Method Statement for Installation of Central Battery System

Contents:
1.Scope of Works.......................................................................................................................................................... 4
2. References................................................................................................................................................................ 4
3. Definition & Abbreviations....................................................................................................................................... 5
4.Personnel................................................................................................................................................................... 5
5. Resources Mobilization Plan..................................................................................................................................... 7
6.Equipment and Tools................................................................................................................................................. 7
7.Site Procedure........................................................................................................................................................... 8
8.Method Statement.................................................................................................................................................... 8
8.1 Materials......................................................................................................................................................... 8
8.2 Handling and storage ..................................................................................................................................... 8
8.3 Installation of Central Battery System ........................................................................................................... 9
9. Quality Assurance / Quality Control....................................................................................................................... 13
10. Health and Safety / Risk Controls..………………………………………………………………. ................................................. 13
10.1 Personal Protective Equipment (PPE) Requirements……………………………………. ............................................... 13
10.2 Additional PPE / RPE Requirements……………………………………………………… ....................................................... 14
10.3 Personnel Training Certification……………………………………………………………. ....................................................... 14
10.4 Site Security………………………………………………………………………………….. ............................................................... 14
10.5 First Aid Facilities……………………………………………………………………………. ............................................................. 14
10.6 Start Talks (Daily Briefing)…………………………………………………………………. ........................................................... 14
11. Environmental Measures……………………………………………………………………………... ................................................... 15
Appendix A: Risk Assessment..................................................................................................................................... 16
Appendix B: Environmental Risk Assessment……………………………………………………………………………………………………….. 40
1) SCOPE OF THE WORK:
The purpose of this method statement is to describe the procedure for Material Delivery Inspection,
Installation, Inspection and Testing of the Central Battery system for the Doha Metro Gold Line. The Intent
of this report is also to explain, the methods to be adopted to ensure works conducted on site are in
compliance with approved design & material approvals, recognised installation practices / manufacturers
recommendation that are safe and compliant with the project safety plan and safety procedures.
The Scope of Works includes the site inward inspection, material delivery inspection, installation to be
adopted to ensure that the Central Battery system are supplied, installed, tested and inspected for the
works is in accordance with the project requirements.
More specifically these locations are the following:
• Ras Bu Abboud
• Qatar National Museum Station
• Souq Waqif Station
• Bin Mahmoud Station
• AI Saad Station
• Joaan
• AI Sudan Station
• AI Waab Station
• Sport City Station
• Al Aziziyah Station
• Emergency exit Sharq
• ACN Stabling yard
• Switchboxes
• Centralised Cooling Plant
2) REFERENCES:
• QCS 2014 – Section 21, Part 12, Electrical Works, Emergency Lighting
• Project specifications M006-GDB-MEP-SPE-00006 – Material and workmanship specification for electrical
works
• Material Submittal : M006-GDB-ELE-MAR-00086
• ITP: M006-GDB-MEP-ITP-00060

• Project Safety Plan M006-GDB-HSE-PLN-00001

• Project Environmental Plan M006-GDB-ENV-PLN-00001
• Project Quality Plan M006-GDB-QMS-PLN-00002
• Design / Installation /Combined Service Drawings
• ER Volume ‐6, Clause 13.3.3.3, e
3) DEFINITION & ABBREVIATIONS
PQP : Project Quality Plan
MS : Method Statement
ITP : Inspection and Test Plan
IRP : Incoming Material / Equipment inspection
IRE : Inspection Request
HSSE : Health Safety and Environmental
PPE : Personal Protective Equipment
MSDS : Materials Safety Data Sheet
QGEWC : Qatar General Electricity and Water Corporation
4) PERSONNEL
• Construction Manager
Organize the site so that work is carried out to the required specifications with a minimum risk to
employees, equipment and materials. Adhere to the Project Specific Quality Management and HSSE
Requirements.
• QA/QC Manager
Responsible to ensure quality control and assurance of the works within the project scope. QA/QC
Manager manages the QA/QC engineers to full fill all the requirements of the project.
• QA/QC Engineer(Inspector)
Identify the Projects Specific Quality Requirements, Develop the Project Specific Quality, Inspection and
Test Plan (ITP), Operational and Control procedures, Mechanism and Forms and ensure effective
implementation of Method Statement & ITP. Responsible for the work of entire Quality Assurance, Quality
control and inspection programs on site. Produces all quality related documents and necessary quality
reports as requested by ALYSJ JV and the client in relation to this work. To coordinate in formalizing the
Method Statement with the Site Engineers to describe the job specific quality control work for each stage / activity.

