Ajv DPW 10 525 El MSS 2200 - 00 PDF

0 UEP 26/01/2020 APPROVED FOR USE
BA UEP 22/12/19 Issued forFOR

ISSUED Review & Approval
APPROVAL
REV.NO. BY DATE REVISION DETAILS
CLIENT
PROJECT
DUQM INTEGRATED POWER & WATER PLANT ("DIPWP") PROJECT
CONTRACTOR
CONSORTIUM FOR DIPWP PROJECT IN OMAN
OWNER'S ENGINEER CONTRACTOR'S CONSULTANT
L&T-SARGENT & LUNDY LIMITED
SUBCONTRACTOR LOGO & NAME
TITLE
METHOD STATEMENT & RISK ASSESSMENT FOR INSTALLATION OF ELECTRICAL

EQUIPMENTS
Date Name AJV DOCUMENT NO. Size A4
Drawn Index/Rev.
Designed
AOD10-DD09-ARA-8225479
AJV-DPW-10-525-EL-MSS-2200
Checked REV. A
0
Approved
ORIGINATOR PROJECT FACILITY SYSTEM CODE DISCIPLINE DOC. TYPE SEQUENTIAL Page No.
AJV DPW 1000 525 EL MSS

DVW 2200
DUQM INTEGRATED POWER & WATER PLANT
Rev. A
(DIPWP) PROJECT
METHOD STATEMENT FOR INSTALLATION OF ELECTRICAL EQUIPMENTS
Page 1 of 39
Document Ref. No(UEP): UE‐035/2019/S/S‐MS/001

CLIENT DUQM POWER COMPANY L.L.C
CONSORTIUM FOR DIPWP PROJECT IN OMAN

CONTRACTOR
ALGHANIM, COBRA, TEDAGUA, SOJITZ POWER & WATER LLC
ELECTRICAL SUB‐ UNITED ENGINEERING PROJECTS COMPANY LLC
CONTRACTOR

Issued for
A 22/12/2019 UEP ACTS DPC
Approval
Rev Description Date Prepared by Checked by Approved by

Rev. A
(DIPWP) PROJECT
Page 2 of 39

CONTENTS
Description Page no.
1.0 Purpose 03
2.0 Scope 03
3.0 Reference 03
4.0 Plant, Machinery &Tools 03
5.0 Manpower 04
6.0 Procedure 04
7.0 Safety Precautions and Measures 38
8.0 Responsibilities 39
9.0 Emergency 39
10.0 Records 39

Rev. A
(DIPWP) PROJECT
Page 3 of 39
1.0 Purpose
This method statement describes the sequence of activities related to installation of
all electrical equipments in respect to the subject project.

It gives details of how the work will be carried out and what health and safety issues
and controls are involved. The content of this method statement reflects the finding
of the relevant risk assessment.
2.0 Scope
This procedure will cover in detail the sequence of activities in each element and the
order of execution related to installation of all electrical equipments, conforming to the
contract, specifications and approved drawings for construction.
3.0 Reference
- Tender Specification
- Project HSE Plan
- Project Quality Plan
- Approved Drawings
- Manufacture erection procedure
- Approved vendor drawing
4.0 Plant, Machinery and Tools
- Crane (100T) ‐1Nos
- Hiab (12T) ‐1Nos
- Oil filtration plant (6000Ltr/Hr) ‐1Nos
- Nitrogen cylinder ‐ 1Nos
- Open end spanner set ‐1 Set
- Box spanner set ‐1 Set
- Fibre slings ‐2 Set
- Pipe wrench 12inch ‐2Nos
- Measurement tape (5Mtr) ‐1Nos
- Spirit level ‐ 1Nos
- Rope (20mm& 12mm) ‐ 1Nos (Each)
- Torque wrench ‐ 1Nos
- Pressure gauge ‐ 1Nos
- BDV kit ‐ 1Nos
- D – shackles ‐ 1Nos

Rev. A
(DIPWP) PROJECT
Page 4 of 39
5.0 Man power

- Construction Manager ‐ 01
- Project Engineer/CEP ‐ 04
- QA/QC Engineer ‐ 01
- HSE Officer ‐ 01
- Electrical Supervisor ‐ 03
- Erection Crew ‐ 04
- Helpers ‐ 20
- Fabricator ‐ 12
- Crane & HIAB Operator ‐ 01
- Banks Man/Rigger ‐ 01

6.0 Installation Procedure for 132KV GIS
Step by step procedure to be undertaken:

1. Prepare for site condition

2. Prepare by using other type of hand Skates 2 Pecs

3. Arranging of transportation requirements

4. Loading and Unloading the package boxes

5. Dismantling of wooden package boxes (Unpacking of Main body & Sub part package
boxes

6. Transportation of GIS equipment into GIS room (1)

7. Transportation of GIS equipment into GIS room (2)

8. Transportation of GIS equipment in GIS room (1)

9. Transportation of GIS equipment in GIS room (2)

10. Lifting the Packing Module

11. Lifting the Circuit Breaker 2700kg/set of heaviest part

Rev. A
(DIPWP) PROJECT
Page 5 of 39
1 – Prepare for site condition.

2 ‐ Prepare by using other type of hand Skates 2 Pcs.

Rev. A
(DIPWP) PROJECT
Page 6 of 39
3 ‐ Arranging of transportation requirements.

Transportation within onsite

It can be used the following equipment to
transport the product to the work site:
1) Truck or other vehicle
2) Forklift
3) Mobile or stationary crane
4) Transportation roller system
5) Hydraulic jack
6) Winch (Rope position, rack and pinion jack)
7) Roller
8) Crowbar
9) Various ropes

4 ‐ Loading and unloading the package boxes.

Rev. A
(DIPWP) PROJECT
Page 7 of 39
Notice:
When using a truck to transport the product, keep the speed to less than the following:
Rough road: Max. 20 km/h (12.5 mph)
Paved road: Max. 60 km/h (37.3 mph)

When transporting the product to the work site are as follows:
4.1 Do not stand under the product held up high. Otherwise, a heavy object may
fall down, resulting in an injury or death.
4.2 Do not exceed the permissible load on the truck of the box. Otherwise, a
heavy object may fall down, resulting in an injury or death.
Remove the transportation plate only after fastening the product securely to
4.3 prevent the product from falling down. Otherwise, a heavy object may fall
down, resulting in an injury or death.
Fix the transportation vehicle in the place with supporting frame or jack and
4.4 engage the brake during loading and unloading the product. Otherwise, the
unloading platform may fall down or spring up, making the product to fall
down or causing an injury.
4.5 When using wire ropes, use wooden blocks to prevent the box from being
chafed or cut by the ropes.

5 ‐ Dismantling of wooden package boxes (Unpacking of Main body & Sub part package
boxes.

Rev. A
(DIPWP) PROJECT
Page 8 of 39
6 ‐ Transportation of GIS equipment into GIS room (1).

7 ‐ Transportation of GIS equipment into GIS room (2).

Rev. A
(DIPWP) PROJECT
Page 9 of 39
8 ‐ Transportation of GIS equipment in GIS room (1).

Sequence Operation
The explanation gives on how to carry in main‐body equipment in GIS room.

9 ‐ Transportation of GIS equipment in GIS room (2).

Rev. A
(DIPWP) PROJECT
Page 10 of 39
10 ‐ Lifting the Packing Module.

11 ‐ Lifting the Circuit Breaker 2700kg/set of heaviest part.

Rev. A
(DIPWP) PROJECT
Page 11 of 39
INSTALLATION PROCEDURE FOR 132KV SCMS, FMS & TELEPROTECTION PANELS

 Ensure that all reference documents are available at site.
 Ensure that valid permits are obtained from concerned authorities wherever applicable.
 Check the Base frame and its level is completed and conforms to the specifications.
 Check Base frame bolts are properly grouted as per requirement
 Check Base frame height are completed as per requirement.
 Check the FFL and conform that the floor is levelled.
 Check whether the scaffold arrangement is properly done in Raised floor.
 Physically inspect the Panels for any damage, compared with that mentioned packing list of the
panels as enclosed.
 Mark the centre point and corner point of the base frame as per the Measurement.

Mechanical Lifting Procedure

 Mechanical lifting machines, tools and tackles shall be inspected and approved by competent
third party inspection authorities.
 Safe working load shall be assessed prior to commence the lifting activity and necessary
precautions shall be taken.
 Proper barricading shall be done to prevent the entry for unauthorized persons to the worksite.
Toolbox talk shall be given to the persons who are going to involve in the installation work by
the competent person before commencing the specified task.

a) Operators of all lifting machines shall possess valid plant operator license by ROP.
b) The Panel areas shall be properly barricaded and signage’s provided and banks men shall
be provided for monitoring the work.
c) Taglines shall be used for all suspended loads that are liable to swing.
d) Employees shall never walk under a suspended load and a suspended load shall not be
moved above the employees.
e) Ensure to use rated sling to lift the load.
f) The load to be lifted must be within the Safe Working Load (SFL) of the crane.
g) Shift the Panels from storage yard to operation building by using the fork lift (4 Ton). Then
unload the panel in 132KV building.
h) Then by using hand operated 2.5ton hydraulic trolley shift the panel to the CR room and
place the mobile scaffold and move near base frame and place the panel on the base frame
where we are going to install.
i) Check the levelling and alignment of the Panel with spirit level and make necessary
corrections with shims etc. for correct alignment.
j) Tighten the foundation bolts wherever applicable as per the requirement of manufacturer.

