SCIENTECH CREATES VALUES FOR CLIENTS…

SCIENTECH CREATES VALUES FOR CLIENTS…

Engineering and services

Method Statements
 TABLE OF CONTENT

1 EXECUTIVE SUMMARY……………………………………………………………...…
2 PLANNING /PRE-EXECUTION OF WORK………………………………………….….
3 PROJECT MANAGEMENT…………………………………………………………..…..
4 MATERIALS MANAGEMENT/LOGISTICS……………………………………...…….
5 GENERAL EXECUTION………………………………………………………………....
6 EXAMINING THE WORK SCOPE………………………………………………..……..
7 DAILY PRE-WORK MEETING…………………………………………………..……...
8 CONSTRUCTION SITE ORGANIZATION CHART………………………………….…
9 FUNCTION OF KEYS OFFICER………………………………………………...……….
10 SITE HSE OFFICER/FIRST AIDER………………………………………………………
11 PROCUREMENT/LOGISTICS………………………………………………………..….
12 FIELD SURVEYS…………………………………………………………………………
13 INSTALLATION /TEST OF TRANSFORMER…………………………………..……….
14 INSTALLATION /TEST OF HV/LV PANELS…………………………………………….
15 INSTALLATION OF GANTRY TOWER………………………………………………….
16 INSTALLATION OF SWITCHYARD EQUIPMENT STRUCTURE…………………..…
17 INSTALLATION /TEST OF SWITCHYARD EQUIPMENT (AIS)………………………
18 INSTALLATION /TEST OF SWITCHYARD EQUIPMENT (GIS)………………………
19 TESTS AFTER ERECTION ON SITE……………………………………………………..
20 SUBSTATION EARTHING……………………………………………………..…………
21 TESTING/COMMISSIONING……………………………………………………..……..
22 DOCUMENTATION…………………………………………………………….…………
23 ENVIRONMENT………………………………………………………………………….

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 SCIENTECH ENGINEERING & SERVICES (SES)

WORK METHOD STATEMENT

EXECUTIVE SUMMARY

The client, SES required the services of Customer/Host for corporate Substation upgrade services for
its operations.

SES is required to oversee the following phases of the compact

- Engineering
- Procurement / Fabrication
- Installation – Electrical (substation)
- Cable Laying & Termination
- Testing/ Commissioning

SES will work closely with Customer/Host in the Project planning, executive monitoring team and
operation team throughout the active phase of the project enumerated above.

The SES/host community would also be carried board on all the execution phases. The essence of this
interfacing relationship is to allow for smooth and timely and safe delivering of the project since the
execution would likely be within Customer/Host operation areas.

PLANNING / PRE-EXECUTION OF WORK

SES Project management team would ascertain following prior to Sub-station Execution works.

 Develop and maintain a workable project schedule.

 Perform installation analysis.
 Plan and execute the pre-lay survey
 Procure /fabricate /transport materials
 Arrangement for equipment remobilization
 Preview all HSE documentations.
 Provide site office
 Execute /mobilized required skilled, semi-skilled manpower
 Train relevant indigenous manpower
 Interface with Customer /host community leaders
 Communicate with Customer representatives
 Arrange for relevant permits
 Ensure regulatory compliance
 Ensure compliance with Existing and new safety regulatory (LSR)
 Implement project control/ procedures.
 Arrange for invoice
 Develop site security
 Accomplish all necessary HSE planning

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PROJECT MANAGEMENT.

The Project Management Team will cover all aspect of Project organization, planning, administration,
supervision of subcontractors, finance and general coordination of the entire Project. This activity spans
through the entire Project.

MATERIALS MANAGEMENT / LOGISTICS

SES is to provide logistics for transportation of all Materials relevant to the Project to site. Only pre-
mobbed equipment would be used in all our operations. Whenever necessary, Customer/Host would be
required to provide permission for the cranes, and operator to load out permanent materials in site.

SES would however manage, supervise and direct the handling of items to be loaded out.

GENERAL EXECUTION

As the overall site activities, responsibilities and authorities of SES/Sub-contractor’s activities

and interface management between SES/Customer or Host would be managed by our Site Manager
who is also our site representative who overseas our day-day activities on site documentation report
on the site progress to SES and client. SES would only mobilize professionally registered manpower
resources to this project as to guarantee quality device.

EXAMINING THE WORK SCOPE

We are always agreed to do only what we can or confident on. After getting the proposal, we first
look on the scope of assign work and then we do a meeting with our respective team for any
clarification. According to the work requirement we assign our manpower with relevant tools &
tackles to meet the expected work completion time as per customer’s consent.

DAILY PRE-WORK MEETING

We believe that a pre-discussed job can elevate the field work pressure and it can expedite the actual
completing time. And that is the reason we do pre-work meeting regularly to make everything clear to
everyone involved in that particular job.

