Date: 03-May-2023 MSD-DD-7600-CONS-PRO-0006

METHOD STATEMENT OF
GROUNDING INSTALLATION
Rev. A Page 1 of 8

METHOD STATEMENT OF GROUNDING INSTALLATION

MSDP PROJECT
AUTHORIZED
STATUS
NAME SIGNATURE DATE
REVIEWED/
APPROVED

REVIEWED/
APPROVED WITH
COMMENTS AS
MARKED

NOT APPROVED TO
BE RESUBMITTED

(Not Applicable to IFIR)

REASON FOR NOT APPROVED

OWNER : PT. FREEPORT INDONESIA

CONTRACTOR : BLACK & VEATCH INTERNATIONAL
SUBCONTRACTOR : PT. TIGA PILAR ENERGI
MANYAR SMELTER DESALINATION PLANT PROJECT
 METHOD STATEMENT OF GROUNDING
Black & Veatch Intl. INSTALLATION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0006 2 of 8

A Issued For Internal 03-May-2023 Agustinus Agus Salim Deddy R.

Review Sitohang Harahap Sembiring
Rev. Description Date Prepared Reviewed Approved
 METHOD STATEMENT OF GROUNDING
Black & Veatch Intl. INSTALLATION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0006 3 of 8

TABLE OF CONTENT

COVER

TABLE OF CONTENT

1.0 TITLE 3 OF 8

2.0 PURPOSE 3 OF 8

3.0 SCOPE 3 OF 8

4.0 REFERENCES 3 OF 8

5.0 PERSONNEL QUALIFICATION 3 OF 8

6.0 DESCRIPTION OF PROCEDURE 3 OF 8

7.0 INSPECTION AND TESTING 6 OF 8

8.0 MANPOWER 7 OF 8

9.0 TOOLS AND EQUIPMENT 7 OF 8

10.0 RISK AND SAFETY ANALYSIS 7 OF 8

11.0 ATTACHMENT 8 OF 8
 METHOD STATEMENT OF GROUNDING
Black & Veatch Intl. INSTALLATION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0006 4 of 8

1. TITLE

Grounding installation procedure for cable tray, equipment and lightning protection at Manyar Smelter
Desalination Plant Project

2. PURPOSE

2.1 To ensure against dangerous electric shock voltage exposure to any person who may come in
contact with electrical equipment , cable tray and devices.
2.2 To provide a current carrying path of sufficient capability to adequately accept the ground fault
currents that may be allowed to flow before the fault is cleared by the circuit over current protective
devices. This requirement must be met without danger or creating a fire or an explosive hazard.
2.3 To make the electrical system function properly when a grounding condition develops, i.e., the
protective devices will function because the ground path is properly designed.

3. SCOPE

The provisions of this procedure apply to electrical safety of installation of earthing grounding conductor
system wiring, connection and bonding of electrical installation and testing, to required facilities when
normal electrical supply or systems is interrupted.

4. REFERENCES

3.1 Black & Veatch Specification and Construction Drawing

3.2 Black & Veatch, TPE Inspection Test and Plan (For Electrical)
3.3 IEC 62035 Lightning Protection Standard
3.5 PT. Tiga Pilar Energi Engineering’s written Practice Procedure.

5. PERSONNEL QUALIFICATION

Personnel performing the execution of wiring and connection of grounding conductor and testing to the
requirements of this procedure shall be Electrician Class I/Class II and the result of testing shall be
evaluated by Electrical Engineer, Supervisor and QC Inspector.
 METHOD STATEMENT OF GROUNDING
Black & Veatch Intl. INSTALLATION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0006 5 of 8

6. DESCRIPTION OF PROCEDURE.

6.1 Technical Requirements.

1. For grounding system above ground for cable tray adopt 70sqmm bare copper.
Bare copper copper ground shall be installed along the entired of all single conductor power
cable trays. The ground conductor shall be installed on the outside of the cable tray rail and
attached to each straight section and fitting. Ground conductor also be secured to the cable
tray at intervals not exceeding 1.8 meters .Bolts heads on burndy type GC-CT shall be
installed to the inside of the cable tray side rail. Can see at drawing (MSD-DD-5400-ELE-
DWG-4953.

The multi conductor power,control and electronic/instruments cable tray shall be bonded to
the single conductor power cable tray or structural steel by means of AWG bare copper at
intervals not exceeding 30M.

All single conductor power cable trays that service electrical power distribution equipment
shall have their tray ground conductors connected to the associated equipment ground bus.

All single conductor power cable tray that terminated at pull boxes have their tray ground
conductor connected to the pull box ground conductor.

For installed bonding jumper horizontal tray dropout to vertical tray and bonding jumper
vertical tray drop out to horizontal tray can see at attachment drawing (MSD-DD-5400-ELE-
DRG-4953.

