ELECTRICAL EQUIPMENT INSTALLATION PROCEDURE

ELECTRICAL EQUIPMENT INSTALLATION PROCEDURE

  1. All permanent materials (including fabricated and pre-fabricated supports), consumables, equipment to be installed and its accessories, construction area and resources shall be prepared and checked prior to installation works.
  2. Ensure that working areas are safe and ready for installation in coordination with other discipline for the use of the area and scaffolding materials.
  3. Work Transfer Sheet shall be duly signed and processed by other subcontractors or discipline for the preceding works to avoid confusion and discrepancies in the work responsibilities.
  4. Study erection procedures of heavy electrical equipment and other sensitive equipment prior to installation.
  5. Special tools shall bear a valid calibration certificates traceable to a national standard indicating calibration validity and periodically (at least six months) checked by a third party laboratory testing facility.
  6. Electrical materials shall conform to all applicable requirements, standard, and specifications prior to release to be used as part of the work. Refer to Schedule “Q” Att. IV Para 7.1.
  7. Review all references such as the latest approved for construction drawings, layout, and Technical Scope of Work.
  8. All equipment related to substation works shall be checked after confirming the availability at company. Visual Inspection shall be conducted for possible factory or handling damage and recorded in appropriate QC Material Receiving Inspection Report form.

STORAGE AND HANDLING OF EQUIPMENT INSTALLATION PROCEDURE

  1. Upon delivery of materials,  QC Inspector will conduct receiving inspection as per Schedule G for Handling and Preservation to verify conformance to vendor drawings. Any deviation shall be documented through a QCIR.
  2. Electrical equipment should be moved and stored in an upright position
  3. Electrical equipment should be stored indoor in a clean dry area as per NFPA 70, NEC Art.110.3 (B) & manufacture recommendation.
  4. Keep sufficient gap between stored materials and equipment for easy access, lifting and moving.
  5. Electrical Equipment should be covered with plastic sheets and all doors should be sealed tight. All equipment parts must be kept in the unopened original shipping case with all braces and plugs intact and shall be covered with plastic sheets.
  6. Air intake openings should remain covered to reduce dust, waster or other unwanted entry accumulation.
  7. Regular visual inspection shall be conducted to check any dust accumulation or dampness on the electrical equipment.
  8. Necessary protection shall be provided in transporting of electrical equipment in accordance with vendor requirements or recommendations and Saudi Aramco standard and specifications.

 

DRY TYPE TRANSFORMER INSTALLATION

  1. Prior to hauling, review all possible routes and check obstructions to avoid delays in the activities. Hydraulic pallet jack and other necessary tools in mounting the equipment shall be check and ready upon receiving of equipment.
  2. Install dry type transformer to its mounting support in a safely manner and following the procedure provided by the equipment vendor (if any), and Approved for Construction (IFC) drawings.
  3. Formworks, grouting and finishing touch for concrete foundation shall be executed with respect to project standard specification.
  4. Perform resistance measurement through bolted connections with a low-resistance ohmmeter, if applicable in accordance with NETA ATS 2009. All bolted connection shall be properly torqued using the calibrated torque wrench in accordance with the manufacturer’s data, applying the approved torque indicated in the transformer data sheets provided by the equipment vendor.
  5. Conduct preliminary inspection to the completed installed equipment to ensure that all components have been installed completely and properly for final inspection.
  6. Ensure that nameplate and warning signs are properly installed accordingly to the equipment as per latest Approved for Construction (IFC) drawing.
  7. Base supports for the free standing equipment shall be sufficient and properly installed as per  latest Approved for Construction drawing and standards.
  8. Transformer installed shall be properly grounded to the system grounding as per latest Approved for Construction drawing.
  9. Equipment and its components shall be tested as per vendor’s recommendation and approved by Company. Testing result shall be recorded/filed.

NEUTRAL EARTHING EQUIPMENT INSTALLATION

  1. Study and check possible routes when bringing the equipment to its location to consider overhead clearances, turn radius and path are clear from any obstructions.
  2. Assemble all components carefully, following the instructions provided by the equipment vendor. Perform resistance measurement through bolted connections with a low-resistance ohmmeter, if applicable in accordance with NETA ATS 2009.
  3. Align the equipment and level to its location. Surveyor shall check its alignment and directions using the surveying equipment, as required.
  4. Install the equipment carefully avoiding possible damages to the equipment and maintain a safe work activity.
  5. Initial inspection to the completely installed equipment shall be conducted making sure that all requirements has been followed with respect to the latest Approved for Construction (IFC) drawings and equipment vendor’s instructions. Panels shall be opened up and   inspected for cleanliness to ensure no foreign bodies are present.  Dust and dirt shall be removed by using appropriate vacuum cleaner or rags.
  6. Perform resistance measurement through bolted connections with a low-resistance ohmmeter, if applicable in accordance with NETA ATS 2009. Connect all power connections and torque all bolted connection with the required value including bus bars using calibrated torque wrench in accordance with the manufacturer’s data and marked with a visual indicator.
  7. Form works, grouting and finishing touches for concrete foundation shall be executed with respect to standard specification.
  8. Power capacitor and grounding resistor shall be properly connected to grounding system as per  latest Approved for Construction drawing.
  9. Ensure that nameplate and warning signs are properly installed accordingly to the equipment as per  latest Approved for Construction (IFC) drawing.

Initial testing for insulation shall be conducted by Field Operation Group (FOG) and witnessed by QC Inspector; results shall be recorded and submitted to company prior to pre-commissioning.

