cbs method statement general

8/9/2019 CBS Method Statement General

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1.0 Introduction

1.1 The method statement aims to provide necessary information for Installation andTesting and Commissioning of Emergi-lite Central Battery System installed atPresidential Flight

1.1.1 This procedure will be adopted for all Central Battery Systems unit on this Project:

1.1.2 All Testing & Commissioning of CBSs will be carried out by Prime Technologies LLCunder the supervision of MEP Contractor.

2.0 Prerequisites to Procedure

Following are the prerequisites to the commissioning procedure:

2.1 Installation of Luminaries

2.1.1 All the luminaries need to be installed in accordance with civil defence requirements,

consultants specifications and manufacturers instructions.2.1.2 All the luminaries circuits need to be labelled to identify their locations.2.1.3 The shop floor drawing should be updated with the addresses of the luminaries

immediately after installation of the luminaries at the particular location.2.1.4 Installation details of the each luminaries or LTC wiring (If converted fitting) are

available.2.1.5 Ensure Exit / Escape route fittings are installed as per local civil defence regulations.2.1.6 The luminaries can be configured into 3 conditions

a) Maintainedb) Non-Maintainedc) Dimming

2.1.7 The wiring concepts for the LTC wiring for the above three conditions will be

provided to the site engineer to avoid wiring mistakes.2.1.8 Ensure rotation of the installed emergency luminaries is as per min Lux level

requirements are per BS-EN Standards and local civil defence regulation.

2.2 Power Requirement2.2.1 The substation require, 1 Phase, 230 V AC, 50 HZ

2.3 Installation of Substation2.3.1 All the substation should be installed as per the approved civil defence drawings.

2.3.2 The substation should be mounted on a rigid surface with a 50mm clearance at therear side of the substation.

2.3.3 The substation can be mounted on the slotted C channel.2.3.4 The cables entering and exiting the substation should be properly glanded with the

PG glands, and the cables should be labelled to and front of the feeder and the load,for future monitoring and maintenance.

2.3.5 The substation should be installed at a distance of 1.6 m from the finished floor levelfor maintenance accessibility.

2.3.6 The gap between substations to substation is 50mm.


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2.3.7 The trucking above and below the substation must be spaced at a distance of100mm for easy access of cables.

2.3.8 There should not be and chilled pipe, raw water pipe lines running above thesubstation.

2.4 Installation of Batteries

2.4.1 The battery blocks to be connected according to manufacturers instructions withcorrect polarity.

2.4.2 The battery cabinets need to be connected to their respective panels.2.4.3 Clean the battery panels before installation.2.4.4 The room must be air-conditioned before placing the batteries inside the central

battery room2.4.5 Each bank connects to separate MCB in the control section of the charger / inverter

cubicle, labelled as MCB2A, MCB2B etc.2.4.6 The location of battery cabinets needs adequate ventilation to maintain the ambient

temperature @ 25 deg C2.4.7 The battery terminals should be tightened with the insulated box spanner and should

have a tightening torque of 15 Nm with a Calibrated torque wrench.2.4.8 Excess tightening of the batteries might lead to breakage of the Bolts and the battery

terminals cannot be replaced and the battery has to disposed2.4.9 The battery interloping cables between bank to bank and bank to the battery MCB

should be indentified properly and used as it Come in different lengths.2.4.10 When all connections are complete, coat each exposed terminalwith petroleum jelly

to protect against corrosion.2.4.11 Cover the Terminals of the batteries with the terminal cover.2.4.12 The lead marked BLACK connects to the negative (-) terminal onthe battery. The lead

marked RED connects to the positive (+)Terminal of the battery. Battery terminals are marked with a - orn+ Symbol to indicate polarity.

2.5 Installation of panels

2.5.1 The panels need to be installed as per relevant electrical standards.2.5.2 The cabling between the panels need to be complete.2.5.3 CBS room is clean and no other civil, mechanical or electrical work is pending in it.2.5.4 Ensure no water / chillers pipelines are passing above the CBS system or battery cabinet. If any work

related to pipelines, it has to be finished before installation of the CBS system.

2.5.5 CBS room is maintained at 25 deg C by provision of air conditioning unit.2.5.6 Minimum height of 500mm is maintained above the CBS from the roof.2.5.7 Minimum distance of 75 mm is maintained to the backside of CBS system from the wall.2.5.8 CBS system and battery cabinets are fixed in final location as per the shop floor drawing.

2.6 BMS Interface

2.6.1 Interface to BMS required for all the main panels.

3.0 Design Parameters

3.1.1 Specification reference3.1.2 The system is designed in compliance with specification for Central Battery Systems.3.1.3 The BOQ is as per the value added engineering design by Prime Technologies LLC.


