Method Statement for Bus Duct (Fire Rated) Installation

method-statement-for-bus-duct-installation

This method statement for bus duct (fire rated) describes the installation activity to ensure that it complies with the project requirements, HSE, specifications, and standards.

Scope

The scope of this method statement covers the installation of the fire-rated bus duct which gives guidelines for the job execution in compliance with the requirement of the specification and as approved by the concerned authority.

Definitions

Client-xxxxx

Project Management-Construction Management (PM-CM)-xxxxx

Construction Supervision Consultant (CSC)-xxxxx

Main Contractor-xxxx

MEP Contractor-xxxxx

Manufacturer- EAE Elektrik

References

Project Specifications-(Enclosed Busway Assemblies)

Approved Shop Drawings and Manufacturer’s Procedure

Approved Material Submittal

Abbreviation

PM – Project Manager

PE – Project Engineer

QC – Quality Control

HSE – Health, Safety, and Environment

ITP – Inspection & Test Plan

MST – Method Statement

PPE – Personal Protective Equipment

MSDS – Material safety data sheets

RA – Risk Assessment

QCP – Quality Control Procedure

INR – Inspection Request

QA/QC – Quality Assurance/Quality Control

Responsibilities in Method Statement for Bus Duct (Fire Rated) Installation

6.1. General

The Project Manager will be responsible to manage, execute complete and handover the MEP construction activities within approved budgets and resources in compliance with Project Requirements as specified in Project Specifications. He will be overall in charge of implementing the Method Statement for Bus Duct (Fire Rated) Installation in accordance with QA/QC and HSE requirements.

The Construction Manager will be responsible for managing MEP construction activities and will lead and communicate with site supervision, subcontractors, and vendors to assist them in working to the project schedule by conforming to QA/QC and HSE requirements at the site.

The HSE Manager will be responsible for plan, coordinate, and implement issues and directives within the organization. He ensures safe environmental working conditions for all MEP employees.

The QA/QC Manager Manager will be responsible for supporting the project MEP team in implementing and maintaining Quality Management System for the project through PQP, ITP, Method Statement for Bus Duct (Fire Rated) Installation, and Procedures in compliance with Project specifications, Codes, and Standards.

The Site Engineer will be responsible for carrying out all construction-related activities as per contract specifications, drawings/documents, codes, and standards and In-line with HSE and QA/QC requirements together with Project Engineer for fire-rated duct bus works.

The QA/QC Engineer will be responsible for conducting inspections as per PQP.

HSE Officer will ensure enforcement of safety procedures in accordance with the approved HSE Plan. He will be closely monitoring the site engineer’s strict implementation of the Method Statement for Bus Duct (Fire-Rated) Installation and Risk Assessment, the use of proper tools and equipment to maintain safety, certifications of equipment and their adherence to safety regulations, reporting of any unsafe work or stopping work that does not comply with HSE procedures.

Electrician/other tradesmen will be responsible for assisting his superiors during all installation work-related activities. Work shall be in line with HSE and QA/QC requirements. Supervise closely, the activities designated to them and ensure that all instructions and safety procedures are followed and strictly adhered to.

Store in-charge receives and inspects all incoming materials and reconciles with documents; processes and distributes documentation; reports, documents, and tracks damages and discrepancies.

List of Contractors/Subcontractors

Main Contractor-xxxx

Sub- Contractor for MEP-xxxx

Supplier Name-xxxx

Material Brand-EAE Electrik, Turkey

Handling, Storage, and Transportation

Upon receiving the material, it must be inspected and ensured that they are free from any manufacturer defects.

The material shall be handled with care and shall be stored at the designated area as per the manufacturer’s recommendation prior to installation.

Any discrepancies, damages, etc., shall be notified and reported for further action.

The busbar is protected from minor water ingress by means of an overall outer polythene wrap and individual polythene stretch wrap around the ends of each busbar.

The material will be delivered at the site in undamaged condition in the manufacturer’s packaging with identifying labels intact and legible.

Each shipment must be blocked and securely fastened to avoid damages during transportation.

Unloading at the site must be controlled by site management following the manufacturer’s instructions. Manufacturer recommendations shall be followed strictly while handling the material during installation activity.

