ADP-263623-007 R0 Generator Synchronizing Panels
ADP-263623-007 R0 Generator Synchronizing Panels
ADP-263623-007 R0 Generator Synchronizing Panels
Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 2 of 22 Rev 000
Hold
Para. Description of Hold
No.
Page 2 of 22
Abu Dhabi Plaza – Astana, Kazakhstan Document No.
Work Package 4 – Main Works ADP-263623-007
Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 3 of 22 Rev 000
Table of Contents
1.0 Purpose
3.0 References
5.1 Competency
5.2 Roles and Responsibilities of Commissioning Engineer
5.3 Roles and Responsibilities of QC Engineer
5.4 Roles and Responsibilities of Foreman
5.5 Roles and Responsibilities of Equipment Specialist
7.1 General
7.2 Pre-Commissioning
7.3 Commissioning
7.3.1 LV Panel Installation Tests
7.3.2 Synchronization and Load Share Test
7.3.3 Interfacing
9.1 Induction
9.2 PPE
9.3 Hazard Identification, Risk Assessment & Control
9.4 Toolbox Talks
9.5 Permit to Work
9.6 Environmental Impact
9.6.1 Safety Training
9.6.2 Trades & Qualifications
9.7 Training of Personnel
10.0 Attachments:
10.1 Inspection & Test Plan (ITP) – Generator Synchronizing Panels: ITP-1122-407 T&C
10.2 Form No: FM-MS-ADP-263623-007-001
10.3 Form No: FM-MS-ADP-263623-007-002
10.4 JSTI
10.5 Risk Assessment
Page 3 of 22
Abu Dhabi Plaza – Astana, Kazakhstan Document No.
Work Package 4 – Main Works ADP-263623-007
Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 4 of 22 Rev 000
1.0 PURPOSE
The main purpose of this method statement specifies the sequence and methodology for the execution of the
Generator Synchronizing Panels Testing and Commissioning in this project.
3.0 REFERENCES
Project Health & Safety Plan ADP-013529-002.
Specifications: 260126 – Operation, Maintenance, & Testing of Electrical Systems
Specifications: 263623 – Automatic Transfer Switches
Approved Testing & Commissioning Plan by CML, Ref.ADP-CML-CO-RPT-W-00016
General Method statement for winter working, Ref. No.: ADP-015000-036
Risk Assessment Plan Ref. No: ADP-013529-028.001.
Project Quality Plan Ref. No.: ADP-014000-020
QMP Ref.: ADP-014000-040 rev.003 Field Inspection & Testing.
Fall Protection Procedure, Ref No: ADP-013529-026
Lock-Out and Tag-Out, Ref No. ADP-013529-026
Generator LV Switchgear Panel Sequence of Operation: ADP-262413-042
Block B - Outline Drawings & Wiring Schematics for Generator Power Synchronization &
Distribution Panel: ADP-262413-021
Block O – Outline Drawings & Wiring Schematics for Generator Power Synchronization &
Distribution Panel: ADP-262413-022
Block P - Outline Drawings & Wiring Schematics for Generator Power Synchronization &
Distribution Panel: ADP-262413-023
Block R - Outline Drawings & Wiring Schematics for Generator Power Synchronization &
Distribution Panel: TBA
Method Statement for Testing & Commissioning of Main Distribution Board: ADP-262413-027
4.0 DEFINITIONS
MML: Mott Macdonald LTD.
CSC: Construction Supervision Consultant. (AECOM-KZ)
ACCL JV: ACCL Joint Venture.
RBG: Robert Bird Group (JV Design/Structural Consultants).
P & T: P & T Architects (JV Architect/Lead Design).
RED: Red Group Services FZ-LLC Dubai, UAE (MEP design consultant).
PPE: Personal Protective Equipment.
MIR: Material Inspection Request
MAR Material Approval Request
CXA: CML International (Commissioning Authority)
Page 4 of 22
Abu Dhabi Plaza – Astana, Kazakhstan Document No.
Work Package 4 – Main Works ADP-263623-007
Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 5 of 22 Rev 000
Equipment Specialist
5.1 Competency
The competency of all construction personnel shall be controlled in accordance with the
Competent Persons Designation Procedure Ref: ADP-013529-066.
Page 5 of 22
Abu Dhabi Plaza – Astana, Kazakhstan Document No.