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CONSTRUCTION SITE ORGANIZATION CHART

The proposed project would be staffed as on the chart shown below:

MANAGING DIRECTOR

ADMINISTRATION &
ACCOUNT

PROJECT MANAGER

TECHNICAL SUPPORT. SITE MANAGER

ENGINEER ENGINEER SITE HSE OFFICER/FAST

Erection & Testing, EIDER
Installation Commissioning &
Quality

LOGISTICS
/procurement of equip SUPERVISORS
/ material and (Electro-mechanical)
inventory management as per site req.

SUB
CONTRACTORS

ELECTRICIANS TECHNICIANS

LABOURS

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FUNCTION OF KEYS OFFICER

THE PROJECT MANAGER

Our project manager will manage the execution of the contract in a safe manner by discharging all
contractual responsibilities. He has the responsibilities, authority and accountability for the fulfillment
of Contractual obligations.

The Project Manager has overall management authority for all operations on site, and is also responsible
for ensuring that all project activities are completed in accordance with Project requirements, in this
plan. In the absence of the Manager, the Engineering Manager will assume his responsibilities. His
functions include:

 Implementing the company HSE management project plan

 Ensuring compliance with the HSE plan
 Requiring a prompt and thorough investigation of all accidents.
 Scheduling and leading an Accident Review Board with 2 days of an injury
 Developing and reviewing of HSE management guidelines
 Monitoring of actual HSE performance.

THE SITE MANAGER

He provides the technical interpretation required to get the job/task executed. He will direct and
supervises the development of installation specification, standards and procedures for the project.

 the coordination with the overall engineering/fabrication interface

 Performing regular and frequent site inspections to find hazards and observe employees at work
 Stopping work when necessary to prevent injury
 Develop and implement corrective action plans to mitigate hazards
 Conducting daily tool box meeting
 Collection of data for HSE monitoring program

SITE HSE OFFICER/FIRST AIDER

He is responsible for the safety of all personnel at the work site. He is also responsible for HAZOP and
SAFOP reviews as well as conducting HAZID

 Manages HSE issues at site in accordance with the procedures set forth in the HSE policy/plan,
 Ensure all HSE risks are reduced to as low as practicable.
 Also liaise with Clients liaison officer to deal with community issues
 He is the custodian of SES HSE site documentations.
 He ensures site HEMP management and also development our site HSE statistics & reports to
our client representative.
 He administers the site safety activities with the site HSE Officer.

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PROCUREMENT/LOGISTICS

 Oversees the procurement of local and foreign equipment and materials

 The transportation of equipment, personnel and materials to work site

FIELD SURVEYS

Soil Resistivity Surveys, carried out to determine site specific earthing requirements.
Design of site-specific earthing systems based on known local soil resistivity or the results of a Survey.
Installation of earthing systems for (but not limited to):

 Standby Generators
 Static (complete with disconnect assemblies for tanker loading/unloading)
 LV and HV supply systems
 Technical Earthing for equipment sensitive to fault currents
 Transformers
 Feeder Pillars
 Telecommunications Systems
 Wind Farms
 Deep drilled boreholes, (for poor soil resistivity or limited available space), up to 100m deep
and back-filled with conductive slurry or conductive cement.

ELECTRICAL WORK
INSTALLATION /TEST OF TRANSFORMER

TOOLS AND EQUIPMENT FOR TRANSFORMER INSTALLATION

We shall ensure tools and equipment needed is in good condition and will be checked by
Supervisor / Safety Engineer prior to use in the construction area. These includes but not
limited to:

 Electrical Hand Tools

 Crane
 Spirit Level
 Torque Wrench
 Common Hand Tools
 Measuring tape
 Insulation Resistance Test Set
 Transformer Turn Ratio (TTR) Test Set
 Transformer Winding Resistance Test
 Current Transformer Test Set
 Digital multi-meter, Clamp on Ammeter
 3ph, AC power Supply

All tools utilized in a classified area will be intrinsically safe and suitable for
hazardous areas.

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STORAGE, HANDLING AND PRESERVATION OF POWER TRANSFORMER

1. Upon delivery of materials, Customer representative along with our erection engineer
will conduct inspection for Handling and Preservation to verify conformance to
supplier drawings. Any deviation shall be documented/ noted.
2. Verify impact recorder should have been attached to transformer during shipment.
Customer representative along with our erection engineer check the graph and observe
abnormalities during transportation.
3. If possible, the transformer will be stored in its correct position on the prepared
foundation at the installation site. If the permanent foundation is not ready, then the
transformer will be stored on a solid platform that is suitably prepared to provide proper
support for the transformer base.
4. Transformer will be covered with plastic sheets. All equipment parts will be kept in the
unopened original shipping case with all braces and plugs intact and will be covered
with plastic sheets.
5. Air intake openings will remain covered to reduce dust, waster or other unwanted entry
accumulation.
6. The bushings and external surface will be kept clean and the unconnected valves will
be closed.
7. Regular visual inspection will be conducted to check any dust accumulation, dampness,
oil level, and silica gel air dryer on the transformer.
8. Transformer will be lifted only through lifting points provided for attaching the slings
or lifting chains.
9. Total weight of the transformer will be checked prior for lifting to ensure that the
capacity of the crane to be used in lifting the transformer is suitable to the weight of the
transformer.
10. The tires of trailer truck and specification will be checked (whether low bed or high
bed) prior to loading the transformer.
11. The right position of the transformer at the trailer bed will be ensured and it will be
lightened with the steel chains prior to dispatch for installation.