Lay down area must be arranged for offloading the material prior to transport to the site.

Ensure that the storage area is at a minimum height of 1 ft from the ground level.

Ensure that the proposed storage area for the material is clean.

A separate area in the storage zone must be marked for different materials.

Ensure that the material is stored in a shaded area to protect it from exposure to direct sunlight.

If the busbar is not to be installed immediately upon delivery, it should be stored in a clean and dry area to prevent condensation. Do not allow the busbar to contact with corrosive fumes, liquids, and other foreign matters.

Material Inspection

For material to be inspected after receiving at the site (as per approved material submittal) the following points are to be followed:

Each material item shall be allotted a distinct and separate reference number and mentioned on the material requisition. Make sure that material is approved/examined by the consultant, QAQC, and associated documents/test certificates are approved.

The store in-charge shall ensure that all approved supplies be delivered to the site as per the approved material submittal with the manufacturer’s seals, labels, or other proof of origin. These labels and seals shall not be removed until the material is required for use and shall be retained for inspection by the consultant and QA/QC.

Store in-charge shall initiate material inspection for all incoming material to QA/QC and the material shall be inspected against reference documents and as per approved material submittal. Moreover, the physical condition of the material shall be checked. Afterward, an INR shall be raised by QA/QC to the consultant and inspection will be carried out by the consultant.

Materials, which do not conform to the given specification/approved material submittal, shall be rejected. Any discrepancy or damages will be notified and reported for further action.

For any material inspection (especially pipes, fittings, other accessories), the items shall be segregated as per their types/sizes and placed items separately in racks or on different pallets.

Each rack/pallet shall have an identification posted on a laminated paper with the description of the items are clearly written on it.

There shall be appropriate spaces between the pallets so that the engineer/inspector can freely go around them and inspect the materials thoroughly.

Staking the materials all over each other & in one corner is strictly not allowed.

Resources

Tools and Equipment

The job will be carried out by manual means. The following are the types of Tools identified for works:

Fork Lift for transporting Busbar

Chain Block pulley (suitable capacity)

Portable Hand Tool

Measuring Tape

Marker Tape

Spirit Level (1.5m to 2m long)

Drilling Machine

Torque Wrench tools

Level Threads

Hammer

Multimeter

Standard Electrical tool kits

1000V Megger

Simple Electrical Tools (plier, screwdriver set and etc.)

Ladder

Note:

All testing equipment and measuring tools to be used shall have valid calibration certificates prior to usage.

Equipment and machines shall be 3rd party verified with valid certificates

Operator’s competency certificates shall be checked and maintained as quality and HSE records.

The contractor’s HSE inspection for all light and heavy equipment prior to site acceptance shall be carried out.

HSE inspection sticker shall be posted on the windshield to indicate that the equipment passed inspection.

Materials

Material includes but is not limited to the following:

KXC series Copper Bus Bar

Epoxy paint – RAL 7038 (Light Grey)

Class B insulation and tinplated joints

IP55 protection housing for vertical

IP65 protection housing for horizontal

List of Manpower

Project Manager

Construction Engineer

Senior Engineer

Site Engineer

Supervisor/ Foreman

QA/QC Manager

Electrician

Helpers/Laborers

Safety Officer

First Aider

QC Engineer

Methodology-Bus Duct (Fire Rated) Installation

Preparation for Installation

The start of the busbars installation shall be done in accordance with approved shop drawings and properly coordinated with site engineers for the exact locations and levels. The. mark on-site to be carried out prior to commencement of installation works.

Prior to the commencement of the works, inspect the areas for safe access and confirm the same are in suitable condition for the works.

All materials and documentation relevant to this particular works shall be checked by the project Engineer to confirm adequacy and compliance with the requirements prior to the commencement of works.

Only approved materials shall be used for the site works. Material inspection approval shall be checked and verified by the Project Engineer.

The Project Engineer or Site Engineer should check the approved isometric drawings of busbar layout and ensure that all sections of the busbars are received at the site.

During shifting to the installation location, lift the busbar and its associated fittings using proper lifting equipment or manually with an adequate number of people. Never drag the busbar across the ground, handle with care to avoid damage to internal components and enclosure.