• HSSE Manager
Responsible for entire HSE matters and preparing Risk Assessment (RA) in line with method statements for
particular activity. Liaison with Engineer and Engineer’s Assistant for HSE issues. Monitoring the HSE
requirements as per Project Specifications and Engineer/Engineer’s Assistant requirements.
• Safety Engineer(Officer)
Ensure that all workers have a safe working place, advice safe system of work and provide adequate
instructions, training and supervision to enable employees to work in safety. Carry out site survey on daily
basis to ensure that the HSE methods of working are in operation & that all regulations are being
observed. Report, determine & analyse the cause of any accident or dangerous occurrence and
recommend measures for preventing recurrence.
• Environmental Manager
Responsible for entire environmental matters and preparing Environmental Risk Assessment (ERA) in line
with method statements for particular activity. Liaison with Engineer and Engineer’s Assistant for
environmental issues. Monitoring the environmental requirements as per Project Specifications and
Engineer/Engineer’s Assistant requirements.
• Environmental Engineer
Monitoring works implementation as per project’s environmental requirements. Advice for
environmentally sound operations and provide adequate instructions, training and supervision to enable
employees to work avoiding environmental impacts. Carry out site survey on daily basis to ensure that the
environmental mitigations measures of working are in operation & that all regulations are being observed.
Report, determine & analyse the cause of any environmental incidence and recommend measures for
preventing recurrence.
• Surveyor
Chief surveyor will be in-charge of the survey department and responsible for entire survey works. He will
lead the survey team and will coordinate with all the concerned parties and ensure survey works is in time
and with proper quality. The surveyor will be responsible for all survey work and will report to chief
surveyor.
• Site Engineer
Adheres to the Project specific method statements, procedures, quality requirements and inspection
programs and HSE instructions to get the activities performed to Client’s satisfaction with full coordination

with the HSE and Quality personnel.

• Foreman/ Work Supervisor
Responsible for daily activities and resources (labour, machinery, material etc.) are effectively utilized and
monitored in order to achieve HSE and Quality requirements.
• Workforce(Labour):
Carry out their work under direct supervision by their Foreman and Charge Hand and under instruction
from the Site Engineer to ensure all works are undertaken in a safe manner. The workforce to attend a
daily Tool Box Talks and morning task briefs prior to starting any new works, EHS (Environmental Health
Standard) plans and Policies. The workforce shall receive a full Project briefing and site rules induction
prior to commencing any work on site.
5) RESOURCES MOBILIZATION PLAN:
Prior site mobilization careful planning and preparation as per works programme will be implemented.
These include appropriation of sufficient number of staffs and labour’s, equipment, materials, site offices
and facilities/services. Actual mobilization to site is dependent on accessibility to site and availability of
space allocations. Contractor will have to advise ALYSJ the schedule and requirements for site
mobilization. Meanwhile, ALYSJ after a thorough study and careful planning must confirm immediately
with contractor the schedule requirements in order to mobilize within sufficient period of time.
Appropriate and sufficient temporary services such as power, lighting, waters, communications,
ventilations, lifting cranes, trolleys, working areas, scaffolding shall be provide by ALYSJ.
6) EQUIPMENT AND TOOLS:
The following equipment and tools are required to perform works:

7) SITE PROCEDURE
It is of crucial importance that the works are conducted in accordance with DVE certified design/ Shop
drawings. The below quality control and quality assurance scheme shall be followed for this purpose.
When work is ready to be inspected the Site Supervisor and QC inspector inspect the works as per this
method statement and Test Pan (ITP). If any deviation, corrections will be requested to rectify. It is
checked and submitted to ALYSJ JV by Subcontractor Site Team.
8) METHOD STATEMENT
8.1 Materials
All material delivered to the site must be according to the make and relevant model numbers approved by
consultant and client. All materials when delivered will be first inspected by the store in charge/site in
charge, to check that it is in accordance with the site requirement, the approved design and material
qualification and also that it is free from any damage caused during transportation to site. Delivery
documentation shall be checked for completeness. Defective or damaged materials shall either be
returned to their supplier’s facility or stored on site at a suitable quarantine location. The inward
inspection of materials will be carried in accordance with relevant QA/QC procedure and as mentioned in
ITP. Materials should be kept in a location and condition according to the MSDS recommendations before
and after the material inspections. No materials will be permitted to enter the works locations without
being inspected on arrival to the site.
8.2 Handling and Storage of materials
On receipt of the central Battery system at site, necessary precautions shall be taken for unloading, shifting
and storage. The received materials shall be inspected and ensured that materials are as per approved
material submittal and shop drawings. After inspection, the central battery cabinets shall be re-packed. All
packages shall be stored under protected dust free and packed for protection against damages during
handling, transport, storing and installation. Inspect materials on site in enclosures or under protective
coverings. Store under cover out of direct sunlight and dust. Do not store materials directly on the ground, handle
units and other accessories in such manner as to ensure delivery to site and during installation in
undamaged condition
Batteries shall not be left on site for prolonged periods without being trickle charged to maintain their
condition i.e. if delivery is some weeks before commissioning of the charger
Due care shall be observed when handling acidic substances
• Care shall be taken to store the central battery cabinets as per the manufacturer recommendations.