 

SWITCHGEAR AND MOTOR CONTROL CENTER (MCC) INSTALLATION

  1. Prior to hauling, review all possible routes and check obstructions to avoid delays in the activities. Hydraulic pallet jack and other necessary tools in mounting the equipment shall be check and ready upon receiving of equipment.
  2. Equipment shall be brought inside the unit substation in sequential manner in such a way as to minimize unnecessary movements within the set point. Equipment shall be handled with caution to avoid undue stress or damage to the metal finished surfaces.
  3. Align the equipment before on its channel base. Surveyor shall thoroughly check its alignment using surveying equipment (if necessary) to ensure that the equipment is leveled and plumbed. Bus bar sections or links shall be inserted and where specified, shall be insulated. The links in bus wire shall be connected.
  4. Base supports for the free standing equipment shall be sufficient and properly installed firmly to hold the weight of the particular equipment. Cable entry point and bus duct connections shall be considered in mounting the equipment, avoiding possible stress of the cable to be terminated and to bus bar connections.
  5. Assemble all components and compartments as safe as possible and use only proper tools appropriate in the internal parts. Draw out type compartment shall be assembled using special trolley provided by the equipment vendor. Protection relays shall be inserted carefully and connected to which settings will be adjusted as required by the equipment vendor.
  6. Perform resistance measurement through bolted connections with a low-resistance ohmmeter, if applicable in accordance with NETA ATS 2009. Torque all bolted connection using approved tools (i.e. calibrated torque wrench) applying torque value provided by the equipment vendor in the data sheets and marked with a visual indicator. Cable bus duct, bus bars and other connections shall be fixed to supports and aligned. External flanges couplings of bus ducts shall be sealed and made weather proof.
  7. Switchgears and MCC shall be properly grounded to system grounding in accordance with latest approved for construction drawing.

CABLE BUS DUCT INSTALLATION

  1. Check the status of Substation Building wall opening for cable bus entry, embedded steel materials, concrete flooring and concrete foundation outside substation for self standing steel columns.
  2. Execute anchor bolt leveling, templating and chipping for auxiliary equipment concrete foundation.
  3. Fabricate and install self standing steel column and support in accordance to the company latest approved for construction drawing.
  4. Primer, finishing and touch-up painting shall be applied to every steel surface, edging caused by cutting, drilling, welding and grinding.
  5. For grounding bus bar and ground bonding installation for supports and equipments refer to other article in this website.
  6. Removal of dust and dirt from cable bus shall be executed using vacuum cleaner and clean bus bar by contact cleaner, polishing cloth etc.
  7. Install cable bus duct in accordance with the latest approved for construction drawing. Check cable bus duct alignment and plumbness.
  8. Additional support shall be installed wherever it is required base on site condition.
  9. Interconnection between cable bus duct, wire links and offset cable bus shall be properly fixed and connected as per company latest approved for construction drawing.
  10. Inspection for cable bus duct contact resistance, insulation and hi-pot test through complete connection end to end point shall be witnessed by QC Inspector and result shall be filed and recorded to appropriate inspection and test form reflected on approved SATIP and shall be submitted to company.
  11. Seal all cable bus duct connection window, entry and substation wall penetration after interconnection and testing has been done using flammable high resistant sealing compound.

 

 

CONTROL, DISTRIBUTION AND MISCELLANEOUS PANEL INSTALLATION

  1. Categorized the indoor and outdoor equipment relative to hazardous and non-hazardous locations in accordance with the  latest Approved for Construction drawings.
  2. Install adequate structural supports and necessary fixing rails with respect to the company latest approved for construction drawings.
  3. Mount carefully the panel and/or equipment to its supports and avoid undue stress or damage to its metal finished surfaces.
  4. Package type equipment and special panels shall be installed in accordance with equipment vendor’s drawings and instructions.
  5. The complete miscellaneous equipment and panel assembly shall be checked to ensure alignment, level and connections prior tightening of bolts. Only the recommended bolting materials and torque values shall be used in assembling the equipment as per vendor’s recommendation.
  6. Panels and/or equipment shall be properly grounded to system grounding in accordance with company latest approved for construction drawing.
  7. Touch-up paint for panel support according to painting specification and procedure.

TOOLS AND EQUIPMENT

Tools and equipment needed should be in good condition and must be checked by Supervisor / Safety Engineer prior to use in the construction area.  These includes but not limited to:

  • Boom Truck
  • Electrical Hand Tools
  • Welding Machine
  • Mobile Crane
  • Hydraulic Pallet Jack
  • Straight/Telescopic Step Ladder
  • Spirit Level
  • Torque Wrench
  • Common Hand Tools
  • Measuring tape

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

Industry Codes

  • NFPA 70                             National Electrical Code

SAFETY PRECAUTION

  1. Secure the approved work permit from the concerned company Representative before starting any work.
  2. Fire Watcher with Fire Extinguisher shall be assigned at work area whenever there is hot work.
  3. All electrical tools shall be checked and color-coded.
  4. Hazardous area and its precautionary measure requirements shall be properly discussed to the working crew following all safety requirements.
  5. Continuous monitoring and checking shall be conducted by concerned supervisor/foreman to detect and correct unsafe practices while performing the work activities.
  6. Provide warning sign and sufficient barricade on working areas to avoid unauthorized entry. Only assigned personnel shall be allowed in the area.
  7. Safety harness with double lanyards shall be used when working at elevated temporary platforms (1.8 meters and above).
  8. Safety Supervisor shall monitor the work activities to help and protect all assigned workers against exposure to safety hazards. He shall ensure that Personal Protective Equipments (PPE’s) are being supplied and used and shall comply with company and Saudi Aramco applicable general instruction and standards.
  9. Toolbox meeting shall 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 shall be maintained and working area shall be kept clean and tidy in accordance with Site Housekeeping Procedure.
  11. Job Hazard and Risk Assessment of this procedure shall be disseminated and explained to workers for safety awareness.

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