Prior to the start of the installation works, the team shall coordinate with the builder’s work activities at the site to ensure the proper work installation.

Prior to installation, ensure that approved shop drawings for construction details of bus duct arrangement and bus duct routing are available as approved by the supervision consultant. This drawing should be followed carefully to ensure a proper busbar system.

All involved personals will wear appropriate protection at all times during the entire period of unloading/ shifting.

Hazard analysis and risk assessment shall be explained to all personnel involved in the installation of the busbar and its accessories.

After satisfactory completion of the above steps, works shall commence in the respective areas.

Works shall be carried out at site under strict supervision and guidance of the supervisors/engineers.

Installation/Work Sequence

Installation of busbar starts from the transformer to MV Panel. During the installation, a chain block (1-2 tons) will be used to lift the busbar and its components to their proper position as per the approved drawing. During the installation process workers involved wears appropriate safety protections.

Distribute pieces of the busbar and its associated fittings to each level as per the approved drawing details of bus duct arrangements. In shifting the materials to each level tower crane/forklift will be used or manually with an adequate number of people. All involved personnel must wear appropriate personnel protection during the entire period.

Install horizontal busbars & vertical busbar riser including its supports in accordance with the approved specification, manufacturer’s recommendation & approved shop drawing.

Horizontal Mounting Support

Use approved channel/hanger flat & down the rod as per manufacturer’s recommendation.

Busbars are installed by tightening the “one bolt joint”. Belleville spring washers on both ends of the bolt retain the original contact pressure, ensuring a more secure, reliable, and maintenance-free joint.

Once the busbar is aligned and jointed properly, the bolt is tightened to 83Nm (60 lb-ft) using the torque spanner.

During the installation maintain good alignment of the drop rods along the busbar run; do not support the busbar at the joints. After the busbar is secured in the hangers, adjust the hangers on the rod for the correct elevation.

Use min 10mm galvanized steel bolt to fix busbar to supports with required nut and washer.

The joint shall be done as per the manufacturer’s recommendations; this is to avoid any ingress of moisture into the bus duct system.

Prior to joining, both sections of the bus duct to be joined undergo continuity & insulation resistance tests and record the results in the approved format. Joints shall be made by simply sliding together the bus duct unit, and tightening the clamping bolts progressively to the specific torque (83Nm). Ensure that all joint contact surfaces are free of contamination and dirt.

Install expansion joint wherever required in accordance with contract documents, approved shop drawing & manufacturer’s recommendations as well as on every building expansion joint.

Panel Connection Units

Supplied with suitable flange as standard (See fig below).

busbar figure 1
busbar figure 2
busbar figure 3
busbar figure 4
busbar figure 5
Busbar Flanges Connections

After the erection, use vinyl or corrugated cardboard or polythene sheets to cover the power busbar system, protection for concrete, plaster, and water damage, etc.

Transformer Terminal Connection

Make sure the rigid busbar is connected properly. On the top of the LV cable box, the transformer connection unit is to be installed, and then flexibles are used to connect the connection unit to transformer terminals.

Joints shall be made by simply sliding together the unit, and tightening the clamping bolts progressively to the specific torque (83Nm). Ensure that all joint contact surfaces are free of contamination and dirt.

Any missing tools or equipment shall be provided for perfect installation.

Upon completion of installation manufacturers or dealers, engineers will inspect and certify the installation.

Ensure a danger notice is fitted to all access panels where a voltage exceeding 200V and the power busbar system is protected until the building is clean, and the system is ready to be energized.

When installing a busbar section with a fire barrier ensure that the fire barrier protrudes from both sides of the wall. Final sealing between fire barrier and wall to be completed.

Continuity testing of Bus bar

Prior to installation of power busbar system and before electrical circuitry has been energized, demonstrate product capability and compliance with requirements.

Perform continuity test to both sections of bus duct to be joined and to be recorded to ensure proper connections. If satisfactory readings cannot be achieved, remove and replace mal-functioning busbars with new units and retest.

Measure resistance between phases, and earth using megger. (The mega ohm readings should not be less than the value recommended by the manufacturer.)