Rev. A
(DIPWP) PROJECT
Page 12 of 39
6.1 Installation Procedure for DC UPS & Associated Panels
1. Receipt and Storage of material:

 Batteries, Racks, Inter link bars, Cables, Charger Panel, Distribution Board and all
other associated equipment shall be received as per applicable Job order & delivery
note and verify with an approved drawings as applicable. Consignment shall be
checked on receipt for any shortages as per packing list and intimated immediately.

 Upon receipt of equipment mentioned above at site, thorough inspection shall be
carried out for any abnormality and mechanical damage during transport.

 Type, Model, UPS rating, Ground fault sensors, Voltage sensors, Monitoring relays,
Voltmeter, Ammeter, Circuit Breakers and Isolators shall also be verified and
inspected upon receipt at Site.

 Store all the equipment and accessories in an enclosed area not to expose to direct
sunlight and environment which harm to the equipment. It shall be covered with
suitable tarpaulin sheets or suitable means if required.

 Inspect and confirm the Battery room is ready and the environment within the
Battery room shall be in acceptable limits to allow equipment and Battery
installation to take place without any obstructions, as mentioned in respective user
manuals.

 The equipment to be installed in the battery room shall be verified and inspected for
its suitability. Manufacturer’s certificates shall be verified and accepted.

 Completeness of supply / delivery of equipment including loose

2. Assembly and Installation of Battery banks:

 Transport Batteries and its accessories, UPS Panels, DCDB and associated equipment
with suitable vehicle to the designated location for installation. Proper care shall be
taken while handling the equipment.
 Prior to the start of activities, it shall be ensured that the Battery room floor is level
and completed with Alkaline resistant type tiles/wall paints and the room is
thoroughly cleaned.
 Ensure that no pockets to accumulate hydrogen gas inside the battery room.
(Especially near the roof top, as hydrogen being lighter will try to accumulate near
to the top)
 Ensure that Exhaust fans of suitable Size & capacity are installed and the room is
adequately ventilated to limit the hydrogen concentration to well below 1 % of the
battery room volume at all times.
 Prior to the start of installation of Battery Racks, it shall be ensured that all
components are free of damage and approved for construction drawings. Vendor’s
Manuals are available at site for ready references.
Rev. A
(DIPWP) PROJECT
Page 13 of 39
 Steps for the handling and unpacking:

o Before installation, the concerned area shall be clean and free from dust.
o By using the crane, the pallets containing UPS shall be removed from the
truck and it will be placed temporarily in the corridor as close to UPS room as
possible in order to avoid unnecessary ways. Plywood packing boxes
containing batteries shall only be handled by forklifts and shall not be
handled by cranes or other lifting mechanisms.
o Ropes shall be attached far enough on the hoisting tackle so that they cannot
exert any forces on UPS.
o The ropes shall be slung around the ends of the wooden pallet.
o It shall be ensured that nobody is standing in the swinging area of lifted UPS.
o Unload the transport units in packed condition and leave as long as possible.
o After unloading all pallets in the temporary place, each pallet shall be
dismantled carefully to take the subject materials out
o Using forklift, UPS and batteries shall be moved to the place of installation in
the Telecom room.
o While moving through corridor and inside the room, it shall be ensured that
materials should not hit the side walls and other panels already installed in
the room
o While positioning the batteries and UPS, it shall be ensured that clearance
between them and from the wall is as per approved drawing.

 Battery Racks shall be installed vertical and plump conform to AFC drawings and
Vendor’s installation procedure. Suitable Shims if required shall be used for proper
alignment of Racks.
 Suitable Bolts Nuts as recommended by the Manufacturer shall only be used for
fixing the battery racks on the floor.
 Ensure that sufficient spaces/clearances are provided to allow access to all sides of
each Battery bank for easy access and maintenance purposes.
 Install / place the batteries on the racks as shown in the drawing and align properly.
Polarity of the Cells checked and confirmed.
 Interconnection of batteries shall be carried out using approved cables / links
supplied by the Manufacturer as per the approved drawings and tightened properly
as per Manufacturer’s recommendations using a Calibrated Torque Wrench and
ensure that suitable Shrouds fitted to the terminals.
 Ensure that suitable grease/jelly applied to all terminal connections prior to the
fittings of Shrouds.
 Ensure that all Batteries are provided with suitable cell numbers / labels of
Corrosion Resistant type as per AFC drawings / Vendor’s Manual / drawing.

Rev. A
(DIPWP) PROJECT
Page 14 of 39
3. Preparation and Filling of Electrolyte:

 Prior to the start of preparation and filling of Electrolyte, all possible safety
measures shall be taken to prevent any accident to the personnel handling the
Electrolyte.
 The distilled water to be used for topping up during operation and used for
preparing the electrolyte shall conform to IEC 60993 requirements.
 Ensure that appropriate SHOC card of the Electrolyte is displayed and the personnel
made aware of in the event of any accident while handling of Electrolyte. Vendor’s
Manuals are available for reference.
 Ensure that the room is having adequate natural and mechanical ventilation (Grills,
Exhaust fans etc.) and necessary medical supplies especially Eye Washes, enough
water supply etc. are available.
 Ensure that appropriate Personal Protective Equipment like protective Gloves
(Rubber/PVC),
 Goggles, Apron, Safety Shoes are worn by the personnel while handling the
electrolytes. No spark / naked lights / smoking are allowed inside the Battery room.
 Mixing of Electrolyte shall be carried out as per Vendor’s instruction manuals under
the supervision of experienced personnel or Vendor’s Representative and ensure
that suitable equipment are available for mixing and the electrolytes mixed to the
requirements.
 Temperature and Specific gravity of electrolyte shall be monitored and recorded
while mixing and filling.
 Ensure that Electrolyte is filled up to the marking provided on the cell containers.
Follow the instructions for filling the electrolyte as per battery user manual.

3.1 SAFETY PRECAUTIONS

 Use only clean vessels of plastic or steel for preparing the electrolyte.
 Copper, aluminium or Galvanized Vessels must not be used.
 Do not use accessories already used for lead acid batteries.
 Transfer the Electrolyte into the cells using a clean plastic jug.
 The electrolyte must not be exposed to air for long periods to ensure that the
electrolyte does not get contaminated.
 The alkaline electrolyte (solution of potassium hydroxide in DM/DI water) is a
strong caustic agent.
 Wear rubber gloves, eye protection and long sleeved clothing when working on the
battery.
 Before working with electrolyte, make sure that water for washing is easily
available.
 If electrolyte is splashed on the skin or clothing, wash immediately with water for 10
to 15 minutes.
 If eyes are affected, flood with water followed by eye wash solution and obtain
immediate medical attention.

Rev. A
(DIPWP) PROJECT
Page 15 of 39
4. Installation of UPS Panel and DC DB:
 Transport UPS Panels, DC DB and associated equipment with suitable vehicle to the
Designated location for installation. Proper care shall be taken while handling the
equipment.
 Prior to bring the Panel to the location of installation, ensure that the Panel room
floor is level, clean and tidy.
 Installation of the Panel shall be vertical and plump. Bolting shall be carried out
using suitable Bolts and Nuts as recommended by the Manufacturer.
 All Bolts shall be tightened properly using a calibrated Torque Wrench to the
satisfaction of the Customer Representative.
 Panel doors shall be checked for correct operation and locking and all components
inside the panel verified and conform to the AFC drawing and project requirements.
 Internal wiring of Panels shall be verified and confirmed with the approved
schematic diagrams. Size of wires shall be as per specification requirements. Ensure
that any loose items supplied along with the Panels / DBs are fixed and wired
according to the Manufacturer’s drawings and manuals.
 All Power and Control fuses and Circuit Breakers shall be checked for its correct size
and operations as per approved Schematic diagrams.
 Battery Disconnectors Switch shall be installed outside the battery room and
checked the installation as per approved drawing.
 Ensure that the Panel heater and illumination circuits wired as per approved
drawings and Specifications. The operations of Panel heater and Lights shall be
checked and confirmed.

5. Cable Installation and Connections:
 Cables shall be laid and terminated as per approved cable schedule and drawing.
Ensure that the continuity and Insulation Resistance of the cables are checked and
conformed prior to lay the cables.
 Approved Cable Glands and Lugs shall be used for terminating the cables.
 Single core Flexible cables of approved make shall be used for interconnecting
Battery and Battery Isolation Switch which is installed outside of battery room.
 It shall be ensured that no undue stress/strain shall be placed on battery terminals
while connecting cables.
 All cable cores shall be terminated inside the Panels as per the approved
interconnection diagrams.
 Cable entries and unused holes shall be sealed off using approved sealing
compound.
 All Cables gland body shall be earthed to earth grid using suitable size of earth
cables.

6. Earthing and Bonding:
 Battery Rack, UPS panels, DC Distribution Boards etc. shall be earthed as per
approved earthing layout drawing.

