STAFFING DURING COMMISSIONING PHASE: EHV & HV POWER CABLE PROJECT

High Voltage Cable Test Equipment

Professional Staffing During Project Pre-commissioning and Commissioning

During pre-commissioning the Service provider should provide all necessary supervisory and operating staff. The only involvement of the Employer’s staff will be in accordance with the training and instruction as in this specification.

During the commissioning phase, the Employer’s operating staff will operate plant and equipment under the supervision of the Service provider’s supervisors.

Prepare the Project for Commissioning Operation

The Service provider should have satisfied himself as to the capability of the Employer’s operators to carry out such operations as he may direct and should remain responsible for the successful performance of such operations. 

Throughout the whole of the Commissioning Period the Service provider should provide suitably qualified and experienced operating staff, who should instruct the Employer’s staff in the correct operating procedures.

Qualified Team of Staff for Commissioning

The Service provider should provide a team of suitably qualified and experienced engineers and technicians to pre-commission and commission the overall plant. 

The Service provider should also ensure that a suitably qualified commissioning engineer from the respective manufacturer’s own service organization should visit the site to check the erection or installation of each significant plant item, and to supervise the commissioning of the plant item until the basic functioning of the item has been demonstrated to the Engineer’s satisfaction.

Ensure Safety Induction during Commissioning

At all times the Service provider should ensure that his staff and any Sub-Service provider’s or seconded staff, observe all prescribed safety rules and permit systems.

For satisfaction of the employer, the service provider must ensure and certify that the project is ready to commissioning and all safety measured are passed as per specified standard.  

TERMINALS AND TERMINAL BOARDS FOR CABLE

Power Cable Termination and Terminal Boards Assembling Procedure

Terminal Assemblies should be of the unit form suitable for mounting on a standard assembly rail, to give the required number of ways. The units should be spring retained on the assembly fail. Each individual terminal block should have independent terminals and outgoing cabling.

Terminal Screwing

It should be possible to replace any unit in an assembly without dismantling adjacent units. Molding should be mechanically robust and withstand the maximum possible operating temperatures and torque which may be applied to terminal screw. All live parts should be recessed in the molding to prevent accidental contact.

 

Terminals should be of the screw clamp type for lower current rating which compresses the conductor or termination between two plates by means of a captive terminal screw. Contact pressure of screw clamp terminations should be independent of each other. For higher current ratings bolted type terminals are permitted. Current carrying parts should be non-ferrous and plated.

Terminal Testing Facilities

All terminals for ‘incoming’ cabling should have testing facilities, which permit the examination of the state of the circuit without disconnecting the associated cabling. Terminal blocks for current transformer secondary should be fitted with shorting/disconnect facilities.

Terminal Isolating Facilities

Terminal blocks for voltage transformers secondary should be isolatable. Terminal blocks in telemetry marshalling cubicles should be isolatable. The means of isolation should be fixed and give visual identification of the status of the terminal.

Not more than 1 wire should be connected to each terminal and cross-connection facilities should be provided where numerous cores are connected together.

Each terminal block, and every individual terminal should be identified. The terminal identification number should be included on associated schematic and wiring diagrams.

The mounting rail may only be used to provide an earth connection, when firmly bonded to the earth bar and to be approved by the Employer.

Termination Work Procedure

The Contractor should submit samples of the terminal blocks/mounting rail assemblies together with details of his proposed cabling/termination system to the Engineer for approval.

Adjacent terminals to which wires of different voltage, polarity or phase are connected should be separated by a protruding insulating barrier; this requirement also applies to terminals carrying wires of the same voltage but originating from different sources.

Wires should be grounded on the terminal boards according to their functions. Terminal blocks for connections exceeding 110V should be fitted with insulting covers.

Terminal blocks should be mounted not less than 150 mm from the gland plates, and spaced not less than 100 mm apart, on the side of the enclosure.

Terminal for Multi-core Cables

Sufficient terminals should be provided to permit all cores on multi-core cables to be terminated. Terminals for spare cores should be numbered and be located at such position as will provide the maximum length of spare core. At least 10% spare terminals should be provided in all cases.

The tails of multi-core cables should be bound and routed so that each tail may be traced without difficulty to its associated cable. All spare cores should be made off to terminals.

Recommended Terminal Block

When two lengths of screened cable are to be connected at a terminal block (i.e. junction box) a separate terminal should be provided to maintain screen continuity.

Should the terminal block manufacturer recommend that specific types of terminal tools are used (exm- parallel sided screw/drivers) the Contractor should provide three sets of these at each sub-station site. In addition the Contractor should provide 8 numbers, test leads of minimum 1500 mm length which can be inserted into the test terminals of the terminal blocks, at each sub-station. The test leads should be capable of being ‘jumpered’ together for multi-instrument use.

