GENERIC METHODOLOGY FOR ERECTION &INSTALLATION OF SUGAR FACTORY METEC DATE 19/2/2012
PREPARED BY CORPORATE PROJECT MANAGEMENT-
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1. CONSTRUCTION METHODOLOGY OF CIVIL WORKS 1.1.
INTRODUCTION
1.2.
CIVIL WORK METHODOLOGY
1.2.1. SITE CLEARANCE 1.2.2. EXCAVATION 1.2.2.1.
BULK EXCAVTION
1.2.2.2.
PIT EXCAVTION
1.2.3. BACKFILINIG WORK 1.2.4. STONE MASONRY FOUNDATION 1.2.5. STRUCTURAL STEEL (REINFORCEMENT ) WORK : 1.2.6. CONCRETE AND ALLID WORKS FOR SUB-STRUCTURE 2. ELECTRO –MECHANICAL INSTALLATION METHEDOLGY 2.1.
MECHANICAL EQUIPMENT INSTALLATION
2.1.1. INTRODUCTION 2.1.2. GENERAL GUIDELINE FOR EQUIPMENT INSTALATION 2.1.3. PLANT COMMISSIONING PROGRAM 2.1.3.1.
METHOD FOR DEFING COMMISSIONING TEST
2.1.3.2.
SCOPE OF PLANT COMMISSIONING PROGRAM
2.1.3.2.1. PRE- OPERATIONAL TEST 2.1.3.2.2. INITIAL START -UP TEST 2.2.
ELECTRICAL SYSTEM INSTALLATION
2.2.1. Introduction 2.2.2. Objective 2.2.3. Codes &standards 2.2.4. Scope 2.2.5. Planning &Scheduling of the projected 2.2.6. Material Handling Methodology 2.2.7. Project Team Preparation 2.2.8. Material Transportation And Delivery 2.2.9. Mobilization of Project Team And Machinery 2
2.2.10. General Safety 2.2.11. Installation of HV/LV system 2.2.11.1.
Installation of high voltage (HV) system
2.2.11.2.
Installation of high voltage (LV) system
2.2.12. Methodology for Electrical Equipments 2.2.13. Generator Assembling /Erection Procedures 2.2.13.1.
Installation of Turbine & Generator System
2.2.13.2.
Installation of Water and Steam Line System
2.2.13.3.
Connecting Electrically /Pneumatically Activated Controls
2.2.14. Substation (Switch Yard ) Erection 2.2.15. Installation of protection 2.2.15.1.
Fire alarm system installation
2.2.15.2.
Earthling System Installation
2.2.15.3.
Lightening Protection System Installation
2.2.16. Testing And Commissioning 2.2.17. Project Energizing And Site Hand Over
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1.1.
INTRODUCTION
Construction Methodology: in these section only the methodology of civil works are covered and sub – divided as follows:
Site clearance Earth Work (Including Borrow Production ) Concrete And Allied Works For Sub- Structure Structural Steel (Reinforcement ) Work :
SCOPE This Construction Methodology describes the methods. Equipment and labor resources the contractor intends to employ, as well as the duration of the resources utilization, for the execution of the major activities. The methodology is expected to provide a summary and explanation that would be taken to smoothly execute the project. General description of the major project activities within the above major sections are covered by Work Methodology.
MOBILIZATION AND SITE ESTABLISHMENTS During mobilization period, the task of acquiring of unrestricted access to site and selection of camp site is to be carried out. The project management staff consisting of project manager, office engineer, material engineer, laboratory technician, surveyor, and site superintendent will mobilize soon after issuance of notice to commence. All necessary machineries and equipment will be mobilized during the mobilization period. It is planned to establish temporary facilities in the vicinity of the project area. Layout of the camp drawings for the various blocks shall be prepared and submitted to the client for approval. The surveying crew, together with the consultant surveyor, will be engaged in identify in benchmarks and control points. After confirmation of existence and condition of GPS and BM points by joint condition survey, handing over of these points will be held .then reestablishment of bench marks which are damaged or which are in the construction limit will be done to start main surveying work. Material engineer and laboratory technicians will be engaged in search of borrow and quarry sites for local construction material.
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1.2.
