Arabian Industries Projects LLC

PROJECT : AL NOOR MGI ,SAKHIYA MINIFLOOD & ZALZALA GAS INJECTOR CONSTRUCTION

CLIENT : PETROLEUM DEVELOPMENT OMAN L.L.C

CONTRACT No : C 311211

MAIN CONTRACTOR : ARABIAN INDUSTRIES PROJECTS L.L.C

AIP PROJECT : P1201014

TITLE:METHOD STATEMENT FOR INSTALLATION & TESTING OF UPS /

BATTERIES

Doc. No.: ANR-107-104265-BA-6070-43010-0001

Rev Date DescriptionPrepared

ByReviewed

By Checked By Approved By

DE QA\QC CM PDO

01 05.03.13 Issued for Approval SIDDESWARA Gopa Kumar

Area Contract Management

Arabian Industries Projects LLCSub Area Quality Management

Sub Doc Type Method Statement

Title / Description

Method Statement for Installation & Testing of UPS /BATTERIES

Area Code Facility Code Originator Code Discipline Doc

TypeSequence

No. Sheet

ANR 107 104265 BA 6070 43010 0001

Al Noor MGI , Sakhiya Miniflood and Zalzala Construction

Contract No. C311211Method Statement for Installation & Testing of

UPS/BATTERIES

INDEX

Sl. No. CONTENTS Page No.

1.0 INTRODUCTION 3

2.0 SCOPE 3

3.0 REFERENCES 3

4.0 EQUIPMENT & INSTRUMENTS 3

5.0 ABBREVIATIONS 3

6.0 RESPONSIBILITIES 4

7.0 UPS INSTALLATION 4

7.1 RECEIVING OF MATERIALS 4

7.2 TRANSPORTATION OF UPS TO THE LOCATION 4

7.3 ASSEMBLY & ERECTION 5,6

7.4 BATTERIES & ACCESSORIES 6

7.4.1 BATTERY [Ni-cd] 6

7.4.2 ELECTROLYTE 6

7.4.3 INTER CELL CONNECTIONS 6

7.4.4 TESTING 7

7.5 BATTERY CHARGER 7

8.0 HEALTH SAFETY & ENVIRONMENT 8

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Contract No. C311211Method Statement for Installation & Testing of

UPS/BATTERIES

1.0 INTRODUCTIONThis procedure establishes the method for installation & commissioning of UPS System, Battery and Battery Charger.

2.0 SCOPEThis procedure covers the installation and commissioning of UPS System, Batteries and Battery Charger for the project-AlNoor MGI,Sakhiya Miniflood & Zalzala construction project.

3.0 REFERENCESSP-1099 Electrical Installation Practice.SP-1109 Specification for Earthing and Bonding Procedure.DEP–63.10.08.11 Field commissioning and maintenance of electrical

Installations and equipment.

4.0 Tools and equipment required Vehicle mounted crane Lifting belt and “D’ shackles Hiyab Truck Toolbox with complete set of tools Safety belt.

4.1 Instruments required 500 – 5000V insulation tester Torque Wrench Earth Tester Fluke Multimeter, clamp meter Tool box with complete set of tools

5.0 ABBREVIATIONSDM De-MineralisedITP Inspection and Test PlanNi – Cd Nickel – CadmiumQC Quality ControlUPS Un-Interrupted Power SupplyPDO Petroleum Development of Oman AIP LLC Arabian Industries Projects LLC

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Contract No. C311211Method Statement for Installation & Testing of

UPS/BATTERIES

6.0 RESPONSIBILITIES

6.1 Electrical Engineer /Testing Engineer/ Supervisor/VendorElectrical Engineer /TE/ Supervisor /Vendor is responsible for the following activity including, but not limited to

Confirming the Installation locations from schedule of approved construction drawings.

Organizing tools and equipment required to the work site. Assigning work crew. Sequence of activities is carried out for the work as per this procedure. Maintaining all Safety Regulations. Notification to the QC for inspection on completion of activities.. Ensuring approved method and material are being used and

conformance of the specifications. Coordination with Vendor for testing & commissioning.