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4.0 Reference Documents / Drawings

4.1 Emergency lighting system drawings:-4.2 Schematic Diagram:-4.3 Emergency lighting layouts:-

5.0 Prestart Checks / Pre Commissioning

5.1 Pre commissioning

5.1.1 Visually inspect the installation of panel, batteries, emergency and exit lights.5.1.2 Visually inspect the installation of converted light fittings.5.1.3 Ensure correct addressing of all the light fittings. The shop drawings are to be followed

for addressing the lamps.5.1.4 Short circuit test on all the luminaries circuits before their termination to the panel.5.1.5 Check for availability of mains supply for the panels.5.1.6 Check the overall output dc voltage from the batteries.5.1.7 Check the connections between main panel and battery panel5.1.8 Check the connection of sub circuit monitoring inputs. Ensure that all the inputs are

active.

6.0 Commissioning / Test Procedures

6.1 Start up procedure

6.1.1 Ensure all control, charger / inverter module and distribution MCBs (if fitted),are OFF. If distribution is remote, isolate the output at the remote distributionboards

6.1.2 Ensure the mains input switch (SW1) is OFF.

6.1.3 Ensure the mains supply is isolate at the external isolator.6.1.4 Check correct battery polarity using a DC voltmeter at each battery MCB (MCB2)6.1.5 Energies the mains at the external isolator. Check the mains voltage at the input

terminals. Ensure that the maintenance load circuits are safe to energies andclose the mains input switch (SW1) and distribution MCBs. These energiesmaintained output. Check the output circuit load using a clamp type ammeter.

6.1.6 Close all battery MCBs (MCB2), located on the rear control chassis.

6.1.7 Close all modules AC MCBs. The RED LED on the front of each module will light.Check that each RED LED extinguishes (charger modules LEDs go outimmediately, inverter module LEDs may take up to 20 minutes).

IF A RED LED REMAINS LIT THERE IS A BATTERY POLARITY FAULT ORA DC SHORT CIRCUIT. IF A FAULT EXISTS FOLLOW THE SHUTDOWNPROCEDURE AND CALL THE SERVICE DEPARTMENT

6.1.8 Close the control circuit MCBs (MCB3 and MCB4), located on thecontrol chassis in the top left of the control cabinet.

6.1.9 Close the circuit monitor MCB (MCB6), if fitted.


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6.1.10 Close the charge DC bus MCB (MCB7), if fitted.

6.1.11 Close the charger MCB (MCB1), located on the rear controlchassis. Check the display metering and LEDs are operating andthe DC meter is displaying battery voltage.

6.1.12 Close all module DC MCBs . The GREEN LED will light on thecharger modules. The GREEN LED on inverter modules will notlight if the battery has insufficient charge; the RED BATTERY-DISCHARGED LED on the display indicates this condition.

6.2 System Programming6.2.1. Ensure Central Monitoring PC is placed in its final location and

Data-cable is pulled as per requirement.

6.2.2 Ensure Modem supplied along with the PC is made available alongwith RJ 45 plug in socket near Inverter panel.

6.2.3 Power ON PC and Install the EMEX Software and connect Data-Cable to the modem.

6.2.4 Start programming as required for the project and verify theFunction.

6.2.5 Give function test from the PC and verify for any further failuresAnd rectify the same.

6.2.6 Program Automatic function test.

6.2.7 Ensure operation and Maintenance Manual are placed in everyInverter panel and a maintenance Log is maintained in InverterPanels.

6.3 Final Testing

6.3.1 Conduct Function Test and record the results on Test Protocol.

6.3.2 Conduct Duration Test and record the results on Test Protocol.

6.3.3 System Operation Check with reference to CommissioningChecklist.


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7.0 Interface Procedure

InterfacedSystem

How itsinterfaced

Special requirements Action required

8. Documentation

8.1 Commissioning Report8.2 Commissioning Checklist,8.4 Commissioning Report.8.5 Lux level Report,8.6 Battery discharging Report.

9.0 Demonstration Procedures

9.1 Demonstration to the Project Consultant Site Engineer

9.2 Commissioning reports supported by Test Protocol will beSubmitted.

10.0 Equipment and Instrumentation

General Tool box

Digital Multi Meter

Lux Hi tester

11.0 Staffing Compliance Sign off Sheet:

We confirm that we have read and understood the attached method statement for thecommissioning of CBS systems. We accept and agree to follow the procedure laid out in this

method statement.


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NAME COMPANY DATE SIGN

12.0 Safety Aspects & Permit to Work Requirements

12.1.1 Qualified & experienced Service Engineer will be responsible forTesting & Commissioning and submission of reports.

12.1.2 General site safety measures as advised by site safety engineer.