CIVIL WORKS METHODOLOGY 1.2.1. SITE CLEARANCE Any obstacles, including the stumps of trees to a minimum of 60cm below ground level or 150 cm below foundation level whichever is lower, shall be removed. The area shall be cleared of fences, trees, plants ,logs , stumps, bush ,vegetation , rubbish , slush , etc and other objectionable matter. The pits formed due to removal of uprooted trees shall be bake filled with selected earth material and well compacted .The materials so removed shall be burnt or disposed off as directed by the Engineer. Well ahead of commencement of clearing and grubbing activities, the following operations will be undertaken under the supervision of the Engineer:
Resurveying of the plant area. Identification of corners of each block Getting approval of limit for clearing and grubbing Arranging disposal site for unsuitable cleared and grubbed materials
The methodology we follow for Site Clearing work shall be the following 1. means of taking the elevation ,angle , alignment of the profile boards ; Can be achieved by one or combination of: total station. Theodolite, leveling etc. 2. method of investing physical obstruction ; This will be achieved together with the material engineer`s consultation. 3. Means of top soil removal ; This can be achieved by using a bull –dozer of required capacity based the soil property 4. The beginning and ending time of the activity ; Based on the volume of work we will determine the ending time of the clearance work after we know the commencement of work. 5. Instant remedy /immediate action to be taken if ,during execution ,unwanted quality or destruction effect or over looked items , the leveling etc. encountered
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1.2.2. Excavation All excavation shall be carried out by mechanical excavation unless ,in opinion of engineer , the work involved and time schedule permit manual work . Excavation for permanent work shall be carried out to such widths, lengths, and depths as are shown on the drawing or such other lines and grades as specified by engineer. 1.2.2.1. Bulk Excavation The methodology we follow for bulk excavation work is the following : 1. Method of investigating underground physical obstruction ; This will be achieved together with the material engineer`s consultation. 2. Disposal distance of the excavated material ; It is the responsibility of the main contractor to allocate the area for the spoil. 3. Equipment to be applied for this activity; Back –Hue excavators will be used for bulk excavations generally 4. The beginning and ending time of the activity; Based on the volume of work we will determine the ending time of the bulk excavation work after we know the commencement of work. 5. Instance remedy /immediate action to be taken if, during excavation, unwanted quality or destruction effect or over looked items, the leveling etc. encountered
1.2.2.2. PIT EXCATION WORK The methodology we follow for Pit Exaction Work shall be the following 1. Method of side wall of pits form falling in: It is to provide protection to the adjacent structures when excavating to any appreciable depth. 2. Equipment to be applied for this activity; Bake –hue excavators will be used for bulk excavations generally.
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3. Beginning of producing appropriate size and quality of concrete spacers; Concrete spacers that will be used for footing pads according to the cover provided on the drawing will be prepared. 4. Method of investing underground physical obstruction This will be achieved together with the material engineer`s consultation. 5. Way of pre excavation reading: Can be achieved by one or combination of: total station, Theodolite, leveling etc. 6. The beginning and ending time of the activity; Based on the volume of work we will determine the ending time of the pit execution work after we know the commencement of work and plan together with the master schedule. Instant remedy/immediate action to be taken if, during execution, unwanted quality or destruction effect or over looked items, the leveling etc. encountered.
1.2.3. BACK FILLING WORK: In placing backfill and fill, the following precautions and methods will be employed:-
Excavated areas around structures will be backfilled with approved material in horizontal layers, not exceeding 200mm in depth after compaction, to the level of the original ground surfaces. Each layer will be moistened or dried to optimum moisture content for the material and compacted to a density to a density to the satisfaction of the Engineer.
The mythology we follow for Back Filling Work shall be the following: 1. Specifying the Back fill material;
The material engineer shall specify the material for backfilling according to the specification to be followed.
2. Volume of back filling materials;
It is the obligation of the quantity surveyor to determine the volume of material
required for backfill. 3. Method of re checking the reduced level reading;
Can be achieved by one or combination of; total station, the dolente, leveling etc.
4. Method of sprinkling water;
This can be achieved by using water trucks . 7
5. Method of spreading Selected material;
This can be achieved by grader, loader together with man power .
6. Method to protect Sanitary and Electrical pipes during compaction (preferably to be executed after back filling);
The engineer shall make due notice where sanitary and electrical pipes are located, and give order to protect them.
7. Compaction Test schedule;
We engineer shall part by part density test on partly completed sections together with the consultation of the Engineer.
