Method Statement for Central Battery System (CBS) Installation

method statement central battery system

The Method Statement For Central Battery System (CBS) Installation describes the sequential approach as outlined in the project contract requirements which ensures that safety, quality assurance, and quality control are implemented by the contractor.

References

This method statement is subject to the requirements as stated in the following regulatory & statutory documents, applicable standards/specifications/building codes:

Project Specifications

Relevant Sections of IEC/BS

Project approved materials/shop/IFC drawings

Approved Project HSE Plan

Approved Project Emergency Response Plan

Approved Project Waste Management Plan

Logistics

MEP subcontractor will deploy a dedicated team for the required logistics and material movement in–out of the project.

Health & Safety Hazards

Extreme heat and humidity

Extreme cold, high winds, and dusty condition

Mobile Equipment-Crane, forklift, etc. for material loading/offloading, transfer of materials to work locations

Temporary electrical supply for lighting, use of power tools, etc.

Improper stacking of materials Internal, external Light fitting, etc.

Manual handling/offloading & installation of internal, external light fitting, etc.

Working on the unsafe scaffold for the installation of internal, external light fitting, etc.

Damaged hand tools-installation of internal, external light fitting, etc.

Uninspected power tool

Unsafe working on ladders

Poor housekeeping & waste management

Permits and Certificates

Hot work permit (cutting/grinding)

Lifting plan

Confined space

Lockout/tag-out permit

Working at heights/working on scaffolding

MEWP – Third-party certification for the operator and the equipment. Competence certification for workers.

Definitions

MST–Method Statement

QCP–Quality Control Procedures

ITP–Inspection and Test Plan

ITA–Independent Testing Agency

CBS-Central Battery System

Responsibilities

Project Manager

The Project Manager shall be responsible for overall project planning, procurement, technical submissions, and drawing submissions.

The Project Manager shall coordinate activities within the site team and with the management for the timely completion of activity in accordance with contract requirements.

Construction Manager

The Construction Manager is responsible for the work execution in compliance with the approved method statement, HSE Risk Assessment, project specification, issued for construction drawings, sections, and details.

Site Engineer

The Site Engineer is responsible to carry out the work as per approved shop drawings and method statements. He is also responsible to ensure adequate tool kits required for the works are in place prior to the starting of work. The Site Engineer reports to the Construction Manager.

The Site Engineer is responsible to ensure work has been done as per the specification and drawings; inspections are carried out based on approved Method Statement for Central Battery System (CBS) Installation, ITP, and quality control procedures and coordinate with QA/QC department for inspections.

The Site Engineer is responsible to ensure that all safety precautions are ensured in place and that all personal on-site are using the required personal protective equipment like helmets, gloves, shoes, and reflective jackets. The Site Engineer in coordination with safety officers will ensure all relevant permissions are taken prior to commencement of works.

The Site Engineers shall ensure that the works are supervised by a competent supervisor till the completion of the task.

QA/QC Department

The QA/QC department will be responsible for overseeing the quality requirements and quality control measures for the project in coordination with the project engineer and construction manager.

Safety Engineer

The HSE Officer will be responsible for the safety, health, and environmental aspects on site as per the project safety and environment requirements/safety standards in coordination with the project engineer and construction manager.

Method to be Employed-Central Battery System (CBS) Installation

Site Planning & Preparation

Before installation takes place, the following pre-installation task is essential:

Identify and ensure that the pertinent document like the approval for Shop Drawings, MEP coordination drawing, CBS installation details, load schedule approved life and safety drawing shall be available at the site.

Permits shall be applied prior to commencement of works.

Please ensure to obtain the necessary PTW (Permit To Work), prior to allowing to work. Frequently training should be conducted by the site supervisor/foreman. A daily safety briefing should be conducted.

Applicable permits shall be applied prior to the commencement of works.

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

Conduct site safety briefing prior to commencement of work.

Identify and obtain appropriate installation tools and equipment.

Determine the staffing required and assign tasks to team members.

Perform lockout/tag-out procedures (where applicable) during installations.