8.3 Installation of central Battery system

General work methodology

• Installation of the central battery system shall be carried out as per manufacturer’s recommendation.
• Prior to start of installation ensure that all the required materials are available at site as per approved
material submittals.
• The area of installation shall be checked and ensured for civil clearance, painting where required,
completeness of the required foundations, cleanliness and surface levels.
• Inverters, Chargers, Inverter and Charger cabinet, batteries and battery cabinets in the storage or
installation site must be kept upright all the times and handle with care; damage may be caused if dropped
or subjected to severe impact. When moving the equipment with a fork lift or hydraulic pallet
• Avoid the excessive hammering and jarring which would damage the electrical equipment therein.
• Mark the fixing position of the central battery system as per the DVE certified approved shop drawings.
• Work space clearances and clearance for equipment access doors shall be maintained as per
manufacturer recommendations. If required wall distances shall be at least equal to the bending radius
of the cables in use.
• Once the necessary markings are completed at the area of installation, shift the identified central battery
unit to the location of installation, with a forklift or hydraulic pallet. The packing of the unit shall be
removed at the place of installation
• Arrangement shall be made to permit incoming and outgoing cables, control wires to enter the cabinets
as indicated on the approved single line diagram and manufacturers drawings. All cables and control wires
shall be connected at respective terminals without inconvenience to installation or maintenance.
• All elements and surfaces shall be examined to receive Central Battery system for compliance with the
installation tolerances and other conditions affecting performance. Installation will be proceeded only
after unsatisfactory conditions have been corrected.
• Individual who install, operate or maintain central Battery system shall be trained and competent
Persons.

• All cabinets and panels shall be lifted using fork lift and a trained rigger shall be present for the purpose
to lift the load and it shall be release on strip timber.
• Hydraulic pallet ( Trolley ) of suitable capacity or pipe rollers shall be used for central battery inverter
cabinets panels slowly and steady the load to prevent falling or unintentional rolling and tripping. Access
fencing, Doors and structures shall be removed or replaced to provide pathway for moving all the cabinet
in place.
Central battery Inverters and cabinets
• Central Battery inverters system shall be installed according to the manufacturers printed instructions, and
manufacturer will be arranged to inspect and certify the installation.
• The rating of the central battery system shall be as per approved DVE certified shop drawing and single line
diagram.
• The layout and Central battery and inverter components shall be coordinated with other construction &
Electrical works, including conduits, piping, equipment, adjacent surfaces, raceways, electrical boxes and
fittings and cabling/wiring works.
• All incoming, outgoing cable supports, Cable ends and termination fittings required for power and control
cables as per the associated approved method of statement.
• Central battery inverter system shall be labelled with engraved metal or laminated-plastic name plate
according to the project specification.
• Ambient temperature of the installation shall be in the range pof 15 – 25°C. Air-conditioning is required,
where ambient exceeds 25°C
• Sufficient cooling shall be provided for the installation room so that ambient temperature is maintained
within the stated limit as per the manufacturer requirements.
• Battery room shall be provided with sufficient ventilation, as per manufacturer recommendation, to remove
the gases being released during charging of the batteries.
• Equipment grounding connections for all equipment with ground continuity to main ground bus shall be
done. Electrical connectors and terminals shall be tighten including screws and bolts according to
manufacturer torque tightening values and check prior energization. All connections are to be bolted and
strengthened against the fault stresses.