Rev. A
(DIPWP) PROJECT
Page 16 of 39
 Suitable size of Earth cables and Lugs shall be used as per specification and project
Requirements.
 It shall be ensured that all non‐current carrying metallic parts are bonded to main
earth grid using suitable size of earth cables.
 Integrity of all earth connections shall be checked and value of earth resistance
measured and recorded.

7. Charging and Discharging of Batteries:
 Battery charging and discharging shall be carried out strictly in accordance with the
Manufacturer’s instructions only.
 Experienced personnel / Vendor’s Representative shall be present while carrying
out the charging and discharging of Batteries and adequate ventilation inside the
battery room shall be ensured.
 It shall be ensured that 24 hours of time shall be completed after filling the
Electrolyte in to the batteries before the commencement of charging of Batteries.
 Charge the battery bank with 0.2 C 5 Amps (20 Amps for 100 Ah battery) current for
10 hours to provide 200 % charge input at room temperature of 20‐30 degree C.
 Provide rest period of 1‐2 hours before discharging the battery bank for capacity
testing
 After rest period, discharge the battery bank at 0.2 C 5 Amps till the battery bank
end voltage of “N” Volts (where N is the no of cells in the battery bank being tested).
The discharge duration shall be > 5 hours, before the battery bank voltage reaches
“N” Volts.
 Five cycles of charge/ discharge are allowed during capacity test as IEC 60623,
which however can be terminated after 1st cycle which meets the requirement.
Minimum 12 hours rest time is to be provided before initiating charging of the
battery after a previous discharge, to allow the cell temperatures to reach ambient
temperatures.
 After this capacity test and providing gap of 12 hours, the battery shall be boost
charged for 10 hours with 0.2C 5 Amps current and put in to float mode @ 1.40 Volt
per cell.
 Electrolyte temperature shall be monitored and recorded during charging and
discharging of Batteries.
 It shall be ensured that no naked light / sparks / smoking inside the battery room
while charging and discharging of batteries.
 Calibration status of the Charger and Discharge units shall be verified prior to the
commencement of activities and calibration certificates verified and accepted.
 Prior to the commencement of Charging and discharging of Batteries, it shall be
ensured that the mechanical interlock is provided between Rapid charge switch and
Rectifier outgoing switch.
 Level of Electrolyte in the cells shall be checked upon completion of battery
charging. If required, electrolyte shall be added to maintain the level to MAX level
mark (upper level line permanently embedded on the container). Once electrolyte
level is correctly adjusted, only distilled water shall be used for topping up during
battery service life. The distilled water to be used for topping up during operation
and used for preparing the electrolyte shall conform to IEC 60993 requirements.
Rev. A
(DIPWP) PROJECT
Page 17 of 39
 Readings of individual Cell voltage and voltage in the UPS panel shall be taken while
the load is connected at the beginning and at the end of the test and at the specified
intervals during the period of test.

8. INSPECTION AND TESTING:
 Barriers / signs shall be erected if necessary to ensure personnel approaching the

work area are adequately informed of the operation in progress.
 Test sheets for Battery charging and discharging (Vendor’s Formats) shall be
verified and accepted by the authority concerned prior to the commencement of
Testing.
 Connect load equivalent to 50% of Charger rating and with Charger switched off.
Check the battery discharges correctly, also the low voltage alarm relay operates.
 Check the operation of Earth Fault detector by connecting each pole of the system to
earth through a variable potentiometer.
 Check and measure the Continuity and Insulation Resistance value of Battery wiring
using a calibrated Multimeter and 500V DC Megger. Values shall be recorded.
 Check and measure the Earth Resistance values using a calibrated Earth tester and
the values shall be recorded.
 Indications, displays and alarm on the UPS panel shall be checked during testing and
confirmed as per project requirements.
 All functional tests as per the project requirements and specification shall be carried
out in the presence of Vendor’s Representative.
 All site test results shall be verified and compared with Factory Acceptance Connect
load equivalent to 50% of Charger rating and with Charger switched off. Check the
battery discharges correctly, also the low voltage alarm relay operates.
 Switch on the Charger to ‘Float’ position when batteries are fully charged. Check the
DC
 Voltage is within the limits as per the specification and Project requirements.
 All barriers / signs removed leaving the workplace as it was found.

6.2 Installation Procedure for LV Switchgear Panels

Handling and Storage

On receipt of LV Panel and accessories at site, necessary precaution shall be taken for
unloading, shifting and storage, as follow:

 Material shall be stored in a covered / dry space at all the time.
 All materials received at site shall be inspected and ensured that the materials
are as per approved material submittal.
 Any discrepancies, damage etc, found will be notified and reported for the further
action.
 Site engineer has to ensure that the LV panels used at site area of free from any
damage or deformity of any kind. Any minor damages observed shall be repaired
Rev. A
(DIPWP) PROJECT
Page 18 of 39
suitably and in case if the repairs could not be done properly, the LV panels are to
be sent to assembler for rectification, after all formalities carried on.

Installation Procedure for LV Switchgear Panel

 All required installation shall be accordance to applicable regulations.
 All components such as relays, fuses, CT’s contractor’s meters, breaker size,
busbar size etc. Shall be verified against the approved material submittal.
 All installation shall be carried out according to the approved shop drawing
construction for the panels.
 Ensure the floor surface is ready with base frames grouted on the open trenches
inside the LV room to install the LV panel.
 Minimum clearance of 800mm shall be maintained at rear side of the panel so
that easy access for termination of cables and other maintenance of cables and
other maintenance works can be carried out.
 LV panel shall be installed in accordance with the manufacturer’s
recommendations, approved site layout and as per site requirement.
 All knockouts made on the panel covers shall be filed and provided with
grommets to avoid sharp edges and unused knockouts shall be covered.
 The connection of busbar trucking with LV panel shall be done rigidly with
proper supports.
 Cable bending radius should be not less than 12 times of the cable diameter in
line with the manufacturer’s recommendations & as per specifications.
 Cable pulling, termination & crimping shall be done as per cables method
statement.
 Termination of cables shall be done using approved material submittal for cable
glands and lugs. Glanding and connections should be done only by competent
technicians/electrician.
 Switchgear shall be provided with proper earthing connections as per approved
shop drawings and authority regulations.
 Manufacturer recommendations are to be followed for all relay and other breaker
current setting, as per the total connected loads and the discrimination study of
the system.
 Identifications labels of approved type shall be fixed on the LV panels.
 Ensure that all cable entries and other openings of electrical / LV room, All /
Floor are carried out with proper approved sealant.
 The manufacturer’s representative to verify the site installations and provide
acceptance of same prior to energisation of LV panel after obtaining clearance
from site engineer.
 Ensure that adequate A/C provided to the LV panel room and unit of the A/C
shall not be installed inside LV room as per contract drawing. The A/C unit shall
be installed outside the room and to be connected with duct to LV room. And no
water services allowed inside LV room as per authority regulation.
Rev. A
(DIPWP) PROJECT
Page 19 of 39
 Connecting cables between the switchboard and battery unit, and between the
switchboard and AC control panel shall be neatly run on cable trays supplied by
the contractors.
 The connecting cables between the switchboard and battery unit shall be at least
4mm in size and shall be run in ring configuration. Physically, the cables for entry
and exit of the same loop should not be the same. All wiring and termination of
connecting cables shall be carried out by the contractor. Conductors used for AC
& DC circuits shall not be mixed in the same multi‐conductor cable.
 Upon completing the installation of LV panel, ensure all the works carried out as
per authorised regulations.

6.3 Installation Procedure for MV Switchgear Panels
Preliminary Preparation

Sequence Operation
Area should keep clean, tidy and dust proof. All ventilation and floor
0.1 openings should be closed. Installation area should have sufficient lighting
facilities.
0.2 Gas handling involved in this switchgear installation area should be
secured and only authorized personal are permit to enter this area.
0.3 All the instruments used for installation, testing shall have a valid
calibration test certificates and must be made available.
0.4 All commissioning results shall be prepared, obtained and maintained by

the commissioning team as given in this procedure.

1 – Packaging

Sequence Operation
Delivery is effected in terms of prefabricated single switchgear panels. One

1.1 transport unit consists of max. 2 individual switchgear panels which are
fastened to the pallet.
The bus bar compartment with three‐position switch, the circuit‐breaker
1.2 compartment, the drive mechanisms and the supporting structures are
mounted ready for connection and routine‐tested. The individual bus bar
links are mounted on site.
The WS series switchgear panels are delivered with the circuit‐breaker set
1.3 to “OFF”, the energy storing device released and the disconnector and
earthing switch set to “OFF”.
1.4 The make‐proof bus bar earthing switch is supplied in position “ON”.
Rev. A
(DIPWP) PROJECT
Page 20 of 39
1.5 The standard accessories are included.
1.6 If packed exclusively for truck transport, the panels are delivered on a
pallet with PE protective film.
For sea transport, the units are packed in sealed aluminum foil with
1.7 desiccant and in a closed wooden case with tightly closed wooden base
(also for container transport).
In case of air transport, the panels are packed in wooden crates with a
1.8 protective PE film hood (dust protection) or in wooden cases, also with
closed wooden bases, however without protective hoods (dust protection).

Note: the weight of the entire transport unit is indicated on the packaging.

2 – Transport

Sequence Operation
Warning!