7.0 UPS INSTALLATION

7.1 Receiving of materials: When UPS is received, check against manufacturer's drawings to ensure

correct material is delivered.

7.2 Transportation of UPS to the location: Ensure the access to Control Room /Sub-station is available in all

respects as per drawing before transporting the UPS. Ensure that the lifting gears, slings and spreader bar are of adequate

capacity and certified. Ensure that the correct equipment is transported from store to the

erection site by using proper material handling equipment and tackles in a safe way and shifted to the required area. Use the lifting hooks is permitted only for lifting the panel.

Unload the UPS to the access platform and place it above pipe rollers / trolleys. Transport the UPS System Cabinets on the floor by means of rollers or wooden boards.

Ensure that the UPS is properly supported during the transportation from stores to site.

7.3 Assembly & Erection: Ensure that the approved equipment layout, schematic drawings and

other reference documents are available at site. Ensure the foundation is released by Civil for the erection. Ensure Heat Ventilated Air Conditioner (HVAC) is functioning inside

Control Room / Sub-station.

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Contract No. C311211Method Statement for Installation & Testing of

UPS/BATTERIES

Ensure that valid work permit & electrical safety documents are available for carrying out the job.

Ensure that approved / recommended tools and tackles of appropriate type are available.

Check the false flooring, cable entries, and floor supporting steel work, for levelling and cleanliness, before transport of UPS System cabinets.

Prepare the necessary mounting base frames and place them at the location as per the Control Room Layout drawing.

Unpack the UPS System Cabinets at the designated position, as per the layout drawing. The crates to be cut by saw only.

Level the base frames. Liners are to be inserted close to the anchor bolts, to ensure proper levelling.

Align the UPS System Cabinets accurately and fix (bolt) their base frames with the mounting base frames.

Check foundation and base frame with drawing for correctness of bolt fixing holes and correct level all through the foundation frame.

Ensure that the equipment to be installed has been already inspected. Inspect the equipment for possible damages during transport. Make sure that the cut-out made on the ground floor slab / raised floor

for cable entry does not foul with the equipment. The transport eyehooks have to be strained perpendicularly. Install the equipment on the pedestal matching with the central lines

already marked. Ensure fixing bolts provided by vendor are used at all positions & are

tightened properly. Ensure for perfect verticality and proper alignment as each section is

completed. Check for proper alignment and intactness of door gaskets etc. Tighten the panel couplings etc. to the required torque level as

mentioned by the manufacturers. Ensure connections of all power, control and earth bus are completed as

per drawing. Ensure that the earth buses on the either side of the panel are

connected to the main Earthing grid. Connect all Incomer Power supply, Battery Bank connection and

Outgoing Feeder Cables, as per relevant technical approved drawings. Application of touch - up paint wherever required. Ensure proper mounting of instruments, relays, meters, and indication

lamps which are supplied loose. Ensure all the inter panel wiring is completed as per the drawing. Ensure all external power / control cabling and terminations are

completed as per approved drawing.

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Contract No. C311211Method Statement for Installation & Testing of

UPS/BATTERIES

Ensure that the equipment identification / labels are properly placed as per approved drawing.

Switch-off all the circuit breakers. Set the UPS service bypass switch in normal operation. Switch-on the Incoming Power supply, and check the voltages at the

Incoming terminals of the UPS. Power-on the UPS System - Rectifier circuit. Check the Rectifier output voltage. Check the Polarity at the battery terminals. Switch on the Battery connection. Switch on the Inverter circuits. Check the UPS Inverter Output voltages. Check the functioning at all modes of operations - such as normal,

redundant and bypass, and rectifier fault, inverter fault, etc.

7.4 Batteries & Accessories:

7.4.1 Battery (Ni - Cd): Batteries are shifted and kept in a secured place before the installation. Corrosive materials like acid / alkalis are kept separately with danger

notice to caution the unauthorized handling of such substances. Check the flooring, for levelling and cleanliness, before transport of

Batteries and other accessories. Exhaust facility is made ready before mixing and filling operation of the

electrolyte. Ensure the batteries are kept in upright position throughout the

sequence of the installation. Batteries are assembled in its racks before electrolyte filling operation. Assemble the Battery Rack as per the relevant approved drawings /

Manufacturing Drawing. Position the battery racks as per the layout drawings.