POWER TRANSFORMER INSTALLATION

1. Before installation we will review all possible routes and check obstructions to avoid
delays in the activities. Necessary tools in mounting the equipment will be checked and
ready upon receiving of equipment.
2. Form works, grouting and finishing touch for concrete foundation will be checked.
3. We will use crane(s) of required load capacity for installation of radiator, conservator,
bushing, fans etc. on a proper place with customer/host approval.
4. We will assign Vacuum Machine to vacuum the Transformer after installation of
radiators and necessary pipes.
5. We will assign centrifuging machine in parallel to vacuum work for oil centrifuging in
a separate oil tank.
6. After finishing oil centrifuging in separate tank, we will start oil filling from oil tank to
Transformer and again centrifuging the oil to get the required test result.
7. All the required testing of Transformer before and after installation of Bushing and
whole set-up will be done.
8. Transformer and its components shall be tested as per customer’s recommendation.
Testing result shall be recorded/filed and submitted to Customer.
9. Connecting the LV/HV Power cable to the Bushing considering proper tension of
cables with approved heat sink tube or any further requirement(s).

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 10. Neural and earthing connection (body to base, base to ground & body to ground mesh)
11. Conduct preliminary inspection to the completed installed transformer to ensure that all
components have been installed completely and properly for final inspection.
12. Control/Power cable termination & pre-commissioning
13. Installed transformer will be properly grounded to the system grounding as per
standard.

*SES will follow the installation as per Installation Guide/Manual.

SAFETY PRECAUTION FOR TRANSFORMER INSTALLATION

1. We will secure the approved work permit from the concerned representative before
starting any work.
2. Fire Extinguisher will be at work area whenever there is hot work.
3. All electrical tools will be checked.
4. Hazardous area and its precautionary measure requirements will be properly discussed
to the working crew following all safety requirements.
5. Continuous monitoring and checking will be conducted by concerned
supervisor/foreman to detect and correct unsafe practices while performing the work
activities.
6. We will provide warning sign and sufficient barricade on working areas to avoid
unauthorized entry. Only assigned personnel will be allowed in the area.
7. Safety harness will be used when working at elevated temporary platforms (1.8 meters
and above).
8. Safety Supervisor will monitor the work activities to help and protect all assigned
workers against exposure to safety hazards. He will ensure that Personal Protective
Equipment’s (PPE’s) are being supplied and used properly.
9. Toolbox meeting will be conducted by Electrical Supervisor daily so that work
activities will be properly coordinated to all concerned and all safety measures will be
carried out on the entire work duration.
10. Housekeeping will be maintained and working area will be kept clean and tidy in
accordance with Site Housekeeping Procedure.
11. Job Hazard and Risk Assessment of this procedure will be disseminated and explained
to workers for safety awareness.

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INSTALLATION /TEST OF HV/LV PANELS

TOOLS AND EQUIPMENT FOR PANELS INSTALLATION

We shall ensure tools and equipment needed is in good condition and will be checked by
Supervisor / Safety Engineer prior to use in the construction area. These includes but not
limited to:

 Tool Box
 Electrical Hand Tools
 Crane
 Spirit Level
 Drilling Machine
 Common Hand Tools
 Measuring tape
 Insulation Resistance Test Set
 Digital multi-meter, Clamp on Ammeter
 1ph, AC power Supply

All tools utilized in a classified area will be intrinsically safe and suitable for hazardous areas.

STORAGE AND HANDLING

On receipt of panels and accessories at site, necessary precautions will be taken for
unloading, shifting and storage as followings:

1. Material will be stored in a covered / dry space at all the time.

2. All materials received at site will be inspected and ensure that the materials are as per
approved drawings.
3. Any discrepancies, damage etc. found will be notified and reported for further action.
4. Site engineer will ensure that the panels used at site are of free from any damage or
deformity of any kind. Any minor damages observed will be repaired suitably.

SAFETY PRECAUTION FOR PANELS INSTALLATION

1. We will secure the approved work permit from the concerned representative before
starting any work.
2. Fire Extinguisher will be at work area whenever there is hot work.
3. All electrical tools will be checked.
4. Hazardous area and its precautionary measure requirements will be properly discussed
to the working crew following all safety requirements.
5. Continuous monitoring and checking will be conducted by concerned
supervisor/foreman to detect and correct unsafe practices while performing the work
activities.
6. We will provide warning sign and sufficient barricade on working areas to avoid
unauthorized entry. Only assigned personnel will be allowed in the area.
7. Safety Supervisor will monitor the work activities to help and protect all assigned
workers against exposure to safety hazards. He will ensure that Personal Protective
Equipment’s (PPE’s) are being supplied and used properly.

