Emk-elc-mst-000029 Mv Switchgear .docx

Construction, Completion, Furnishing and Maintenance for Kuwait International Airport New Passenger Terminal (Terminal II) Method Statement Medium Voltage Switchgear CPB & T2 Building & Switching Substation Doc.No: EMK-ELC-MST-000029/Rev.00

Date: 15/08/2018

REVISION HISTORY

Rev No

00

Date

15/08/2018

Description Approval / Reason For Prepared by Reviewed Checked by HSE Issue Electrical by Manager Engineer Electrical Engineer Issued for Internal JasonGAO Bilal ASIF M. MASSIHULLAH Review

Checked by Electrical Manager

Approved MEP Manager

Erol ZOR

Cem OGUN

CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

Table of Contents 1.

INTRODUCTION........................................................................................................ 2

2.

REFERENCES........................................................................................................... 2

3.

PREPARATION ......................................................................................................... 4

4.

CONTROL MEASURES ............................................................................................ 5

5.

WORK SEQUENCE................................................................................................... 6

6.

METHOD ................................................................................................................... 7

7.

QUALITY AND TESTING ........................................................................................ 12

8.

EQUIPMENT ............................................................................................................ 14

9.

RESOURCES .......................................................................................................... 15

10. SAFETY ................................................................................................................... 15 11. ENVIRONMENT....................................................................................................... 16 12. APPENDICIES ......................................................................................................... 17

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CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

1. INTRODUCTION This method statement covers the procedure to be followed during the planning, site preparation and installation of Medium Voltage Switchgear.  SCOPE OF WORK The scope of work includes and comply with Section 26 11 13 for switching substation, section 26 13 00 for Medium Voltage Switchgear at CPB and T2 Building in Kuwait International Airport Terminal 2. This document also describes a safe system of work through Risk Assessment. 2. REFERENCES This Method Statement makes reference to the following documents (Refer the ACONEX), and should be considered as part of a system of documents;                 

Quality Plan- LKW-QAC-PLN-000001 Inspection Procedure LKW-QAC-PRO-000001 Non-Conformance Report Procedure LKW-QAC-PRO-000002 Incoming Material Inspection Procedure LKW-QAC-PRO-000003 HSE Program LKW-HSE-PLN-000001 HSE Requirement for Subcontractors LKW-HSE-SPC-000001 Waste Management Plan LKW-LED-PLN-000003 Erosion and Sedimentation Control Plan LKW-LED-PLN-000001 Emergency Response Plan LKW-HSE-PLN-000002 Elmak Enerji QA/QC Plan LKW-QAC-PLN-000011 Elmak Enerji HSE Plan. Project Approved Shop Drawings Section 26 11 13 Section 26 13 00 MEW Regulations R-1, S-1 Inspection & Test Plan (ITP) - LKW-ELC-ITP-0000××× Approved Material submittal - MAS-LKW-MPW-000×××

2.1 RESPONSIBILITIES Top management of ELMAK is responsible to ensure that the responsibilities and authorities for relevant roles are assigned, communicated and understood within the ELMAK. MEP PROJECTS DIRECTOR  Responsible for the organization and good order of the project through the management and coordination of the different teams involved in the project, economic control and deadlines, monitoring the start-up and follow-up with the LIMAK.

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CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

 Observing, maintaining and enforcing ELMAK's policies and management systems: quality and environment, safety, occupational health and safety, and good corporate governance. MEP MANAGER  The MEP Manager is responsible for planning, design, fabrication on and installation works related to mechanical and electrical scope of works of the project in accordance to project specifications and requirements.  Ensure adequate resources and manpower in order to effectively implement the MEP works as required in the project specifications.  Establish the requirements related to specialist products / materials. i.e., source of materials, delivery constraints, or conditions under which personnel may work.  Ensure proper coordination with the QA/QC Department to ensure that all quality requirements are clearly specified for materials and equipment's in accordance to specifications.  Determine inspected activities in ITPs, Factory Acceptance Test (FAT) and maintain material inspection records such as Material Release Reports.  Determination of the working conditions of mechanical Sub-LIMAK. Getting the coordination between the LIMAK in the application.  Construction and approval of appropriate tests to test procedures.  Planning of equipment and materials supply and supply periods.  Follow up of the construction procedures. QUALITY ASSURANCE / QUALITY CONTROL ENGINEER  Verification of the implementation and effectiveness of the project quality system through quality system audits, surveillances, and management reviews.  Verification of the conformance of the project quality system (Project Quality Plan) with the requirements of the contract.  Verification of the establishment, implementation, and maintenance of the ELMAK Quality Plans.  Verification of inspection, testing, and other quality activities performed by ELMAK through surveillance.  Performance of appraisal audits of bidders if requested or if required to demonstrate competence and/or compliance with requirements. SITE ENGINEERS  Site Engineers are responsible to supervise, coordinate and monitor all site construction works which are assigned according to a particular section of the works by discipline. They report to their respective Managers.  Supervision of all field work including HSE, quality requirements and other facilities based on approved procedures.  Coordinate with Sub-LIMAKs at all meetings (where appropriate) in order to communicate and confirm sufficient work force to achieve performance commitments and project requirements.  Monitor and report progress against the construction schedule and arrange sufficient resources. 3

CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

 Report any discrepancies on any shop drawings and coordinate with Design & Drawing Department or resolution.  Maintain records related to the field work (material receiving report, concrete placement, pre-work execution check list and other quality records identified. 3. PREPARATION Prior to any works commencing permission to commence the work will be taken from the Limak and Supervision Engineer.  All equipment and material required to complete this task have been selected, approved and procured.  The work is planned to be executed during both day and night shift and as such temporary lighting towers will be mobilized to the site.  Establishment of access and emergency routes as per the Emergency & Rescue Plan.  Necessary Welfare facilities like drinking water, toilet facilities and smoking area shall be provided by the contractor.  Fire prevention & Fire Fighting.  Scaffolds and working Platforms.  Site Engineers and Supervisory staff  All equipment and material required to complete this task have been selected, approved and procured.  The work is planned to be executed during both day and night shift and as such temporary lighting towers will be mobilized to the site.  Permission from the Limak and Engineer will be taken for night works before any activity at night takes place.  Electricity is supplied to the Temporary site construction offices via Generators. And it is inspected by the contractor as per the manufacturer’s recommendation.  All approved submittals, drawings, Method Statement and ITP’s, are on hand for review by Engineer.  Elmak Enerji will inform in advance all related internal sub-contractors and if necessary will organize a meeting to prevent future problem during the installation of Medium Voltage Switchgear.  Welfare arrangements suitable for th amount of personnel at site shall be mobilized. 3.1 Material All material be used in this method statement shall be as per the schedule according to the Specifications 26 11 13 and 26 13 00.

3.2 Delivery, Handling, Storage and Material Inspection 3.2a Delivery and Transportation: 4

CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

 The switchgear has four lifting rings. It can be handled by cranes, forklifts or manual jacks. Take care to protect personal safety and possible property damage. Do not invert.  Crane lifting: · Choose the appropriate lifting ring and sling. · Dispose of the extraction unit (handcart) separately. 3.2b Delivery Inspection and intermediate storage :  The Elmak Enerji shall rised MIR via Limak to the Engineer upon delivery to site and internal inspection has done, the material shall be inspected through MIR request and accordance to approved ITP.  After the goods arrive at the scene, the following inspections should be carried out: · Check that the switchgear is in good condition and is damp; · Check the missing parts or shipping damage according to the packing list and issue a certificate to the shipper or the carrier; It is best to take pictures of the damaged parts.  Optimal intermediate storage conditions: (according to the minimum conditions required for switchgear and components) · Simply or no packaging required; · Dry and well ventilated storage room, air quality in accordance with relevant standards; · The indoor temperature is not lower than -5 °C; · no other harmful conditions; · Vertically placed switchgear; · Can not stack switchgear; · The cover on the cabinet should not be too much, ensuring good ventilation of the switch cabinet;Perform the necessary checks regularly before installation.

4. CONTROL MEASURES The sub-contractor and contractor shall confirm that there are sufficient personnel at the site to supervise the works that are taking place and to deal with any unforeseen event that may occur. Controls to be implemented are as follow:  Permit to Work for installation will be issued in accordance to the Contractors Permit to Work Procedure. Permit for Live works and LOTO shall be provided.  Security Guards at the access/ egress points shall confirm that only authorized personnel are permitted to enter the Project Site.  All manpower at site shall have their Personal Protective Equipment (PPE) on, and all safety measures shall be taken.  Safety shoes, Saftey Helmet, Reflectors, Goggles, Gloves are essential part of PPE and shall be taken under serious consideration during execution, installation ot even visiting and coordinating at the site. 5

CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

 The Subcontractor`s and Contractors MEP, HSE and QA/QC Team shall confirm that all works are completed as per the specifications of the contract.  Coordination meetings with the other trade contractors will be carried out in order to notify their interfacing works 5. WORK SEQUENCE     

Shop Drawings Preparation Delivery, Handling and Storage Inspection of material deliveries Installation of MEDIUM VOLTAGE SWITCHGEAR and its Termination Inspection and Testing

The above sequence shall be followed as a flow work chart mentioned below: 1. 2. 3. 4. 5. 6.

Material Preparation Shop Drawings Method Statements ITPs Others(if any)

Limak and Engineers Review Commets

Material Procurement and Delivery to Site

Rejected Material Inspection as per Approved ITPs

Installation of Switchgears as per ITP Rejected Inspection of Switchgears as per approved ITP

Connection & Termination of Switchgears with for Medium voltage cables Rejected Final Inspection

APPROVED BY LIMAK/ENGINEER

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CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