Handling of Materials

Upon receiving the materials, all must be inspected and ensured that there are no manufacturing defects and delivery damages. Upon receiving the materials, all must be inspected and ensured that there are no manufacturing defects and delivery damages.

Arrange internal and external inspection to ensure conformity of the delivered materials against approved material submittal.

All materials shall be stored and handled as per the manufacturer’s written recommendations. It is important to note that in the case of controllers & batteries proper handling care and humidity conditions shall be taken care of. The maximum operating temperature and humidity conditions shall be observed at the place of material storage.

During shifting to the installation location, as possible keep the packaging/pallet intact and lift using proper lifting equipment or manually with an adequate number of people. Handle with care to avoid damage to internal components and the enclosures. (Follow handling guidelines recommended by the manufacturer).

Store the materials in the manufacturer’s original packaging in the manner that labels are so arranged for easy identification, to avoid mismatches of loose components.

Only required materials to be shifted to site and store temporarily and ensure extra materials are not dumped on-site and congest the working area.

Once work is completed extra materials and tools are to be returned back to stores.

Installation of Central Battery Panel

Pre-installation Work

All workers to attend safety induction training on the safe installation methods by the safety department.

Ensure all central battery system materials received are inspected by the consultant and found acceptable as per approved materials submittal.

Ensure that all related materials are of approved make and are available before carrying out any work.

Ensure all drawings are the latest revision, approved for construction issue, and are fully coordinated with all other services and installations

A safe start procedure shall be prepared before commencing the work. Permit to work system to be followed for the installation of central battery panel.

The area to be cordoned off and all other works should be kept at a safe distance. Suitable firefighting equipment’s to be provided at the working area.

Prior to commencing any works, a risk assessment must be conducted, taking into account all possible risks and the appropriate precautions put in place, i.e. fire extinguishers, fire blankets, safety harnesses, etc. Refer to the risk assessment/risk management section of this method statement for central battery system installation.

All works shall be undertaken in a neat and workmanlike manner to ensure a quality installation.

Permit to work system to be followed if required proper PPE to be worn by all operatives always on site.

Installation

Ensure the installation central battery system and other accessories are as per the approved method statement for the central battery system, material, and shop drawings and coordinated with other services.

Ensure prior to installation all CBS’s are approved by consultant and it is free of damages.

The location should be marked for the installation of the CBS panel as per approved shop drawings.

Ensure the installation of the central battery system panel/cabinet is as per approved shop drawings and coordinated with other services. Ensure the installation of the CBS panel/cabinet is as per manufacturer recommendation and the procedures to be followed.

Verify the CBS panels are tagged correctly before they are prepared for site installation as per project specification.

Drill holes on the concrete wall and install the raw bolts. The size of raw bolts should depend upon the size of the CBS and should be as approved detail drawing.

Installed CBS panels and securely attached to the walls with expansion anchors. Check the horizontal and vertical alignment by a spirit level.

Assemble the batteries adopting the following procedures:

  • Cells/Batteries should be connected ensuring that the positive terminal (+ or RED) of one cell/battery is connected to the negative terminal (- or BLACK/BLUE) of the adjacent cell/battery. Positive and negative conductors should not pass through the same holes. After connecting the battery ensure that each link surface and battery terminal is covered with an even coating of petroleum jelly to ensure good electrical connection and protection against corrosion of terminals during service life.
  • When the battery has been fully assembled, check that all nuts and bolts are tightened as per the battery manufacturer’s instruction and that all nuts, bolts, and pillars of the cell have been coated with petroleum jelly.
  • Make a visual check from the start to the finish of the battery to ensure that the cells/batteries are connected as described above.
  • Remove battery fuses, charger fuses, and ensure that MCB and external remote isolator are OFF. Check all inverter modules MCB’s (Miniature Circuit Breaker) are OFF and remove all inverter module fused (they are small cartridge types and should be kept in a safe place).
  • Connect the battery to the battery cable with care positive lead to the end marked + or RED end of the battery, negative Lead to the end market, or blue/black end of the battery.
  • Check that all the required wires/cables are completed and ready for final termination/connections. Carry out insulation resistance test and continuity test for the wires/cable prior to final termination works.
  • Bring the incoming mains cables and load output cables in the cable gland holes provided in the charger compartment and connect as detailed, referring to the wiring diagram supplied. When using gland plates for cable termination, remove the gland plate before drilling.
  • Connect the live lead to the terminal marked L or in the case of 3 phase input L1, L2, and L3. Connect the neutral lead to terminal marked N. Connect the earth lead to the earth stud provided.
  • Maintained system only – should a remote maintained circuit switch be required, remove the factory fitted link between the terminals marked RSL or LK2 and replace it with a remote switch.
  • The remote monitor relays should be required to remove the factory-fitted link between terminals LK1 and connect the remote monitor contact normally open series loop between the terminals.
  • Connect the load circuit to the output terminals, fused or MB’s. Observe the correct polarity. If the system is complete with an integral sub-circuit monitor, fire alarm relay terminals for the connection of a remote alarm unit, or terminals for remote indication of system fault via volt free change over contact these should be connected as required.
  • Ensure that the inhibit switch located inside the cubicles is in the inhibit position. Install the central PC and associated devices in the allocated control room as shown in the approved shop drawings.
  • Check the completed installation against the checklist for the installation inspection of the emergency lighting central battery system that is attached in the approved method statement.
  • Once the completed installation is confirmed to have satisfactorily complied with the installation inspection checklist mentioned above a request for installation may then be initiated in order to obtain the required consultant’s approval for the completed installation of the emergency lighting central battery system.

Training

All required training for stipulated installation activities is provided to all technical staff for ensuring quality workmanship.

Working Hours

Site operational time shall be followed as per project progress requirements, all relevant local authority schedule of holidays to be observed.

Housekeeping

Working areas will be kept clean by disposing of the waste materials at the designated areas. At the end of the days’ work, the installation supervisor will ensure that the debris is disposed of during the course of the activity on regular basis. Dust created by work e.g. drilling, of the slab, grinding, and polishing.

The area must be isolated/protected by a green net and required additional PPE for the operatives. Any materials stacked in the site shall neither obstruct the emergency evacuation route.

Manpower

Subject to main contractors’ programmer and scope/area available for MEP activities, but not limited to below:

Electrical Engineer

QA/QC Engineer

Safety Engineer

Riggers

Equipment Operators

Foreman

Charge hands

Electricians

Assistant Electricians

Scaffold erectors

Welder (for support/bracket fabrication)

Helpers

Material

CBS panel and accessories.

Wires and cable (includes accessories such as lugs, ferrule, cable ties, etc.)

Bolt, nuts, and washers

Raw plugs and screws

Anchor bolts/hammer set anchor

Strut channels

Personal Protective Equipment Requirement

Safety helmet

Safety goggles

Safety boots

High visibility vest

Hand gloves

Earplugs

Respiratory protection

Full body harness

Tools & Equipment

The following equipment and tools shall be used for the works:

Standard Electrician Tools and Toolbox

Electric Drill and set of bits

Cutting Tools (e.g. Jigsaw, Grinder)

Set of wrenches (fix or adjustable)

Set of files

Hammer

Plumb bob/Spirit Level

Air Blower/Vacuum Cleaner

Measuring tape

Hand gloves

Lifting Equipment (e.g. mobile crane, forklift for loading and unloading during delivery/shifting)

Appropriate Safety equipment (PPE)

Ladders (Appropriate Type)

Scaffolding (and fittings/accessories)

Notes:

1. Third-party certification (Competence Certificates) for workers, operators, equipment valid registration, insurance and fitness certificates, operator daily inspection checklist should be available for Safety Officer validation before commencing the works.

QA/QC Requirements for Method Statement for Central Battery System (CBS) Installation

Follow approved MST, ITP, QCP, HSE Plan, and Material Approval & Checklist.

Attachments

Risk Assessment

Inspection & Test Plan

Quality Control Checklists

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