Work Package 4 – Main Works ADP-263623-007
Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 6 of 22 Rev 000
The following tools & equipment will be used during the Testing and Commissioning of the Synchronizing
Panel.
Standard Electrician Tool Kit
Digital Multimeter
Torque Wrench
Insulation Resistance Tester
Hi-Pot Tester
Low Resistance Ohmmeter
CB Full Function Test Kit
Secondary Injection Test Kit
Load Bank (Resistive Load)
Scaffolding/Ladder
PPE (Hand Gloves, Safety Goggles)
Safety harness while working in high level in ladders or scaffolding
Note: All tools and equipment’s will be inspected and colour coded before use at site. All testing
instruments shall have valid calibration certificates.
7.1 General
All necessary work permits shall be approved before commencement of the work.
Prior to commencement of work, a tool box meeting shall be held for proper distribution of testing
personnel and relocation of other workers working during the testing.
Prior to start the work, conduct pre-work start tool box talk and related method statement shall
be read and signed off by concerned engineers.
All personnel involved carrying out the testing activity shall be briefed via HSE Tool box talk, on
site condition, work area, task in hand, risk, hazards, and mitigation of potential of risk.
Secure valid calibration certificate for all testing equipment, which will be used for test.
All safety precaution shall be followed as per established project safety plan.
Only experienced and skilled technician shall be engaged for carrying out the start-up and
commissioning of the Synchronizing Panel.
Appropriate warning signs and tapes shall be placed during start-up and commissioning as
required.
All PPE shall be worn as appropriate according to the nature of job.
Work area shall be maintained neat and clean.
Lock-Out & Tag-Out procedure (Ref. ADP-013529-026) shall be followed during entire activity
related to Testing and Commissioning as applicable
Page 6 of 22
Abu Dhabi Plaza – Astana, Kazakhstan Document No.
Work Package 4 – Main Works ADP-263623-007
Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 7 of 22 Rev 000
7.3 Pre-Commissioning
Room conditions shall have a maintained room temperature of about 25°C and the room must
have sufficient lighting and ventilation.
Ensure Synchronizing Panel installation is completed with RFIT signed off.
Ensure Generator is tested with RFIC signed off or Generator installation is completed
with RFIT signed off if it is to be tested simultaneously with the Synchronizing Panel.
Ensure LV Cable is tested with RFIC signed off.
Ensure ATS is tested with RFIC signed off.
Ensure Earthing System is completed with RFIC signed off.
Ensure latest approved shop drawings, system layout, schematic diagram, equipment
schedule, method statement & T&C checklists are available at site.
Verify the nameplate data and tags match with the drawings or schedule.
Verify ratings, quantity, and make for all components in the nameplate as per drawing or
design specifications.
Check for the metering, indication lamps, and selector switch arrangements on the panel.
Check tightness and termination of the cable entries.
Check the equipment in respect of any exterior damages.
Check the equipotential bonding of the equipment.
Check the drawing in the pocket is available.
Check the cables are bunched neatly and dressed properly.
7.4 Commissioning
After the pre-commissioning, has been completed, the system will be ready for Testing and
Commissioning. The entire system will be checked for full functionality as per the project specific
sequence of operation. The system is applicable only to generators running in parallel (Block B, P,
O, & R) and will be sequentially tested and commissioned.
Synchronizing Panels shall be tested according to the approved T&C method statement
of Main Distribution Board (ADP-262413-027). The tests to be carried out where
applicable are as follows:
Torque Test.
Insulation Resistance Test (Before and After Dielectric Test).
Dielectric Test.
Contact Resistance Test on the busbar with the bus coupler closed.
Circuit Breaker Test for Electronic Trip Units.
Current Transformer Tests (Secondary Injection).
Energy Meter Test (Secondary Injection).
Mechanical and Electrical Operation Test.
Refer to the Forms in ADP-262413-027 and record the results relevant to synchronizing
panels testing.
Page 7 of 22
Abu Dhabi Plaza – Astana, Kazakhstan Document No.
Work Package 4 – Main Works ADP-263623-007
Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 8 of 22 Rev 000
The Actual Testing Condition and Consequence or Result shall be fully described in the
report. Testing may include simulated conditions or manual overrides and control. Verify
the load sharing parameters as well and record the measurements in FM-MS-ADP-
263623-007-002.
7.4.3 Interfacing
Integration shall be validated during the testing & commissioning of BMS and FAS.
MEP RFIC should be issued by T&C Engineer for verification before submission to CSC & CxA.