6. METHOD Prior to any works commencing all applicable drawings, inspection & test plans and safe work procedures will be disseminated to all appropriate individuals. All safety control measures that need to be implemented will be disseminated to the workers by their supervisor. 6.1 Examination & Preparation: The readiness and cleanliness of site shall be checked in accordance to the HSE requirements. 6.2 Pre-Installation:  Ensure that the civil work (Foundations) for Medium Voltage Switchgear location has been completed.  Ensure that size and dimension of Medium Voltage Switchgear are as per approved manufacturer drawings.  The risk assessment mentioning necessary control measures is attached to this method statement to follow and implement the requirements.  Site Engineer shall confirm that all material received at site are as per approved material submittal and also rating shall be verified.  There shall be adequate opening available for the Medium Voltage Switchgear to enter the Electrical room.  Ensure cable tray entry to substation and outgoing to transformer room cable routine correctly installed. Foundation for Medium Switchgear completed as per drawings. Placing, fixing and termination of Medium Voltage Switchgear is to be done during installation.  It shall be confirmed that the orientation of the Medium Voltage Switchgear with regards to the spare position size.  All the rating shall be as per the shop drawings and manufacturing data. 6.3 Installation of AIS: 6.3.1 Installation of cabinet  Firstly, according to the size of the design, the line of the whole row of screen cabinets is drawn up. According to the design position and size, the first cabinet is aligned with wire hammer and level ruler. According to the specifications, the verticality error of the cabinet should be less than 1.5mm per meter. If it fails to meet the requirements, the bottom cushion block of the cabinet can not exceed three and the cushion block can not be loosened. After meeting the requirements, the first disc 7

CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

should be welded on the four bottom corners of the switchgear cabinet or fixed with bolts for drilling holes.  After the first switchgear is installed, the other switchgear will be assembled according to the standard of the first switchgear. Usually the 11KV distribution cabinet is installed with the main transformer inlet cabinet as the first cabinet, and then assembled on both sides. If it is found that the horizontal error of the foundation channel steel is large, the installation position of the first cabinet of the main transformer inlet cabinet should be selected  In turn, the plates are positioned piece by piece close to each other. Check the screw holes between discs should correspond to each other, if the position is not correct, the screw holes can be repaired with a circular file. Take the Interdisc screw (don't tighten), take the first disc as the standard, adjust the disc with the crowbar, adjust the thickness of the pad iron and the tightening of the Interdisc screw, so that each disc meets the required requirements, and fix each disc in turn. Finally, it is required that the height difference of the top level of the cabinet should not be more than 5 mm, the irregularity of the cabinet surface should be less than 5 mm, and the gap between cabinets should be less than 2 mm. 6.3.2 Installation of busbar  Busbar manufacturers in cabinets are equipped. The installation of connecting busbar between cabinets should be correctly arranged according to the sectional drawing, phase sequence, number, direction and sign; the overlap surface of busbar should be tightly connected, and a layer of electric compound grease should be coated on the contact surface. Connecting bolts are fastened with moment wrenches, and their tightening moment values shall be in accordance with Specification.  he enclosed bus-bar bridge is measured from the manufacturer to the site and then sent to the site for installation after being manufactured by the manufacturer. Before installation, the scaffolding is erected. According to the installation height of the busbar bridge, the bus-bar boxes are lifted to the scaffolding one by one according to the installation drawings. When assembling and connecting, the bus-bar boxes are connected from both ends to the middle, and the busbar is adjusted by short wooden beam.Installation height of wire box should be adjusted by suspender at the place where suspender is installed. In splicing process, bolts between two busbar boxes should not be tightened. There should be some clearance to uniformly adjust the gap distribution of busbar bridge. After splicing the whole busbar box, the distribution of overall level and assembly clearance should be checked. After adjusting, bolts should be tightened step by step, and the suspender should be kept in position. Appropriate stress state. Bus installation shall meet the following requirements: 

Fixed or other supporting fittings of AC busbar should not be closed magnetic circuit 8

CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

   

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

When the busbar is horizontal, the upper part of the bus support splint should keep a gap of 1-1.5 mm with the busbar; when the bus is vertical, the upper pressure plate should keep a gap of 1.5-2 mm with the busbar. Busbar to ground and minimum electrical distance between phase and phase should comply with the regulation: 11kV not less than 125mm When installing busbar bridge, attention should be paid to the beauty of bus bridge body to ensure that it is horizontal and vertical, and the gap between bridge body and bridge body, cabinet body should be less than 2mm. Check busbar after installation

6.3.3Adjustment of circuit breaker and disconnector  Adjustment of circuit breaker (car type and fixed type switch are applicable): The vacuum circuit breaker manufacturer in high voltage switchgear cabinet has been adjusted. We are not allowed to disassemble and adjust on site. If some mechanical characteristic parameters of circuit breaker do not meet the requirements, the manufacturer should be notified to adjust on site immediately  Adjustment of disconnector (fixed switch applicable): Check whether the disconnector meets the specifications, and notify the manufacturer to adjust on site if it fails to meet the requirements. Specific inspection items of disconnector: threephase synchronization, eccentricity of contacts, contact with contacts  After the installation of the MV cabinet, it is necessary to conduct a comprehensive inspection and clean up the tools on the work site 6.4 Installation of GIS: 6.4.1 general requirments of equipment installation  Equipment installation must be carried out in strict accordance with the installation instructions of the equipment product manual and under the guidance of the manufacturer. The components and components assembled by the manufacturer shall not be disassembled during installation.  Work site should be kept clean. Workers should also keep themselves clean, wear clean overalls and use disposable gloves.  Before installation, the equipment should be inspected in good condition, and the pot insulator and protective cover are in good condition. Once the covering is removed during transportation, the installation of flanges must be completed uninterruptedly  Equipment installation should not be carried out on rainy days or on-site humidity is too high. 6.4.2 Installation of channel steel  Find out whether the highest point of embedded iron in civil engineering of indoor foundation steel meets the ground design elevation by level instrument; if it meets the design, the highest point of embedded iron in civil engineering should be the reference elevation; all elevations of steel in the same indoor must be the same. 9

CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

 Installation dimensions should be checked repeatedly before construction. Installation positions and dimensions should not be changed at will. The splicing of multi-row channel steel should be reduced as far as possible during cutting. Cutting cutters should not be used and any openings on channel steel should not be allowed.  Angle steel is added between foundation section steel and embedded iron in civil engineering to adjust the height of section steel. The welding between angle steel and embedded iron, angle steel and section steel should be firm  Paint should be perfected in time after installation of basic section steel  After installation, the top of the foundation section steel is 100 mm higher than the height of the ground.Obviously reliable grounding of foundation section steel at least 2 points per row  The errors in horizontal and vertical directions of foundation channel steel installation are not more than 1 m m/m, and the errors in full length are not more than 2 mm 6.4.3 Installation of Switchgear  Comparing with the design drawings, the cabinet is basically moved in place according to the number. The switch cabinet and the equipment inside the cabinet are firmly connected with each component. The model and specification of the switch cabinet are in accordance with the design. The paint of the cabinet body is in good condition.  Bolt connection is used to fix the cabinet, and direct welding connection is strictly prohibited between cabinets and cabinets  The switchgear alignment method uses wire hammer and steel angle ruler to leveling and alignment.  Verticality deviation of cabinet body less than 1.5m m/m  Horizontal deviation of the two adjacent cabinets is less than 2 mm, and that of the cabinets in rows is less than 2 mm.The deviation of adjacent two cabinets is less than 1 mm and the deviation of row cabinets is less than 2 mm.The indirect seam of the cabinet is less than 2mm.  he cabinet body and the foundation channel steel are bolted to fix the bolt with 2-3 bolts.  The grounding of cabinet body should be firm and good, and the open door equipped with electrical appliances should be reliably connected with the grounding metal frame by transparent sheathed bare copper soft wire.  Mechanical locking and electrical locking should be accurate and reliable.  The center line of the moving contact and the static contact should be the same, and the contact should be close. 6.5 Precautions:  Do not touch the power terminals.  Fix cubicle as soon as placed on foundation structure for prevent falling down.

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CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

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Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

6.6 Testing & Commissioning Procedure of Medium Voltage Switchgear: On-site commissioning must be carried out by the power supply department(MEW) or its accredited professional organization, or ask the manufacturer to send personnel to participate in on-site commissioning. The power supply department or a qualified professional organization shall calculate and design the various protection values, and the microcomputer protection device shall be input by professionals at the site. Close the Main circuit breaker of Incomer in testing substation Visual read and record the data of incomer electricity indication,phase voltage and Frequency.. Close the bus riser and section circuit breaker to see downstream indication and make records in energize report. According to the design drawings, the switchgear has on-site manual operation, remote operation and backup station operation, and has functions such as telemetry, remote signaling and remote control. The analog quantity of current, voltage, power, power factor and other continuous changes of the system can be continuously collected, analyzed, processed and recorded in real time, for some important quantities, such as the three-phase current, voltage, transformer power and capacitance of the busbar. The cabinet power factor, etc., as a constant, is displayed on the display in real time and has an over-limit alarm function. It can supervise and alarm the switch quantity and protection action in real time.At the same time, it is sent to the backup station for the operator to observe and operate at any time; and the status of the switch in each cabinet, accident trip, overcurrent, quick disconnection, temperature, etc. are recorded in real time for the operator to observe and operate at any time. Backup station operation, input the corresponding station number, switch number, combination, opening and other signals through the computer keyboard. Signals such as succession, closing, failure, relay failure, and switch status are displayed on the English interface, and the time, type, and switch number of the operation are recorded in real time 6.7 Connection From Generator Feeding to SWC panels:

 Transfer to generator occurs as soon as preset minimum load is meted the normal supply breaker will be open, and close the feeding from generator side cubicles.  There is a time delay of about 2 to 3 seconds after the normal supply cuts off for the relays to initiate the signal to the generator panels which will supply after there is no detection of normal supply in the time delay seconds.  If the normal supply load returns above preset value then the switch back to normal sequence will be started.

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CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

Transformer outgoing and 11kv DG outgoing Diagram

7. QUALITY AND TESTING Quality Assurance system will be operated in accordance ISO 9001:2015 unless otherwise accepted by the Engineer. All works shall be completed within the specification and quality level, Subcontractor and Contractor will confirm the following items are in place;  Approved Shop Drawings,  Approved Method Statements,  Approved Materials,  Approved ITP (Inspection and Test Plan)  Approved Subcontractor/s (if any)  Approval of Material Inspection (MIR) All inspection and testing will be carried out according to the approved Inspection and Test Plan in accordance to the specification requirements. (ITP Ref. No: LKW-ELC-ITP000021). Subcontractor to coordinate with Limak Electrical Representative Engineer to iniate the inspection 48 hours before inspection and testing time. Subcontractor/s shall confirm that each individual inspection activities accordance to the related Contractor's specified specifications and international standards and ITP. If any checks/examinations and tests given in ITP are evaluated and found “not acceptable” a Non-Conformity (NCR) will be raised. If the required corrective action has already been implemented, then no Non-Conformity will be raised. Inspection and testing for Medium Voltage Switchgearshall be undertaken in the presence of Engineer's. Where a Subcontractor/s involved in the task that will be evaluated as per the approved documents. Activities shall be controlled, monitored and measured using approved quality control forms, techniques or similar documents.