Danger due to tipping load.
2.1 ►Transport units must be
protected sufficiently against
slipping and tipping
during transport.
Transport with forklift truck
The panel may only be transported on a pallet. The entire length of the fork
s must be placed under the transport unit.

2.2 Warning!
Risk of injury due to insufficiently secured load!
►Make sure the rope is strong enough to bear the weight of the panels and
complies with the appropriate regulations for hoisting equipment.
Rev. A
(DIPWP) PROJECT
Page 21 of 39
Transport by means of a crane

1. Remove transport packaging
(protective films).
2. Attach rope/chains to the jack
rings located on the bus bar tank
(Fig. 2).
2.3 3. Release transport fastening
device of the panel from the
transport pallet.
4. Lift the panel carefully with the
crane. If necessary, mount transport
rollers (Fig. 4).
5. Lower the panel slowly to the
floor at its place of destination

3 – Delivery

Sequence Operation
Warning!
Risk of injury due to tipping or uncontrollable breaking away of load!
3.1

 Sufficient stability and evenness of the supporting area (floor) must
3.2 Handle shipping units carefully when unloading and unpacking them.
Shipping units must be checked upon receipt. Any damage which may have
3.3 occurred in transit must be recorded and reported to the manufacturer
immediately.
3.4 The consignment must be checked for completeness based on the shipping
documents.
3.5 The supplier must be notified in writing without delay about any possible
deviations.

4 – Storage

Sequence Operation
Warning!
Risk of injury due to tipping or uncontrollable breaking away of load!
4.1
►Sufficient stability and evenness of the supporting area (floor) must
be ensured
Rev. A
(DIPWP) PROJECT
Page 22 of 39
If the panels are not installed immediately after delivery, they can be
stored under the following conditions:
- Panels must be stored in vertical position, and must not be stacked.
4.2 - Storage only admissible indoors
- Switchgear panels and accessories must be sealed with desiccant in
aluminium foil and be packed in a wooden crate (storage for max.
two years after the date of packaging).
Warning!

Risk of injury due to tipping panels!
4.3 ►Move panel by rolling it towards the installation area over the foundation
bar structure parallel using the transport device.
►Pay attention to flooring ducts ‐ risk of accidents!
►To reduce the accident hazard; have the panel rolled to the installation
area over the foundation bar structure by two fitters.

5 – Installation of a switchgear panel with transport device

Sequence Operation
Insert transport device (included under "transport aids" in Accessories) in
5.1 panel
Supporting structure, and screw‐fasten.
5.2 Lower panel using the transport device. Release transport device from the
panel supporting structure.
For the distance dimension between wall and panel, please refer to the
Installation plan. Align the rear of the panel supporting structure to the
5.3 outer
Edge of the foundation bar structure. Do not yet screw fasten the panel to
the
5.4 Remove transport covers and rear cover plate on new extension panel (Fig.
6)
Rev. A
(DIPWP) PROJECT
Page 23 of 39

6 – Insert adjustable bridge elements

Sequence Operation
6.1 Adjustable bridge elements under "transport aids" in accessories.

Place bridge elements over the foundation bar design, adjust and clamp
6.2 one side of the bridge elements with the foundation bar (wing nut screw
coupling)
Warning!

Risk of injury due to tipping panels!
6.3 ►Roll the individual panels to the installation area using the transport
device, over the bridge elements and parallel over the foundation bar
structure.
►Pay attention to flooring ducts! Risk of accidents.
Move panel by rolling it towards the panel already installed leaving a
6.4
distance of
Rev. A
(DIPWP) PROJECT
Page 24 of 39

6.5 Coat sealing surfaces.
6.6 Lower panel using the transport device. Release transport device from the
Panel supporting structure.

7 – Screw fastening the switchgear panels

Sequence Operation
Before screw‐fastening
the panel to the adjacent
panels or the
7.1 appropriate end plate,
fasten the lateral rubber
profiles to the panel as
shown in the assembly
Screw‐fasten panel to
the front cover and in
7.2 the low‐voltage cabinet
to the adjacent panel or
the end plate.
Coat the sealing surfaces
between the bus bar
compartments and the
7.3 toroidal sealing ring
with SF6 multipurpose
lubricant MS. Insert
toroidal sealing ring.
Rev. A
(DIPWP) PROJECT
Page 25 of 39
Push panel to the panel

7.4 already installed with
the sealing surfaces
Align panels with the

7.5 panel front (front cover
/ circuit‐breaker area)
using a rule.
Screw‐fasten panels to each other along the bus bar sealing surfaces:
‐ without bus bar cladding: Tighten screw couplings M8 with a torque of
7.6 36 ± 4 Nm
‐ with bus bar cladding: Tighten screw coupling M8 (not greased) with a
torque of 20 + 4 Nm

Rev. A
(DIPWP) PROJECT
Page 26 of 39

8 – Fastening the panels to the foundation bar

Sequence Operation
8.1 Before fastening the panel, make sure that all the previous steps have been
accomplished for all panels.
8.2 Drill four fastening points Ø 8.5 mm through the panel supporting
structure in the foundation bar. Tap a thread M10.
8.3 Slip any required shims in directly besides the fastening points. Relieve
set‐screws (turn back).
Screw‐fasten panel supporting structure with foundation bar. Tighten
8.4 screw couplings M10 with a minimum torque of 40 Nm (applies only to
ratchet bolts with a sufficient thread depth of 8 mm)

9 – Installation of bus bar sections
Sequenc
Operation
e
Standard panel ‐ (Bus bar rated (service) current up to 2500 A)
Bushings, bus bar sections and hardware in switchgear accessories. In case
9.1 of bus bar compartment cladding, coat grooves in bushing, in flange, and
toroidal sealing rings with SF6 multi‐purpose lubricant MS. The individual
cladded compartments are sealed optimally against each other by means of
toroidal sealing rings and coating with SF6 multi‐purpose lubricant MS.
Rev. A
(DIPWP) PROJECT
Page 27 of 39
9.2 Insert toroidal sealing rings. Screw down bushings and flanges. Tighten
screw couplings M6 with a torque of 8 ± 1 Nm
Coat contact surfaces with contact lubricant KL. Contact surfaces must not
9.3 get into contact with screw locking compound "Loctite". If the two agents are
mixed, con‐ tact will be impaired.
9.4 Wet threads with screw locking compound "Loctite".
Insert bus bar sections, taking account of the installation position of the two
9.5 disc springs located on either side, "center" between the bushings and screw
down. Tighten screw couplings M10 with a torque of 10 Nm.
The bus bar is screw‐fastened to a post insulator on the left and right end
9.6
panels, and in the case of bus coupler panels.
Check disconnector blades for "hitting" the fixed contact on the bus bar (for
switching on the dis‐ connector, refer to the operating instructions). Due to
the jerky movements of the disconnector blades, it may not be possible to
9.7 adhere to the dimension 5 +2/. The following setting is admissible in these
cases: If the distance at 9.5 revolutions of the actuating crank amounts to
≤10 mm, then the disconnector blade may touch the stop of the contact
during the last 0.5 revolution of the actuating crank.

Rev. A
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10 – Bus bar contact resistance

Sequenc
Operation
e
10.1 Comply with the manufacturer’s specifications regarding the contact

resistance measuring unit.
Measure transition resistance R between the individual bus bar sections
with 100 A DC
10.2
.
The measured resistance values should be comparable. If one value exceeds
10.3 the average of the other measured values by max. 20 % or more, undo bus
bar screw fastening; clean contact surfaces carefully and repeat the

11 – Evacuation of bus bar gas compartment

Sequence Operation
Activating the desiccant bags
a. Clean bus bar gas compartments including mounting parts,
removing loose particles such as abrasion, paint, dust or
precipitated moisture by means of a dry, non‐fibrous cloth.
b. The desiccant bag is located below the mounting orifice underneath
a cover.
c. Open the underneath cover and tear poly cover of desiccant bag and
place back on the same location and tight the fix screws.
11.1
Rev. A
(DIPWP) PROJECT
Page 29 of 39
Screw fasten mounting cover

a. The welding bolts on the bus bar chamber must not get into contact
with SF6 multipurpose lubricant MS
b. Coat the sealing surfaces on the bus bar chamber, the mounting
cover and the toroidal sealing ring with SF6 multi‐purpose
lubricant MS. Insert toroidal sealing ring. (see fig. 9)
11.2
c. Screw fastens mounting cover. The following tightening torques
apply to screw coupling M8:
‐ Steel cover, hex. Nut with ratchet 14 +2 /‐2 Nm
‐ Aluminium cooler cover, hex. Nut without ratchet 8 +2/‐2
Nm
Note:
Evacuation of the bus bar gas compartments

a. Refer to gas compartment diagram. Normally, the filling and
extraction valves for the bus bar gas compartment are located on
the last but one panel.
b. Remove cap from extraction valve of bus bar compartment. Connect

the service instrument (vacuum compressor and filling equipment)
c. Evacuate the bus bar gas compartment of the entire switch gear to
11.3
≤1 KPa abs.