Refer to ITP No. ITP-1122-407 T&C and strictly follow inspections steps.
Refer to QMP-ADP-014000-625 for RFIC submission process.
Work should be approved by consultant (submitting RFIC).
9.1 Induction
Prior to commencing work all personnel shall have attended the HSE induction course conducted by the
JV HSE department. No work shall be undertaken by personnel who have not attended the Project HSE
induction. In all aspects, work is to be carried out in a safe manner and in accordance JV approved Health
and Safety Plan and in accordance with HSE requirements
All personnel involved in the Testing and Commissioning will comply with the Project requirements for
PPE:
Work Boots with toe protectors
Safety Helmet
Eye Protection with side shields
Dust masks (as required)
Additional PPE identified by the task risk assessment shall also be provided. Personnel shall sign and be
responsible for their own items of PPE issued to them and the Engineer shall ensure that his team is
complying with the minimum required PPE and that damaged or defective PPE is replaced or repaired
immediately.
Page 8 of 22
Abu Dhabi Plaza – Astana, Kazakhstan Document No.
Work Package 4 – Main Works ADP-263623-007
Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 9 of 22 Rev 000
Hazard identification, risk assessment and control are detailed in the appropriate risk assessment and
Job Safety Task Instruction (JSTI) attached herewith. Hazards may vary as the works progress and shall
be re-evaluated. All personnel undertaking testing and commissioning activities shall be aware of
particular location hazards. The Project Risk Assessment Procedure ADP-013529-028 is to be referred
to during the planning stages. Should changes occur during the course of commissioning which alters
the associated risks then the risk register shall be updated to reflect any additional risk and mitigation
measure.
The attached JSTI is provided to cover the initial work tasks relating to Testing and Commissioning of the
Generator Synchronizing Panels- JSTI (attached). This JSTI is prepared based on theoretical information
interpreted from the project documents. A further assessment will be required at the actual work site to
verify the control measures and address any additional hazards. Reference is to be made to the relative
Health, Safety, Environmental & Security procedures to control the risks associated with activities where
they occur.
Prior to the commencement of site activities the Engineer, with support from the HSE Officer, shall
conduct a pre-start toolbox talk with all the crew present. The MEP Supervisor shall explain the testing
and commissioning activities, focusing on the hazards and risks involved in the activity and the mitigation
measures that shall be taken as detailed in the Risk Assessment. Regular Toolbox talks shall be
conducted in order to prevent complacency within the crew. The Engineer shall conduct a Pre-start
toolbox talk for the new person/s prior to starting work.
A Permit shall be obtained when and where applicable in accordance with the requirements of Permit to
Work Procedure (ADP-013529-034) prior to performing the Installation, Testing and commissioning of
the Generator Synchronizing Panel. The supervisor will ensure that all relevant risk assessments, method
statements and permit to work control measures are in place and that all relevant procedures contained
within these documents are fully understood by the operative personnel.
10.0 ATTACHMENTS
Page 9 of 22
Abu Dhabi Plaza – Astana, Kazakhstan Document No.
Work Package 4 – Main Works ADP-263623-007
Document Title:
Inspection & Test Plan (ITP) – Generator Synchronizing Panels Page 1 of 1 Rev.000
(JV REF. ITP-1122-407 T&C)
Legend: S – Surveillance Inspection W – Witness Inspection Point H – Mandatory Hold Point for Inspection R – Record Review
ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN
Station Reference:
ACCEPTANCE STATUS
REQUESTED DOCUMENTATION SUBMITTED
Yes/No REMARKS
1. T&C MS
7. Equipment Schedule, Schematic Diagram, Single Line Diagram, & Layout Drawings
ACCEPTANCE STATUS
ACTIVITIES / ITEMS TO BE INSPECTED
Yes/No REMARKS
1. Nameplate data and tags match with the drawings or schedule.
2. Ratings, quantity, and make for all components in the nameplate are as per
drawing or design specifications.
3. Metering, indication lamps, and selector switch arrangements on the panel are Ok.
FM-MS-ADP-263623-007-001
ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN
Acceptance Status
Activities / Items to be inspected for Load Bank
Yes/No Remarks
1. Load Bank technical details/documents are attached.
2. Rating of installed cables for Load bank is suitable, properly tested and barricaded
the whole cable run area.