7.4.2 ElectrolytePrepare the required quantity of Electrolyte as specified below and also with reference of manufacturer specification. Use clean plastic vessel for preparing electrolyte. Electrolyte mixing is done in a controlled manner without any spillage

and over heating of electrolyte to be controlled during preparation. Add the appropriate quantity of Lithium Hydroxide crystals, as

recommended by manufacturer, with constant stirring. Add Potassium Hydroxide flakes, as recommended by manufacturer,

with constant stirring.

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Contract No. C311211Method Statement for Installation & Testing of

UPS/BATTERIES

After cooling the solution at room temperature, add DM water to adjust the density as required.

Remove the transport seal from the vent cap of battery cells. Check the Electrolyte levels in all the battery cells. Add the electrolyte into the battery cells, using a siphon or a clean

plastic funnel and jug, from the top of vent. Check the battery cells for electrolyte levels after 30 minutes, and add

the electrolyte, if the level has dropped.

7.4.3 Inter Cell Connections Place the battery cells on the rack suitably, so as to permit connection of

the Positive and Negative terminals, according to the wiring diagrams. Connect inter - cell and inter - row connections by using Ni plated lugs. Use the correct torque wrench, for the torque settings recommended by

manufacturer. Connect the battery bank terminals to the charging equipments, viz. UPS

or Battery Charger. Ensure that the terminal connections are made as per the approved

drawings and that sufficient grease is applied on the terminals. The completed batteries are released to the testing team for further testing.7.4.4

Testing Verify the polarity of all the cells are in the order before connecting the

battery links. Links are tightened to the manufacturer’s recommendation.

Check the polarity at the battery terminals. Perform the final check up for completion of the installation. Ensure that cell vent caps are in closed position before charging. After installation & necessary terminations hand over to Vendor

Engineer for their necessary testing, pre-commissioning & Commissioning activities.

Provide necessary assistances for testing, pre-commissioning & Commissioning of UPS to the Vendor Engineer.

Check for the duty cycle (charging / discharging) of batteries as per Manufacturer specification.

7.5 Battery Charger: Check the flooring, cable entries, and floor supporting steelwork, for

levelling and cleanliness, before transporting of Battery Charger. Prepare the necessary mounting base frames and place them at the

location as per the Layout drawing. Transport the Battery Charger on the floor by means of rollers or wooden

boards. Unpack the Battery Charger at the designated position, as per the layout

drawing. The crates to be cut by saw only.Document No. Revision No. Page No.

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Contract No. C311211Method Statement for Installation & Testing of

UPS/BATTERIES

Level the base frame. Liners to be inserted close to the anchor bolts to ensure proper levelling.

Align the Battery Charger accurately and fix (bolt) their base frames with the mounting base frames.

Connect Incomer Power supply, Battery bank connection and Outgoing Feeder Cables as per relevant technical documentation.

Carry out the Installation checks. Provide touch - up paint wherever necessary. Switch off all the circuit breakers. Set the Battery Charger switch for manual operation. Switch on the Incoming Power supply, and Check the voltages at the

Incoming terminals of the Battery Charger. Power on the Boost charger first and then the float charger. Check the Polarity at the battery terminals. Check the Charger output voltage and battery bank voltage. After both these voltages reach the same level, allow the battery bank

to trickle charge across the float charger. Switch over to the auto operation of the Battery Charger. Check the functioning of all modes of operations - such as normal - auto / manual, Float /

Boost charging and Fault diagnostics, etc.8.0 HEALTH SAFETY & ENVIRONMENT

Before commencement of this activity all the personnel shall be briefed about the possible risk & hazards associated with the job. In general following precautions shall be taken while handling and assembly of Structural steel material.

a. Permits available in the site prior to the commencement of the work.b. Involved personnel shall be provided with appropriate PPEc. All equipments shall be checked for the general safety, prior to use.d. Only trained & competent personnel shall be allowed for the work.e. The work area shall be barricaded by the warning tape.f. In case of emergency applicable approved emergency plan shall be followed.

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