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. Mobilization of equipment
D. Transport of materials loading & Unloading
E. MV Switchgear Assembly and Installation.
MV Switchgear Installation Procedure and Method Statement
1 PURPOSE
This procedure covers the Method Statement pertaining to installation and assembly of medium voltage switchgears
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.
REFERENCE STANDARDS
• IEC International Electro-technical Commission
• NEC (NFPA 70) National Electrical Code
• Project and Manufacturer’s Specifications.
• Project Technical Specifications
• Applicable/ Approved International Standards
• Approved/Issued for Construction Drawings
• RESPONSIBILITY
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.
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.
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.
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.
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.
Vendor Representative
Lead testing and commissioning activities for the equipment supplied in accordance to project specification and contract requirements. He ensure assembly and installation of switchgear conforms to manufacturer’s requirements and project specification prior to required test and pre-commissioning activity.
MATERIALS AND CONTROL
• Ensure that materials and equipment are stored and handled in accordance with project and vendor requirements.
• Check all supplied materials are in conformance with Purchase Order or Specifications or Drawings. Any discrepancies shall be reported immediately to ABENER.
• 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.
• Space heater energization must be coordinated with Contractor during storage period to prevent damage to components due to condensation and negative accumulation.
• PRE-REQUISITE
• Switchgear shall be installed in an indoor, as per project specifications and approved drawings.
• 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.
• 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.
• Sections shall be inspected for mechanical damage and megger checked to ensure it has no direct connection to earth.
• 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.
• The joints between sections shall be neat and inconspicuous and each cabinet section shall be flush with those adjacent to it.
• Where arc ducts for MV switchgear are situated on the top of switchboards the required height to the top of the duct shall be checked against IFC drawing.
• The joints between each section shall be neat and inconspicuous and each cabinet shall be flush with those adjacent to it.
• All enclosures shall be provided with an earth terminal of no less than 12 mm in diameter to which all internal apparatus, screens and supporting material shall be connected.
• Switchboard earth bars shall be connected to the main earthing grid at each end of the equipment.
• 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.
• Stranded conductors shall be terminated accordingly; larger conductors shall use an approved crimped termination lug,
• All exposed terminals and cable terminations will be shrouded using a transparent non-flammable material to prevent accidental contact.
MV SWITCHGEAR INSTALLATION/ASSEMBLY
WORK SITE PREPARATION PRIOR TO INSTALLATION
• Check manufacturer’s instructions for transporting, loading and unloading activity for switchgear.
• Sequence of installation and general assembly must be considered when transporting the equipment. Check the equipment’s identification tag to determine equipment or parts need to be transported first.
• When transporting the equipment to work site, ensure that equipment is firmly secured on the trailer/truck.
• 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.
• 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.
• Equipment will be lifted through the lifting members that are usually bolted to the top of packaging group.
• Lifting activity must not be done during bad weather condition. All lifting activity must follow the safety requirement initiated by HSE department.
• Check that loading and unloading area has enough space for the activity.
• 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.
• 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.
• 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
INSTALLATION AND ASSEMBLY
• Area must be prepared; install warning sign and barricade the area. Unauthorized person must not be allowed at the activity area.
• Inside substation, safe practices for shifting and lowering of sections from pallet jack shall be observed. A void using metallic levers to protect paint finishes.
• Remove barrier bags and loose items of equipment’s sections. Check for cleanliness and ensure that no foreign bodies are present inside.
• 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-out.
• 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.
• 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.
• Assemble/reconnect bus bar as per manufacturer/vendor detailed drawings. All bus bar bolts will be torque tested (see manufacturer’s manual torque settings)
• Reconnect all auxiliary wirings and accessories removed during shipment.
• Bolt the equipment’s sections together through the tie bolt holes.
• 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.
• 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.
• Install and exercise all breakers, starters, and miscellaneous devices and assure that the equipment is suitable for electrical energization.
• The draw-out circuit breakers and controllers shall be properly installed in their housings, with any rails adjusted as required for smooth travel.
• 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.
• After completing the installation and assembly of switchgear and control gear, energize the space heater when needed.
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