Learnings From Project_1

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1 Learnings from project 1 Sonadih2nd clinker line Project Learning from Project -KV Siva ram sarma

description

Construction safety best practices

Transcript of Learnings From Project_1

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Learnings from project

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Sonadih2nd clinker line Project

Learning from Project

-KV Siva ram sarma

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Sonadih2nd clinker line ProjectContents

A. Project construction safety

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Sonadih2nd clinker line ProjectContents

1. Electrical distribution system

2. Earthing

3. General guidelines for electrical safety

4. Specific equipment required

5. Cable laying

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Sonadih2nd clinker line Project1. Electrical distribution system

1. Electrical distribution system

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1. The Power will be given at one source – 3 Ph+ 1N+ 1E

2. The Internal distribution is in the Erection company scope.

3. For a construction site – Clinker line the power source should be suitable for an operating load of 500 kW.Connected Load of 800 kW ( 2 batching plants+ aux)

4. The Voltage level to be – 415 V, 50 HZ.(Based on Indian conditions).

5. The Erection company should distribute the power in the following Voltages.

i. shop level / Main Distribution Board Level - 415 V, 3Ph+1N

ii. Sub Distribution Level –

a. 415V, 3Ph+1N – For welding machines, Water Pumps - All with independent ELCB of 30 mA at each Out going

b. 110 V Ph- Ph – for power tools Like angle Grinders, drill Machines and other power tools all with independent ELCB of 30 mA at each out going.

c. Lighting

• Area Lighting – 230 V (Ph- N) with ELCB of 30 mA at the each out going.

• Confined space – 24V(Ph- N) With ELCB of 30mA for the Transformer incoming.

(Refer Animation in Next slide)

1. Electrical distribution system

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Sonadih2nd clinker line Project1. Electrical distribution system; Cont’d

415 /110 (Ph-Ph)Transformer

230/ 24 V transformer

110V power tools Like angle grinder etc

24 V confined space Lighting

230 V General area Lighting

Incoming source

ELCB with 30 mA

MCCB

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Protection against indirect contact can be achieved by the following

1. Electrical distribution system; Cont’d

Extract from IS 3043 – Indian standard derived from IEC 364

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Sonadih2nd clinker line Project1. Electrical distribution system; Cont’d

Extract from IS 3043 – Indian standard derived from IEC 364

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Extract from IS 3043 – Indian standard derived from IEC 364

1. Electrical distribution system; Cont’d

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Sonadih2nd clinker line Project2. Earthing

2. Earthing

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Sonadih2nd clinker line Project2. Earthing

a. Back ground

b. Concept of Double earthing

i) In Design

ii) In construction

c. Ensuring & control methods

i) Contract stipulations

ii) Site controls during erection

d. Additional methods adopted for Electrical safety

e. Operation & maintenance of earthing system

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Sonadih2nd clinker line Projecta. Earthing !! Back ground – Learnings from Surma plant

Electrical safety is always an area of concern considering the high potential. The recent fatalities in Surma (Bangladesh) reveal the importance for earthing . Based on the Learnings from the group Lafarge India wanted to enhance the Electrical

safety in the design & erection.

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Sonadih2nd clinker line Project b.Concept of double earthing – Design

(Contract E 2.9 & 3.0)

Method adopted – TTNS

The ground conductor should be redundant – 100% spare

The Ground conductor should be preferably bare (Except electronic earthing)

Earth mat for limiting touch & step potentials in switch yard

Separate Grounding systems for

Electrical earthing

•For Medium voltage grid resistance < 1 ohm

•For Low voltage grid resistance < 4ohm

Automation earthing

•Grid Resistance < 1ohm

Lightning protection

• Grid resistance < 10 ohm

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Sonadih2nd clinker line Projectb. Concept of double earthing – Design

(Contract E 2.9 & 3.0)

Earth conductor selected – Galvanized Iron Flat Ground Conductor design according to IEC. Grid system is with 2 runs of GI Flats buried 500 mm below ground connecting all the

respective earthing stations in the plant. All the transformer neutral points are grounded by two separate and distinct earthing

stations. All the MV & LV switch boards, JBs are also grounded by two separate ground conductors

(Local regulation) All the MV & LV motors are also to be grounded by two separate ground conductors (Local

regulation)

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Sonadih2nd clinker line Projectb. Concept of double earthing – In Design E2.9

Indicates additional grounding conductor/ system

Green line Indicates additional requirement

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Sonadih2nd clinker line Projectb. Concept of double earthing – In Design E2.9

Indicates additional grounding conductor/ system

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Sonadih2nd clinker line Projectb. Concept of double earthing – In construction

Existing utilities substation

Incoming board for civil contractor

LS Reclaimer area distribution board

Blending silo area Distribution board

Water Pump

Welding Machines

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Sonadih2nd clinker line Projectb. Concept of double earthing – In construction

Provision double earthing stations at all the construction fronts Like LS crusher, raw mill, coal mill, coal crusher, CF silo, Wagon tippler,kiln, clinker cooler,heat exchanger,coal crusher

Earth pits to be prepared separately for civil construction job Earth pits under preparation for the mechanical erection Earth pits prepared for Electrical fronts

The earthing conductor from Main distribution panels to site site distribution panels – 2 runs of 25 x 3 GI flat.