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CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

Material Certifications of MEDIUM VOLTAGE SWITCHGEAR and testing results shall be furnished and submitted to F+P/GC on daily basis through ACONEX for review and record.

7.1 Visual and Mechanical Inspection: Inspect exposed section of MEDIUM VOLTAGE SWITCHGEAR for physical damage and verify model and part No. as per approved manufacturer drawings. 7.2 Test Report: After testing and commissioning, all the reports and details shall be provided to LIMAK and Consultant for their approval before final operation. Testing and Commissioning procedures are mentioned above in Section 6. 7.3 Complete Emergency system test: After the above installation, complete Emergency system with MEDIUM VOLTAGE SWITCHGEAR and 11KV Diesel Generator feeding SWC labeld cabinet shall be tested for designed operation by initiate load factor of the Mains supply coming from transformer. Also the transfer system of MEDIUM VOLTAGE SWITCHGEAR shall be thoroughly inspected for proper operation in emergency cases. For gas insulated switchgear system,seal test has to be done before charge SF6 gas media following code required.Pressure monitoring,alarming,triging need to be tested by simulation. 7.4 OUT OF COUNTRY EQUIPMENT INSPECTION AND/OR TEST WITNESS. The contractor shall arrange for out of country factory inspection/test/training visit subject to engineer’s approval and as specified in section 01 45 29.

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CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

8. EQUIPMENT All equipment and plant will be supplied to the project site in good working orderand all will only be operated by competent qualified personnel that have previous experience of operating the equipment that they are using. Operators will complete daily pre-start checks at the beginning of their shift to ensure that the equipment is functioning in an efficient and safe manner. The plant and equipment required for this task is listed below in Table 1:

Sl No:

Equipment Type

Quantity

1

Helper’s Tool Box

2

Torque Wrench

3

Electric Drill

4

Round File Reamer

5

Hole Puncher

6

Cordless screw gun

7

Megger

8

Nylon hammer

9

Tape meter

10

Sling set

11

Multimeter

12

Lifting platform

1

13

Withstand voltage tester

1

14

Switch features tester

1

15

Multi-function test bench

1

16

Fork Lift

1

Min 1 each

Brand, Type/Model and Power.

Standard Tools and Equipment

TABLE 1

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CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

Materials required for the task should be detailed as below in Table 2; Material required Medium Voltage Switchgear

Quantity As per approved drawings and MIR

Remarks As approved by the Engineer

TABLE 2

9. RESOURCES Names and / or positions of key personnel for the task shall be as shown below in Table 2: Sl No: 1

Position

Number

Senior Electrical Engineer

1

2

Electrical Engineer

1

3

Foremen

2

4

Safety Engineer/ Supervisor

2

5

QA/QC Engineer

1

6

Electrician

2

7

Helpers

As per the Site Requirements. TOTAL

TABLE 3

10.

SAFETY

All activities that are taking place under this Method Statement will be performed in accordance with the contractors HSE Program LKW-HSE-PLN-00001 the salient points being; 15

CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

All Personnel/Workforce involved in the activity to be inducted, and received the required training/competencies BEFORE commencing the activity. Prior to this task commencing all persons involved in the task will take part in a toolbox talk / safety awareness delivered by the site supervisor and a member of the safety team; where they will have the salient points of the method statement and risk assessment explained to them along with what control measures they need to implement to mitigate the risks to as low as reasonably practicable” All personnel will wear the site mandatory P.P.E (steel toe cap boots, high visibility vest or jacket & hard hat) in addition to these any additional PPE requirements that have been highlighted on the Risk Assessment will be worn. Activity to be adequately supervised by competent staff (both Construction & HSE). Required Permits (including Permits to Work, if necessary) to be obtained ahead of time (BEFORE commencing the activity). All Plants/Machines/Vehicles/Equipment used in the activity to be pre-inspected and approved by the competent authorized personnel. HSE Procedures relevant/applicable to the activity to be reviewed by the Engineer/Supervisor In-Charge, and specific precautions to be conveyed to the Foreman/Charge-Hand and Workforce through JSTI and other forms of communications. Use adequate and visible HSE signage, posters and board to promote awareness. Ensure adequate rest areas (welfare facilities) are accessible. Supply toilets and cool drinking water at the vicinity of the activities prior to commencement of works. Engineer/Supervisor/Foreman/Charge-Hand to be familiarized with Emergency Response Plan & Contact Numbers. Emergency contact numbers to be posted on site. A Task Specific Risk Assessment has been prepared for this job and is attached an appendix to this document. The construction task will be monitored regularly and if it becomes apparent that improvements can be made in the process the methodology will be adapted as appropriate. Should this deviate from the risk assessment a Job Safety Analysis (JSA) will be prepared and the contents discussed with the work force.