The use of pre-formed factory tested cable connections to field mounted marshalling boxes should be to the Engineer’s approval.

GALVANIZING WORK FOR POWER CABLE PROJECT CONTRACT

Fig-Disel Tank Plant at Mountain Area

How Ensure Galvanizing the Steel Structure Correctly in Your Project

This article on the introduction and guide line for hot-dip galvanizing and zinc coating procedure followed by IEC and BS standard for underground power transmission cable line. 


In this power transmission project, the outdoor and indoor steel structure like cable termination and surge arrester support structure, cable supporting ladder, cable joint bay accessory, towers and others steel structure   galvanizing should be carried out by the hot dip process and unless otherwise specified, must conform in all respects with IEC standard.

All drilling cutting, welding, forming and final fabrications of unit members and assemblies should be completed before the structures are galvanized. 
The surface of the steelwork to be galvanized should be free from welding slag, paint, oil, grease and similar contaminants.

Attention should be paid to the detail of members in accordance with IEC standard. Adequate provision for filling venting and draining must be made for assemblies fabricated form hollow sections. Of course vent holes be plugged suitably after galvanizing.

All surface defects in the steel, including cracks, surface laminations, laps and folds should be removed in accordance with IEC standard. 

How Works Zinc Coating

The most effective and economical features of zinc coating or galvanizing engineering and technology on steel structure for any country may map up as below:

·        Increased strength;

·        Low cost;

·        More corrosion resistive;

·        Maximum recyclability;

·        Light weight.

Corrosion is a silent killer for steel structure, the industrialized country who have calculated the destruction of corrosion, it found a remarkable figure around 4% of country’s GDP, big amount.

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Zinc Coating Technology and Environment

The zinc is an integral part of our environment, naturally it’s found in air, water, soil and rock.  Though zinc is essential micro-organism for animals and plants, then if its natural ratio is changed destructively then human and environment will experience hues impact.

Many expert think that hues zinc is required in our surrounding to biological process and technology able to maximize recycling steel and zinc from zinc coated steel, means negative impact is in acceptable.

Zinc coating or galvanizing steel recycling may happen in-

·        During galvanizing;

·        Manufacturing product;

·        Structure installation;

·        After life cycle of product.

Why is Used Zinc Coating

A perfect zinc coating may bring a lot of benefit for steel structure that emphasize industrial galvanizing. Here go some of the important factors of zinc coating:

·        Corrosion resistance- zinc coating resist the steel from corrosion and extend the life time;

·        Barrier protection- zinc coating acts like a physical barrier and protect moisture what is the main cause of corrosion for steel;

·        Cathodic Protection- zinc coated steel can protect corrode in scratch or cut edge due to cathodic protection, means adjacent zinc corrosion not happen;

·        Painted zinc coating- Zinc coating is used before painting that prevent steel even paint is damaged.

Zinc also may use as zinc-painting like metalizing, plating, sherardizing and zinc-rich paint etc.

How Ensure Proper Galvanizing Coating in Your Project

The Galvanizing Coating should be as specified in BS 720 or equivalent National standard. Structural steel items should initially grit blasted to BS 4232, second quality SA2.5 and the minimum average coating weight on steel sections 5 mm thick and over should be as specified in the table below:

THICKNESS OF STEEL        THICKNESS OF SIZE           MINIMUM AVERAGE

            SECTION                               COATING                  COATING WEIGHT

              mm                                       microns                                g/m²

               5                                           80 – 90                                600

             10                                          100 – 120                             750

             20                                          120 – 150                             900

Wit intermediate values will be on a pro rata basis.

On removal from the galvanizing bath the resultant coating should be smooth, continuous, and free from gross surface imperfections such as bare stops, lumps, blisters and inclusions of flux, ash or dross.

Galvanized contact surfaces to be joined by high strength friction grip bolts should be roughened before assembly so that the required slip factor as defined in BS 3294.

How Works Hot-Dip Galvanizing (HDG)

Hot-Dip galvanizing is a galvanizing process where steel galvanizing is perform in a vessel filled with molten zinc. 


During galvanizing steel in the vessel metallurgical react with molten zinc that formed a coating with tightly bonded on steel. 
This thick zinc coating acts like a strong physical barrier against forming corrosion on steel. The outdoor steel structure get a long life because of unique hot-dip galvanizing on it.
The galvanizing process has defined the minimum thickness standards based on the range of steel section thicknesses.

The hot-dip galvanizing standard defines minimum requirements for coating thickness and appearance. 

Practically hot-dip galvanizing ensure the materials long life time, sustainable structure, cost effective of the plant.

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How Ensure in Your Project Hot Dip Galvanizing and BS Standard

Bolts, nuts and washers, including general grade high strength friction grip bolts as BS 3139 and BS 4395 part 1 should be hot dip galvanized and subsequently centrifuged in according to BS 729. 