12 – SF6 gas filling on bus bar compartment

Sequence Operation
12.1 Switch service instrument over to “filling” mode. Connect gas filling device.
Insert insulating gas until the rated filling pressure is reached. Watch rated
12.2 filling pressure on secondary pressure gauge of the gas refilling device.
Rated filling pressure, refer name plate (e.g.) pr 0.03 Mpa rel, pre 0.05 Mpa
rel., Pre
Rev. A
(DIPWP) PROJECT
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12.3 Disconnect gas refilling device. Screw‐fasten cap on filling valve.
12.4 Gas filled compartment should have kept approx. 24 hours to check
leakage and quality of SF6 gas.

13 – SF6 gas leakage and quality check

Sequence Operation
SF6 leakage check
a. A test for leakage is required whenever gas‐tight flange couplings
have been made. After approx. 24 hours. Leakage test should have
performed.
b. Use a leakage detector. Observe the instructions of the leakage
13.1 detector's
Manufacturer.
c. Check the flange couplings mounted during installation by holding
the leakage detector close to them. The flange coupling's tightness
is ensured if the leakage detector does not react or give alarm in full
scale deflection.
SF6 Quality check
a. Use a SF6 quality measuring device. Observe the instructions of the
manufacturer of the quality measuring device.
b. Connect hose form measuring device to a filling valve. The
13.2 measuring procedure is described in the operating instructions for
the gas quality measuring device. The dew point temperature must
not be higher than –15 °C.
c. Disconnect SF6 quality measuring device. Screw‐fasten cap on
filling valve

Rev. A
(DIPWP) PROJECT
Page 31 of 39

14 – Earth conductor fixation and control wiring connection

Sequence Operation
Earth conductor fixation

a. Sections of the earth conductor, plates and hardware included in
switchgear accessories.
b. Coat contact surfaces on earth connector (underside of bus bar
chamber), plate and section of earth conductor with contact
lubricant KL.
c. Screw‐down plate. Tighten screw couplings M8 with a torque of 20
± 2 Nm.
d. Screw‐down section of earth conductor. Tighten screw couplings
M10 with a torque of 40 ± 4 Nm.
14.1 e. Connect earth conductor of switchgear to existing earth conductor
of the switchgear building.

Control wiring connection
a. Remove transport securing device (screw coupling M6) from the
swing frame.
b. Fold swing frame out. Introduce external control lines to the cable
irons through the opening in the base plate. Fix external control
lines to cable iron using cable clips.
c. Connect wires to terminals according to diagram.

14.2

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15 – High Voltage / Power frequency with stand test of the bus bar

Sequenc
Operation
e
The bus bar can be subjected to a power frequency withstand test. The test
voltage is supplied via the high‐voltage terminal of a panel. To this effect, a
test unit and test cables are required, which are not included in the scope of
supplies.

Note: All the switching operations mentioned in this context must be per‐
15.1 formed in
Accordance with the applicable Operating Manual WS.

15.2 All panels must be isolated from the power supply and earthed.
15.3 Earth the bus bar voltage transformer and capacitive measuring connectors.
15.4 Close open high‐voltage terminals on cable compartment with surge‐proof

dummy plugs.
Remove the dummy plugs from rear end test socket (Fig. 22). Mount test
15.5 cable to a phase of the high‐ voltage terminal. Earth the residual phases
using commercially available earthing devices.
15.6 High‐voltage terminals must be closed surge‐ proof during the test phase.
Earth the residual phases using commercially available earthing devices.
15.7 High voltage should apply at any panel by keep closing of disconnector and
CB in closed condition. Cover all cable entry by dummy plugs.
Rev. A
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Page 33 of 39

Connect high voltage test unit to the test cable. Switch earthing switch in the
15.8 extension feeder panel to open position. Switch disconnector and circuit‐
breaker to close position.
Perform power frequency withstand tests successively for all phases (L1, L2,
15.9 L3) according to the specifications of the test unit manufacturer. All phases
should with stand for the 33 kv test voltage.
15.10 Once the power frequency withstand has been completed, earth all the
tested high voltage lines again
Once the power frequency withstand test has been completed, remove the
test unit and the test cable.
15.11
Reconnect earthed or removed voltage transformers, capacitive measuring
connectors
15.12 Mount surge‐proof covers (dummy plugs) on the extension feeder.
Before and after the High voltage test, Megger the switchboard and note
15.13 down the insulation values. Ensure and compare the test results of the
insulation values.

Rev. A
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Page 34 of 39
6.4 Installation Procedure for all Type of Transformer’s

- Ensure all reference documents should be available at site.
- Valid permits will be obtained from concerned authorities wherever applicable.
- Tool box talk will be conducted by the CEP/Site supervisor prior to start of work
and attendance will be recorded.
- Competent Electrical Person with valid license for receiving LOA/PTW will be full
time available at site.
- Ensure to provide proper barricade to the nearby live areas, caution signage’s
before starting any activity to prevent the entry of unauthorised persons inside the
work area.
- Check the transformer foundation is completed conforms to the foundation drawing
and specifications.
- Ensure to use the lifting material (D‐shackles, belts, chains) with the calibration due
period.
- Check oil drainage pit, cable trench etc., all are as per requirement.
- Physically inspect the transformer parts for any damage, compared with that
mentioned in the packing list of the transformer an enclosed herewith.
- Check for positive pressure of main tank if it is transported with nitrogen filled.
- Mark the centre line of the foundation as per drawing.
- Mark the centre line of the transformer as per measurement.
- Follow DPC mechanical lifting procedure at all time during installation of
transformer parts.
- Mechanical lifting machine, tools and tackles will be inspected and approved by
competent person/HSE Officer.
- Safe working load shall be assessed prior to commence the lifting activity and
necessary precautions will be take
- Operators of all lifting machines will possess valid operator license.
- The transformer foundation area will be properly barricaded and signage provided
and banks man will provide for monitoring the work.
- Proper working platform will be erected with the help of scaffold supports/gratings
to installed before erecting the transformer and ensure that it is safe to work on
that.
- Tagline will be used for all suspended loads that are liable to swing.
- Employees will never walk under a suspended load and a suspended load shall not
be moved above the employees.
- Ensure to use rated sling to lift the load.
- Ensure that the load to be lifted must be within safe working load (SFL) on the
crane.
Rev. A
(DIPWP) PROJECT
Page 35 of 39
- Shift the transformer main tank from storage yard using the crane and trailer
vehicle. Position the crane close to transformer foundation. Position the main tank
on the foundation properly according to the lifting procedure.
- The weight of transformer main tank assembly is 36,000kg, as per the vendor
drawing.
- While placing the transformer make sure that the primary and secondary sides of
the transformer are matching with the layout drawings.
- Check the levelling and alignment of the transformer with spirit level make
necessary corrections with shims etc. for correct alignment.
Installation of transformer accessories & oil filling purification: (After
transformer main tank erection)
- Main tank of the transformer is installed on the transformer foundation.
- Drain valve, top & bottom sampling valves of transformer and conservator are fixed
and are in closed condition.
- If radiators are not filled with oil transportation, drain the used oil and tight the
train plug before installation.
Site Arrangements
- Safe working platform will be prepared.
- The availability of calibration certificates for the tools and testing equipment’s will
be ensured at the site.
- Third party inspection certificates of lifting machinery will be available at site.
- Necessary competency certificate for the concerned personal will be available.
- Required tools and equipment will be available.
Installation of transformer accessories:
- Installation work for transformer accessories can be done and the transformer oil
filtration after fixing of radiator and PRV.
- During the installation of accessories, the nitrogen gas present inside the
transformer main tank will be released through the top drain valve/ by opening the
inspection cover on the main tank.
- Install the bushing properly in each phase and connect the BCT.
- Install the radiators properly with the help of HIAP. Final tightness to be done only
after placing in proper alignment.
- Install the piping arrangement of main tank, OLTC and conservator tank of
transformer properly. Mount the conservator as shown in general arrangement
(GA) drawing.

Rev. A
(DIPWP) PROJECT
Page 36 of 39
Transformer oil filling:

- After installing the transformer on the foundation dry gas in the transformer should
be replaced with the treated oil. Oil should be tested for break down voltage it
should be above 55kv & 2.5mm gap. Make sure the hose and pipe interiors are
cleaned in advance.
Measure the insulation resistance between:
- HV – Earth (Tank)
- LV/IV – Earth (Tank)
- HV – LV/IV
- Core Frame – Earth (Tank)
- Vacuum oil filling is adopted at approved oil filling procedure.
- The vacuum will be created using the oil filtration the plant evacuation valve
connected to the pipe flange of the buchholz relay. Negative pressure of 380mm hg
will be maintain for vacuum and it will be checked at the vacuum connected at the
piping flange for the main tank conservator breather.
- Open the top filter valve or any other bolted covers on top most point on the
transformer for realising dry gas at the time of oil filling.
- Open the bottom filter valve on the transformer and top air release valve on the oil
storage tank. Oil should be filled up to level above the insulation transformer
winding. A small gas space (approx. 5 – 10 %) should be left above oil for expansion
of oil
- During oil filling, if the filter press stops due to any reason to filter valve any other
opening on top of the transformer should be closed immediately to prevent air
getting into the transformer. Oil level continuously monitored during oil filling.
- Fill the transformer oil inside the oil tank to the transformer main tank through
bottom drain valve using the oil filtration plant.
- The inlet valve of the filtration machine will be connected at the drain valve of the
oil tank and the outlet valve will be connected to the bottom drain valve of the
transformer
- Repeat the procedure as mentioned for above oil filling until oil level reached one
third of the level of the main tank conservator
- Then close the transformer bottom drain valve and shut off valve for the main tank
conservator. Retrieve the oil filtration plant from the transformer.
- Open the top of sampling valve and fill nitrogen up to 0.1 pressures, close the valve.
- Install the buhholz relay properly as per drawing and complete the piping to main
tank.
- Install breather for both main tank & OLTC conservator properly.
- The sensing bulbs of the oil and winding temperature indicator to be fitted on the oil
filled pockets provided on the tank top,

Rev. A
(DIPWP) PROJECT
Page 37 of 39
- Complete cabling work as per schematic drawing.