The earthing conductor from site distribution panels to Individual electrical equipment – 2 runs of 16 SWG Galvanized Iron wire

All joints Flat conductor through welding In Round conductor through Nut & Bolt system.

Ground conductor 2 No should be laid along with the main power cable The earth resistance of individual earth station should be < 5 ohm

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* Captured from contract –G3 (safety document for New projects)

Animation Next slide

Electrical Hazards in Welding (rod and others)Each welding machine should have double Earthing.

Each welding machine should be with individual switch

Multi welding machines with one switch is not acceptable

Return earth wire from job piece is compulsory

c. Ensuring & control - Contract stipulations

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Proper Method

•Double earthing for welding machine.

•Return earth wire from job to welding machine

•No direct earthing of job

Welding machine

Job piece

Return earth wire

Double Earthing for welding

c. Concept of double earthing – In construction

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Welding machine

Job piece

No Earthing not allowed

Double Earthing is must

Direct Earthing not allowed. Return wire to welding machine is required

c. Concept of double earthing – In construction

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Weleding machine

Job piece

Existing structure

Direct Earthing not allowed. Return wire to welding machine is required

c. Concept of double earthing – In construction

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Sonadih2nd clinker line Projectc. Concept of double earthing – In construction

Extract from IS 3043 derived from IEC 364

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Sonadih2nd clinker line Projectc. Ensuring & control methods - Electrical Charging Approval

Charging approval is mandatory for all electrical equipment.

Even if it is disconnected once or the location of the equipment is changed fresh approval

need to be obtained.

The charging approval is filled & signed by the contractor supervisor

Lafarge Engineer will verify the charging approval at site & then approval is given.

Safety department pastes a green color sticker

Sample charging approval is attached next slide.

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c. Ensuring & control methods - Electrical Charging Approval

Equipment charging approval (Electrical)

Certificate No : Date : Issued by : Request reference : Date: Requested by : Equipment Name:

Equipment location & S.No of the equipment

Incoming source / Feeder / Feeder rating

Incomer Fuse/ MCCB rating

ELCB rating / common or Individual

Incoming cable size/Type (Armoured/ Unarmoured)

Out going cable size/Type (Armoured/ Unarmoured)

Condition Cable (If flexible cable – condition of the flexible cable) & cable route (Under ground/ Over head) If under ground burial depth>500mm.

Double earthing done / Type (GI or copper) &Size of earth conductor

Insulation resistance (Megger value of the equipment & cable in Mega Ohm)

Connected to earth pit NO & Earth resistance value

Captured in SLD & Submitted

Comments / Remarks : Approved : (Each time a separate certificate to be issued if the location or the equipment is changed)

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Green sticker indicates the equipment is cleared for charging

c. Ensuring & control methods - Electrical Charging Approval

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d. Additional methods adopted for electrical safety – Part of construction contract

All equipment are provided with residual current devices of 30 mA at the each out

going.

All the equipment are provided with individual switches

All the distribution cables for lighting & water pumps are laid over head

No joint is accepted in flexible cables

All under ground cables are with armour for mechanical protection

Cables under ground are buried at not less than – 500mm depth

Under ground cables are provided with mechanical protection jackets at road

crossings

All the under ground cables are captured in drawings

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e. Operation & maintenance of earthing system

All the earth results are to be recorded after construction of the earth pits The Individual earth pit value should not be more than 5 ohm used for equipment

earthing not more than 10 ohm if used for lightning protection. A reading in summer is a must as it gives the worst reading.

For the construction sites the earth resistance to be monitored after every two months & to be recorded.

For the operating plant it is mandatory to conduct the earth testing at least once in a year & to be recorded (Statutory requirement)

During summer periodical watering of earth pits (at least once in 15 days) to be arranged.

As far as the earth wires are to be laid above ground (Except the earthing grid conductor) so that any disconnection is easily identifiable.

Splicing/ twisting joints are not allowed – only welded / bolted joints are allowed. If GI flats are welded the welded portions are to be provided with at least two coats of

bituminous paint and two coats of aluminum paint to avoid corrosion.