For bonding jumper elevation change using adjustable splice plates can see at attachment
(MSD-DD-5400-ELE-DRG-4953)

Bonding jumper for trays without continuous ground conductor shall be AWG bare copper

2. Grounding system above ground for equipment at MSD Plant Project consist of :
- B1 95 sqmm. PVC Green/Yellow Insulatetd Copper Cable
- B2 70 sqmm. PVC Green/Yellow Insulatetd Copper Cable
- B3 35 sqmm. PVC Green/Yellow Insulatetd Copper Cable
- B4 16 sqmm. PVC Green/Yellow Insulatetd Copper Cable
- B5 6 sqmm. PVC Green/Yellow Insulatetd Copper Cable

All ground stingers to equipment or structural steel shall be PVC Green/Yellow insulated
copper cable unless otherwise indicated on the drawings. PVC Green/Yellow insulated
copper cable from ground plate to electrical equipment by ground clamp one-hold surface
mounted. The insulated copper cable shall be routed though cable gland and steel plate of
 METHOD STATEMENT OF GROUNDING
Black & Veatch Intl. INSTALLATION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0006 6 of 8

floor opening (See attachment MSD-DD-3311-ELE-DWG-5312). For installation details, see

drawing MSD-DD-5400-ELE-STA-5951 thru 5955.

3. For lightning Protection all ground grid conductors shall be 70 sqmm bare soft drawn stranded
copper conductor unless otherwise indicated on the drawings.
All grounding grid conductor shall be buried a minimum of 500 mm below grade unless
installed under a concrete foundation. Ground conductors under foundation shall have 150
mmof earth cover between conductor and bottom of foundation. All ground stingers to
equipment or structural steel shall be PVC green/yellow insulated copper cable unless
otherwise indicated on the drawings. For installation details see drawing MSD-DD-5400-ELE-
STA-5951 thru 5955.
Lighting protection shall be carried out in accordance with IEC 62305.

6.1 Preparation

6.1.1 Verify grounding system is in compliance with construction drawing and specifications.
6.1.2 Survey to the location and coordination with civil work contractor to marking of the main
grounding copper conductor route for excavation.
6.1.3 Check and make sure the specification, size and length of the material before mobilize to
the location.
6.1.4 Provide the grounding copper conductor drum jack if necessary on the right position.

6.2 Work Sequence

6.2.1 For cable tray The ground conductor shall be installed on the outside of the cable tray rail
and attached to each straight section and fitting. Ground conductor also be secured to the
cable tray at intervals not exceeding 1.8 meters .Bolts heads on burndy type GC-CT shall
be installed to the inside of the cable tray side rail.
6.2.2 For Equipment use exothermic welding for connected grounding from main earthing loop
to ground rod connection and from rod connection to equipment use conductor PVC
insulated yellow/green according to requirement.
6.2.3 For Lightning grounding conductors shall be 70 sqmm bare soft drawn stranded copper
conductor, All grounding grid conductor shall be buried a minimum of 500 mm below grade
unless installed under a concrete foundation. Ground conductors under foundation shall
have 150 mmof earth cover between conductor and bottom of foundation. All ground
stingers to equipment or structural steel shall be PVC green/yellow insulated copper cable
as per requirement.
6.2.4 For crane rail grounding connection, ensure flate steel 120mmx150mmx4mm already
provided by civil erection, prepare cable 70 sqmm yellow/green insulated and lug for 70
sqmm according to requirement, connect cable grounding side flate steel and crane rail
with hexagon bolt M10-25 with nut and washer 304 SS
 METHOD STATEMENT OF GROUNDING
Black & Veatch Intl. INSTALLATION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0006 7 of 8

6.2.5 For embedded, connect grounding from ground plate to embedded 400 mm with using
cable grounding 70 sqmm yellow/green inside 3/4” UPVC SCH 40 conduit c/w strap

6.2.6 Use exothermic welding for connected grounding from main earthing loop to ground rod
connection

6.2.7 For safety first TPE recommends use safety glass and gloves when making thermal weld
connections.

6.2.8 For connection between horizontally buried copper conductors or and vertical electrodes
shall be used exothermic welded connections, before conduct connection clean surface
copper conductor by brush properly and welding by molding thermal weld

6.2.9 Thermal weld metal is a mixture of copper oxide and aluminium and thermal molds is a
semi-permanent graphite molds, it is used for making most thermal connections.
6.2.10 Use thermal Mold Part Number and Weld Metal Number as according to copper conductor
size or ground rod size.
6.2.11 During welding do it with the following steps:
- Dry the mold and cables
- Clean the cables
- Place cable ends in the mold
- Close the handles to lock the mold.
- Drop the metal disk into the cubicle
- Pour the weld metal into the crucible
- Sprinkle the starting powder over the weld metal and onto the lip of the mold
- Close the cover and ignite
- Open the mold after the metal solidifies in 10 seconds.
- Remove slag from mold before next connection