- The WTI BCT leads will be connected to the heating coils of the winding
temperature indicators check the shorting links of the BCT
- Fix the transformer earthing terminals as indicated in the position in the general
arrangement drawing. Release any air trapped in the bchholz relay and mercury
switches will be put in service position. Release the trapped air from the radiators
by opening the air release plugs/ screws provided at top of the radiator.
- Note down the insulation resistance reading for the transformer terminals after oil
filling as mentioned in the starting of oil filling.
Transformer oil purification:
- The transformer oil filtration plant is connected between the drain valve of the main
tank and the main conservator top filter valve or outlet point on the buhholz relay
line, delivering the hot oil at the bottom drain valve of the main tank.
- Before starting the oil filtration process, the old filter to be replaced with the new
one.
- The process will be continued till the minimum required BDV values as per the
manufacture requirement. Final condition of the oil after oil purification process
should be at least 60 KV @ 2.5 mm2 sphere gap and water content should be less
than 5ppm.
Leak test:
- Train oil & create vacuum of 200 inside the tank, close the valve between vacuum
pump and tank and stop the pump hold the vacuum, there should be no appreciable
loss of vacuum over one minute.
- If there is leak, find out the leak and rectify, start the pump and open the valve and
continue till a vacuum of 10 is achieved.
- Close the vacuum valve and stop the pump.
- There should not be an increase of pressure of more than 1 over half an hour.
- If the rise in pressure is more, find out leak and rectify.
- Check the HV & LV bushing, if any leakage should be rectified.
- If result are satisfactory, restart the vacuum pump open the valve continue pumping
to obtain a vacuum of 1 tore or better and maintain this vacuum for more than 24
hrs before and during subsequent oil filling operation.

Rev. A
(DIPWP) PROJECT
Page 38 of 39
SAT Installation and Testing & Commissioning Procedure:

 Ensure the material received at site is in good condition.
 Check for the appropriate capacity of crane to lift the transformer safely. Ensure proper
positioning of the crane, firmness of the ground, boom length and lifting accessories.
 Clean the equipment foundation and ensure the foundation is free from particles, dust
and undulations.
 Mark centre line on the foundation as per approved drawings and make it visible.
 Lift the equipment slowly from the trailer with the help of Crane and ensure the weight
is within the safe operating capacity of the crane.
 Slowly place the transformer on the foundation and align it properly as per the centre
line marked.
 Immediately after positioning the transformer, first and foremost thing is to ground the
transformer main tank to the main earth grid.
 Megger the transformer and record the value.
 Oil BDV test shall be carried out.
 Clean the area after completing all the works.

7.0 Safety Precautions and Measures
- Prior to commencement of any activity, all personnel involved on the job will attend
the Client’s HSE Induction training.
- The site management, supervisors and safety officers will closely supervise and
monitor all phases of activities in connection with the compliance of safe working
models.
- Personnel will use protective gears and clothing in accordance with the project
general safety guidelines. All personnel working in this project shall wear proper
personal protective equipment (PPE) such as safety helmets, safety glasses, safety
shoes, hand gloves etc. as required.
- All equipment will be inspected by competent personnel prior to use at site.
Equipment will be regularly checked and inspected by the safety officer.
- Any accident / Injury / near miss will be reported immediately to appropriate
authorities.
- Project Engineer / HSE officer will be responsible for presenting all employees with
a Pre‐work briefing / Tool box talk using the approved risk assessment schedule
before work starts.
- Project Engineer /Site supervisor will immediately correct any hazards observed or
reported to him. In the case of major hazards, work shall be stopped and
appropriate action will be performed to remove the hazard permanently.
- Ensure all HSE regulations are followed as per Client’s requirements.

Rev. A
(DIPWP) PROJECT
Page 39 of 39
8.0 Responsibilities
- Construction Manager is over all responsible for Safety, Quality and Progress of the
Project.
- Project Engineer/Permit holder is responsible for monitoring the daily activities at
site.
- HSE Officer will be monitoring all works are being carried out in accordance with
the safety requirements on site.
- Civil Engineer shall be responsible for the site construction activities and
implementation of all plans.
-
9.0 Emergency
In case of Emergency,
- Stop the work.
- Switch off the work equipment, tools and machineries.
- Alert the nearby workers to reach to the nearest assembly point.
- Do not to get panic and do not run.
- Inform the site HSE officer and other key personnel from the emergency contacts
numbers displayed in the site.
- Call emergency services (9999 / 80077700) if required.
- Supervisor shall make head count and report.