Cummin’s Representative
JV Commissioning Engineer
JV QA/QC Engineer
(CSC) AECOM KZ
(CxA) CML
FM-MS-ADP-263623-007-001
ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN
RFIC No.: Date: Block: Level: System: Low Voltage Sub System: Engine Generator System
Voltage - Line to Line (V) Voltage – Line to Neutral (V) Current (A) Active Reactive
Power Freq.
Generator Power Power Remarks
L1-L2 L2-L3 L3-L1 L1-N L2-N L3-N L1 L2 L3 Factor (Hz)
(KW) (kVAr)
FM-MS-ADP-263623-007-002
Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза
Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
Step 1: Task Planning (task identification and details)/ Шаг 1: Планирование задания (выявление задачи и деталей)
Step 3: Risk Management (list any nearby activities that may impact the work) Шаг 3: Управление Рисками (перечень деятельности которые могут повлиять на работу)
Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза
Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
Step 4: Job Safety/Hazard Analysis/ Шаг 4: Анализ/Оценки Рисков
Activity
(What must be done? i.e. tools, Hazards Risks
equipment, and material used) (How could an injury occur?) What Can Happen Recommendations
Item
(Can hazards be eliminated or modified?)
Планирование работы. Опасность Риски Меры контроля
Номер (Что надо для работы. Например: (Как может произойти (Что может произойти) (Как опасность может быть устранена)
инструменты, оборудование и травма)
материалы)
Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
Ensure that personnel engaged of working at
Serious injury to personnel height are trained and competent to the given
or even fatality due to fall task.
Fall of material from height. Supervisor must provide full body harness for
Fall from height Injury to personnel due to personnel engaged of working at height.
Working at heights Collapse of scaffold falling debris. Workplace place must be barricaded underneath
3
Cold weather Injury to personnel or even prior to start the work.
fatality due to collapse of A proper work platform should be provided
scaffolds. Monitor the temperature, and wind chill index.
Hypothermia Work rest period implemented.
Wear Winter PPE. (as per weather condition)
Provide hot beverage for employees.
Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
Wear all required PPE’s.
Slips, trips and fall due to work boots/ rubber boots with toe
Slips
scattered materials or protector
Trips hard hat
rubbish.
Fall visibility vest / jacket
Foot injuries
7 Housekeeping Dust safety glass
Hand injuries
Dust Mask ( as required )
Personnel injury due
Gloves
slippery surface
Supervisor must ensure that used materials
must be stored in designated, to prevent
scattered at work area
Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза
Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
Step 5: Unplanned Events (if any of the following occurs, stop work and talk to your supervisor)/ Шаг 5: Незапланированные мероприятия: если следующие случаи имеют
место, то остановите работу и известите супервайзера
Nearby work hazards Chemical spills or release
Excessive noise Fires and explosions Unusual odours Heat stress
Опасности на рабочем Утечки химических
Черезмерный шум Пожар и взрывы Странный запах Тепловой удар
месте веществ
Extreme weather/high
winds
Significant near miss Change in the following work conditions:
Evacuation alarm Экстримальные
Существенное, возможное Изменение в процессе работы:
Эвакуация/тревога погодные условия и
происшествия
сильный ветер
Step 6: Unplanned Events (if any of the following occurs, stop work and talk to your supervisor) Шаг 6: Незапланированные мероприятия: если следующие случаи имеют
место, то остановите работу и известите супервайзера
Emergency telephone number: Alarm Code (for commission period)
Телефон экстренной связи: +77015301064 Код сигнализации (при пусконаладке)
Nearest Muster Point/Safety Shelter location: Nearest First Aid Station location:
Ближайший пункт Место Сбора: Ближайший пункт Первой Помощи:
Evacuation Route (Supervisor to explain to workers): Safety shower / eye washer location:
Пути эвакуации(Супервайзер должен объяснить работникам): Пункт промывки глаз:
Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
10 35
11 36
12 37
13 38
14 39
15 40
16 41
17 42
18 43
19 44
20 45
21 46
22 47
23 48
24 49
25 50
Supervisor Name:
Ф.И.О Супервайзера: ________________________________________ Signature/ Подпись: __________________ Date/Дата: ____________________________ /______/________
This JSTI is prepared based on theoretical information interpreted from the project documents. A further assessment will be required
at the actual work site to verify the control measures and address any additional hazards. Reference is to be made to the relative
Health, Safety, Environmental & Security procedures to control the risks associated with activities where they occur.