Extract from IS 3043 derived from IEC 364

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3. GUIDELINES & GENERAL PROCEDURES FOR SUPPLY AND USE OF ELECTRICITY AT SITE

3. GUIDELINES & GENERAL PROCEDURES FOR SUPPLY AND USE OF ELECTRICITY AT SITE

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a. Mandatory safety requirements

b. Conditions for issuing construction power supply

c. Installation

d. General

e. Protection class of construction equipment

f. LOTOTO

g. Operation & maintenance

h. Operation & maintenance of portable equipment

Contents

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• All Lafarge Mandatory safety requirements are applicable to construction site

a. Mandatory safety requirements

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Following safety requirement must be complied with before use of power supply. • Contractor shall submit a list of licenced electrical staff to be posted at site.

• Provide and maintain complete installation on the load side of the supply point with regard to the safety requirements at site.

• All cabling and installation shall comply with the appropriate statutory requirements given below and shall be subject to approval of the LIPL- Electrical • Where distribution boards are located at different places the submit schematic drawing indicating all details like size of wires, Over Head or cable feeders, earthing etc., The position and location of all equipments and switches shall be given.

• The Contractor shall make his own arrangements for main earth electrode

• Method of earthing :Installation and earth testing results shall conform to relevant I.S. Specifications (IS-3043).

b. Conditions for issuing construction power supply

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• All three phase equipment shall be provided with double earthing. • All light fixtures and portable equipment shall be effectively earthed to main earthing.• All 3 phase equipment are to be connected with 4 core cables out of which one core is for

earthing.• All single phase equipment are to be connected with 3 core cables out of which one core is

for earthing.• All Light fittings are fed with 3 core cables out of which one core is for earthing.

• All equipment are to be earthed with two no distinct & visible earthing

• No gas pipes and water pipes shall be used for earth connection.

• Neutral conductor shall not be treated as earth wire.

• The Contractor shall not connect any additional load without prior permission of LIPL - Electrical.

• Joints in earthing conductors shall be avoided. Loop earthing of equipment shall not be allowed. However tappings from an earth bus may be done.

b. Conditions for issuing construction power supply cont’d

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•The entire installation shall be subjected to the following tests before energisation of installation including portable equipment.

a) Insulation resistance test.

b) Earth electrode resistance.

The contractor shall submit a test report for his complete installation every 2 months or after rectifying any faulty section in the specimen test report. One such test report for the complete installation shall be submitted before onset of monsoon.

b. Conditions for issuing construction power supply cont’d

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 • Only persons having valid wireman’s licence/competency certificate shall be employed for carrying out electrical work at site.The job shall be supervised by a qualified licenced Supervisor

• Electrical equipment and installations shall be installed and maintained as to prevent danger from contact with live conductors and to prevent fires originating from electrical causes like short circuits, overheating etc. Installation shall not cause any hindrance to movement of men and materials.

• Grounding conductor of wiring system shall be of corrosion-resistant material (GI/ Copper) • Each equipment shall have individual isolating switches.

• Wires and cables shall be properly supported and an approved method of fixing shall be adopted.

• Loose hanging of wires & cables shall be avoided.

• Lighting and power circuits shall be kept distinct and separate.

• Reinforcement rods or any metallic part of structure shall not be used for supporting wires and cables, fixtures, equipment, earthing etc.

c. Installation

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• All cables and wires shall be adequately protected mechanically against damages.

• In case the cable is required to be laid under ground, it shall be adequately protected by covering the same with bricks. Plain cement Concrete (PCC)tile or any other approved means

• All armoured cables shall be properly terminated by using suitable cable glands.

• Multi stranded conductor cables shall be connected by using cable lugs/sockets. Cable lugs shall preferably be crimped. They shall be of proper size and shall correspond to the current rating and size of the cable.

• Twisted connections will not be allowed

• All cable glands, armouring and sheathing of electric cables, metal circuits and their fittings, metallic fittings and other non-current carrying parts of electrical equipment and apparatus shall be effectively grounded

d. General

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• All the Distribution Boards, Switch Fuse units, Bus bar chambers, ducts, cubicles etc. shall have MS enclosures and shall be dust, vermin and water proof. The Distribution Boards, switches etc. shall be so fixed that they shall be easily accessible. Changes shall be done only after the approval of the Departmental Electrical Engineer.

• Proper enclosures/covers must be provided for protection of all the switch board, equipment etc. against rain

• Exposed live parts of all electrical circuits & equipment shall be enclosed permanently.

• Iron clad industrial type plug outlets must be used for additional safety.