Modular AC/AC central power supply system

10 Ampere chargers
 Control panel
Battery Cabinet
• Insulated tools shall be used (insulated battery spanner, Allen key, Screw driver etc.).
• Batteries are always live. Remove all metal objects such as rings, chains, watches etc. before working on the
batteries. All tools used to connect the batteries should be of the insulated type. Care must be taken to
ensure battery terminals are not short-circuited.
• Batteries shall not be left on site for prolonged periods without being trickle charged to maintain
their condition i.e. if delivery is some weeks before commissioning of the charger.
• Assemble batteries on the lowest shelf first. Position batteries on each shelf as detailed on the battery layout
drawings. Battery are heavy, and care is required to observe correct lifting techniques to prevent injury.
• Care should be taken when fitting shelves above batteries not to allow the shelf to short-circuit batteries
on lower shelves. Do not trap cables, links or temperature probe beneath battery. Each battery cell should
be numbered with adhesive numbers supplied with the unit. These should be attached to each battery cell
to match the number on the battery layout.
• Connect the batteries as shown on the battery layout drawings. Do not shorten battery leads. All battery
leads on multiple banks systems must be of equal length. Start at the rear of the bottom shelf of each
battery cabinet and connect the back row of battery cells. Proceed towards the front of the shelf, connecting
each row in turn. When the shelf is complete, continue to the next shelf until all batteries are connected.

Pre-bend all cables before installing to eliminate excessive stress on battery terminals when hardware is
tightened.
• Ensure that all inter-shelf links are fitted. These pass between the edge of the shelf and the side panels as
required. Tighten terminals as per correct torque requirements. Do not over tighten the cell terminal bolts,
as this may damage the cell.
• When all connections are complete, coat each exposed terminal with petroleum jelly to protect against
corrosion and terminal shrouds should be fitted. Connect the battery leads to the battery MCB, then to
correct battery terminal (Negative lead marked with Black band, Positive lead Red band).
• Connect temperature compensation probe to one of the battery cabinets. The probe connects to the TEMP
terminals using the 2-core cable supplied.
• Connect the Incoming mains supply to the terminals marked Ll and Ni. The earth connects to the earth stud
adjacent to the mains terminals. Connect the load circuit to the terminals marked AC L (Live) and AC N
(Neutral).
• Due care shall be observed when handling acidic substances
• Batteries shall not be left on site for prolonged periods without being trickle charged to maintain their
condition i.e. if delivery is some weeks before commissioning of the charger Wiring installation.
• Where the emergency lighting system installation is via a central battery unit, the wiring to emergency
luminaries shall be using fire resistant Low Smoke and Fume, Zero Halogen (LSFOH) type cables unless
specified otherwise.
• Where the emergency lighting scheme is self-contained emergency packs, the wiring system shall either be
in MICC Cables as above or in Fire resistant cables insulated in conduits or surface installation using fire
rated clips.
• Conduit shall be HDPE embedded in concrete and all exposed shall be HDG.
• Generally, cables shall be 2.5 mm2 cross-sectional area unless specified otherwise.
• Routing and schedule shall follow as per DVE certified shop drawings and design reports.
• Luminaries connected and within the limits specified in the MEP Basis of Design Report Electrical Services
(Doc. No. M006-GDB-ELE-RPT-00001) section 1.5.1.

Battery Cabinet Zoom View

External System components (for monitoring and control interfaces)

• All the external system components like MXC substation, MXKP station adapter kit, LTC addressable
interface, DIM LTC addressable interface and BACNET interface Etc. should be installed and connected as
per manufacturer recommendations and the DVE certified shop drawings and design reports.

MXC substation MXKP station adapter kit

LTC addressable interface DIM LTC addressable interface BACNET interface Etc.

Notes:
• BACS interface shall be provided for Central Battery Inverter System
• Equipment installation shall be carried out under the direct supervision of a qualified technician

Testing:
• A visual, mechanical inspection and electrical test shall be performed as per related ITP for Central Battery
System.
• The incoming and outgoing cables insulation resistance of between phase, neutral and earth shall be
checked by a 1000V Insulation Tester and the results shall be recorded and checked by QC Engineer and
recorded on the appropriate form.
• The test results shall be checked and signed off by the Site Electrical QC and Site Electrical Engineer.
• To witness the inspection/result as per the related ITP
• The name plate details of the central battery unit shall be checked and confirmed to be in accordance to the
material submittal and the unit to be installed shall be identified with respect to the location in the drawings.
• Check the label / marking to ensure the right system before installation
• Fix the central battery system with proper metal plugs and bolts. Ensure the installation is straight and
levelled.
• Suitable knock-out at the top / bottom of the unit, as applicable shall be used for incoming / outgoing cable
entry.
• File the knock-out to suit the cable glands and lugs for rigid terminations.
• Suitable earthing / bonding shall be provided as per specifications
• Ensure the incoming terminals and the interconnecting terminals are free from dust and damage.
• Check the breaker as per the approved drawings.
• Megger the cables prior to termination
• Terminate all the circuits to its respective breakers with proper ferrule identification
• Double check the connections by tightening the terminations.
• Clean the central battery cabinets after dressing, with blower to blow out all the small particles and dust after
termination works.
• Provide identification labels as per specifications
• Place the approved schematic diagram copy inside the central battery cabinet door
9) QUALITY ASSURANCE/ QUALITY CONTROL
All works will be executed as per the above detailed methodology and sequencing and will be inspected
and tested in accordance with the requirements described in the ITP: M006-GDB-MEP-ITP-00060.
10) HEALTH AND SAFETY/ RISK CONTROLS