Page-9
 8. Toolbox meeting will be conducted by Electrical Supervisor daily so that work
activities will be properly coordinated to all concerned and all safety measures will be
carried out on the entire work duration.
9. Housekeeping will be maintained and working area will be kept clean and tidy in
accordance with Site Housekeeping Procedure.
10. Job Hazard and Risk Assessment of this procedure will be disseminated and explained
to workers for safety awareness.

PANELS INSTALLATION PROCEDURE

1. We shall ensure that the work area is ready and safe to start the installation of panel.
2. Before starting installation, we will check the manufacturer drawings and necessary tools
availability at site.
3. We will also check the panel condition before installation such as whether panel is damaged or
in good condition, panel accessories such as relays, fuses, breakers, busbar sizes etc. are
according to manufacturer drawing or not.
4. We will check the floor surface with base frames grouted on the open trenches.
5. All panels will be placed in correct position according to approved / customer given layout
drawing using hydraulic hand trolley.
6. Cable pulling, termination & crimping will be done as standard.
7. Termination of cables will be done using good materials and competent technicians.
8. After installation, panel will be grounded properly as instructed by manufacturer engineer /
customer.
9. Completion of termination, we will test the necessary accessories of panel such as protection
relays and meters as per PGCB standard and customer requirement.
10. Prior to completion of all work done in panel, we will ensure that cable entries and other
openings will be properly sealed.
11. Manufacturer engineer / Customer representative will verify the installation and instruct for
energization of panel after obtaining clearance from site engineer.

INSTALLATION OF GANTRY TOWER AND SWITCHYARD EQUIPMENT STRUCTURE

TOOLS AND EQUIPMENT FOR GANTRY AND STRUCTURE INSTALLATION

 Electrical Hand Tools

 Crane
 Lifeline belt
 Chain Pulley, Open Pulley
 Spirit Level
 Torque Wrench & Pipe Wrench
 Common Hand Tools
 Nylon lifting belt, PP rope, guide rope
 Derrick Support
 Measuring tape
 Spanners, Hammer & Tool kit
 Spades, digging bars etc
 Drilling machine
 3ph, AC power Supply

All tools utilized in a classified area will be intrinsically safe and suitable for hazardous areas.

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STORAGE, HANDLING AND PRESERVATION OF GANTRY TOWER & EQUIPMENT
STRUCTURE

1. Upon delivery of materials, Customer representative along with our erection engineer
will conduct inspection for Handling and Preservation to verify conformance to
supplier drawings. Any deviation shall be documented/ noted. Material is to be
inspected as per packing list and any damages or shortages are to be informed to client.
2. After receiving material and completing inward formalities, packages are shifted to lay-
down area in truck and safely unloaded by using Crane.
3. Before Unloading, materials keep storage area clean, well-drained, well compacted and
sharp particle free.
4. Steel structure are unloaded on wooden planks placed on compacted land.
5. Material are stored in order of legs, bracings, cleats etc. as per tower/gantry for ease of
identification during shifting and installation works.
6. Avoid in stacked Material one above another. Only identical materials are stacked
together.

INSPECTION

1. Check the Foundation level and assure the foundation measurement, bolt alignment.
2. Check the size and hole-to-hole distance of the structure members as per drawing.
3. Check the cut bracings for tower erection.
4. Check the Tower foundation bolts and threads clean.
5. Leveling of Nuts respect to FGL and all nuts kept at same level according to drawing.
6. Sorting all the materials by size and section according to drawing.

SAFETY PRECAUTION FOR INSTALLATION

1. We will secure the approved work permit from the concerned representative before
starting any work.
2. All electrical tools will be checked.
3. Hazardous area and its precautionary measure requirements will be properly discussed
to the working crew following all safety requirements.
4. Continuous monitoring and checking will be conducted by concerned
supervisor/foreman to detect and correct unsafe practices while performing the work
activities.
5. We will provide warning sign and sufficient barricade on working areas to avoid
unauthorized entry. Only assigned personnel will be allowed in the area.
6. Safety harness will be used when working at elevated temporary platforms (1.8 meters
and above).
7. Safety Supervisor will monitor the work activities to help and protect all assigned
workers against exposure to safety hazards. He will ensure that Personal Protective
Equipment’s (PPE’s) are being supplied and used properly.
8. Toolbox meeting will be conducted by Supervisor daily so that work activities will be
properly coordinated to all concerned and all safety measures will be carried out on the
entire work duration.
9. Housekeeping will be maintained and working area will be kept clean and tidy in
accordance with Site Housekeeping Procedure.
10. Job Hazard and Risk Assessment of this procedure will be disseminated and explained
to workers for safety awareness.