11.

ENVIRONMENT

All activities that are taking place under this Method Statement will be performed in accordance with the contractors Waste Management Plan LKW-LED-PLN-00003 & Erosion and Sedimentation Control Plan LKW-LED-PLN-000001. All work has been assessed and planned so as to limit the adverse effect on the environment. All applicable controls will be implemented to ensure compliance with the applicable Legislation in Kuwait for the protection of the environment.

16

CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Rev. No: 00

Waste will be segregated and disposed of in a manner that does not cause excessive harm to the environment. All combustible waste are stored separately and all firefighting precautions are taken at the storage places as arranged by the contractor. Where applicable temporary roads will be damped down to reduce the amount of dust and dust clouds created. Any spills or accidental releases of substance will be notified immediately to the HSE manager or Environmental Engineer who will dispatch the spill response team, who will first prevent any substance finding its way to the water source- then will remediate the area as per the recommendations found in the MSDS, all persons of the spill response team will have been trained and issued with the appropriate P.P.E to deal with this. Spiling or accidental releases is not applicable for this MST.

12.

APPENDICIES

Appendix 1: Risk Assessment. Appendix 2: Emergency and Rescue Plan.

17

CONSTRUCTION, COMPLETION, FURNISHING AND MAINTENANCE FOR KUWAIT INTERNATIONAL AIRPORT NEW PASSENGER TERMINAL (TERMINAL II) Doc.No:EMK-ELC-MST000029

Method Statement for Medium Voltage Switchgear of CPB & T2 Building & Switching Substation

Appendix-1: Risk Assessment

Rev. No: 00

Project Name Doc Name EMK-ELCMST-000025

Kuwait International Airport New Passenger Terminal (Terminal II)

Risk Assessment for

Medium Voltage Switchgear CPB & T2 Building & Switching Substation

Doc No: Prepared Date:

11-08-2018

Residual Degree of Risk

Risk Degree

Falls, Slips & Trips leading to personnel injury

All site team

4

4

16

High Risk

Materials shall be stored in a way that it shall not block access/egress.

2

1

2

Site Engineers & Foremen

Poor Housekeeping

Cause fire

All site team

4

5

20

High Risk

1

4

4

Site Engineers & Foremen

Unsafe stored Materials

Cause injury

All site team

4

4

16

High Risk

Regular housekeeping shall be practiced and all waste shall be segregated at designated waste collection points. All materials shall be stored in a safe way. Proper illumination shall be provided for clear visibility.

2

2

4

Site Engineers & Foremen

Poor communication

Cause injury

All site team

4

4

16

High Risk

Educate the workers about their duties and responsibilities Copy of approved JSA should be kept at work area. Ensure that the workers are fully understood the job activities to be done by providing translation to appropriate language of nationality.

2

2

4

Site Engineers & Foremen

Result

Priority

Severity

Person Responsible for Control Measure(s)

Probability

Block Site Access & Egress,

Control Measure(s) to be implemented

Who Effected

Priority

General site works

Consequence of hazard

Severity

1.

Hazard and/or occurring of risk

Probability

Ref

Activity and Location

Risk Degree

Degree of Risk

1

Project Name Doc Name EMK-ELCMST-000025

2.

Use of power tools

Kuwait International Airport New Passenger Terminal (Terminal II)

Risk Assessment for

Medium Voltage Switchgear CPB & T2 Building & Switching Substation

In-appropriate PPE

Cause injury

All site team

3

4

12

High Risk

Drilling Operation: Tool jamming

Wrist/hand injury

Operator

4

4

16

High Risk

Doc No: Prepared Date:

11-08-2018

All involved crews get related safety training. Properly satey suppervising Offer suitable personal protective equipment. Check tool is appropriate for the job and used in accordance with manufacturer’s instructions. Work shall be under proper supervision. Ensure tools are maintained according to manufacturer’s instructions.

1

2

2

2

2

4

Site Engineers & Foremen

Site Engineers & Foremen

2

Project Name Doc Name EMK-ELCMST-000025

Electric shock

Kuwait International Airport New Passenger Terminal (Terminal II)

Risk Assessment for

Medium Voltage Switchgear CPB & T2 Building & Switching Substation

Serious injury or fatality

Operator

4

5

20

High Risk

Doc No: Prepared Date:

11-08-2018

Damaged cables shall not be used. Safe industrial sockets shall be used for connecting wires. & inspect the machine, cable and socket prior to its use every time. All electrical equipment including extension leads are subject to a regime of regular inspection by a competent person whom shall place a colour coded tag or sticker on the equipment if it’s found to be safe for operation. Prior to the task commencing the operative or his supervisor will visually inspect the equipment to be used for visible signs of defect, damage or misuse. Any equipment that is found to be defective will be removed to the workshop until such time that it can be made safe. Persons that are using this equipment shall be instructed on how to use the equipment properly ensuring that its carried by the handles not by the cable etc.