• Isolating switches / ELCBs shall be provided close to equipment for easy disconnection of electrical equipment or conductors from the source of supply when Operation or maintenance work has to be done on them. •Adequate working space shall be provided around electrical equipment which require adjustment or examination during operation

• All connections to lighting fixtures, starters or other power supplies shall be provided with PVC insulated, PVC sheathed twin/three/four core wires to have better mechanical protection for preventing possible damage to equipment or injury to personnel. Taped joints shall not be allowed and the connections may be made in looping system.

• Electric starter of motors, Switches shall not be mounted on wooden boards. Only sheet steel mounting or iron frame work shall be used.

• After installation of new electric system and or other extensive alterations to existing installations, thorough inspection shall be made by LIPL - Electrical before the new system or new extension is put in use.

d. General Cont’d

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• All the dewatering pumps should be of IP55 protection class• All the grinding machines should be of IP55 protection class• All the welding machines should be properly protected from rain water. If they are to

be placed out side buildings then it should be provided with cover on three sides ( Refer animation below)

• All the drilling machines also to be of IP55 protection class if they are used out side buildings

• All the electrical distribution boards used should be of IP55 protection class • All the flexible cables should be double insulated

e. Protection class of construction equipment

ELCB Board

Welding machine

Cover of 3 sides & top

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• Separate work permits shall be issued for individual group leaders working on the same system which shall be returned after the completion of the work to Safety Supervisor and no system shall be energized without the clearance of the respective individual group leader.

• Before any maintenance work is commenced on electrical installations / equipment, the circuits shall be de-energized and ascertained to be dead by positive test with an approved voltage testing device and to be locked by an individual lock by the group leaders & a permit to be pasted on the equipment on the name of the group leaders.

• The person issuing the permits is to be authorized by the function head and he is fully aware of the system and system de- energizing methods & the having the license issued by the local statutory authorities.

• Switches shall be tagged out or the fuse holders withdrawn before starting the work. Adequate precautions shall be taken in two important aspects viz.

i) That there shall be no danger from any adjacent live parts and 

ii) That there shall be no chances of re-energisation of the equipments on which the persons are working

• During final stages of electrical erection – lot of parallel activities are envisaged like – group no load trials, loop testing for PLC , cable laying & termination

-during that period substation wise switch board attendants are required substation wise .- Basic responsibilities include issue of electrical permits & administration of Lototo.

f. LOTOTO

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 • All persons who work with electrical installation/equipment shall be aware of the electrical hazards, use of protective devices and safe operational procedures. • They shall be given training in fire fighting, first aid and artificial resuscitation techniques.

• The supervisor shall instruct the proper procedure, specify and enforce the use of necessary protective equipment such as adequately insulated pliers, screw drivers, fuse pullers, testing lamps and similar hand tools.

• Only wooden ladders shall be used to reach the heights in electrical work.

• No material or earth work shall be allowed to be dumped below or in the vicinity of the bare overhead line conductors.

g. Operation & Maintenance

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•Operation of electrical equipment shall be avoided when standing on wet floor or when hands are wet.

• Before blown fuses are replaced, the circuit shall be locked out

• When two persons are working within reach of each other, they shall never work on different phases of the supply.

• When structural repairs, modification or painting work are to be undertaken, appropriate measures shall be taken for the protection of persons whose work may bring them into the proximity of live equipment/circuit. • It shall be ensured that the insulation and wire size of extension cords are adequate for the voltage and current to be carried.

•While tapping electricity from the socket, plug top must be used.

•It shall be ensured that no extension boards are over loaded while tapping. Only standard three pin plugs shall be used for tapping electricity.

•Broken sockets/plugs shall be replaced immediately with good ones.

•Only joint free cables shall be used for connecting equipment/apparatus

• Floors shall be kept free from trailing electrical cables to avoid tripping hazard

• Power supply to all the machines and lighting fixture shall be switched off when not in use

• Un-authorized tapping of power by others from distribution boards under the control of the contractor shall be prohibited at all circumstances

• No flammable materials shall be stored in any working area near the switch boards

g. Operation & Maintenance Cont’d

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 • Safety work permits shall be used for switching off the main feeder and equipment by the contractor.

