AND RESPONSIBILITIES.
4 MATERIAL INSPECTION, STORAGE, AND HANDLING.
5 METHOD OF INSTALLATION WORKS.
5.1 Work Site Preparation prior to Installation.
5 .2 Transport, Loading and Unloading of Bus Sections.
5.3 Bus Duct Installation.
5.4 Bus Duct Contact Resistance.
5.5 Bus Duct Insulation Test & AC Hi-Pot Test.
6 TOOLS AND EQUIPMENT.
7 SAFETY PRECAUTION.
8 INSPECTION.
MV Segregated Bus Duct (MV SBPD) Installation Procedure
SCOPE
This method covers the installation procedure of MV Segregated Bus Duct to be implemented in SEC Construction of Waad AI-Shamal ISCCPP – Electrical Installation Works. Specific activity will be done according to the Project’s Scope of Work and contractual obligation.
2 REFERENCE DOCUMENTS
a) Applicable/ Approved International Standards
b) Issued For Construction Drawings
c) Manufacturer Instructions
3 AUTHORITIES AND RESPONSIBILITIES
Site Manager –Determine all requirements needed in order to comply with contractual requirements and safety standards.
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.
Field Engineer – Ensure that all related works are carried out in accordance with approved Released for Construction drawings, specifications, schedule, quality and safety. Report to Construction Manager.
Safety Officer — Ensure that “Safety, Fire, Loss Prevention” program or Safety Plan was been implemented and monitored. Supervisor/ Foreman – Supervise all field installations Reports to Electrical Superintendent.
QC Inspector – He shall be 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 the Quality inspection with the client, owner representative as required.
4 MATERIAL INSPECTION, STORAGE, AND HANDLING
a) Check delivery packing list. Perform visual inspection of equipment’s nameplate and specification according to the approved equipment data sheet and vendor packing list.
b) Perform visual and physical inspection of equipment and its accessories for completeness and any damage. Check to make sure that all parts described in the shipping list are complete.
c) Check manufacturer’s instructions for the proper storage and handling of equipment. If equipment parts and accessories are to be stored, a suitable storage area and acceptable to the Client must be obtained.
d) Store busway sections and fittings in a clean dry location with adequate air circulation to prevent condensation. The location must be free from dirt, fumes, water and physical damage.
e) Check manufacturer’s instructions for handling of bus sections. Weight and length of bus section to be considered in using lifting equipment.
f) Caution is necessary for lifting and moving of equipment. Failure to follow proper handling procedures could cause equipment to tip and lead to severe personal or damage to equipment.
g) Any damage found during this activity will be inspected and reported to determine the corrective action needed.
5 METHOD OF INSTALLATION WORKS
5 .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.
b) Prepare tools and materials to be used. Broken or damaged tools must not be used.
c) Obtain 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 step by step of work to be done and safe practices to be made.
e) Check if area is also clear for access; check any obstruction and foreign materials are removed. Verify clearance from civil contractor prior to start of work.
f) Verify layout plan and route for the installation and mounting of panel.
5.2 Transport, Loading and Unloading of Bus Sections
a) Check manufacturer’s manual for safe instructions in loading, unloading, and lifting of panel.
b) Check the bus identification tag to determine sections need to be transported, loaded, and unloaded consecutively.
c) Weight and length of the equipment to be considered in selecting the lifting equipment needed for the activity. Lifting equipment (boom truck, forklift, chain block, etc.) must have a suitable capacity and is safe to perform the activity.
d) Lifting activity must not be done during bad weather condition. All lifting activity must follow the safety requirement initiated by HSE department.
e) Check ifloading and unloading area has enough space for the activity.
f) Do not drag bus across the floor. Handle busway with care to avoid damage to internal components, enclosure, and its finishes. Never subject the busway to twisting, denting, impact or rough handling.
5.3 Bus Duct Installation
a) Check if the area is clear and approved to proceed for the installation of busduct. Ensure that the location is free from obstruction, clean, and debris removed.
b) When planning for the installation of bus duct, check location of switchgear and transformer for proper route, centering and alignment purposes.
c) Ensure that support is completely installed prior to the installation of bus duct. Support may be welded or bolted structures as per approved drawing. Check that supports are secured, properly spaced and aligned.
d) Unpack all bus duct accessories, check for cleanliness and completeness in accordance with the layout plan and vendor drawing. Remove and dispose unused wooden planks or boxes of packing materials. Check for any visible damage during unpacking.
e) Handle the bus sections carefully when lifting. Check if the rope or sling is secured and tight during lifting. Bus will be installed according to its direction and the sequence identified and described in the drawing arrangement. A void rough handling, denting and impacts during handling.
f) Prior to assembly and jointing of bus sections, clean the contact surface and ensure that contacts are free from contaminants.
g) Bus duct sections must be aligned horizontally and vertically before tightening and torque. Firmly secure hold clamp after alignment and plumbing of section.
h) Tighten all the interconnecting bolts using calibrated torque wrench set in reference with the recommended value by the manufacture
i) After ensuring that all interconnecting bolts are torqued and fixed, install enclosure/molding for all open area of bus connections.
j) Mounting of tap-off box.