8. The beginning and end of the activity;
Based on the volume of work we will determine the ending time of the backfill work together with the master schedule.
9. Instant remedy/immediate action to be taken if, during execution, unwanted quality or destruction effect or over looked items, correction to be made if density tests fail to meet the requirement of the specification and retaking of the test will be made etc. encountered.
1.2.4. STONE MASONRY FOUNDATION:
The Methodology we follow for Stone Masonry Foundation is as follows: 1. The contractor shall be provided with approved final working drawings 2. Means of protecting trench wall from falling in; Braced walls using walls &struts 3. Bedding material preferred; The bedding material shall be as the provision of the working drawing . 4. Method of placing each course to Battered Stone Masonry and to Masonry thicker than 50 cm.; 5. The proportioning of the courses uniformly throughout the height. 6. Program to take cube tests The contractor shall cast test cubes every time for new works or for any material change (either cement or sand) or any time by the order of the engineer. 7. Quality and quantity of mixers; It`s the duty of the contractor to use qualified mixers both in quality and quantity, and the engineer should check as the mixer used is according to the specification. 8
8. Submittal of scaffolding design (if needed); The contractor shall submit scaffolding design for approval if requird.
1.2.5. STRUCTURAL STEEL (REINFORCEMENT) WORK The methodology we follow STRUCTURAL STEEL (Reinforcement)work, is as follows: Reinforcement will be bent in accordance with schedules of bars and specified conditions prior to fixing in position . Reinforcement bar shall be tested for all requirement (as cleanliness of the bar ,tensile strength test ) Submittal of form work design; Check the conformity with approved formwork design i.e. dimension, Submittal of shop drawing showing Diameter, Spacing, number, length, shape, method
of tying and bending dimension of main reinforcement bar in accordance with
the drawing; The form work we use shall be mild steel and shall be clean &smooth. The Method we use to treat the formwork for preventing adherence of concrete /coating with oil or any other release agent / Usage of top form work for casting concrete on surface steeper than 20º from horizontal to enable the concrete to be properly compacted;
During placing and fixing of reinforcement:-
Reinforcement will be placed as shown on the Drawings securely against displacement during the placement and compaction of the concrete. Projecting ends of ties or clips will be restrained of encroaching into the concrete cover. Where protruding bars are exposed to the elements for an indefinite period the bars shall be adequately protected against corrosion and damage and shall be properly cleaned before being permanently encased in concrete.
1.2.6. CONCRETE FOR STRUCTURES This work covers the manufacture, transport, placing, and testing of concrete used in the Work. 9
The metrology we follow for concrete works is as follows: 1. The contractor shall make sure the availability of aggregate, cement & equipment for producing the required volume of concrete. 2. The engineer shall submit mix proportion for the mix design, maximum size of aggregated allowed in the mix, specify the type of admixture in the mix design. 3. Quality of cement The quality of cement shall be tested before any work is to begin. 4. Units for measuring aggregates As specified in the mix design. (e.g. either in volume or weight basis). 5. The water we use for concrete mixing should be free of any contamination. Protection of water from contamination 6. It`s the engineer`s responsibility to check availability of enough number of mixer & vibrator for ensuring continues supply &compaction of concert ,and the contractor should ensure this . 7. Method of placing concrete ; Before placement of concrete, forms and reinforcement shall be inspected and approved by the engineer`s representative. Then the placing will be achieved by using one of the following; concrete pump, by using concrete chute or directly pouring from the mixer truck to its final position. 8. Workability of concrete for ensuring proper handling and placing of concrete without segregation /low, medium, high/ The concrete shall by the order of the engineer take slump test on site &make sure the water /cement ration of freshly mixed concrete is the limit of the mix design. 9. Casting test cubes The contractor shall cast test cubes any time by the order of the engineer.
2. ELECTOR – MECHANICAL WORKS 2.1.
Mechanical Equipment installation 2.1.1. Introduction This guideline given an Into how mechanical equipment is installed and commissioned also is been developed for correct installation, and handover of equipment in order for preventing its failure at a later date. Scope: This installation covers installation; commissioning and handover equipment is installation in general. Purpose: It provides a general instruction on how correctly to install, commission and handover a range of mechanical and electrical engineering system and also it establishes equipment installation 10
minimum requirements for Receiving equipment’s, Equipment foundation construction, installation, equipment commissioning and integration up to final certificate/handover. Applicability: it is compulsory for all planed sugar factory construction and future other industries.