Nuts should be tapped up to 0.4 mm oversize after galvanizing and the threads oiled to permit the nuts to be finger turned on the bolt for the full depth of the nut. No lubricant, applied to the projecting threads of a galvanized high strength friction grip bolt after the bolt has been inserted through the steelwork should be allowed to come into contact with the faying surfaces.

During off-loading and erection, nylon slings should be used to protect galvanized surfaces. Galvanized work which is to be stored in works on site should be stacked so as to provided adequate ventilation to all surfaces to avoid wet storage staining.

During erection the plant, small area galvanized coating may damage in any way should be brought to the attention of the Engineer who should authorize repair.

Cleaning the area of any weld slug and though wire brushing to give a clean surface. After fixing, bolt heads, washes and nuts should receive two coats zinc rich paint.

Chromium Plating

The chromium plating of those components of the plant where specified and where offered by the service provider should comply with the requirements of BS 1224 or equivalent national standard.

PLANT AND EQUIPMENT INDENTIFICATION LABELS & NAMEPLATES

Water Cooling Plant Pipe Line Arrangement

Identification Labels and Nameplates for the Plant and Equipment

The purpose of this article is to provide guidance to service provider on their responsibility to ensure the plant and equipment identification labels and nameplates in the electricity safety, quality and standard regulations. 

Also, clarify the necessary actions for service provider to demonstrate compliance with the employer requirements for a construction of new or extension project.

Drawing Identification Number

The Service-provider should prepare comprehensive Plant or Equipment identification Schedules. 

The Schedules should include the respective flow sheet or Drawing/Diagram identification Numbers.

Drawing Sizes

Drawing sizes to be used are in this project is as 1: 10, 1: 20, 1: 25, 1: 33-1/3, 1: 50, 1: 100, 1: 250, 1: 500, 1: 1000, 1: 2500 (Overall Plot Plan Only).

Size Designation	Drawing Dimensions (mm x mm)
A4 A3 AG AF A2 A1 A0	210 × 297 297 × 420 297 × 630 297 × 840 420 × 594 594 × 841 841 × 1189

Numbering of Drawings

Drawing number should be as standard manner, like as PX-XX-XXXX-X/X-AX to identify the drawing easily. 

Where, PX is plant location and XX is the unit number. XXXX is the four digit serial number. Multiple drawing may have the same serial number but different unit number, again when drawings have the same title and function, they must have the same serial number and must be identified by using X/X sequential number/total number. AX is define the size of design.

 

Labels and Nameplates

The Service-provider should supply and install all labels, ratings, instruction and warning plates necessary for the identification and safe operation of the Works.

 

All label and name tag should be clearly visible, positioned in the line of sight, and free from any obstructions. Post the label and nameplate at appropriate distance, lighting, order if grouping and direction.

Label and Nameplate Material Characteristics

Nameplates of labels should be non-hygroscopic material with engraved lettering of a contrasting colour or, alternatively in the case of indoor circuit-breakers, starters, etc. of plastic material with suitably coloured lettering engraved thereon. 

Items of Pant such as valves, mounted outdoors or subject to harsh operating conditions, should be provided with engraved chromium plated brass or stainless steel nameplates or labels with engraving filled with black enamel.

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Labels and Nameplate Fixing Procedure

All the above labels and plates should be securely fixed to items of plant and equipment with stainless steel rivets, plated self tapping screws or other approved means. The use of adhesives will not be permitted.

 

Language and Alphabet of Label and Nameplate

The language of labels, plates and notices should comply with the requirements of the Contract. Sometime it’s may be in bilingual.

 

All label and nameplate should be easy to read and understand for employees and visitors by using clear language and symbol. A signs with symbol and language is more efficient.

 

Design and Graphics of Labels and Nameplate

Individual plant items and all relevant areas within the contract works where a danger to personnel exists should be provided with plentiful, prominent and clear warning notices.

 

These warning notices should draw attention to the danger or risk with words which attract attention and summarize the type of risk or danger. The notices should also carry a large symbol which graphically depicts the type of risk.

 

Electrical Plant and Equipment Label Diagram

All equipment within panels and desks should be individually identified. The identification should correspond to that used in schematic and wiring diagrams.

Typical Sub Distribution Board Diagram

Each circuit breaker panel, electrical control panel, relay panel etc., should have circuit designation label mounted on the front and rear. Corridor type panels should additionally have circuit designation labels within the panels.

 

All equipment and apparatus mounted there on should be clearly labeled in an approved manner. The function of each relay, control switch, indicating lamp, MCB, link etc. should be separately labeled.

 

Withdrawals relays, or items which can be detached from a base plate, or rack should carry an identification label on both fixed and withdrawals portions. The identification should correspond to that used in the associated schematic and wiring diagrams.