Upon installation, measure the resistance of each major branch. In case of low readings, re-tighten all joint bolts in the busbar section being tested using a torque wrench. If satisfactory readings cannot be achieved, remove and replace mal-functioning busbars with new sets and retest.

Inspection and Test plan

The engineer should verify that the supervisor/foreman with construction responsibilities for installation is familiar with this method statement and is issued with copies of the inspection checklists and test plans.

The engineer should satisfy the procedures provided by QA/QC inspections to ensure the as-installed condition of the Busbars installation meets the specified engineering requirements and approved drawings.

As part of the assessment, the QA/QC Inspection Procedures must ensure quantitative or qualitative acceptance criteria for determining the prescribed activities have been accomplished satisfactorily.

The QC inspection personnel in coordination with the Site Engineer and Supervisor should verify that the quality of the related Busbars installation activities is within the prescribed criteria.

The Site Engineer should verify any as-built record of Busbars installation. Confirm that the information meets the project requirements.

Quality Control Engineer along with Project Engineer and Site Supervisor will monitor that all components are installed as per contract specifications and approved submittals.

Inspection Request (INR) shall be submitted by QA/QC Engineer for verification and inspections along with the manufacturer Engineer Site inspection report with the stamp.

Readable stamped approved drawing to be available during installation and inspection.

All the equipment engaged for testing shall have a valid calibration and a certificate should be furnished.

Health and Safety Analysis

Risk Assessment

Refer to Risk Assessment/Job Hazard analysis on Appendix A

Environmental Impact Assessment

This activity does not have a feasible impact on the environment.

Generated waste will be managed by an approved waste management company.

Welfare Facilities

All welfare facilities which include: Mess Hall, Toilet Facilities, First-aid room, Clinic, etc. shall be provided and properly maintained, cleaned, and neat.

Periodic Inspection of these welfare facilities should be done to make sure they are up to required standards.

All workers involved shall be equipped with adequate PPE as state below:

Safety Helmet with Company Logo.

Safety Boots, Safety Goggles, Hand Gloves.

High Visibility Vest.

Twin-Tail Harness, Max 1 m long (when working on height) All special PPE (Harness) are considered as last resort when we cannot engineer, administratively eliminate, or guard against hazards.

Information to Personnel

Safety Induction

Job Training

Superintendents

Notices/Memos

Toolbox Talks

Briefings before starting work

Housekeeping

Working areas will be kept clean by disposing of the water materials at the designated areas. At the end of the days’ work, the installation supervisor will ensure that the debris is disposed of.

Quality Assurance and Quality Control

Quality Assurance and Quality Control of Method Statement for Bus Duct (Fire Rated) Installation

The contractor shall provide the required documents for consultant approval prior to initiating the execution of this activity as per the project specification.

The quality control requirement shall include related QCP’s, ITP’s and other related documents as applicable.

Applicable codes and standards for materials

Project Specifications

Quality Assurance Process

The contractor shall notify the Engineer 24 hours in advance prior to starting of activity and comments from the Site Instruction will comply with the satisfaction of the consultant.

Follow up and Evaluation

The contractor shall consult the public utility authorities not less than one month before it is proposed to commence work to ascertain whether any underground installations will be affected by the proposed work, in which event the contractor shall make all necessary arrangements with the public utility authorities to safeguard the installation.

Follow up on quality performance shall be carried out through an in-house monitoring system such as progress reporting to the planning department, daily, weekly, and monthly reports generated by the planning department to closely monitor site performance in general and reflect on the quality performance in specific

All the above shall be in close coordination with the quality department to monitor any deviations from the normal quality requirement and induce corrective actions whenever required to eliminate non-conformance or quality deviations

All remedial actions to be taken, if any, shall take into account the official schedule which is used as guidelines for performance and most importantly under the close supervision of the quality control department.

Records

Checklist (CL)

Inspection Request (INR)

Inspection and Test Record (ITR)

List of Appendices

Appendix A: Risk Assessment

Appendix B: Inspection Test Plan

Appendix C: Checklist for installation of Fire Rated Bus Duct

Appendix D: Manufacturer’s Installation Procedure

Appendix E: Approved Material Submittal

Appendix F: Reference Drawings

Appendix G: Organization Chart

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