Major activates on mechanical equipment installation
Receiving machine or parts 1. Receive machine 2. Temporary storage 3. Site construction 4. Assembling and Installation 5. Commissioning
Temporary Storage
6. System Integration 7. Defect liability period 8. Machine handover
Foundation construction Yes
No Assembling and Installation
Commissioning 11
System integration?
2.1.2. General guideline for Equipment Installation 1. Receive machine/parts from supplier/ Manufacturer either assembled or disassembled with its full documentation. The documentation should minimum include the below listed manuals. A.
Operation Manual
B.
Erection and Installation manual (Mechanical and Electrical)
C.
Spare part list manual
D.
Civil Drawing, Mechanical drawing and Architectural drawing Ref. Equipment list
S/N
Equipment Name
Description
1
Diffuser
Type=Electric variable speed type
U/M
Qty.
Origin
Status
Remark
Parts/disassembled Set
1
Foreign
12
Length= 65.9m Width=9.1m Height=11.3m etc.. 2
Pump
Type=End suction process
Set
10
foreign
Assembled
Set
2
Local
Parts/disassembled
Capacity= 750m3/hr Head=150m etc… 3
clarifier
4 Tab le 1.1 Sample Equipment list format. N.B The equipment list should minimum complete the above listed information. 2. Temporarily storing the machine/parts After receiving the equipment’s/parts should be handled with maximum care with the supplier recommendation. During temporary storing make sure: Appropriate material handling mechanisms are followed during loading and unloading of the equipment’s. All the equipment’s are stored in appropriate place in order to avoid rust, material damage, material exposed to outside temperature etc. All the equipment’s are in their protective casing. All the identification card is available on the equipment. Ref. Operation manual, erection and installation manual for safety machine handling and proper material handling. 3. Foundation construction Site Construction is where all construction for equipment, steel structure, office building and all supportive systems are included During the foundation construction make sure: The machine lay out is correct 13
The machine foundation is as per the design ( respective of each machine) The spacing between consecutive machine and the neighboring machine Enough working space is provided All underground electrical and sanitary constructions are provided (as per the design) Finally confirm for the foundation construction is capable for installation or not. Ref. Civil drawing, Mechanical drawing, erection and installation manual for respective of each machine/equipment 4. Start assembling/Installation process Before starting the assembling process make sure: To create awareness of basic safety procedures to be followed in all assembling process. All the material handling mechanisms are available, the tools used for assembling process are available (respective of each machine), weather you have enough available space/area for assembling and finally follow the installation steps for correct assembly. Pre-installation activates e.g. site accessibility, utilities availability, installation consumables, documentation availability Installation activities e.g. adhering to risk assessment ,other relevant safety standard ,authority to carry out activity to carry out the installation activities, providing of safe access and working arrangements, safe isolation of services ,disposing of waste items in a safe and environmentally acceptable manner, leaving the work area in a safe condition. Methods and techniques e.g. slings, cranes, fork lift, portable lifting devices, block and tackle ,rollers , hoists, jacks Making connections e.g. mechanical, electrical wired, fluid, power, utility service Testing that the installation works Checking and testing activities and testing activities e.g. input –to- output , functional testing ,self- diagnostics , emergent problem sequence ,injection and sampling, unit substitution Completing relevant paper work e.g. installation records, company specific paperwork, job card Ref. operation manual, erection and installation manual for each machine.
5. Equipment Commissioning
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Commissioning tests serve as a progressive transition between the erection , installation and the start of normal operation of the various plant systems. These tests may take place in-factory, on specific test facilities or on-site. The choice depends on the type of equipment, on the level of a system’s integration that can be simulated off-site and on the ability to obtain specific conditions on- site. plant commissioning tests cover all operations performed on equipment, systems and structures in order to ensure that they behave as specified in the design requirements. It also ensures new equipment is ready for occupancy and use,i.e. fit for purpose, train staff in the operation of new equipment and safety procedures, identify any minor defects which require rectification, receive all warranties and procedure manuals. Principles of The Method Since the main purpose of commissioning tests is to ensure that plant systems will perform according to their design, the analy0sis is based on reference documents that define and describe the system-related functional aspects and specification. This reference material is mostly obtained from plant system manuals and from specification in plant equipment lists.