Page-11
INSTALLATION

Method-1

1. This method consists of erecting the towers manually step by step.

2. Gantry tower first four legs will be mounted by using Pipe, Rope, Chain pulley etc.
3. Completing first four legs erection on foundation, properly fixed upper nuts and
washers.
4. Assembling and fixing cross bracings of the first four legs.
5. Tightness of base legs nuts are properly with wrench.
6. To keep base legs in exact position we use rope guy and temporary fixed on the ground.
7. The cross bracings are assembled and raised one by one as a unit and bolted.
8. Generally we use one derrick for smaller base towers and wide based towers we use
two derricks.
9. For assembling the second section of the tower, the derrick is placed on the top of one
corner leg.
10. The legs of the second section are kept in position by fixing the temporary rope guys.
The bracings of the second section are then hoisted and assembled.
11. Derricks and the temporary rope guys for the leg members are thus moved up as the
tower is built up. This process is continued till the complete tower is erected.

Method-2

1. The two opposite sides of the gantry section are assembled on the ground. Each
assembled side is then lifted clear of the ground with Crane and lowered into position
on bolts to stubs or anchor bolts. One side is held in place with rope guys while the
other side is being erected.
2. Heavy section are lifted by crane and after lifting nut bolts are fixed with first legs and
shall be tightened properly, Opening of sling after complete fixing shall be carried out
with proper safety belt and the boom should be free from load.
3. For beam erection half - half sections are assembled on ground and the same shall be
lifted with crane.
4. Person going on top of the tower for erecting Gantry shall be through step bolts and
then to be shifted on tower.
5. Crane capacity shall be checked with load chart.
6. Guy rope is to be fixed with all assembled sections while lifting with crane, and after
assembling the same rope shall be fixed with Guy rope on both side of assembled
sections.
7. The last lift raises the top of the towers. After the tower top is placed and all side
bracings have been bolted up.

Tightening of Bolts & Nuts

1. All nuts tightened properly using correct size spanners. Before tightening it should be
ensured that filler washers and plates are placed in relevant gaps. Spring washer placed
under the outer side of nut.
2. The tightening carried on progressively from the bottom to top, care being taken that
all bolts at every level are tightened simultaneously.

*SES will follow the installation method 1 or 2 as per customer’s requirement.

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INSTALLATION /TEST OF SWITCHYARD EQUIPMENT (AIS)

TOOLS AND EQUIPMENT FOR HV AIS EQUIPMENT INSTALLATION

We shall ensure tools and equipment needed is in good condition and will be checked by
Supervisor / Safety Engineer prior to use in the construction area. These includes but not
limited to:

 Tool Box
 Electrical Hand Tools
 Crane
 Spirit Level
 Drilling Machine
 Common Hand Tools
 Measuring tape
 Insulation Resistance Test Set
 Digital multi-meter, Clamp on Ammeter
 1ph, AC power Supply

All tools utilized in a classified area will be intrinsically safe and suitable for hazardous areas.

STORAGE AND HANDLING

On receipt of panels and accessories at site, necessary precautions will be taken for
unloading, shifting and storage as followings:

1. Material will be stored in a covered/ Dry space at all the time.

2. All materials received at site will be inspected and ensure that the materials are as per
approved drawings.
3. Any discrepancies, damage etc. found will be notified and reported for further action.
4. Site engineer will ensure that the panels used at site are of free from any damage or
deformity of any kind. Any minor damages observed will be repaired suitably.

SAFETY PRECAUTION FOR HV EQUIPMENT INSTALLATION

1. We will secure the approved work permit from the concerned representative before
starting any work.
2. Fire Extinguisher will be at work area whenever there is hot work.
3. All electrical tools will be checked.
4. Hazardous area and its precautionary measure requirements will be properly discussed
to the working crew following all safety requirements.
5. Continuous monitoring and checking will be conducted by concerned
supervisor/foreman to detect and correct unsafe practices while performing the work
activities.
6. We will provide warning sign and sufficient barricade on working areas to avoid
unauthorized entry. Only assigned personnel will be allowed in the area.
7. Safety Supervisor will monitor the work activities to help and protect all assigned
workers against exposure to safety hazards. He will ensure that Personal Protective
Equipment’s (PPE’s) are being supplied and used properly.
8. Toolbox meeting will be conducted by Electrical Supervisor daily so that work
activities will be properly coordinated to all concerned and all safety measures will be
carried out on the entire work duration.

Page-13
 9. Housekeeping will be maintained and working area will be kept clean and tidy in
accordance with Site Housekeeping Procedure.

Job Hazard and Risk Assessment of this procedure will be disseminated and explained to
workers for safety awareness.

The equipment will be procured from The Original Equipment Manufacturers after fabrication via
agency subcontractor where applicable. Then after fabrication, SES and Customer/Host will witness the
Factory Acceptance Test at an agreed date. Any Punch list/snags would close the out before shipment
to Customer/Host for safe and secured storage before installations.

The following work Procedures are to be followed.