6.2.12 Each weld mold is precision engineered to give precise and reliable results. Only the finest
materials are utilized so that these molds can withstand continuous heat-cooling cycles. All
molds are categorized into eleven different price codes according to their connection type.
These molds have a minimum service cycle of approximately 50 connections. However it
is not uncommon to achieve 80 – 100 connections when proper care is taken during
usage.
6.2.13 After get-away of inspection and testing, grounding conductor trenches with the original
soil and compacted.
 METHOD STATEMENT OF GROUNDING
Black & Veatch Intl. INSTALLATION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0006 8 of 8

7. INSPECTION AND TESTING

7.1 Verify ground system is in compliance with drawings and specification.

7.2 Perform fall-of-potential test on vertical electrode or system
7.3 Perform point-to-point test to determine the resistance between main grounding conductor
system and all major electrical equipment frames, system neutral, and/or derived neutral points.
7.4 Test values of resistance between the main grounding vertical electrode is made up of:
(1) Resistance of the (metal) electrode
(2) Contact resistance between the electrode and the soil
(3) Resistance of the soil, from the electrode surface outwards, in the geometry set up
for the flow of current outward from the electrode to infinite earth.

8. MANPOWER

8.1 Electrical Supervisor = 1 Person

8.2 QC Inspector = 1 Person
8.3 Electrician = 4 Person
8.4 Unskill = 5 Person

9. TOOLS AND EQUIPMENT

9.1 Tools

9.1.2 Tool box 3 layers = 2 Pcs

9.1.3 Safety glasses = 11 Pcs
9.1.4 Hand gloves = 11 Prs
9.1.5 Hoe = 5 Pcs
9.1.6 Cable cutter manual 120 mm2 = 1 Pc
9.1.7 Hack saw 12” = 2 Pcs
9.1.8 CADWELD mould and handle = 1 Lot
9.1.9 Flint ignitors = 2 Pcs
9.1.10 Wire brush 10” = 10 Pcs
9.1.11 Combination plier 8” = 4 Pcs
9.1.12 Measuring tape 50 meter = 1 Pc
9.1.13 Screw driver set (+/- ) = 2 Sets
9.1.14 Half round file 15” = 3 Pcs
9.1.15 Cable roller for pulling cable = 30 Pcs
9.1.16 Digital Earth Tester = 1 Set
9.1.17 Fire extinguisher = 1 Set
 METHOD STATEMENT OF GROUNDING
Black & Veatch Intl. INSTALLATION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0006 9 of 8

10. RISK AND SAFETY ANALYSIS

10.1 Thermal Weld Metal is a mixture of copper oxide and aluminium, package by size in plastic tubes.
Each tube contains the starting material at bottom of the plastic tube, with the Weld Metal on top.
These materials are not explosive and not subject to spontaneous ignition. These containers are
packaged in boxes along with metal disk. Each weld uses one disk. For safety first when making
Thermal connections the workers should consider with all tasks to provide fire extinguisher, and
to wear safety glasses and hand gloves.
10.2 Quick action, resourcefulness and skill are the main factors for successfully rendering first aid to a
victim of burnt skin. First immediately sprinkled his skin with water and send to the clinic and
handled by a medician.
10.3 For safety first when cutting, drilling, drilling and welding connections the workers should consider
with all task to provide fire extinguisher, and to wear safety glasses and hand gloves.
10.4 Use the isolated tools when connection and testing of cable to prevent electric shock incident.
10.5 Follow to MDS (Material Data Sheet) before using the paint materials.
10.6 Use the full body harness with absorber when working at high and put hook to line wire/
scaffolding
10.7 Unnecessary materials shall be removed from the work area to prevent impact to another (Human
& Material)
10.8 Inspection of all tools/equipment and its calibration certificate prior to used
10.9 Provision of appropriate barricade and signage
10.10Floor/Cable trench opening should be identified and provided with physical barriers and signage,
cover it properly as necessary
10.11Ensure proper illumination in the work area
10.12Pre-work inspection, identify potential pinch/crush points and discuss with workers during toolbox
meeting.
10.13Ensure tools and equipment used only for its intended purpose and according to proper handling
technique or manufacturer recommendation
10.14Do not work on electrical tools or equipment when clothing is wet or any part of body is in contact
with water.
10.15Disconnect equipment when not in use, but do not pull cable to disconnect; pull the plug.
10.16Provide additional fire extinguisher at hot work area and fire watch.

11.0 ATTACHMENT