2.1.3.2
SCOPE OF THE PLANT COMMISSIONING PROGRAMME
The plant commissioning phase ranges from installation to commercial operation.It is organized into tow test categories: A. Pre-operational tests and B. Initial start-up tests (operation tests). Pre-operational tests Pre- operational testing begins after completion of the erection and installation phase and it is normally completed before the initial core is loaded. Pre- operational tests are conducted using specific test procedures as well as operating procedures according to designers/ manufactures manual. The tests are organized by sequences so that the satisfactory completion of one test ensures the safe performance of subsequent tests (Conditional) Moreover, when a pre- operational test can not normally be completed before initial core loading, due to unavailability of associated equipment and/ or systems or when its results are deemed unsatisfactory, then the test may exceptionally be carried out or repeated after loading has taken place. However, neither test performance nor lack of test rest results may in any way conflict with the safety requirements. Initial start-up test (operational test) Operational tests are carried out under actual operating conditions. The operational test programmed is designed to meet the following major objectives: 1. Demonstrate that the plant unit operates in accordance with design bases, specifically with regard to safety requirements. 2. Show that the plant is capable of delivering output required under the specified operating conditions, 3. Provide measured data for use as a reference in subsequent plant operation during plant-life. 15
The Plant Commissioning Programmed is carried out in three main phases: Pre-operational test program Phase I: includes the preliminary tests and controls, the first start-up of equipment, functions or group of functions, without any interaction. Phase II: includes functional tests with supplementary equipment e.g. ambition water, steam etc.initial start-up test program me Phase III: includes actual start –up, including a “Demonstration Run”, up to “Commercial Operation Date”. Commissioning procedure: Pre- start up e.g. checking for damage, correct positioning, correctly secured, utilities operative, appropriate fluid levels, clear of obstructions, correct labeling, guards, fences and systems operative Methods, techniques and procedures e.g. running system (low speed), checking for leaks, sensory checks, incrementally load, conducting trial run, monitoring and recording measurements, shutting down and isolating Using instruments e.g. devices (such as alignment, measuring), testing, electrical measurement Completing relevant paperwork e.g. commissioning log/ report, corrective action report, job sheet, customer- specific documentation, handover report Ref. Operation and erection and installation manual 6. Equipment integration When the equipment is commissioned, the process element needs to be connected to the system and integrated to become a functional part of the process. Ref. operation and erection and installation manual 7. Maintenance during defects liability period The defects liability period is__________ (specify time). During the defects liability period the maintenance procedure should be established to include: Maintenance monitoring through maintenance records incorporating all comments, rectification works and any new defects. Each_________ (specify time )the superintendent is to provide a report to the principal indicating: Maintenance is required Maintenance has been undertaken Defects have been completed/ rectified New faults have been discovered Any recommendations, suggestions, comments or any other relevant issues needing attention or action 16
The reports are to be incorporated in to and the maintenance manuals as part of the quality assurance, recording and tracking of asset conditions. 8. Machine handover Prior to the end of the defects liability period, all the responsible personnel/ department in conjunction with the principal`s reprehensive and the principal consultant ensure that all final defects have been addressed and full operation is approved. Handover procedures: Run the installation Confirm all safety procedures are working Give instructions e.g. modifications, unusual features, operating instructions, service/ maintenance requirements Handover documentation People involved e.g. commissioning engineer, maintenance supervisor, production/ process supervisor Compete all relevant paperwork e.g. job card, installation and commissioning report, handover Paperwork Confirm handover of responsibility for the equipment.
2.2 Generic methodology of electrical system installation 17
2.2.1. Introduction A sugar factory is an area where different equipments with different capacity, power requirement, and way of installation, protection system, and control system is going to be performed. In order to properly manage and execute the required installation work, this methodology is by considering the major tasks expected to be done,
2.2.2 Objective The main objectives of this methodology can be summarized as to adopt or set: Safe, economical and harmonious working condition Time & cost effective project Ease installation work Reliable & quality system that meet the required standard 2.2.3. Codes & standards All codes and standards would be referred from EBCS -10 2.2.4. Scope This methodology is prepared as a guide line for the installation of the following main tasks. But methodology of some activities like equipment calibration, equipment setting, and modification works will not be included. High & low voltage system installation Equipment installation Telephone & data system installation Safety & security system installation Generator erection & installation and Test and commissioning
2.2.5. Planning & scheduling of the projected Period to start the installation work, it is mandatory to give answer for questions like what is the type of project, where is the location of the project, what major tasks of work of work are going to be done, what resources are required for accomplishing the work, how the work can be conducted, etc and how long it take to complete the project work, should be answered by the contractor. Man power required /human resource/. Materials and equipments required Time required /starting & completion date/. Financial & capital budget. Possible risks & their mitigation method.