- Check out the tap-off box as per material packing list. Check for any damage and defonnation.
- Cover of box may be removed when needed, make alignment of slot and locating screw to insert the tap-off box.
- Close the tap-off box after tightening hook screw and door latching screw.
5.4 Bus Duct Contact Resistance Test.
- Check the area is clear ensure that no body is work in the location and were you perform the contact resistance
- Test equipment must be verified for good operating condition and validity of calibration certificate.
- Testing shall be performed by qualified technician
- Prepare Bus duct drawing for reference of joints to be tested. Verify and check tag and identification. Testing shall be conducted in de-energized condition.
- Where no requirements specified in the Project specifications. Contact resistance test of 100 amps. should be applied for every joint or each phase LI , L2 , L3 and to be short at other end L 1 &L2 , L2&L3.
- Perform contact resistance Measure and record the value in micro ohms.
- Where no standard specified, contact resistance value should be greater than lmicro ohms to 2000 omhs.
5.5 Bus Duct Insulation Resistance Test & Hi-Pot Test
a) Perform continuity check between cores/phases, ground, armour or shield. Insulation resistance must be performed after passing the continuity check.
b) Conduct insulation resistance before an after Hi-pot test with SkVdc for each phase of Bus duct.
c) Check that test equipment is in good working condition; ensure that the input voltage to Check test set and test lead at testing voltage level.
d) High voltage line of Hi-pot equipment will be connected at phase to be tested. Phases which are not under test will remain grounded at both ends.
e) Test voltage shall be in accordance to manufacturer’s specification or as approved in the project specification. High potential test value will be applied in an equal increment until maximum test voltage is reached.
f) No increment shall exceed the voltage rating of the bus-duct. AC leakage current at each step will be recorded after a constant stabilization time is consistent with system charging current. (Step voltage and maximum time and voltage test will follow the approved inspection and test checklist for AC hi-pot test).
g) As an acceptance result, step voltage should reasonably linear for the graphic plots of leakage current versus step voltage at each increment. Capacitive and absorption current should decrease continually until steady state leakage is approached for the graphic plots for leakage current versus time at the final test voltage. All test result shall be recorded.
h) Discharging after High Potential Test; At Hi-pot test equipment where automatic discharging was initiated, always presume that the tested core is still under full voltage load. Use a grounded discharge stick to completely remove stored electrical charge after testing a cable core. Perform insulation resistance test after Hi-pot test and record the result
Note: For specific operation and use of HI-pot test equipment please refer to equipment’s manual instructions
6 TOOLS AND EQUIPMENT
a) Electrician’s standard tool box (pliers, spanners, screw drivers etc.)
b) Boom truck, forklift
c) Measuring tape
d) Spirit level and plumb line
e) Calibrated Torque Wrench
9 Chain block
g) Warning sign and barricade tape
h) Electrical drill and drill bits
i) Rope
j) AC High Potential Test
k) Insulation Resistance Test (MEGGER) Multimeter (VOM)
1 ) Warning sign and barricade
7 SAFETY PRECAUTION
a) All work activities to be performed in a safe manner following the Company Safety Policies and Procedures. Safety checks are to be performed before any work is executed.
b ) Ensure that work permit is obtained identifying the applicable work to be performed. Safety requirements may also be indicated in the work permit. It must also be kept available and
visible to work area.
c) Ensure that all personnel in adjacent areas throughout any system are aware of the activities and the hazard that could lead to potential danger.
d) Concern working personnel must always wear PPE such a safety hard hat, glasses, safety shoes, hand gloves, cover all, etc.
e) Perform daily tool box or safety talk to keep all worker regarding safe procedure and safety requirements.
f) Ensure that all tools and equipment to be used are free from damage.
8 INSPECTION
Quality Control personnel verify that bus duct installation conforms to the approved engineering drawing, manual instructions and specifications of the project. Request for Site Inspection (RSI) will 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.