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Label and Nameplate Relocation for Construction Plant

During expansion work in an existing plant, including nameplate and numbering system some facilities may need to change or re-locate. 

Re-located equipment or total equipment of plant label and nameplate may need to replace by new one to ensure uniformity. 

The Service-provider should be responsible for the relocation, or replacement of all labels on existing plant, which became inaccurate as a consequence of the contract works.

 

Pipe and Valve Nameplate and Labeling for Plant

All pipe and valve must be tagged as per described in details plan. Pipe and valve labels should be circular and fitted under the hand wheel captive nut. 

For check valves and normal valves the Service-provider may provide rectangular labels fitted to the valve or secured close by the valve.

The inscription or “name” on each valve label should summarize the duty of the valve, and the number shown on each valve label should be the number in the unified plant valve numbering scheme.

Key point followed for pipe and valve labeling and numbering:

a. All markers to be in positions that are visible to personnel;

b. Marking must confirm to pipe service identification fluid;

c. Must confirm all information noted on drawing;

d. Every point where pipe enter or exit from wall or exchange direction must marked;

e. Must tagged on each riser and tee point;

f. Flow direction, if flow both direction must use double headed arrow;

g. Number of the valve summery;

h. Service controlled location;

i. Location of the valve;

j. Space or area controlled by the valve;

k. Colour code.

Flow Direction Label and Nameplate

Where the direction of flow through a valve or other device is an important requirement for correct functioning, the body of the valve or device should be legibly marked with a cast on, or alternatively, a properly secured arrow, showing the direction of flow.

HEAT STRESS AND OUTDOOR WORK- MIDDAY BREAK IS OBLIGATORY

To manage outdoor work and worker in heat stress region, it’s obligatory follow the midday break:

The manager or supervisor who manage the outdoor worker in the most hot region of the earth especially in summer time they must take care about heat stress what may causes up to heat stroke to worker. 

Particularly sub-Saharan region is the most remarkable region; but recently geographical area increasing adding others site-country due to increasing global warm rapidly. 

During summer temperature increases more than 50oC in MENA countries which is very difficult to stay outside for midday worker. 

Some Asian countries like Bangladesh, India, Pakistan also reaches above 40oC during that time. Every year a remarkable numbers of people die in this countries due to heat stroke, majority of those are outdoor worker.

The discussion of this article is limited on safety awareness and precaution to save the worker who is involved with outdoor works. This is the self motivation to increase knowledge to tackle the critical situation and   reduce losses by heat stress and heat stroke.

Key points to identify and fingering the heat stress:

Heat stress is a normal physical condition which is caused by any physical exertion. However, when directly exposed to sun rays in extremely high temperature for human body, this can exceed 50oC or 120oF which may direct to other adverse health effects.

Heat exhaustion can occur if an employee becomes too hot for long time, expends too much energy and does not drink enough water. While moisture increases in air as well as temperature increase, human body can sense heat exhaustion easily; but while percentage of air moisture falls extremely, human body can’t sense until reach adverse heat exhaustion. Heat exhaustion is generally not dangerous while the symptoms are:

·        Profuse sweating;

·        Muscle cramps, generally in the legs and abdomen;

·        Nausea; and

·        Dizziness.

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First Aid for heat exhaustion:

Reading primary symptoms of heat stress or heat exhaustion any one can recover him taking some First Aid treatment. First Aid for heat exhaustion is as below-

·        Help the patient to lay down in the shade or air conditioned area;

·  Give water in small amounts every 2 to 3 minutes until the employee recover;

·        Shift the patient to, or call for assistance from the Medical centre;

·        Not allow to drink salt or ice water;

·        Apply cool water to the back of the neck and wrists.

 Key points to identify and fingering the heat stroke:

Heat stroke is rare but is potentially life threatening. If failed to identify the primary heat exhaustion, it’s may lead to heat stroke after setting in and has the following symptoms:

• The patient stops sweating but is very hot to the touch;
• The patient will be turn as a disoriented or may become unconscious;
• The patient generally will suffer condition of heat exhaustion prior to heat stroke effects. 

First Aid for heat stroke:

If heat stroke symptoms appear then not wise to delay rather than shift the patient to medical treatment. The first aid for heat stroke is as bellow-

• Call for medical assistance immediately;
• Move the patient into shade or air-conditioned area;
• If available Pack ice, around the patient wrist, under the arms, and groin area;
• Use water if ice is not available;
• If patient is conscious give small amounts of water to drink every 2 to 3 minutes;
• Remove clothing from chest to torso;
• Do not allow stroke patient to swallow ice and salt;
• Keep the patient calm and wait for medical assistance to arrive.

It’s better to take preventive measure before fall anyone on life threaten heat stroke. Most of the Sevier heat stressed region countries labor department imposes law to the employer mandatory midday break for outdoor worker.

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