2.2.6. Material handling methodology
Diversified types of electrical materials are supposed to be installed in factory (sugar factory), so during storing of these materials at site, means of storing or handling of these materials should be with consideration of the following steps. Identifying materials that can be stored indoor & out door 18
Identify materials requiring special care of handling due to adverse weather conditions like strong sun light, humidity , & cold weather and store accordingly.
2.2.7. Project team preparation For the execution of the demanded electrical system installation, the project manager allocates manpower with consideration of skill required to meet desired quality and finish the work within the allocated time schedule. Some of the main and common manpower required for electrical system installation are: Daily laborer Technicians or electricians Forman Supervisor Engineer Project manager Guard Clerk Administrator
2.2.8. Material transportation and Delivery Diversified types of electrical materials are supposed to be installed in a factory (sugar factory), so during supplying of these materials, means of transportation of these materials, means of transportation of these materials should be with consideration of the following steps.
Identifying construction order Identifying materials which need special care of transportation and transporting accordingly Check the materials arrived at site and cross check with the supplier material list Conduct possible test and inspection Write comment and record the result
2.2.9. Mobilization of project team and machinery Untimely mobilizing of the project resource (manpower, machinery) incurs the contractor cost of construction. Therefore a contractor should follow some of the following major steps when mobilizing of manpower, machinery, and other materials to site. Referring construction schedule Determine necessary resource for each task Prepare temporary accommodation(camp) for workers Mobilization of workers Preparing daily, weekly and monthly work progress format in collaboration with the client Preparing payment requisition format Preparing site diary format 2.2.10. General safety This section sets requirements for electrical safety. It specifically addresses working in restricted areas; working near exposed energized overhead lines or 19
parts; working on electrical equipment and systems; personal protective grounding; temporary wiring; disconnect and over current protection; groundfault protection; hazardous locations; and wet locations Follow all electrical safety rules during the process of all installation work Identify electrical system that is potential of hazard (step potential, touch potential, bare live conductors, improperly/ not grounded equipments metal body etc.) Awareness creation for non-electrical personnel (operators, welding technicians, truck drives etc) also the basic safety rules. Follow necessary safety procedures during installation of electrical devices like motors, control panels, distribution boards, generator etc to avoid cause of damage. When installing special hazardous areas like garages, fuel and other flammable material stores, battery rooms etc, follow the necessary safety rules. Make sure that any power carrying conductor is disconnected and grounded properly during installation work.
2.2.11. Installation of HV/LV system According to statutory (national) regulation, high voltage(HV) system is installed by the electric supplying authority (EEPCo).but in a sugar factory it very practical to generate electrical power that can satisfy the factory’s consumption and even for sale for other consumers.Soit is important to set a working methodology for the betterment of the mentioned objectives.
2.2.11.1. Installation of high voltage (HV) system Voltage above 1000V is classified as high voltage and needs guide line for safe (even it can cause fatal shock or death to a person who may step close to it) and good work practice. Disconnect & make sure that the system under installation is properly grounded before starting the installation work. Keep the recommended clearance distance (between conductors, between conductors and metallic structures, between conductors and body frames)during the installation work Measure the termination span (from one pole to another for over hand system or from one terminal point to another for underground system) and prepare wire for installation accordingly. Prepare all the necessary materials and fittings of transformer and perform fitting Install the porcelain insulators to the transformer. Prepare the disconnecting mechanism (disconnector) & install it.