1

5

5

Site Engineers & Foremen

3

Project Name Doc Name EMK-ELCMST-000025

Night works

Kuwait International Airport New Passenger Terminal (Terminal II)

Risk Assessment for

Medium Voltage Switchgear CPB & T2 Building & Switching Substation

Poor visibility to crane operator

Insufficient lighting

falling from height cause by poor & insufficient lighting -Bodily injury

Doc No: Prepared Date:

11-08-2018

Operator

4

4

16

High Risk

lifting crew to wear reflective vest -tower light to be provided at lifting zone area. -to provide lifting crew with torchlight in case of tower light failure during lifting work. Fir-Adequate lighting to be provided inside the confined space when visibility is poor especially during night work -No work to be done unless that particular area been provide with enough lighting(50 lux). -Ensure all personnel wear safety clear glass.

1

2

2

All site team

4

4

16

High Risk

Fir-Adequate lighting to be provided inside the confined space when visibility is poor especially during night work No work to be done unless that particular area been provide with enough lighting(50 lux). Ensure all personnel wear safety Site supervisor and Permit applicant must make sure that the work area been provided with enough lighting before instructing the workers to work.

1

2

2

4

Project Name Doc Name EMK-ELCMST-000025

Kuwait International Airport New Passenger Terminal (Terminal II)

Risk Assessment for

Medium Voltage Switchgear CPB & T2 Building & Switching Substation

Doc No: Prepared Date:

11-08-2018

3.

Cutting & Drilling etc.

Flying particles in eye causing eye injury.

Resulting in minor/major eye injury

Operator

4

4

16

High Risk

Safety glasses and face shield shall be used.

2

1

2

Site Engineers & Foremen

4.

Welding Operation

Electrical shock

Injury to workers,

Welder

4

5

20

High Risk

All cables must be elevated 2m and not lying on the ground by means of insulated hangers. All electrical installation, supply hand tools to comply with regulation. Ensure proper earthing for residual current can be discharge.

2

2

4

Site Engineers & Foremen

Fire

burns, permanent disability due to explosion & damage to property .

Welder/ People nearby

16

High Risk

Fire watchman with workable fire extinguishers must be provided nearby the hot work area. To conduct daily checks on the uses of welding equipment. License Electrical Worker to conduct electrical inspection monthly basis. Monthly check list report must be submitted to the safety department. Avoid others to come near to the hot work area. Fire blanket to be erected to contain the welding & cutting spark. Welders must wear face shield for eye and face protection.

1

2

2

Site Engineers & Foremen

4

4

5

Project Name Doc Name EMK-ELCMST-000025

Kuwait International Airport New Passenger Terminal (Terminal II)

Risk Assessment for

Medium Voltage Switchgear CPB & T2 Building & Switching Substation

Doc No: Prepared Date:

11-08-2018

Qualified & appointed welders to carry out the welding works. 5.

Material handling

Manual handling during Installation

Injury to muscle system – upper limbs disorders

Workers

4

3

12

Medium Risk

6.

Use of mobile Scaffolding for any elevated work

Loss of balance/ falling down

Injury (either minor or fatal)

All persons

5

4

20

High Risk

Where possible manual handling will be avoided making full use of mechanical /hydraulic lifting aids. Where this cannot be avoided team lifting will be implemented where practicable. Loads will be assessed ensuring that they can be lifted or manipulated without causing harm to people. Team members should be able to communicate with each other. Personnel will be trained by the HSE department to the best techniques for lifting and protecting their back. All mobile scaffold should have proper caster wheel with locks, proper guard rail also – Scaffold tag system to be applied. Tag System Red Tag-Do not Use Scaffold. Green Tag-Use Scaffold. No Tag-Do not Use Scaffold.

1

3

3

Site Engineers & Foremen

1

3

3

Site Engineers & Foremen

Scaffolding team shall have a certified third-party training competency card. Full body harness only with double lanyard shall be used

6

Project Name Doc Name EMK-ELCMST-000025

Kuwait International Airport New Passenger Terminal (Terminal II)

Risk Assessment for

Medium Voltage Switchgear CPB & T2 Building & Switching Substation

Doc No: Prepared Date:

11-08-2018

by all during any work on scaffold. At any instance full body harness shall be hooked to scaffold. Continuous supervision will be in place throughout the job to ensure safe work procedure on scaffold. Fall from Heights, Material Falling, injuries or Personal Fall of Scaffold structure.

Injury (either minor or fatal)

Workers

5

4

20

High Risk

Scaffolders must be competent, should possess a certificate of competency. Scaffolding tagging system shall be used. Tag System Red Tag-Do not Use Scaffold. Green Tag-Use Scaffold. No Tag-Do not Use Scaffold.

1

3

3

Site Engineers & Foremen

Full Body Harness with Double Lanyard shall be used. Do not keep unnecessary material in platforms. All scaffolds shall have base plates. Ensure Scaffold is securely supported on a rigid ground. If required-Provide barricading in around the scaffold while erecting. All mobile scaffold should have proper caster wheel with locks, proper guard rail also –

7

Project Name Doc Name EMK-ELCMST-000025

Kuwait International Airport New Passenger Terminal (Terminal II)

Risk Assessment for

Medium Voltage Switchgear CPB & T2 Building & Switching Substation

Doc No: Prepared Date:

11-08-2018

Scaffold tag system to be applied.