10.0 Records
- Quality Records (Approved drawings & Shop drawings).
- Inspection forms (RFI/MRDR).
- As built drawings
- Test reports
Alghanim, Cobra, Tedagua, Sojitz, Power and Water LLC
RISK ASSESSMENT
Site:
DUQM INTEGRATED POWER AND WATER PROJECT
Name: NIZAR AHAMED Position: CONSTRUCTION MANAGER Date: 22/12/19
Assessed by:
Signed:
Description Of Work: ELECTRICAL EQUIPMENT INSTALLATION
Residual
Risk
Risk
Task / Job Component Hazard Risk Persons at risk Rating Controls / Precautions to Reduce Risk
Rating
L/M/H
L/M/H
 Proper lifting technique shall be used while lifting
of goods.
 Proper manual techniques shall be implemented
while handling goods.
 Goods shall be packed as per convenience of
transportation, stacking and handling.
 Fall of goods /  Name of the goods shall be labelled categorised
damage to for identity.
goods,  Goods shall not protrude more than the
personnel transporting vehicle space allocated for it.
Loading, transportation
injuries. Installers, technicians  Goods transported shall be in approved container
and offloading of GIS 4*4*=16 H L
materials  Traffic and labourers specified
obstruction.  Right goods shall be transported in approved
 Damage to container
vehicle/propert  Vehicle carrying goods shall be rated for the load
y. and verified periodically for performance
 All lifting accessories and tackles should be in
good condition and third party certified.
 Lifting tackles regularly inspected, colour coded.
 Use competent and approved operators
 Swinging area to be barricaded with signage to
restrict unauthorised entry.
Doc
Rev A
Date 22/12/19
RISK ASSESSMENT
 Proper lifting technique shall be used while lifting
of goods to vehicle or during offloading.
 Proper manual techniques shall be implemented
while handling goods.
 Goods shall be packed as per convenience of
transportation, stacking and handling.
 Name of goods shall be labelled, categorised for
compensation of dues while handling.
 Name of goods shall be labelled ,categorised for
 Fall of goods/
identify
damage to
 Goods shall not extend or protrude more than
goods
Loading transportation Installers, technicians the vehicle.
 Traffic 4*3=12 H L
and offloading of panel and labourers  Vehicle carrying load shall be rated for the load
obstruction
concerned and verified periodically for
 Damage to
performance.
vehicle
 Right goods shall be transported in right vehicles.
 All lifting accessories and tackles should be in
good condition and third party certified.
 Lifting tackles regularly inspected, colour coded
and regularly maintained.
 Use only competent operators.
 Do not overload and tie the load before loading.
 Strict supervision shall be ensured.
 Swinging area to be barricaded.
 Hand or finger  Use proper working platform.
bruise when  Assistance must be there
caught between  Avoid working on portable ladder for long
Installation/fixing of Installers, technicians
supports and 4*2=8 M duration. L
supports. and labourers
floors  Proper concentration on work.
 Back pain:  Keep back bone straight.
extensive work  Use of appropriate tools.
Doc
Rev A
Date 22/12/19
RISK ASSESSMENT
on floor by
sitting for long
periods,
bending spine
for taking
measurements.
 Competent and certified operator to operate the
 Property
equipment
damage
 Equipment should have valid certification
Defective /incorrect  Tilting of the
Installers, technicians  Equipment regularly inspected and well
equipment spillage of equipment’s 4*2=8 M L
and labourers maintained.
oil/lubricants.  Fall of load
 Daily inspection for hydraulic leaks should be
 Land
done by operator
contamination.
 Drip tray to be used to avoid soil contamination
Lack of knowledge of  Use only competent and certified operators for
operating equipment  Personal injury
such operations
 Property Installers, technicians
 Operate with competent rigger
damage and labourers, other
4*4=16 H  All personnel involved shall be briefed about\ L
 Tilting of contractor workers and
method statement and risk assessment before
equipment site visitors.
starting activity.
 Fail of loaf
 Always ensure load is below SWL
Lack of communication  Property
between rigger and damage and
operator Installers, technicians
personnel  Experienced and certified rigger to be assigned
and labourers, other
injury 4*5=20 H  Coordination between operator and rigger L
contractor workers and
 Tilting of through visual contact at all times
site visitors.
equipment
 Fail of load
 Personnel Installers, technicians  Do not work at heights during strong winds and
Adverse weather
injury 3*3=9 and labourers, other M storms L
condition
 Asset damage contractor workers and  Deploy only trained workers
Doc
Rev A
Date 22/12/19
RISK ASSESSMENT
site visitors and  Ensure competent supervision
equipment  Restart work when it Is safe
 Cranes shall cease operation when wind speed
exceeds 25 knots or as in manufacture
specifications.
 Work shall be stopped if humidity exceeds 80ppm
and temperature exceeds 50 degree centigrade.
 All measuring instruments like anemometer
hygrometer, thermometer should be available
with the supervisor during the entire operation..
 Ensure adequate capacity crane is used
 Loss of
Installers, technicians  SWL to be displayed on the equipment to be used
property
and labourers, other  Only experienced and certified operator to be
 Damage to
Overloading 3*3=9 contractor workers and M deployed L
equipment
site visitors and  Effective supervision
 Personnel
equipment  Prior briefing to operators before starting the
injury
activity.
Installers, technicians  No other activity to be carried out at close
 Personnel
and labourers, other proximity
injury
Simultaneous operation 3*5=15 contractor workers and H  Isolate the swing radius area and proper warning L
 Property
site visitors and signage to be placed
damage
equipment  Proper supervision and briefing.
Installers, technicians  Use proper insulated hand tools
 Electric shock /
and labourers, other  Conduct Toolbox talk prior to work start.
Electrocution
Adjacent live circuit 5*4=20 contractor workers and H  Place caution boards to adjacent live parts. L
 Flash over
site visitors and  Work should be carried under the direct
 Electric burn
equipment supervision of competent person.
 Leak, Inhalation Installers, technicians  Do not vent out the gas into atmosphere.
can cause and labourers, other  Contain the gas in designated cylinders.
SF6 Gas Installation 3*3=9 M L
asphyxiation. contractor workers and  Adequate ventilation.
 Highly potential site visitors and  Use SCBA in case of leak
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RISK ASSESSMENT
greenhouse gas equipment  In case of leak ensure adequate purging
 strictly ensure no entry to trenches or low lying
areas if SF6 leaked is heavier gas and displaces
Oxygen below.
Accident hit on the Installers, technicians
transformer parts while  Body injury 2*2=4 and labourers, other L  Use proper PPE L
working. contractor workers
 Safe scaffold shall be constructed
 Work more than 2 meter height requires to
having full body harness with double hook
lanyard and retractable fall arrester block.
 Use PPE I.e. helmet, safety shoes, hand gloves,
safety glasses, coveralls etc.
 Ensure availability of first aider
 Follow approved safety working procedures
Working at Height on top  Fall injury Installers, technicians  Ensure that all precautions for working at heights
4**5=20 H L
of transformer  Fatality and labourers are taken
 Work more than 2 meter height requires to
having full body harness with double hook
lanyard and retractable fall arrester block.
 Use of PPE i.e. helmet, safety shoes, hand gloves,
safety glasses, coverall etc.
 Deploy only medically fit workers without vertigo
 Ensure competent supervision
 Ensure availability of first aider.
 Clean the oil traces on the transformer.
Falling down by slipping Installers, technicians  Keep the floor always clean.
 Body injury 3*5=15 H L
due to the presence of oil and labourers  Wear PPE.
 Provide proper scaffolding wherever possible.
Contact with chemical  Skin reaction Installers, technicians  Take care while handling chemicals/oil and using
3*4=12 H L
oils  Irritation and labourers chemical and oil resistant hand gloves.
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RISK ASSESSMENT
 burning  Follow safe working procedures.
 Use proper PPE.
 Available of first aider with first aid box.
 bursting of the  keep breather line and valve in the conservator
Installers, technicians
Overpressure inside the tank line open and close maintaining of pressure in the
4*4=16 and labourers, other H L
tank  loss of oil machine
contractor workers
 asset damage  proper maintenance
 Burns due to oil
Installers, technicians  Ensure the pressure within the tanks is within
spillage
Bursting of tank 4*4=16 and labourers, other H safe limits by proper monitoring L
 Land
contractor workers  Follow manufacturers’ instruction
contamination
Improper operation of  Equipment  Operate according to the manufacturer
3*3=9 Equipment L L
machine damage instruction
 Ensure ground is firm and stable
 Ensure proper soil compaction
 Fatality  Extend the outrigger fully
 Equipment Installers, technicians  Keep wooden support beneath outrigger
Uneven /unstable ground 4*2=8 M L
damage due to and labourers  Provide warning signboards
fail.  Ensure availability of banks man during heavy
equipment movement
 Ensure first aid facility
 When specifying/ordering material, consideration
will be given to manual handling requirement and
 Slipping/tripping
will be purchased in packages of 25kg or less
of the load.
where possible
 Imbalance or
Installers, technicians  When planning the operation/activity
Manual handling loss of control 3*3=9 M L
and labourers consideration will be given to use handling aids
 Back pain
where possible
 Cut injuries/
 Where the handling load will be above 2kg
sprain, etc
sufficient number of operatives to be assigned
 Operatives shall be explained about manual
Doc
Rev A
Date 22/12/19
RISK ASSESSMENT
material handling basics
 The surround area will be level and stable where
possible and free from tripping hazard.
 PPE shall be provided and used i.e. gloves for
handling sharp materials and accessories.
 Experienced person to handle GIS material and
avoid contact with sharp edges
 Beware and take extra care about pinch point.
 Training in Safe Manual handling practice
 Wear personal protective equipment’s like safety
helmet, hand gloves, coverall, safety shoes,
Pinch/nip point: goggles, etc.
Finger/hand struck  Finger/Hand Installers, technicians
3*3=9 M  Trained work force L
between injury and labourers
machine/equipment  Maintain good housekeeping
 Avoid horse play
 Cordoned off the area and affix awareness signs
boards
 Supervision should be present within the duration
of work
 Skilled and experience workers shall be involved
 Injury to in the activity
Unaware about work persons Installers, technicians  TBT Should be conduct prior to start of work
3*3=9 M L
procedure  Damage to and labourers  Unauthorized employee not allowed to enter
assets  Qualified first aider to be there in the site
 Ensure good supervision
 ERP should be communicated with concerned
work force
 All tools in use should be inspected and ensure
 Injury to person
Dismantling of Packing Installers, technicians that they are appropriate to the task to be
materials
 Damage to 2*2=4 L L
and labourers performed.
assets
 Maintain good housekeeping and denial all
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Date 22/12/19
RISK ASSESSMENT
dismantled packing materials.
 Remove all scattered nails from the surface.
 Do not store the packing materials in the site.
 Ladders used must be in good condition.
 Wear necessary PPE.
 Presence of first aider at site
 Ensure use of right type of tools for the job being
performed.
 Upper limbs
 All Tools should be Pre‐Inspected/calibrated.
disorder
Use of  Home Made Tools Should not be used.
 Muscular Installers, technicians
improper/substandard 2*3=6 L  Routine inspections to check & replace poor L
Tools sculptor and labourers
conditioned tools.
Disorder
 Periodic rest breaks & job rotation.
 Personal Injury
 Use proper PPE.

 Strict supervision required
 Only competent person to handle the tools
 All electrical installations shall be inspected and
tested prior to use
 All electrical installation and alterations shall be
undertaken by competent electricians only.
Unsafe handling of hand  Adequate earth and ELCB with 0.03 A shall be
and power tools  Major/minor
Installers, technicians provided
/Defective hand injuries/propert 4*4=16 H L
tools/equipmanet electric
and labourers  Regular inspection of electrical equipment, tool,
y damage
shock/poor earth and connections shall be carried out.
 Ensure properly rated cables, sockets are used
and safe condition of insulation cables.
 Electrical equipment’s shall be away from water
to enter inside live wires.
 Tools/equipment’s shall have relevant guards
fitted
Doc
Rev A
Date 22/12/19
RISK ASSESSMENT
 Tools/fittings. Alignment and general condition
shall be inspected prior to use

 All work in the live equipment area shall be
carried out with Electrical Permit by authorized
party.
 Work shall only be under the guidance and
supervision of a competent supervisor
 Tools shall be double insulated and only 110V
tools should be used.
 ELCB to be tested before work starts.
 Authorized and trained persons to carry out the
Job.
 Prevent body contact with earthed surface
 Damage to
Installers, technicians  Ensure adequate information instruction, training
Electrocution assets 5*4=20 H L
and labourers for all workers.
 Legal issues
 Isolate the machine/equipment and to be

connected to primary earth and double insulated
 Affix sign board and cordoned off the area to
avoid unauthorized entry
 All construction activities must be prohibited in
the panel erection area to avoid conflicting
activities
 Complete PPE(Goggles, Safety shoes, safety
helmets ,coverall ,HV resistance hand gloves )
 ERP communicated with concerned work force
 Qualified first aider to be there in the site