Conduct the cabling installation system Provide all the recommended protection system (earthling, lightning 20
Protection, safety guard, fire protection, cooling system) Inspect & test the system procedurally Write comment report for the concerned body
2.2.11.2. Installation of low voltage (LV) system
Disconnect & make sure that the system under installation is properly grounded before starting the installation work. Keep the recommended clearance distance (between conductors, between conductors and metallic structures, between conductors and body frames)during the installation work Measure the termination span (from one pole to another for over hand system or from one terminal point to another for underground system) and prepare wire for installation accordingly. Prepare the disconnecting mechanism (disconnector)& perform the installation work. Provide all the recommended protection system(earthing, lightning protection, safety guard, fire protection,) Inspect & test the system procedurally Keeping the national standards and codes ofinsttallation of low voltage system for different purpose, install lighting system (indoor &outdoor),&receptacles(three phase & single phase),install equipments (motors, lathe machines, welding machines etc) Write comment report for the concerned body
2.2.12. Methodology for Electrical Equipments in sugar factory some of the main equipments require electrical installation are feed table, knife machine, shredder, conveyor belts milling machines, water and juice pump motors, centrifugal machine, sensors and control systems incorporated with all these machines. So this methodology is to offer guide line for proper and correct way of installing these equipments and attaining desired slandered & advantages. Identifying the type of equipments Preparation appropriate cable size Preparation of appropriate control and protestation components Design and manufacturer’s equipment installation manual Prepare working area Preparing necessary installation materials Follow all the recommended safety rules Installing the equipments procedurally Test and inspection 2.2.13. Generator assembling/ erection procedure All continuous process plants like sugar mills, paper manufacturing units, etc always require an uninterrupted input of energy in the form of electric power and steam to sustain the critical production process. In steam turbine based cogeneration system, the steam so produced is then expanded through a steam turbine to produce mechanical power/ electricity and a lowpressure steam. This installation manual is designed as a procedural guide for all steam generators. 21
2.2.13.1. Installation of turbine& generator system
Transportation, temporary storage Unpacking of the parts &checking/examining Placing of foundation bolts. Assembly of laminated rim. Stator assembly Pole assembly Field coil assembly Rotor assembly Turbine assembly Turbine shaft assembly Assembly of turbine coupling Assembly of trust bearing Bolting of spider shaft Assembly of guide bearings Installation of lubrication system Installation of rotor bearing Installation of Generator control system Installation of generator protection system Inspection and testing Commissioning of generator
2.2.13.2. Installation of water and steam line system Connecting the feed water source to the feed water inlet; Connecting the generated clean steam outlet to the clean stem outlet; Connecting the energy source (steam, boiler water, or high temperature water) to the unit; Connecting the condensate and steam/ water return line and piping it to the recycling system; piping the pressure relief valve to an acceptable vent and drain system; Wiring the applicable source of power (if the unit is packaged with an electrically activated pressure or control component);and Connecting the appropriate instrument (control) air source.
2.2.13.3. Connecting electrically/pneumatically activated controls
Install electrically/pneumatically activated water level control valves Install electrically/pneumatically activated pressure control valves Connect the correct power sources the above devices Installation of the control panels Test& inspection of generators (pre-commissioning) Write comment
2.2.14. Substation (switch yard) erection 22
Check for the preparation of structural foundation Erection of supporting structures Installation of over head systems (lightning protection& bass bars) Installation of equipments (voltage transformer, current transformer, disconnector, surge arrestor, transformer, control system, etc. Installation of protection(earthling and lightning protection)control system Test and pre-commissioning Write comment
2.2.15. Installation of protection system For safely operation of the factory, protection facility should be provided to aware during fire hazard, protect equipments and system electrical lines, factory buildings, & all infrastructures from lightning strike protect system & workmen form electrical hazards and etc.
2.2.15.1. Fire alarm system installation This guidance contains brief descriptions of the major components which go to make up a fire alarm system. Preparation of system drawing. See national(EBCS) standard Determine number of zones required Identify maximum alarm load per alarm zone Power supply requirement of the system Understand the type of detectors in the system (heat detectors, linear detectors, smoke detectors, light obscuring, light scattering, carbon monoxide detector) Conduct installation of sound system (horns or bells) Conduct installation of detectors Inspection and testing Write comment.