 Tools & Tackles Shorting & Listing

 Man power Assigning
 Equipment & Materials Shorting
 Foundation marking
 Concrete base cuttings /Dills if necessary
 Equipment Installation with certified Crane
 Anchoring & bolting
 Different test Switchyard equipment’s
 Insulation resistance test
 Earth connection to every equipment’s and structure.
 Cable termination
 Insulation Resistance and Functional test of equipment’s
 All necessary equipment testing.
 Pre- commissioning

*SES will follow the installation as per Installation Guide/Manual.

Upon arrival of Equipment, the necessary Installation works can begin.

INSTALLATION /TEST OF SWITCHYARD EQUIPMENT (GIS)

TOOLS AND EQUIPMENT FOR GIS INSTALLATION

Arrangement of construction equipment that will be needed for the installation We shall ensure
tools and equipment needed is in good condition and will be checked by Supervisor / Safety
Engineer prior to use in the construction area. Final alignment and foundations levelling for
associated devices These includes but not limited to:

 Electrical Hand Tools

 Crane
 Spirit Level
 Torque Wrench
 Common Hand Tools
 Measuring tape
 Insulation Resistance Test Set
 Current Transformer Test Set
 Contact Resistance Test set
 Leakage Test set
 Moisture Test set

Page-14
  Digital multi-meter, Clamp on Ammeter
 3ph, AC power Supply

All tools utilized in a classified area will be intrinsically safe and suitable for hazardous areas.

STORAGE, HANDLING AND PRESERVATION OF GIS

1. Upon delivery of materials, Customer representative along with our erection engineer
will conduct inspection for Handling and Preservation to verify conformance to
supplier drawings. Any deviation shall be documented/ noted.
2. All equipment parts will be kept in the unopened original shipping case with all braces
and plugs intact and will be covered with plastic sheets.
3. Air intake openings will remain covered to reduce dust, waster or other unwanted entry
accumulation.
4. Regular visual inspection will be conducted to check any dust accumulation,
5. GIS will be lifted only through lifting points provided for attaching the slings or lifting
chains.
6. Weight of the GIS will be checked prior for lifting to ensure that the capacity of the
crane to be used in lifting the GIS is suitable to the weight of the GIS.
7. The right position of the GIS at the trailer bed will be ensured and it will be lightened
with the steel chains prior to dispatch for installation.

GIS INSTALLATION ON SITE

1. Before installation we will review all possible routes and check obstructions to avoid
delays in the activities. Necessary tools in mounting the equipment will be checked and
ready upon receiving of equipment.
2. Form works, grouting and finishing touch for concrete foundation will be checked.
3. We use crane(s) of required load capacity for installation of LCC, Support steel
structure Bushing, PT Chamber Feeder etc, on a proper place with customer/host
approval.
4. Assemble of the steel support structure.
5. Mounting of the GIS from shipping units.
6. Installation of the local control cubicles.
7. Secondary cabling between GIS and LCC-s
8. Establishing of the earthling system
9. We assign Vacuum Machine to vacuum the GIS Before Gas filling.
10. The SF6 cylinders handled carefully and stored in a cool, dry, well ventilated area away
from flammable or explosive material.
11. Used Dilo machine for transfer, purifying and recycling of the gas and also the
evacuation and filling of the gas compartments of the GIS.
12. Fill SF6 gas by the manufacturer decided Pressure.

Page-15
TESTS AFTER ERECTION ON SITE
After erection, before putting into service, the GIS shall be tested to check the correct operation
and the dielectric strength of the equipment. These tests and verifications comprise:

Checks and verifications

After erection before the high voltage tests the GIS should have a final inspection. The
followings should be checked step by step:
 Conformity of the primary GIS with the manufacturer's drawings (single line diagram,
gas schematic diagram, layout, section drawings of the different bays)
 Conformity of the secondary control and protection circuits with the manufacturer's
drawings conformity of the earthing system with the manufacturer's drawings
 Proper function of the direct current (DC) and alternating current (AC) auxiliary supply
systems.
 Proper operation, alarm and position indication of each circuit breaker drive according
to the manufacturer's instructions (operational tests)
 Proper operation and position indication of each disconnector and earthing switch drive
according to the manufacturer's instructions (operational tests)
 Proper function of the interlocks operated locally from the local control cubicles. (The
remote operation is to be checked together with the central control equipment.)
 Proper function of the measuring, protective and regulating equipment including the
internal heating and lighting of drives and cubicles.
 Proper condition of each gas insulated flange connection (wholeness, cleanness,
tightness of nuts and bolts, greasing if necessary)

Measurement of gas condition

The gas filling pressure of each gas compartment shall be checked. The moisture content
of the insulating gas shall be checked. The content shall not exceed the following limits
after humidity measurement:
 50 ppm (mass) for circuit breaker poles
 100 ppm (mass) for other components

Gas tightness tests

Leakage test with gas leak detector has to be performed around the flanges.

Moisture Test

All gas chamber gas Moisture should be test.

Resistance measurement of the main circuit

The resistance should be compared with the prescribed values and tolerances given by the
manufacturer.

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 Primary Equipment Test

All primary equipment shale be test and make a report.