7.

Fork Lift operation

Adverse weather conditions. High winds, extreme temperature and heavy rain.

Falls from height/ Falls of materials

Workers on scaffold and surrounding area

3

5

15

High Risk

Forklift fall

Resulting in personnel injury and/or property damage

Forklift operator & near by personnel

4

5

20

High Risk

Fall of lifted material

Resulting in personnel injury and/or property damage

Forklift operator & near by personnel

4

5

20

High Risk

Do not work at height in adverse weather conditions especially in rain and heavy winds. Scaffold Foreman/Supervisor shall check weather conditions prior to commencing work. Operator shall have a valid Kuwait driving license and a third party training card for competency. Pre-operation check shall be done prior to its use and the rated capacity shall be in accordance to the weight to be lifted. Ground conditions shall be monitored prior to use. Operator shall have a valid Kuwait driving license and a third party training card for competency. Pre-operation check shall be done prior to its use and the rated capacity shall be in accordance to the weight to be lifted. During the forklift operation personnel shall stay away from the load. Visibility for the operator shall not be blocked by the lifted load.

3

2

6

Site Engineers & Foremen

2

2

4

Site Engineers & Foremen

2

2

4

Site Engineers & Foremen

8

Project Name Doc Name EMK-ELCMST-000025

Kuwait International Airport New Passenger Terminal (Terminal II)

Risk Assessment for

Medium Voltage Switchgear CPB & T2 Building & Switching Substation

Doc No: Prepared Date:

11-08-2018

No loose material shall be lifted by the forklift.

8.

Crane operation

crane toppling

Fatal and/or property damage

operator & near by personnel

4

5

20

High Risk

Operator shall have a valid Kuwait driving license and a third party training card for competency. Pre-operation check shall be done prior to its use and the rated capacity shall be in accordance to the weight to be lifted. Ground conditions shall be monitored prior to use. Lifting supervisor to ensure that area is cordoned off and cleared of workers not related with lifting operation. Lifting Supervisor to ensure that warning signage is put up. Outrigger to be fully extended and rested on hard ground with steel plates. Lifting zone must be barricaded.

2

2

4

Site Engineers & Foremen

9

Project Name Doc Name EMK-ELCMST-000025

9.

Hurt by falling objects or hit by moving parts of crane

Kuwait International Airport New Passenger Terminal (Terminal II)

Risk Assessment for

Medium Voltage Switchgear CPB & T2 Building & Switching Substation

Serious Injury & Property damage

Nearby person

4

5

20

High Risk

Doc No: Prepared Date:

11-08-2018

Rigger shall have a valid Kuwait driving license and a third party training card for competency. Rigger to provide tag line to restrict swinging of load and to avoid unnecessary crossing of live lines. Rigger to ensure the load is properly secured before giving signal. Conduct Pre job instruction (PJI) Tool box meeting (TBM) before Lifting. Rigger must hold the tag lines to control swinging of load. All persons not stand under suspended load Ensure the Safe Working Load (SWL) of the lifting object before lift. Lifting area must be barricaded. Operator and signal man must properly communicate

2

2

4

Site Engineers & Foremen

10

Project Name Doc Name EMK-ELCMST-000025

10.

Use of Electrical Testing Instrument.

Kuwait International Airport New Passenger Terminal (Terminal II)

Risk Assessment for

Medium Voltage Switchgear CPB & T2 Building & Switching Substation

Electric Shock

Minor / major shock

All people involved in the task

4

4

16

High Risk

Flashing or arcing

Electric shock Burn Eye damage

All people involved in the task

3

5

15

High Risk

Doc No: Prepared Date:

11-08-2018

Follow the manufacturer’s specifications for safe use. Provide earthling of the testing equipment. 1. Do not disconnect the test leads for at least 30 to 60 seconds following a test, allowing time for capacitance discharge. Restrict the testing area only for authorized people. Non-conductive hand gloves shall be used.

Follow the manufacturer’s specifications for safe use. Do not disconnect the test leads for at least 30 to 60 seconds following a test, allowing time for capacitance discharge and thus prevent spark.

2

1

2

Site Engineers & Foremen

2

1

2

Site Engineers & Foremen

2. 3.

Use low voltage testing instrument or a series resistance. 4. Nonconductive hand gloves shall be used. 5.

11

Project Name Doc Name EMK-ELCMST-000025

Kuwait International Airport New Passenger Terminal (Terminal II)

Risk Assessment for

Medium Voltage Switchgear CPB & T2 Building & Switching Substation

RESULT Intolerable Risk (25) Important Risks (15, 16, 20) Mid-Level Risks (8, 9, 10, 12) Acceptable Risks (2, 3, 4, 5, 6) Unimportant Risks (1)

Date

Description/ Reason for issue Issued for Internal Review

Doc No: Prepared Date:

11-08-2018

ACTION STOP activity and make immediate improvements. Assess whether this task needs to be completed. Works cannot be started until this risk has been significantly reduced STOP activity and make immediate improvements. Works cannot be started until this risk has been significantly reduced Aim to reduce the risk within the next 7 days Aim to make improvements by the time of next review Carry on with works

Prepared by HSE Engineer JamesPENG

16/8/2018

12