• “MEN ON LINE” “DO NOT SWITCH ON” “DANGER” or “CAUTION” board as applicable shall be used during maintenance works on the electrical equipment

g. Operation & Maintenance Cont’d

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• Portable electrical equipment shall be regularly examined, tested and maintained to ensure that

the equipment and its leads are in good order. Register shall be maintained for inspection

recording, the testing dates and results of the equipments.• All portable appliances shall be provided with three core cable and three pin plug. The third pin

of the plug shall invariably be earthed. It shall be ensured that the metal part of the equipment

shall be effectively earthed.• All connections to portable equipment or machines from the panel/distribution board/extension

board shall be taken using 3 core double insulated PVC flexible copper wire in one length. No

joints shall be allowed in this flexible wire. In case single length of wire is not sufficient for a

particular location then the supply can be tapped by providing another extension board

comprising of switch and socket.• Flexible cables for portable lamps, tools, and apparatus shall be regularly examined, tested

periodically and maintained to ensure safety.

h. Portable electrical equipment operation & maintenance

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4. Specific equipment for construction site

4. Specific equipment for construction site

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4. Specific equipment for construction site

S.No Equipment Approx cost in MINR

Qty required Remark

1 Portable DG operated inflatable lighting towers9 mtr12 mtr21mtr

0.50.70.9

422

Will be used for illumination improvement during deep excavations

2 Mobile lifting towers trolley mountedBattery operated/Truck mounted

1.5 4

Will be used for Wah activities (Engineering control)

3

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4. Specific equipment for construction site

Adequate illumination plays a major role in the construction site .

To ensure proper lighting during the construction trolley mounted inflated lighting towers can be used.

As these towers are having the option of both DG & grid options they are self sufficient to ensure uninterrupted lighting

Typically for a green field around 6 to 8 no will help.

Approx cost – 0.5MINR each

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Sonadih2nd clinker line Project4. Specific equipment for construction site

Mobile elevated tower for addressing the wah activity like – over head cable tray & cable laying, Light fittings installation, Street light fittings erection etc.

These mobile plat forms come with an option of battery operated/ truck mounted.

Battery operated is preferable as they are light weight(<2 ton), slow speed (4-6 kmph).

They can be lifted can be placed at PH floors for addressing the Wah jobs.

Cost of each machine – 1.5 MINR

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5. Cable laying

5.Cable laying

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1. All Cables to be laid over head2. If possible a walk way to be provided for cable laying so that future cable laying

becomes easier.3. The cables laying through belt conveyor gantries are to be considered in side the

belt conveyor gantries.

Cable laying area

Walk way

Method for cable laying through belt conveyor galleries

Height should be sufficient to walk a person freely >1.8 mtr

5. Cable laying Cont’d

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4. In general cables inside the buildings are to be supported from the beams with insert plates instead of on brick wall. This will avoid the construction delays & facilitates parallel working

5. In side the building cables one floor to another floor to be taken from inside of the building but not out side.

Method for cable laying by using the concrete beam

Method for cable laying from one floor to another

Floor 2

Floor 1

5. Cable laying Cont’d

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6. Where ever possible cable are to be laid along with external stair cases. This will reduce the Wah activity.

Method for cable laying along with the stair case

5. Cable laying Cont’d

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6.Lightning Protection

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Content

a. General design

b. Construction site

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a. General design

• Lightning protection contains the major following components – Vertical air termination,Horizontal conductor, Down conductor & earth station

Earth station

Test jointVertical air termination

Horizontal conductor

Down conductor

• Lightning protection is compulsory for the building when the suggested acceptable risk exceeds 1 in million.

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• One down conductor if the base area of the structure does not exceed 100 square meter

• One down conductor+ one more down conductor for every additional 300 square meter base area.

• One down conductor for every 30 meter perimeter (specifically for silos)

• All the down conductors are to be connected to separate earth stations as shown in the drawing.

• Lightning protection is compulsory as per IS 2309 for all the buildings above 30 meter height.

• The protection angle of a lightning protection system is 30 deg cone formation can be extended up to 45 deg at less critical areas.(Refer animation in Next slide)

• The maximum earth station resistance allowed is 10 ohm.

a. General design cont’d

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30 deg30 deg

Extract from IS 2309 - 1986

a. General design cont’d

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a. General design cont’d

Lightning protection system of Sonadih line-1 (Typical plant)

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b. Construction site

• At construction site the tallest equipment (Height > 30 meter) are to be protected from lightning like

• Tower crane

• Big gantry cranes vertical boom height > 30 meter

• Lightning protection also to be provided for the construction completed buildings with a height> 30 meter.

• They are to be connected to separate earth pits –But not Electrical equipment earth pits

• The value of the earth pits should not be > 10 ohm.

• The testing to be done after every 3 months & record of the same to be maintained.

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7.Other statutory requirements

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• The other applicable statutory requirements are aviation warning system .

• All the construction equipment with height more than 30 meter is to be provided with aviation warning system like

• Tower crane

• Big Gantry crane with vertical boom > 30 meter.

Other statutory requirements – aviation warning