High voltage tests on the main circuits

The high voltage site tests are supplementary to the dielectric routine tests with the aim of
checking the dielectric integrity of the completed installation and of detecting irregularities.
Normally the dielectric test shall be made after the GIS has been fully erected and gas-filled
at the rated density preferably at the end of all site tests, when newly installed. Such a
dielectric test is recommended to be performed also after major dismantling for
maintenance. These tests are to be distinguished from the progressive voltage increase
performed in order to achieve a kind of electrical conditioning of the equipment before
commissioning.

SUBSTATION EARTHING

SAFETY PRECAUTION FOR PANELS INSTALLATION

1. We will secure the approved work permit from the concerned representative before
starting any work.
2. Fire Extinguisher will be at work area whenever there is hot work.
3. Hazardous area and its precautionary measure requirements will be properly discussed
to the working crew following all safety requirements.
4. Continuous monitoring and checking will be conducted by concerned
supervisor/foreman to detect and correct unsafe practices while performing the work
activities.
5. We will provide warning sign and sufficient barricade on working areas to avoid
unauthorized entry. Only assigned personnel will be allowed in the area.
6. Safety Supervisor will monitor the work activities to help and protect all assigned
workers against exposure to safety hazards. He will ensure that Personal Protective
Equipment’s (PPE’s) are being supplied and used properly.
7. Toolbox meeting will be conducted by Electrical Supervisor daily so that work
activities will be properly coordinated to all concerned and all safety measures will be
carried out on the entire work duration.
8. Housekeeping will be maintained and working area will be kept clean and tidy in
accordance with Site Housekeeping Procedure.
9. Job Hazard and Risk Assessment of this procedure will be disseminated and explained
to workers for safety awareness.

STRUCTURE AND EQUIPMENT EARTHING:

1. Two nos. riser flat/copper conductor (above ground) up to apparatus/equipment base directly
from the main earth mat rod will be used for equipment earthing and the same will run parallel
but in opposite direction including loops bonding across structural joints.
2. Steel/RCC columns, metallic stairs etc. will be connected to the nearby main earth mat grid
conductor by two earthing leads. Electrical continuity will be ensured by bonding different
sections of hand-rails and metallic stairs.
3. Railway tracks within switchyard area will be earthed at a spacing of 30m and also at both ends.

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 4. Lighting poles, junction boxes on poles and Sub-station, BMK, CT/PT/CVT JB, Cable and
cable boxes/glands, lockout switches etc. will be connected to earthing grid conductor at
minimum two points.

INSTALLATION OF EARTHING CONDUCTOR:

1. The grounding grid will be constructed by use of corrosion resistant mild steel rod/copper
conductor (as per approved drawing).
2. Wherever earthing conductor crosses cable trenches, underground service ducts, pipes, tunnels,
railway tracks etc. It will be laid 300mm (min) below them and will be circumvented in case it
fouls with equipment/structure foundation.
3. All non-current carrying steel/metal parts in the switchyard will be connected to the grounding
grid including equipment except lightning arrestors, Reactors, power transformers, CVT/PT
etc. which will be earthed directly through earth electrode. This electrode will in turn be
connected to earthing grid through galvanized bolts and nut. Each earthing lead from the neutral
of the transformer will be directly connected to two galvanized pipe electrode treated earth pit
which in turn will be connected to station earth grid. Contractor will submit detail equipment
earthing drawing of all equipment along with detail pipe electrode drawing to be used in
conjunction with treated pit with test link, treated pit without test link and non-treated pit and
structure earthing.
4. All points in steel earthing system will be made by welding except the points with bolted
connection which should be provided for separating the earthing grid for testing purpose. The
point for testing purpose should be so placed that the earth grid can be frequently supervised.
5. Connection between equipment earthing lead and main earthing conductors and between main
earthing conductors will be welded type.
6. Earth pit of earth electrode will be as per approved earthing drawing. The earth pit will be
constructed with RCC (M-15)/brick in surrounding wall and floor (minimum wall thickness
125 mm. and floor thickness 100 mm.) with a removable cover slab of 75 mm. thick with RCC
(M-15) (0.8% reinforcement by volume of concrete). Cover slab will be plastered with cement
mortar (1:4) on all side.
7. The earthing conductor around control building will be buried in earth at a minimum distance
of 1500 mm from the outer boundary of the building and which in turn will be connected to
switchyard main earth grid conductor as per approved earthing lay out drawing for control room
to be submitted separately.
8. Steel to Copper connection if any will be brazed type and will be treated to prevent moisture
ingression.
9. All ground connections will be made by one welding except the point with bolted connection
which should be provided for separating the earthing grid for testing purpose. The point for
testing purpose should be so placed that the earth grid can be frequently supervised for rust
protection. All welded joints will be allowed to cool down gradually to atmospheric temperature
before putting any load to it. Artificial cooling will not be allowed.
10. All C & R panels, PLCC and its Battery charger will be earthed by as per approved design &
drawing (2nos connection one each on opposite side).
11. Earthing conductor for main ground grid in outdoor areas will be buried at least 600 mm below
finished ground level or more as per design consideration for green field Sub-Station. For
existing substation, it will be laid matching with existing earth mat grid level.
12. Earthing conductor or leads along their run-on cable trench, ladder, wall, etc. will be supported
by suitable welding / cleaning at as per approved drawing. Wherever it passes through walls,