 Accidental  Obtain valid Work permit from higher authority
Entry into existing Installers, technicians
contact with 5*4=20 H prior to start work near the live area L
Buildings/Premises and labourers
energized part  Authorized Entry
Doc
Rev A
Date 22/12/19
RISK ASSESSMENT
 Personal injury  Valid gate pass
 Competent person to be used
 Conduct Tool box meeting prior to work starts
 Use all mandatory PPE.
 Ensure Proper communication systems
 ERP should be in place and communicated with
all work force.
 Good supervision
 Maintain good house keeping
 No trip hazard in the area
 Good cable management
 Major/minor Installers, technicians  Enough lighting
Trip, Slip and Falls 4*3=12 H L
body injuries and labourers  Remove the empty paint containers regularly
 Do not block the access
 Working on drums/temporary stands is
prohibited
 Other work shall not be allowed in the vicinity of
GIS/Penel installation area
 Major/minor Installers, technicians
 Strict supervision required
Nearby works injuries/propert 5*4=20 and labourers other H L
 Barricade area coming below and place necessary
y damage contractor workers
warning signs

 Strict supervision required at all time
 Major/minor Installers, technicians  Access shall be free from obstruction of materials
Inadequate access and
injuries/propert 3*4=12 and labourers other H and to be identified easily
egress
y damage contractor workers  Suitable and sufficient safe access by means of
ramps or stair ways.
 Ensure lighting level minimum 100‐150 at
 Major/minor Installers, technicians
Illumination and humid worksite.
injuries/propert 3*4=12 and labourers other H L
temperature  The entire access route to be well illuminated.
y damage contractor workers
 Temperature control shall be ensured, provide
Doc
Rev A
Date 22/12/19
RISK ASSESSMENT
adequate air conditioner.
 Protect the floor opening with adequate
protective cover
 People and Installers, technicians  Provide adequate illumination
Floor openings material falling 5*4=20 and labourers other H  Provide warning signage L
down contractor workers  Never keep the openings open
 Tool box talk shall be conducted every day before
starting work.
 Competent person shall inspect the A type ladder
before using it.
 Stand by peon will be always available for holding
the ladder.
 People should come down every time while
moving the mobile scaffold.
 Work platform shall be fully boarded with proper
 Major/minor
Installers, technicians toe boards and railings
Working at height injuries/propert 4*3=12 H L
and labourers.  Only trained competent person will erect, modify
y damage
or dismantle the scaffold.
 Materials shall not be thrown from height.
 PPE for fall protection system shall be used
 No excess material shall be kept on the platform.
 Working on drums/temporary stands is
prohibited.
 Red tagged scaffolds shall not be used.
 Promote human behaviour campaign.
 Communicate personal loss due to behavioural
 Absent minded Installers, technicians aspects
Human behaviour 2*3=6 M L
/inattention and labourers.  Communicate the hazards and risks involved in
unsafe act
 Provide adequate supervision
Doc
Rev A
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RISK ASSESSMENT
 Counselling the person to understand the
circumstances for remedy.
Chemical Handling
 Acute &  Follow instructions as per MSDS.
Chronic Skin  Avoid direct contact with Electrolyte.
disorders, Installers, technicians  Ensure Adequate Ventilation and Exhaust Fans.
Irritation and laborers, other  Mixing of Electrolyte as per vendor’s instruction.
3*4=12 H L
 Chemical contractor workers  Use of proper PPE‐Safety Googles, Hand Gloves,
Burns and site visitors. and safety Shoes and Apron.
 Burns of  Proper Tool Box Talk should be given to workers
Eyes. covering all safety precautions.

Battery Charging/Testing.  Battery charging/discharging/Testing should be
carried out only as per the instruction of
Manufacturer.
 Experienced person should be present while
carrying out activity.
 Severe injury  There should be adequate ventilation and
 Installers,
to person. Exhaust Fan and ensure that Hydrogen Gas
technicians and
 Utility/Asset should not get Trapped.
laborers, other
Damage  3*3=9 M  Condition of battery should be monitored before L
contractor
 Blast or testing using Hydrometer(Specific Gravity should
workers and
battery acid be analysed)
site visitors.
splash.  Proper Tool Box Talk should be given to workers
covering all safety precautions.
 Use proper PPE.
 Fire Extinguisher & other firefighting aid should
be present

Uneven /Unstable  Personal injury. Installers, technicians  Transformer to be mobilized to site only after pre
4*4=16 H L
Ground/  Equipment and labourers inspection visit from supplier and site clearance
Doc
Rev A
Date 22/12/19
RISK ASSESSMENT
Existing structure/ damage due to from consultant.
scaffold /inadequate fall.  Work to be started only after obtaining permit to
access  Structure or work.
scaffold  Ensure access road and ground is firm and stable.
damage.  Ensure adequate soil compaction, soil density
shall be tested and certified by third party.
 Extend the outrigger fully
 Keep correct size wooden pad under outrigger.
 Provide warning sign boards
 Ensure availability of competent rigger.
 Safe distance to be maintained between scaffold
and crane
 Existing gate barrier has to be temporarily
removed or modified.
 All temporary materials obstructing equipment
and trailer movement shall be removed.
Defective/incorrect use of  All lifting accessories and tackles should be third
lifting tackles party certified.
Installers, technicians  Lifting tackles regularly inspected, colour coded
 Damage to
and labourers, other and well maintained.
assets 3*3=9 M L
contractor workers and  Lifting belts and tackles should be inspected prior
 Legal issues
site visitors. to the lift by rigger.

 Follow safe work procedures.
 Swinging area to be barricaded with signage.
I have read and understand how I am to carry out the activities listed in this RA.
I have been supplied with the personal protective equipment identified on this JSA and I have been given training in the safe use of this equipment.
I have read and understand the requirements set out in the material safety data sheets for the hazardous substances identified in this RA.
Doc
Rev A
Date 22/12/19
RISK ASSESSMENT
Date Position / Job title Name Signed Date Position / Job title Name Signed
Doc
Rev A
Date 22/12/19
RISK ASSESSMENT
Likelihood
How often could the hazard occur? Consider the task, frequency,
duration, method of work, employees involved.
Severity
How serious would the hazard’s effects be if
realised? Consider the type of hazard, biological, ergonomic, physical
and chemical.
Risk = Likelihood x Severity
E.g. Likelihood (4) X Severity (3) = 12 HIGH RISK
Doc
Rev A
Date 22/12/19

Ajv DPW 10 525 El MSS 2200 - 00 PDF

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0 UEP 26/01/2020 APPROVED FOR USE

BA UEP 22/12/19 Issued forFOR

DUQM INTEGRATED POWER & WATER PLANT ("DIPWP") PROJECT

CONSORTIUM FOR DIPWP PROJECT IN OMAN

OWNER'S ENGINEER CONTRACTOR'S CONSULTANT

L&T-SARGENT & LUNDY LIMITED

SUBCONTRACTOR LOGO & NAME

METHOD STATEMENT & RISK ASSESSMENT FOR INSTALLATION OF ELECTRICAL

Date Name AJV DOCUMENT NO. Size A4

AJV DPW 1000 525 EL MSS

METHOD STATEMENT FOR INSTALLATION OF ELECTRICAL EQUIPMENTS

CONSORTIUM FOR DIPWP PROJECT IN OMAN

Rev Description Date Prepared by Checked by Approved by

Description Page no.

4.0 Plant, Machinery &Tools 03

7.0 Safety Precautions and Measures 38

5.0 Man power

1 – Prepare for site condition.

3 ‐ Arranging of transportation requirements.

Transportation within onsite

6 ‐ Transportation of GIS equipment into GIS room (1).

8 ‐ Transportation of GIS equipment in GIS room (1).

The explanation gives on how to carry in main‐body equipment in GIS room.

10 ‐ Lifting the Packing Module.

INSTALLATION PROCEDURE FOR 132KV SCMS, FMS & TELEPROTECTION PANELS

6.1 Installation Procedure for DC UPS & Associated Panels

1. Receipt and Storage of material:

 Steps for the handling and unpacking:

3. Preparation and Filling of Electrolyte:

4. Installation of UPS Panel and DC DB:

 Barriers / signs shall be erected if necessary to ensure personnel approaching the

0.4 All commissioning results shall be prepared, obtained and maintained by

Delivery is effected in terms of prefabricated single switchgear panels. One

1.5 The standard accessories are included.

Transport by means of a crane

6.1 Adjustable bridge elements under "transport aids" in accessories.

Push panel to the panel

Align panels with the

9.4 Wet threads with screw locking compound "Loctite".

10 – Bus bar contact resistance

10.1 Comply with the manufacturer’s specifications regarding the contact

Screw fasten mounting cover

b. Remove cap from extraction valve of bus bar compartment. Connect

12.3 Disconnect gas refilling device. Screw‐fasten cap on filling valve.

15.4 Close open high‐voltage terminals on cable compartment with surge‐proof

15.12 Mount surge‐proof covers (dummy plugs) on the extension feeder.

6.4 Installation Procedure for all Type of Transformer’s

Transformer oil filling:

- Complete cabling work as per schematic drawing.

SAT Installation and Testing & Commissioning Procedure:

Description Of Work: ELECTRICAL EQUIPMENT INSTALLATION

Risk = Likelihood x Severity

E.g. Likelihood (4) X Severity (3) = 12 HIGH RISK

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