The works will be performed in compliance with the Gold Line Metro Project Risk Register & Management
program M006-GDB-HMS-REG-00001.All risks are evaluated prior to any works commencing, utilizing the
matrices to determine the level of significance in terms of likelihood of occurrence and severity of hazard based
on the allocated numerical values. Refer to Appendix A for full and detail Risk Assessments.
All necessary permits for welding, hot works, working in confine space should be obtained and placed prior to
start of installation/activities.
10.1 Personal Protective Equipment (PPE) Requirements
All personnel involved in any of the JV’s operations are to wear the following PPE:
• High Visibility Jacket/Vest
• Safety Helmet
• Safety Footwear
• Eye Protection
• Coveralls
• Safety Gloves (Task Dependent)
• Ear Protection (Where Necessary)
10.2 Additional PPE / RPE Requirements
• Dust Mask (Where necessary)
10.3 Personnel Training Certification
All certificates of competency and training are maintained by the HSE department. Equipment operator’s
qualification certificates should be available on the site for verification by the authorized personnel. Equipment
maintenance certificates and daily checklist will be available with the equipment operators. For specific
personnel training refers to company procedure ref; P2 Training Procedure which is in line with the
requirements of QCS 2010 section 11 2:3:6.
10.4 Site Security
The stations will have 24 hour security with the security guard being placed at the entrance gate at each
station. It will be the guard’s responsibility to ensure that any unauthorized persons do not enter the site and
that any authorized persons. It is the guard’s responsibility to ensure that all persons or vehicles entering the
site are logged within the register. The security guard will have his own office which will be housed directly
inside the boundary fence at the entrance gate.

10.5 First Aid Facilities

A trained first aider will be available at each station location and will be made known to all associated with the
project through the site induction. A first aid kit and eye wash station will be available on site and will be placed
within the welfare facility and will be clearly marked. The first aid kit will have the capacity for up to 50 persons.
Should an accident or incident need medical treatment then a site vehicle will be available to take the IP directly
to hospital.
10.6 STARRT Talks (Daily Briefing)
The STARRT briefing will be held every morning before work commences and will be given by the foreman or
supervisor and will be delivered to all site operatives associated with the task that day. The STARRT card will be
specific to the task to be undertaken that day and will be signed off by all operatives who attended the briefing.
All STARRT briefing cards will be kept within the HSE office and will be available for inspection upon request.
11) ENVIROMENTAL MEASURES
General MEP Environmental measures in Appendix B will be followed and below measures and relevant
Environmental management Plans are to be strictly adhered to.
11.1 Waste Management
• Burning or uncontrollable disposal of any type of waste is strictly forbidden.
• Segregate, collect and store all waste to designated waste storage areas or / and containers,
according to the Waste Management Plan. Types of waste from works:
o Empty containers of Sealants and Paints -- to be disposed in the hazardous waste skip
o Rubber / Mastic and other "plastic" materials -- to be disposed in the plastics skip
o Wrapping film -- to be disposed in the plastics skip
o Cartons -- to be disposed in the paper / carton skip
o Remains metal from panel knock-out / cable -- to be disposed in the metals skip
11.2 Wastewater Management
• Machinery washing / cleaning must take place only at designated areas or facilities.
• Wastewater must be collected in holding tanks and collected by a waste management
11.3 Noise Pollution
• Site equipment will abide by all (CE) standards.
• Regular maintenance will take place on all machinery/motors to ensure operation within normal
noise parameters.

11.4 Dust Control

• The central battery unit shall be protected from dust, dirt, and moisture before delivery until after
installation at the site.
• Works will be avoided in very dusty / windy days.
11.5 Storage and handling of battery:
• Batteries shall not be left on site for prolonged periods without being trickle charged to maintain
their condition.
• Personnel handling battery banks shall not have any metallic objects in their person.