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 floors, etc., galvanized steel sleeves will be provided for passage of conductor and both end of
sleeves will be sealed to prevent passage of water through sleeves.
13. Earthing conductor, i.e., grid perimeter ground conductor will be buried 1000 mm (min.)
outside the switchyard fence. All gates of every alternate post of fence will be connected to
earthing grid. Gravel / crushed stone spreading will also be done 1000 mm (min.) outside the
switchyard fence. However, criterion of gravel / crushed stone spreading will be followed in
line with requirement of approved drawing & schedule of works.
14. Flexible earthing connectors will be installed for moving parts.
15. Tap connection from earthing grid to equipment /structures to be earthed will be terminated on
the earthing terminal of the equipment/structures as per approved drawings.
16. Auxiliary earth mat of same dia of the main earth mat and total size1500×1500 mm with
500×500 mm closely spaced conductor will be provided at a depth of 300 mm from the finished
ground level below the operating handle of MK box of all isolators. MK box will be directly
connected to auxiliary mat which will be connected to main earth mat grid at two points.
17. All above ground conductive metal parts that might accidentally energized will be connected
to main earth mat.
Pipe electrode will be used in the following area (application wise):
a) Pipe electrode in treated pit with test link (Test pit):
Application: Reactor/Power Transformer’s Neutral, Earthing Transformer/ Station Service
Transformers’ Neutral, Grid Corner, LA, CT, PT.
b) Pipe electrode in treated pit without test link
c) Rod Earth electrode in non-treated pit
18. Earthing conductors crossing the road will be laid 300mm below road or at greater depth to suit
site condition.
19. Earthing conductors embedded in the concrete will have approximately 50mm concrete cover.

METHOD FOR CONSTRUCTION OF EARTHING PIT

1. Excavation on earth for a normal earth Pit size is 1.5M X 1.5M X 3.0 M.
2. Use 500 mm X 500 mm X 10 mm GI Plate or Bigger Size for more Contact of Earth and reduce
Earth Resistance.
3. Make a mixture of Wood Coal Powder Salt & Sand all in equal part.
4. Wood Coal Powder use as good conductor of electricity, anti-corrosive, rust proves for GI Plate
for long life.
5. The purpose of coal and salt is to keep wet the soil permanently.
6. The salt percolates and coal absorb water keeping the soil wet.
7. Care should always be taken by watering the earth pits in summer so that the pit soil will be
wet.
8. Coal is made of carbon which is good conductor minimizing the earth resistant.
9. Salt use as electrolyte to form conductivity between GI Plate Coal and Earth with humidity.
10. Sand has used to form porosity to cycle water & humidity around the mixture.
11. Put GI Plate (EARTH PLATE) of size 500 mm X 500 mm X 10 mm in the mid of mixture.
12. Use Double GI Strip size 30 mm X 10 mm to connect GI Plate to System Earthling.
13. It will be better to use GI Pipe of size 2.5″ diameter with a Flange on the top of GI Pipe to cover
GI Strip from EARTH PLATE to Top Flange.
14. Cover Top of GI pipe with a T joint to avoid jamming of pipe with dust & mud and also
use water time to time through this pipe to bottom of earth plate.

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 15. Maintain less than one Ohm Resistance from EARTH PIT conductor to a distance of 15 Meters
around the EARTH PIT with another conductor dip on the Earth at least 500 mm deep.
16. Check Voltage between Earth Pit conductors to Neutral of Mains Supply 220V AC 50 Hz it
should be less than 2.0 Volts.

TEST:
Earth resistance check of the entire grid as per approved earth mat design document.

TESTING/COMMISSIONING

All Installed equipment will be tested as per scheduled test requirements by customer and
commissioned within the allocated period.

DOCUMENTATION

SES shall provide all the updated drawing, Installation Guide, Manual, Packing List, As Build Drawing,
Termination Schedule etc. after the commissioning of the project with required seal & sign.

ENVIRONMENT

Considering the operation of SES in the construction of the purposed substation, the task will be
conducted in a manner that would reasonability minimize any possible impact to the environment.

SES and its /sub-contractors in the project team will comply with all applicable standard to prevent
damages to the environment.

The project team has established the following objectives to achieve goal Zero have to environment.

 Make preservation of environment a priority in our daily operations.

 Reduce the impact of our operation on environment.
 Promote environment awareness and responsibilities in our employees and subcontractors.

SES HSE Officer shall be responsible and accountable for effective implementation of the environment
management improvement process, setting objective, goals and monitoring performance of the
application area.

-Thanks-

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