2.2.15.2. Earthling system installation Earthling of electrical system is required for a number of reasons principally to ensure the safety of people near the system and to prevent damage to the system itself in the event of fault. The function of the protective conductor or earth is to provide low resistance path for fault current so that the circuit protective device operate rapidly. The resistance of the earth path must be low enough so that the potential rise in the earth terminal and any metal work connected to it is not hazardous. Identifying the earthling system (direct connection to earth, neutral,combined,and separate) Selection of earthling materials(earthling conductor, bonding conductor, earth electrode,rod,p.lates,electrode derivatives) Determine point and location of earthling 23
Sorting of necessary materials and accessories Perform earthling/grounding/system Test & inspection
2.2.15.3. Lightening protection system installation
Design and working drawing Referring code and standard of lightning protection system. Preparation of down conductor Preparation of air terminal Preparation of clamping material Preparation grounding electrode Testing& inspection of down conductor and earth rode resistance
2.2.16. Testing and commissioning This testing and commissioning (T&C) procedure aims to lay down the minimum testing and commissioning requirements to be carried out on electrical installation in sugar factories. Such requirements are applicable to both new installation upon completion and existing ones after major alteration.
The objectives of the T&C works are i. To verify proper functioning of the equipment installation ;and ii. iii.
To verify that performance of the installed equipment /systems meet with the specified design intent through a series of tests and adjustments. To capture and record performance data of the whole installation as the baseline for future operation and maintenance. Preparation of testing and commissioning plan Preparation of test and commissioning procedure for systems Assign testing & comm... personnel/ team Conduct T&C for high &low voltage installations. Conduct T&C for safety and protection system Conduct T&C for equipments, control boards and distribution boards/ panels Conduct T& C for generator Analyze the result Write comment
2.2.17. Project energizing and site hand over After the proper testing and commissioning of the electrical installation, the contractor shall notify the appropriate authority, and conduct the energizing or operational test of the electrical system and hand over the project for the client after complete documentation of the result. Notify the concerned bodies Prepare the energizing procedure Step by step energizing (preliminary energizing) System energizing 24
Analyze the result Write comment, sign and submit for the responsible body He beginning of a new construction project is an exciting time. the new challenge is exhilarating and consuming. Possibilities seem limitless. But the excitement can quickly change to frustration and become a source of conflict when there are errors and discrepancies in the construction documents. Errors and discrepancies occur in construction documents on almost every project but they can largely be eliminated with some quality control techniques. Quality control in construction documents can be done by the owner, contractor, engineer or architect. Better still, it should be done by all of these parties as a team. Here are some ideas on how to get a handle on errors in construction documents:
Quality control in construction plans 1. Look for and correct incomplete, unclear and ambiguous statements. Proof read specifications, general and special conditions and contracts to eliminate words missing from sentences and sentences or line missing from paragraphs. Are sentences complete and do they have a meaning? Edit statement that conflict with other statements and make sure that the documents do not contradict each other. 2. Generally, a construction contract is between an owner and a contractor. A construction contract cannot bind sub contractors, manufacturers or suppliers hired by the contractor to perform work. Make sure that the contract documents and specifications assign work responsibility only to the contractor.
3. Define terms. Often an “inspection” is a requirement of the contract
documents but is not defined. When is the “inspection” required? By whom is it performed? Another example: “approved equal.” If using the term “approved equal “be sure to define how to get approval. 4. Verify that all technical reports are referenced. Include report dates and revision and addenda numbers. Quality control in project logistics
5. Review the architectural, structural and engineering plans to make sure
that they agree. Assumptions made about which set of plans is correct may be costly later on. Can the plants be built as shown? Constructing a window with a beam running through the middle will be embarrassing to everyone involved. 6. Ensure that the local building jurisdiction is correctly identified. Often construction documents are prepared from previously used templates. Make sure that job specific details like drawing submittal requirements, job location, delivery constraints and working hours are up dated.
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7. Once on the job make note of any conditions that are not as shown on the plans and communicate the actual jobsite conditions to all parties 8. Confirm that the drawings being used are current. If bidding on preliminary drawings makes sure that the most current version is available and is being used. If the drawings have been approved, are all required signatures and dates shown?
Quality control in ongoing communications 9. Prepare a document checklist and use it to identify missing documents and documents that need to be updated. This checklist can also be used to track submittals and shop drawings during that stage of the project. 10. Communicate with the owner, architect and engineer about construction document discrepancies so that they can be addressed and resolved and resolved quickly.
Quality control in bidding and invoicing 11. If alternates in construction materials or methods are listed in the job specifications make Sure that the bid form includes a place for the bidder to enter prices for proposed alternates. 12. Keep a set of drawing that shows construction progress on the job. This will help with payment processing and will make preparing record drawings at the end of the job easier.
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